HOW TO USE THIS MANUAL This service manual describes the service procedures for the XLIOOOV. Follow the Maintenance Schedule (Section 3) recom- mendations to ensure that the vehicle is in peak oper‘ ating condition. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break<2 Position light 12V*5W Brake/tail light 12V—2'l/5W X2 Front turn signal light 12V—21W Rear turn signal light 12V—21W License light 12V—5W Instrument light 1ZV—1t7W,12V-3t4W ><2 Turn signal indicator 12V—3.4W X2 High beam indicator 12V—1.7W Neutral indicator 12V—3.4W Oil pressure indicator 12V—3AW Fuel indicator 12V—3AW Fuse Main tuse 30 A Subfuse 20AX1,10A><5 Fan motor Start to close (ON) 93* 102 “C (2087216 “Fl switch Stop to open 93797 “C (1997207 °Fi Coolant temperature sensor resis- at 80 °C/176 “F 47—579 tance at 120 °Cl24S "F 14-189 Fuel pump flow capacity Minimum 700 cmJ (237 US oz 24.6 Imp ozilminute at 13 V 1-11 GENERAL INFORMATION TORQUE VALUES TORQUE TORQUE FASTENER 1'er Mm "mm, M“) FASTENER 1'er Mm [Wm M“) 5 mm hex bolt and nut 5 (0.5 , 3.6) 5 mm screw 4 (0.4 , 2.9) 6 mm hex bolt and nut 10 (1.0 , 7) 6 mm screw 9 (0.9 , 6.5) 8 mm hex bolt and nut 22 (2.2, 16) 6 mm flange bolt (8 mm head) 9 (0.9 , 6.5) 10 mm hex bolt and nut 34 (3.5 , 25) 6 mm flange bolt (10 mm head) 12 (1.2 , 9) 12 mm hex bolt and nut 54 (5.5 , 4D) and nut 8 mm flange bolt and nut 26 (2.7 , 20) 10 mm flange bolt and nut 39 (4.0 , 29) 0 Torque specifications listed below are for important fasteners. 0 Others should be tightened to standard torque values listed above. NOTES: 1. Apply sealant to the threads. 2. Apply a locking agent to the threads 3. Apply molybdenum disulfide oil to the threads and flange surface. 4. Apply grease to the threads. 5. Stake. 6. Apply oil to the threads and flange surface. 7. Apply clean engine oil to the O-ring. 8. U-nut. 9. ALOC bolt/screw: replace with a new one. 10, CT bolt. — ENGINE THREAD TORQUE "EM “TV on. (mm) N‘m (kgf-m, rum) REMARKS MAINTENANCE: Spark plug 2 12 14(1.4,10) Crankshaft hole cap 1 30 15(1.5,11) NOTE4 Timing hole cap 1 14 10 (1.0 , 7) NOTE 4 Oil filter cartridge 1 20 10 (1.0 y 7) NOTE 6, 7 Oil drain bolt 1 12 30 (3.1 , 22) LUBRICATION SYSTEM: Oil pressure switch 1 PT 1/8 12 (1,2 , 9) NOTE 1 Oil pressure switch wire terminal screw 1 4 2 (0,2 , 14) Oil pump mounting bolt 3 6 12 (1,2 , 9) Oil pump bolt 2 6 13 (1.3 , 9) Oil filter boss 1 20 18 (1.8 , 13) NOTE 2 Oil pump driven sprocket bolt 1 6 15 (1.5 ,11) NOTE 2 FUEL SYSTEM: Carburetor insulator bend bolt 4 5 1 (0.1 ,o.7) Reed valve cover bolt 4 5 (0.52 , 38) NOTE 2 ENGINE MOUNTING: Drive sprocket bolt 1 10 54 (5.5 , 40) CYLINDER HEADNALVES: Cylinder head cover bolt 8 6 10 (1,0 , 7) Breather plate bolt 4 6 12 (1.2 , 9) NOTE 2 Cam sprocket bolt 4 7 20 (2.0 , 14) NOTE 2 Camshaft holder bolt 16 7 21 (2.1 .15) NOTE 6 Cylinder head bolt 12 10 53 (5.4 , 39) NOTE 6 Cylinder head sealing bolt 2 12 32 (3.3 , 24) NOTE 2 Intake manifold vacuum port socket bolt 2 5 3 (0.34 , 2,5) 1-12 GENERAL INFORMATION — ENGINE (Cont'd) THREAD TORQUE "EM my DIA. (mm) "m (kgf-m, lM-ft) REMARKS CLUTCH/GEARSHIFI' UNKAGE: Clutch spring bolt 5 6 12 (1.2 , 9) Clutch center lock nut 1 25 127 (13.0 , 94) NOTE 5, 6 Gearshift cam bolt 1 8 23 (2.3 , 17) NOTE 2 Gearshift spindle return spring pin 1 8 23 (2.3 , 17) Primary drive gear bolt 1 12 88 (9.0 , 65) NOTE 6 ALTERNATOR/STARTER CLUTCH: Flywheel bolt 1 12 1571160, 116) NOTE6 Starter one-way clutch socket bolt 6 8 23 (2.3 , 17) NOTE 2 Stator socket bolt 3 6 12 (1.2 , 9) CRANKCASE/TRANSMISSION: Cam chain tensioner bolt 2 8 23 (2.3 ,17) NOTE 2 Cam chain guide bolt 2 8 23 (2.3 , 17) NOTE 2 Crankcase flange bolt 1 10 39 (4.0 . 29) Crankcase special bolt 8 10 42 (4.3 , 31) NOTE 6 Crankcase sealing bolt (15 mm) 1 15 29 (3.0 , 22) NOTE 2 (18 mm) 1 18 29 (3.0 , 22) NOTE 2 (22 mm) 1 22 25 (3.0 , 22) (24 mm) 1 24 49 (5.0 , 38) NOTE 2 CRANKSHAFT/PISTON/CVLINDER: Connecting rod bolt 4 9 29 (3.0 , 22) 1 120° NOTE 6, 3 IGNITION SVSTEM: Ignition pulse generator mounting bolt 2 6 12 (1.2 . 9) NOTE 2 ELECTRIC STARTER: Starter motor terminal nut 1 6 10 (1.0 , 7) LIGHT/METERSISWITCHES: Neutral switch 1 10 12 (1.2 , 9) — FRAME THREAD TORQUE "EM 0"" DIA. (mm) N-m (kgi-m. rum) REMARKS FRAME BODY PANELS/ EXHAUST SYSTEM: Exhaust pipe ioint nut 4 7 12 (1.2 . 9) Muffler band bolt 2 8 26 (2.7 , 20) Fuel cock nut 1 22 34 (3.5 . 25) Upper cowl stay mounting bolt (upper) 2 8 34 (3.5 , 25) (lower) 2 10 44 (4.5 , 33) Upper cowl stay mounting nut (head pipe) 1 10 44 (4.5 , 33) COOUNG SYSTEM: Thermo sensor 1 PT1/8 9 (0.9 , 65) NOTE 1 Engine coolant temperature (ECT) sensor 1 12 23 (2,3 , 17) Fan motor switch 1 16 17 (1.7 , 12) 1-13 GENERAL INFORMATION — FRAME (Cont’d) , THREAD TORQUE "EM 0 TV DlAt (mm) N-m (kgf-m, lM-ft) REMARKS ENGINE MOUNTING: Front engine hanger nut© 1 12 64 (6.5 , 47) — Page 7-6 Front engine hanger adjusting bolt (3 1 20 3 (0.3 , 2.2) Front engine hanger lock nut© l 20 54 (5.5 , 40) Center engine hanger bolt © 2 10 39 (4,0 , 29) Rear engine hanger nut© 1 12 64 (6.5, 47) Rear engine hanger adjusting bolt (9 1 20 3 (0.3 , 2.2) Rear engine hanger lock nut Q) 1 20 54 (5.5 , 40) Q Q). ® @, ©, @ FRONT WHEEL/SUSPENSIONISTEERING: Handlebarweight mounting screw 2 6 10 (1.0 , 7) NOTE 8 Throttle housing screw 2 5 4 (0.42 , 3.0) Bystaner lever pivot bolt 1 6 9 (0.9 , 6.5) Handlebar upper holder bolt 4 8 27 (2.8 , 20) Handlebar lower holder nut 2 8 27 (2.8 , 20) Steering stern nut 1 24 103 (10.5 , 76) a Page 13-33 Steering stem bearing adjusting nut 1 26 25 (2.5 , 18) Steering stern bearing lock nut 1 26 — Fork top bridge pinch bolt 4 B 22 (2.2, 16) Fork bottom bridge pinch bolt 4 8 27 (2.8 , 20) Front axle bolt 1 14 59 (6.0 , 43) Front axle holder bolt 4 8 22 (2.2 , 16) Front brake disc bolt 12 6 20 (2,0 , 14) NOTE 9 Fork socket bolt 2 8 20 (2.0 , 14) NOTE 2 Fork cap 2 39 22 (2.2 , 16) REAR WHEEL/SUSPENSION: Rear axle nut 1 18 93 (9.5 , 69) NOTE 8 Final driven sprocket nut 5 12 108 (11.0 , 80) Rear brake disc bolt 4 8 42 (4.3 , 31) NOTE 9 Shock link bracket bolt 1 12 54 (5.5 , 40) 1 14 59 (6.0 , 43) Swingarm pivot nut 1 18 93 (9.5 , 69) NOTE 8 Drive chain slider screw 2 5 4 (0.42 , 30) NOTE 2 Shock absorber upper mounting nut 1 10 59 (6.0 , 43) NOTE 8 Shock absorber lower mounting nut 1 10 44 (4.5 , 33) NOTE 8 Shock Iink-to-bracket nut 1 10 59 (6.0 , 43) NOTE 8 Shock link-to-shock link plate nut 1 10 44 (4.5 , 33) NOTE 8 Swingarm»to-shock link plate nut 1 12 38 (9.0 , 65) NOTE 8 1-14 GENERAL INFORMATION — FRAME (Cont'd) . THREAD TORQUE ITEM QTY m. (mm) Nlm (mNAMN REMARKS HYDRAULIC BRAKE: From brake master cylinder holder bolt 2 6 12 (1.2 . 9) Front brake master cylinder cap screw 2 4 1 (0.15 , 1.1) Brake lever pivot bolt 1 6 1 (0.1 , 0.7) Brake lever pivot nut 1 6 6 (0.6 , 4.3) Brake lever adjuster 1 5 4 (0.4 , 2.9) From brake light switch screw 1 4 1 (0.12 , 0.9) Right from caliper mounting bolt 2 8 31 (3.2 , 23) NOTE 9 Left front caliper pivot bolt 1 8 31 (3.2, 23) NOTE 9 Left front caliper bolt (secondary masterjoint) 1 8 31 (3.2 , 23) NOTE 9 Caliper body B bolt 9 8 32 (3.3 , 24) NOTE 9 Front brake caliper slide pin (main) 3 12 23 (2.3 , 17) Front brake caliper slide pin(sub) 3 8 13(1.3,9) Fad pin 3 10 13(1.8.13) Brake caliper bleed valve 6 8 6 (0.6 . 4.3) Secondary master cylinder push rod nut 1 8 18 (1.8 , 13) Secondary master cylinder connector 2 6 10 (1.0 , 7) Rear master cylinder mounting bolt 2 6 12 (1.2 , 9) Rear master cylinder reservoir mounting bolt 1 6 12 (1.2 , 9) Rear master cylinder push rod nut 1 8 18 (1.8 , 13) Rear master cylinder hose ioint screw 1 4 1 (0.15 , 1.1) NOTE 2 Brake hose oil bolt 12 10 35 (3.6 , 26) Brake pipe ioint 8 10 17 (1.7 , 12) NOTE 6 Brake pipe 2/3 way joint 2 6 12 (1.2 , 9) Brake hose guide bolt 2 6 12 (1.2 , 9) Delay valve mounting bolt 2 6 12 (1.2 , 9) PCV (Proportional Control Valve) mounting bolt 2 6 12 (1.2 , 9) IGNITION SVSTEM: Rear ignition coil mounting bolt 2 6 12 (1.2 . 9) LIGHTS/METERS/SWITCHES: Side stand pivot bolt 1 10 10 (1.0 , 7) Side stand pivot lock nut 1 10 29 (3.0 , 22) Side stand switch bolt 1 6 10 (1.0 , 7) Fuel level sensor 1 18 23 (2.3 .17) OTHERS: Rear turn signal nut 2 10 5 (0.5 , 3.6) Footpeg bracket bolt 2 8 35 (3.6 , 26) Bank sensor bolt 2 8 10 (1.0 , 7) Gearshift pedal linkioint nut 2 8 27 (2.8.20) 1-15 GENERAL INFORMATION TOOLS NOTES: 1‘ Equivalent commercially available. 2. Alternative tool. 3. Newly provided tool. 4. Newly designed tool. Driver attachment Driver handle 07953-MJ10100 07953-MJ10200 DESCRIPTION TOOL NUMBER REMARKS REF. SEC. Carburetor float level gauge 074010010000 5 Oil pressure gauge 075066000000 4 Oil pressure gauge attachment 074060030000 4 Gear holder 077240010100 9 Clutch center holder 077240050002 9 Flywheel holder 077250040000 NOTE 1 10 Rotor puller 077330020001 10 Valve guide remover 077420010100 8 Remover weight 077410010201 6 Adjustable valve guide driver 077430020000 8 Attachment, 32 X 35 mm 077460010100 9, 14 Attachment, 37 X 40 mm 077460010200 9, 14 Attachment, 42 X 47 mm 077460010300 9, 13, 14 Attachment, 52 X 55 mm 077460010400 13, 14 Attachment, 62 X 68 mm 077460010500 14 Attachment, 24 X 26 mm 077460010700 14 Attachment, 22 X 24 mm 077460010300 14 Driver B 077460030100 1 1 Inner driver, 35 mm 077460030400 11 Pilot, 10 mm 077460040100 5 Pilot, 17 mm 077460040400 9, 14 Pilot, 20 mm 077460040500 13, 14 Pilot, 25 mm 077450040600 14 Pilot, 35 mm 077460040800 9 Pilot, 28 mm 077460041100 14 Bearing remover shaft 077400050100 13, I4 Bearing remover head, 20 mm 077460050600 13, 14 Driver 077490010000 8, 9, 13, 14 Valve spring compressor 077570010000 8 Valve seat cutter NOTE 1 8 Seat cutter, 35 mm (45° EX) 077800010400 Seat cutter, 40 mm (45" IN) 077800010500 Flat cutter, 35 mm (32° EX) 077800012300 Flat cutter, 38 mm (32° IN) 077800012400 Interior cutter, 37.5 mm (60° EX) 077800014100 Interior cutter, 42 mm (60" IN) 077800014400 Pilot screw wrench 079084730002 5 Snap ring pliers 07914-SA50001 15 Steering stem socket 07916-3710101 13 Remover shaft 07936~GE00100 6 Remover head, 10 mm 07936-GE00200 6 Attachment, 28 X 30 mm 07946-18701 00 6 Bearing race remover 07946-3710500 13 Needlebeering remover 07946—KA50000 13 Mechanical seal driver attachment 07946-4150400 6 Steering stern driver 07946-M 300000 13 Oil seal driver 07947-KA40200 13 Slider weight 07947-KA50100 13 Driver handle attachment 079480710001 14 Ball race remover 07953-MJ 10000 13 1-16 GENERAL INFORMATION DESCRIP'HON YOOL NUMBER REMARKS REF. SEC. Oil filter wrench 07HAA-PJ70100 3 Peak voltage adaptor 07HGJ-0020100 NOTE 3: 17, 19 lmrie diagnostic tester (model 625) Drive chain tool set 07HMH-MR10103 3 Needle bearing remover 07LMC—KV30100 14 Lock nut wrench 07VMA—MBBOIOO 7 Cutter holder, 6 mm 07VMH-MBBO100 8 Valve guide reamer, 6912 mm 07VMH-MBBOZOO 8 Analog tester (KOWA) TH-SH 16, 17, 18, 19 Analog (ester (SANWA) SP—15D 16, 17, 18, 19 1-17 GENERAL INFORMATION LUBRICATION & SEAL POINTS — ENGINE LOCATION MATERIAL REMARKS Crankcase mating surface Liquid sealant (Three Bond 12073 or equivalent) 0“.“...\ I wm“.\\ \3 5—15 mm (OZ—0.6m) Cylinder head sern «circular area Cylinder head cover gasket mating surface (cover side) Oil pressure switch threads Alternator stator wire grommet seating surface 1-18 GENERAL INFORMA'HON — ENGINE (Cont’d) LOCATION MATERIAL REMARKS Crankshaft main journal bearing sliding surface Molybdenum disul- Crankpin bearing sliding surface fide oil (a mixture of Connecting rod small end inner surface 1/2 engine oil and 1/2 Valve stam sliding surface molybdenum disul- Valve lifter outer surface fide grease) Camshaft journals and lobes Clutch outer sliding surface M3, C2, C4 gear shift fork grooves Each gear teeth and sliding surface Other rotating and sliding area Primary drive gear and sub gear sliding surface Molybdenum disul- fide grease Oil filter cartrige threads and seating surface Engine oil Camshaft holder bolt threads and seating surface Cylinder head bolt threads and seating surface Clutch disc lining surface Clutch center lock nut threads and seating surface Flywheel bolt threads and seating surface Piston outer surface and piston pin hole Piston ring whole surface Connecting rod bolt threads and seating surface Primary drive gear bolt threads Each bearing rotating area Each O—ring whole surface Timing hole cap threads Multi-pu rpose grease Crankshaft hole cap threads Each oil seal lips Oil pump driven sprocket bolt threads Locking agent Oil filter boss threads Reed valve cover bolt threads Breather plate bolt threads Cam sprocket bolt threads Cylinder head 12 mm sealing bolt threads Gearshift cam bolt threads Starter clutch bolt threads Cam chain tensioner bolt threads Cam chain guide bolt threads Crankcase 18 mm sealing bolt threads Crankcase 22 mm sealing bolt threads Crankcase 24 mm sealing bolt threads Meinshaft bearing set plate bolt threads Shift drum bearing set plate bolt threads Pulse generator bolt threads 1-19 GENERAL INFORMATION — FRAME LOCATION MATERIAL REMARKS Front wheel dust seal lips Rear wheel dust seal lips Driver footpeg sliding area Passenger footpeg sliding area Throttle grip pipe inner flange Seat catch hook Gearshift pedal link tie-rod ball joints Gearshift pedal pivot Side stand pivot Rear brake pedal pivot Steering head bearings Steering head bearing dust seal lips Clutch lever pivot Left front brake caliper pivot bearing sliding surface Left front brake caliper pivot oil seal sliding surface Left fork needle bearing sliding surface Left fork dust seal sliding surface Shock absorber dust seal lips Shock absorber needle bearing Shock link dust seal lips Shock link needle bearings Swingarm Iink plate needle bearings Swingarm pivot bearings Swingarm link plate dust seal lips Swingarm pivot dust seal lips Driven flange collar outer surface Multi-purpose grease Throttle cable Cable lubricant Choke cable Clutch cable Steering bearing adjustment nut threads Engine oil Brake pipe ioint threads Front brake Iever-to-push rod contacting area Front brake lever pivot Brake caliper pin bolt sliding surfaces Brake master piston-to-push rod contacting area Secondary master cylinder boot inside and push rod tips Brake caliper dust seals Silicone grease Fork cap O-ring Brake master piston and cups DOT 4 brake fluid Brake caliper piston and seals Fork oil seal lips Fork fluid Brake caliper slide pin bolt threads Fork socket bolt threads Locking agent Handle grip rubber inside Honda Bond Aor equivalent 1 -20 GENERAL INFORMATION CABLE & HARNESS ROUTING FRONT BRAKE HOSE COMBINATION METER 9P COMBINATION METER WIRE (BLACK) CONNECTOR TURN SIGNAL RELAY FUEL CUT RELAY HEADLIGHT RELAY HEADLIGHT RELAY COMBINATION METER 6P CONNECTOR RIGHTTURN SIGNALWIRE LEFITURN SIGNAL WIRE DELAM VALVE HEADLIGHT CONNECTORS 1-21 GENERAL INFORMATION THROTTLE CABLES ‘ y FAN MOTOR SWITCH 2P (BLACK) CONNECTOR ,‘ xv ‘ FRONT BRAKE HOSE 1-22 GENERAL INFORMATION MAIN WIRE HARNESS CLUTCH CABLE CHOKE CABLE IGNITION SWITCH " RIGHT HANDLEBAR SWITCH 6P (RED) CONNECTOR IGNITION SWITCH 3P CON- NECTOR ' ‘u I LEFT HAN DLEBAR SWITCH 2Pv FRONT SPARK PLUG WIRE _ .. ) 9P (BLACK) CONNECTOR LEFT FRONT BRAKE HOSES 1 -23 GENERAL INFORMATION RIGHT HANDLEBAR SWITCH 6P {REDI figIIIIERTgSIITCH 3P CONNECTOR LEFT HANDLEBAR SWITCH 2P, 9P (BLACK) REAR SPARK PLUG WIRE CONNECTOR MAIN WIRE HARNESS REAR IGNITION COIL STARTER MOTOR CABLE ALTERNATOR WIRE OIL PRESSURE SWITCH WIRE NEUTRAL SWITCH SIDE STAND SWITCH WIRE FUELTUBE (RIGHT FUEL COCK-TO-FUEL FILTER) FUELTUBE (LEFT FUEL COCK-TO-FUEL FILTER) \ CARBURETOR OVER FLOW FUEL TANK DRAIN TUBE LOWER RADIATOR HOSE RESERVE TANK OVER FLOW TUBE STARTER MOTOR CABLE WATER PUMP DRAIN TUBE FUEL PUMP WIRE FUEL PUMP FUEL PUMP TUBE FUEL TUBE (FUEL PUMP-TO-CARBURETORS) FUEL TANK BREATHER TUBE 1 -24 GENERAL INFORMA‘HON FUEL RESERVE SENSOR WIRE THROTTLE SENSOR 3? (BLACK) CONNECTOR CRANKCASE BREATHER HOSE THfiomE CABLES SPEED SENSOR 2P (BLUE) CONNECTOR REAR BRAKE LIGHT SWITCH 2P (BLACK) CON NECTOR PAIR’CHECK VALVE TUBE RADIA'IjOR / SIPHONE TUBE LOWER RADIATOR HOSE FUEL TUBE (RIGHT FUEL COCK-TO-FUEL FILTER) REAR BRAKE RESERVOIR HOSE THROTTLE STOP CONTROL KNOB CARBURETOR HEATER WATER OUTLET HOSE 1-25 GENERAL INFORMATION UPPER RADIATOR HOSES THRO‘I'I’LE CABLES A'“ HOSE “1 PAIR CHECK VALVE TUBE BREATHER TUBE \ . CRANKCASE BREATHER HOSE (FRONT) PAIR CONTROL VALVE ) VACUUM TUBE PAIR CONTROL VALVE FRONT CHOKE CABLE REAR CHOKE CABLE FUEL TUBE ENGINE COOLANTT) TEMPERATURE EC SENSOR 3P(GREEN) A'R HOSE CONNECTOR THROTTLE SENSOR 3P (BLACK) CONNECTOR MAINTENANCE VACUUM TUBE AIR HOSE CHANKCASE BREATHER HOSE (REAR) REAR SPARK PLUG WIRE K PAIR CHECK VALVE TUBE FUEL TANK DRAIN TUBE 7 ; O O FUEL TANK BREATHER TUBE 1-26 GENERAL INFORMATION REAR TURN SIGNAL LIGHT CONNECTORS TAIL/BRAKE LIGHT 3F CONNECTOR '> LICENSE LIGHT CONNECTORS FUSE BOX BATTERY POSITIVE (+I CABLE STARTER RELAY SWITCH BATTERY . IGNITION CONTROL MODULE (ICMI MAIN WIRE HARNESS BATTERY NEGATIVE (*) CABLE REAR IGNITION COIL SPEED SENSOR 2P (BLUE) CONNECTOR REAR BRAKE LIGHT SWITCH 2P (BLACK) CONNECTOR SPEED SENSOR WIRE REAR BRAKE RESERVOIR HOSE REAR BRAKE LIGHT SWITCH WIRE BATTERY GROUND CABLE REAR BRAKE HOSES 1-27 GENERAL INFORMATION EMISSION CONTROL SYSTEMS SOURCE OF EMISSIONS The combustion process produces carbon monoxide and hydrocarbons. Controlling hydrocarbon emissions is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydrocar- bons. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase wstem to prevent discharging crankcase emissions into the atmosphere. Blow-by gas is returned to the combustion chamber through the air cleaner and carburetor. AIR CLEANER CARBURETOR <2! FRESHAIR h BLOW-BYGAS 1-28 GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (PULSE SECONDARY AIR INJECTION 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 whenever there is a negative pressure pulse in the exhaust system. 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 This model has the pulse secondary air injection (PAIR) control valve and PAIR check valves. PAIR check valve prevents reverse air flow through the system. The PAIR control valve reacts to high intake manifold vacuum and will cut off the supply of fresh air during engine deceleration, thereby preventing afterburn in the exhaust system. No adjustment to the pulse secondary air injection system should be made, although periodic inspection of the components is recommended. AIR CLEANER PAIR CONTROL VALVE PAIR CHECK VALVE <21 FRESHAIR _ EXHAUSTGAS NOISE EMISSION CONTROL SYSTEM (U type only) TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: law may prohibit: (1) The removal or rendering inoperative by any person, other than for purposes at maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate pur- chaser or while it is in use; (2) the use of the vehicle after such device or element of design has been removed or rendered in- operative by any person 1-29 FRAME] BODY PANELS] EXHAUST SYSTEM BODY PANEL LOCATIONS WINDSHIELD SCREEN UPPER com COVER / 1'” UPPER COWL ’4 FUEL TANK 9‘31»??? 7 SEAT REAR FENDER B REAR CARRIER INNER SIDE coWL UNDER COWL SIDE COVER REAR FENDER MUFFLER NUMBER PLATE BRACKET 2-0 2. FRAME/ BODY PANELS/ EXHAUST SYSTEM BODY PANEL LOCATIONs 2-o NUMBER PLATE BRACKET 2-4 SERVICE INFORMATION 2-1 REAR FENDER B 24 TROUBLESHOOTING 2-1 SIDE COWL 2.5 SEAT 2-2 UPPER COWL 2-6 SIDE COVER 2-2 UNDER COWL 2.1 REAR CARRIER 2-3 MUFFLER/EXHAUST PIPE 24 REAR FENDER 2-3 FUEL TANK 2-1o SERVICE INFORMATION GENERAL AWARNlNG 0 Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN 0 Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced. 0 Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion. 0 This section covers removal and installation of the body panels, fuel tank and exhaust system. 0 Always replace the exhaust pipe gasket when removing the exhaust pipe from the engine. - When installing the exhaust system, loosely install all of the exhaust fasteners. Always tighten the exhaust clamps first, then tighten the mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe may not seat properly. 0 Always inspect the exhaust system for leaks after installation. TORQUE VALUES Exhaust pipe joint nut 12 Nm (1.2 kgf-m , 9 lbfrft) Muffler band bolt 26 N4“ (27 kgf-m , 20 Ibf‘ft) Fuel cock nut 34 N4“ (3.5 kgfrm , 25 Ibf-ft) Rear turn signal nut 5 N-m (0‘5 kgf-m , 3.6 Ibf-fl) Upper cowl stay mounting bolt (upper) 34 Nrm (3.5 kgt-m . 25 lbfrlt) (lower) 44 Nm (4.5 kgf-m , 33 lbf-fl) Upper cowl stay mounting nut (head pipe) 44 N-m (4.5 kgf-m , 33 Ibf-ftl TROUBLESHOOTING Excessive exhaust noise 0 Broken exhaust system 0 Exhaust gas leaks Poor performance 0 Deformed exhaust system 0 Exhaust gas leaks 0 Clogged muffler 2-1 FRAME/BODY PANELS/EXHAUST SYSTEM SEAT REMOVAL Unlock the seat with the ignition key. Pull the seat back and remove it. INSTALLATION Install the seat, inserting the groove to the prong on the fuel tank and the catches into the hooks of the frame. Push the seat fonNard, then down to lock it. SIDE COVER NOTE: At side cover removal/installation, be careful not to damage the tabs on the rear fender, Remove the seat (see above). Remove the socket bolts and side covert Install the side cover in the reverse order of removal. NOTE: Align the grooves on the side cover with the tabs on the rear fender. HOOKS SOCKET BOLT SOCKET BOLTS SIDE COVER FRAME/ BODY PANELS/ EXHAUST SYSTEM REAR CARRIER Remove the seat (page 2-2). REAR CARRIER Disconnect the rear turn signal connectors. BOLTS/COLLARS 7 Remove the bolts and collars. Remove the rear carrier and collarst Installation is in the reverse order at removalt CONNECTORS REAR FENDER Remove the see! (page 2-2). Remove the rear carrier (see above). SEAT LOCK CABLE REAR FENDER Disconnect the seat lock cable from the seat lock Remove the socket boltst Unhook the tabs on the rear tender from the grooves on the side covert Remove the rear lender. Installation is in the reverse order of removal. SOCKET GROOVES FRAM E/BODV PANELS] EXHAUST SYSTEM NUMBER PLATE BRACKET Remove the rear fender (page 2—3). Remove the muffler (page 2-8). Disconnect the lisence light connectors. Remove the bolts and lisence light case. Remove the rubber cushion. Remove the bolts and number plate bracket. Installation is in the reverse order of removal. REAR FENDER B Remove the number plate bracket (see above). Remove the side cover (page 2-2), Remove the battery (page 16-5). Remove the ICM (page 17-5). Remove the bolts and rearfender B. Installation is in the reverse order of removal. BOLTS CONNECTORS RUBBER CUSHION NUMBER PLATE BRACKET BOLTS LISENCE LIGHT CASE BOLTS REAR FENDER B ._., J 4% fl 7 FRAME/BODY PANELS/EXHAUST SYSTEM SIDE COWL INNER SIDE COWL Release the quick screws and remove the inner side cowl. QUICK SCREWS Installation is in the reverse order of removal. INNER SIDE COWL SIDE COWL Remove the inner side cowl (see above). SOCKET BOLTS Disconnect the front turn signal 3P connector. Remove the socket bolts and side cowl, Installation is in the reverse order of removal. 3P CONNECTOR SIDE COWL FRAME/BODY PANELS/EXHAUST SYSTEM UPPER COWL WINDSHIELD SCREEN CAUTION: Do not scratch and damage the windshield screen. Remove the screws, washers and windshield screen. Remove the setting nutsi Installation is in the reverse order of removal. UPPER COWL COVER Remove the screws and socket bolts. Release the quick screws and remove the upper cowl cover. Installation is in the reverse order of removal. %»% WINDSHIELD SCREEN SCREWS! WASHERS SETI’ING NUTS SOCKET BO LTS UPPER COWL COVER 2-6 FRAME/ BODY PANELS/EXHAUST SYSTEM UPPER COWL Remove the windshield screen (page 2-6). BULB SOCKETS Remove the upper cowl cover (page 2-6). Remove the socket bolts. Disconnect the position light 3P connector and headlight bulb sockets. Remove the upper cowl. U PPER COWL Installation is in the reverse order of removal SOCKET BOLTS 3P CONNECTOR UNDER COWL Remove the screws and under cowlt Installation is in the reverse order of removalt SCREWS UNDER COWL SCREWS FRAME/ BODY PAN ELS/ EXHAUST SYSTEM MUFFLER/EXHAUST PIPE REMOVAL Do not service the exhaust system while i 5 hot. Remove the rear fender (page 2-31 Remove the under cowl (page 2-7L Loosen the right muffler band bolt. BAND BOLY Loosen the left muffler band bolt and rear exhaust pipe band bolt. Remove the muffler mounting bolts, washers and nuts. Remove the muffler. Remove the front exhaust pipe joint nuts, gasket and front exhaust pipe. 2-8 FRAME/ BODY PAN ELS/ EXHAUST SYSTEM Remove the rear exhaust pipe joint nuts, gasket and rear exhaust pipe INSTALLATION REAR EXHAUST PIPE 4‘! GASKETS EXHAUST PIPE JOINT NUTS Eérfififlgfi 12 N-m (1.2 kgf‘m , 3 |th) 12 N-m (1.2 k f~m, , 9 "’f' ’ @ BAND BOLTS FRONT EXHAUST PIPE V GASKETS 26 Mr“ (27 kglm I 20 "31.11) Replace the gaskets with new ones. BAND BOl T5 Installation is in the reverse order of removal Tighten the bolts and nuts to their specified torque. TORQUE: Exhaust pipe ioim nut: 12 N-m (1.2 kgf-m , 9 INT!) Muffler hand bolt: 26 N-m (2.7 kgf‘m , 20 |bf~ft) FRAME/BODY PANELS/EXHAUST SYSTEM FUEL TANK m“— Gasalina is extremely flammable and Is explosive under certain condition. KEEP OUT OF REACH OF CHILDREN. NOTE: 0 Drain the fuel from the fuel tank for ease of the fuel tank removal. O Before disconnecting the fuel tube, turn the fuel valve OFF. Remove the seat (page 2-2). Disconnect the fuel tubes from the fuel valvest Remove the socket boltst Remove the front and rear fuel tank mounting bolts/collars. Diseon nect the fuel reserve sensor connectors. Disconnect the drain and breather tubes from the fuel tank‘ Remove the fuel tank, Installation is in the reverse order of removal NOTE: After installation, check for the fuel valves ON position. BOLTS/COLLARS FUEL TANK SOCKET BOLTS BREATHER TUBE FUEL TUBE 2-10 3. MAINTENANCE SERVICE INFORMATION 3-1 SECONDARY AIR SUPPLY SYSTEM 3-16 MAINTENANCE SCHEDULE 3-3 DRIVE CHAIN 3-16 FUEL LINE 3—4 DRIVE CHAIN SLIDER 3-20 THROTTLE OPERATION 3-4 BRAKE FLUID 3-20 CARBURETOR CHOKE 3-5 BRAKE PAD WEAR 3-21 AIR CLEANER 3-5 BRAKE SYSTEM 3-21 SPARK PLUG 3-6 BRAKE LIGHT SWITCH 3-22 VALVE CLEARANCE 3-8 HEADLIGHT AIM 3-23 ENGINE OIL 3-10 CLUTCH SYSTEM 3-23 ENGINE OIL FILTER 3-11 SIDE STAND 3-24 CARBURETOR SYNCHRONIZATION 3-12 SUSPENSION 3-25 ENGINE IDLE SPEED 3-14 NUTS, BOLTS, FASTENERS 3-25 RADIATOR COOLANT 3-14 WHEELS/T IRES 3-26 COOLING SYSTEM 3-15 STEERING HEAD BEARING 3-26 SERVICE INFORMATION GENERAL I Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where the gasoline is stored can cause a fire or explosion. 0 When the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area. - Place the motorcycle on a level ground before starting any work. SPECIFICATIONS ITEM SPECIFICATIONS Throttle gripfree play 2‘6 mml1/16—1/4 in) Spark plug DPRSEVX—S (NGK) Spark plug gap 0.30-0.90 mm (0.03170.035inl Valve clearance Intake 0.16 mm (0.006 in) Exhaust 0.31 mm (0.012 in) Recommended engine oil Honda 4-stroke oil or equivalent motor oil API service classification: SE, SF or 56 Viscosity: SAE 10W-40 Engine oil capacity At draining 3.4 B (3.6 US qt . 3.0 Imp qt) At filter change 3.6 B (3.8 US qt . 3.2 Imp qt) At disassemny 4.1 B (4.3 US qt . 3.6 Imp qt) Carburetor vacuum difference 20 mm Hg (08 in H9) MAINTENANCE ITEM SPECIFICATIONS Engine idle speed 1,200 i 50 min" (rpm) Drive chain slack 35-45 mm (1 3/8—1 3/4 in) Recommended brake fluid DOT 4 Cold tire pressure Driver only From 250 kPa (2.50 kgf/cm’ , 36 psi) Rear 250 kPa (2.50 kgi/cm2 , 36 psi) Driver and passenger Front 250 kPa (2.50 kgf/cm2 , 36 psi) Rear 280 kPa (2.80 kgf/cmZ , 41 psi) Tire size Front 110/80 R19 59H Rear 150/70 R1769H Tire brand ME'IZELER Front ENDUR04A Rear ENDUR04A MICHELIN From TGGX Rear T66X Minimumtread depth Front 1.5 mm (0.06 in) Rear 2.0 mm (0.08 in) TORQUE VALUES Spark plug Crankshaft hole cap Timing hole cap Oil filter cartridge Engine oil drain bolt lmake manifold vacuum port socket bolt Rear axle nut Front brake master cylinder cap screw TOOL Oil filler wrench Drive chain tool set 14 N-m (1.4 kgf-m , 101M") 15 N-m (1.5 kgf~m, 11 Ibf-fl) 10 N-m (1.0 kgf-m , 7 [bf-ft) 10 Nrm (1.0 kgf-m , 7 Ibf-f!) 30 NM (3.1 kngm , 22 lbf-h) 3 N-m (0,34 kgfm , 2.5 lbf-ft) 93 Nm (9.5 kgf-m , 691bf-l‘l) 1 N-m10.15 kgf-m ,1.1 lbf-Il) 07HAA-PJ70100 07HMH-MR10103 Apply grease to the threads. Apply grease to the threads. Apply oil to the threads and O-ring. U-nut 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 Maintenance Schedule specifies all maintenance required to keep your motorcycle in peak operating condition Maintenance work should be performed in accordance with standards and specifications of Honda by properly trained and equipped technicians. Your authorized Honda dealer mam all of these requirements. FREQUENCY WHICHEVER COMES w ODOMETER READING (NOTE 1) REFER FIRST X 1,000 km 1 6 12 18 24 30 36 TO 3 X 1,000 mi 0.6 4 8 12 16 20 24 PAGE ITEM NOTE MONTHS 6 12 18 24 30 36 * FUEL LINE I | | 34 ‘ THROTTLE OPERATION l I | 34 * CARBURETOR CHOKE I I | 3-5 * AIR CLEANER NOTE 2 R R 3-5 SPARK PLUG | R I 3-6 * VALVE CLEARANCE | 3-8 ENGINE OIL Fl R R R 340 ENGINE OIL FILTER R R R R 3-11 * CARBURETOR SYNCHRONIZATION | I l | 342 * ENGINEIDLE SPEED | I I I I l | 3-14 RADIATOR COOLANT NOTE 3 l I R 3-14 * COOLING SYSTEM I I | 3-15 * SECONDARY AIR SUPPLY SYSTEM | | | 3-16 DRIVE CHAIN Every 1 000 km (600 mi) I, L 3-16 DRIVE CHAIN SLIDER | I I 3-20 BRAKE FLUID NOTE 3 | | R | I R 3-20 BRAKE PAD WEAR | | | | I I 3-21 BRAKE SYSTEM | I | | 3-21 * BRAKE LIGHT SWITCH l I | 3-22 * HEADLIGHT AIM l I | 343 CLUTCH SYSTEM I l l l l | | $23 SIDE STAND l I I 3-24 ‘ SUSPENSION I l l 3-25 * NUTS. BOLTS. FASTENERS | I I l 3-25 it w WHEELS/TIRES | | l 3-26 it * STEERING HEAD BEARINGS | | | I 3-26 ‘6 Should be serviced by your authorized Honda dealer, unless the owner has proper tools and service data and is mechanically qualified. a: at In the interest of safety, we recommend these items be serviced only by your authorized Honda dealert Honda recommends that your authorized Honda dealer should road test your motorcycle after each periodic NOTES: 1. maintenance is carried out. 2. 3 mechanical skill. At higher odometer reading, repeat at the frequency interval established here. Service more frequently If the motorcycle is ridden in unusually wet or dusty areas. . Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires MAINTENANCE FUEL LINE Check the fuel lines for deterioration, damage or leakage. Replace the fuel lines il necessary. THROTTLE OPERATION Check for any deterioration or damage to the throttle cables. Check that the throttle grip for smooth operation. Check that the throttle opens and automatically closes in all steering positions. If the throttle grip does not return properle 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 availa- ble cable lubricant or a light weight oil. If the throttle grip still does not return properly, replace the throttle cables. WEE—.— Reusing a damaged or abnormally bent or kinked throttle cable can prevent proper throttle slide operation and may lead to a loss of throttle control while riding. With the engine idling, turn the handlebar all the way to the right and Ielt to ensure that the idle speed does not change. If idle speed increases, check the throttle grip free play and throttle cable connection. Measure the throttle grip free play at the throttle grip flange. THROTTLE GRIP FREE PLAV: 2—6 mm (1/16—1/4 in) Throttle grip free play can be adjusted at either end at the throttle cable. Minor adjustments are made with the upper adjustert Loosen the lock nut, turn the adjuster as required and tighten the lock nut. LOCK NUT ADJUSTER MAINTENANCE Major adjustments are made with the lower adjust- er. Remove the fuel tank (page 2-10). Loosen the lock nut, turn the adjusting nut as re- quired and tighten the lock nutt Recheck the throttle operation and install the fuel tank (page 2-10). CARBURETOR CHOKE This model's choke system uses a fuel enriching circuit controlled by a starting enrichment (SE) valve. The SE valve opens the enriching circuit via a cable when the bystarter valve lever is ON position. Check for smooth bysta rter valve lever operation. If operation is not smooth, check the cable condition. AIR CLEANER scnews N0TE= AIR CLEANER — HOUSING COVER 'The viscous paper element type air cleaner cannot be cleaned because the element contains a dust adhesive. 0 If the motorcycle is used in wet or dusty areas, more frequent inspections are required. Remove the fuel tank (page 2-10). Remove the eight air cleaner housing cover screws. Remove the air cleaner housing cover together with the element Replace the element in accordance with the mainte» nance schedule or any time it is excessive dirty or damaged. Install the air cleaner element and cover, and tighten the screws. Install the fuel tank (page 2-10). AIR CLEANER ELEMENT MAINTENANCE SPARK PLUG SW Rear cylinder: N 01- E: Make sure the fuel tank cap is closed, before fuel tank lift up‘ Turn the right and left fuel valves to “OFF” position, _.‘ Remove the seat (page 2-2). Remove the rear fuel tank mounting bolts, Remove the side cowl socket bolts. Turn the steering handle to right then hold the steering handle to the straight ahead position. Remove the maintenance bar from the seat. Raise the rear of the fuel tank and support it with the maintenance bar. Elth cylinders: Disconnect the spark plug caps and clean around the spark plug bases. NOTE: Clean around the spark plug bases with com- pressed air before removing the plugs, and be sure that no debris is allowed to enter the combustion chamber. Remove the spark plugs. Check the insulator for cracks or damage, and the electrodes for wear, fouling or discoloration. Replace the plug it necessary, If the electrode is contaminated with carbon deposim, clean the electrode using the spark plug cleanert CAUTION: 0 This motorcycles spark plug is equipped with platinum type electrodes. Do not use wire brush to clean the electrodes 0 The plug cleaner should be used with the air pressure of less than 6 lat/cm? {85 psi) and for less than 20 seconds. Replace the plug if the center electrode is rounded as shown. NOTE: Always use specified spark plugs on this motorcy- clel MAINTENANCE CENTER ELECTRODE INSULATOR SIDE ELECTRODE ROUNDED ELECTRODE SPECIFIED SPARK PLUG: DPRSEVX * 9 (N GK) Measure the spark plug gap between the center and side electrodes with a wire type feeler gauge. CAUTION: To prevent damaging the platinum coating of the center electrode, use a wire type Ieeler gauge to check the spark plug gap. Make sure that the 1‘0 mm (004 in) wire type feeler gauge cannot be inserted into the gap If the gauge can be inserted into the gap, replace the plug with a new one. CAUTION: Do not adjust the spark plug gap. If the gap is out ofspecifinatlon, replace with a new one. With the plug washer attached, screw the spark plug in by hand to prevent cross-threading. Tighten the spark plug, TORQUE: 14 N~m (1.4 kgf-m , 10 Ibl-ft) Install the removed parts in the reverse order of removal. WIRE TVPE FEELER GAUGE O >< 724'. 3-7 MAINTENANCE VALVE CLEARANCE INSPECTION NOTE: Inspect and adjust the valve clearance while the engine is cold. Remove the front and rear cylinder head covers (page 84). Remove the timing hole cap and crankshaft hole cap. Rotate the crankshaft counterclockwise and align the “FT” mark on the left crankcase covert The timing marks ("F‘l” for intake and "FE" for “H.- MAHK exhaust) on the from cylinder cam sprockets must be flush with the cylinder head surface and facing outward as shown If the timing marks are facing inward, rotate the crankshaft counterclockwise 360°(1 full turn) and align the "FT" mark with the index mark‘ Measure the front cylinder valve clearance by inserting a feeler gauge between the valve litter and camlobe‘ VALVE CLEARANCES: IN: 0,16rnml0.006in) EX: 0,31 mml0.012 in) 3-8 Rotate the crankshaft counterclockwise 270° and align the "RT" mark with index markt Check the rear cylinder valve clearances. ADJUSTMENT Remove the valve litters and shims (page 8»7). Clean the valve shim contact area in the valve lifter with compressed air, Measure the shim thickness and record it. NOTE: Fifty-one different thickness shims are available from the thinnest (1.200 mm thickness) shim to the thickest (2.450 mm thickness) in intervals of 0.025 mm, Calculate the new shim thickness using the equation below. A=(B-C)+D A: New shim thickness B: Recorded valve clearance C: Specified valve clearance D: Old shim thickness NOTE: 0 Make sure of the correct shim thickness by measuring the shim with the micrometer. 0 Reface the valve seat if carbon deposits result in a calculated dimension of over 2.450 mm. MAINTENANCE VALVE LIFTER 1.80 mm 1.825 mm 1.85 mm 1.875 mm MAINTENANCE ENGINE OIL install the newly selected shims on the valve retainers. Install the valve lifters and camshafts (page 8-21). Rotate the eamshafts by rotating the crankshaft counterclockwise several times. Recheck the valve clearances. Install the cylinder head cover (page 8-26), Coat a new 0-rin9 with grease and install it onto the crankshaft hole cap. Apply grease to the crankshaft hole cap threads. Install and tighten the crankshaft hole capt TORQUE: 15 Nm (1.5 kgf‘m ,11Ihf-ft) Coat a new O-ring with grease and install it onto the timing hole cap. Apply grease to the timing hole cap threads, Install and tighten the timing hole cape TORQUE: 10 N-m (1.0 kgf-m , 7 |bf~fti I l INSPEGTION WINDOW Stan the engine and let it idle for a few minutes, Stop the engine, support the motorcycle upright on a level surface Wait for a few minutes and check that the oil level is between the upper and lower level marks in the inspection window‘ 3-10 If the oil level is below or near the lower level mark, remove the oil filler cap and add the recommended engine oil up to the upper level mark. RECOMMENDED ENGINE OIL: Honda 4-stroke oil or equivalent motor oil API service classification: SE, SF or $6 Viscosity: SAE 10W740 NOTE: Other viseosities shown in the chart may be used when the average temperature in your riding area is within the indicated range. Reinstall the filler cap. For engine oil change, see below ENGINE OIL FILTER NOTE: Change the oil with engine warm and motorcycle on its side stand to assure complete and rapid draining. @— Engine and exhaust system parts became very hot and ran-min hot for some time after the englne is run. Wear insulated gloves or wait until the engine and exhaust system have cooled before handling these parts. Warm up the engine. Stop the engine and remove the under cowl (page 2-7) Remove the oil filler cap and drain bolt, and drain the oil. MAINTENANCE OIL VISCOSITIES 3-11 MAINTENANCE Remove the oil filter cartridge and let the remaining oil drain out. Discard the filter cartridge. TOOL: Oil filter wrench 07HAA»PJ70100 CAUTION: Used engine oil may cause skin cancer if repeated- Iy loft in contact with the skin for prolonged periods. Although this is unlikely unless you han- dle used oil an a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. Apply oil to the O-ring and threads of a new oil filter cartridge and install the filter cartridge. TORQUE: 10 N-m (1.0 kgl-m . 7 lbl-ft) Alter draining the oil completer check that the sealing washer on the drain bolt is in good condition and replace the it if necessary. Install and tighten the drain bolt, TORQUE: 30 N-m (3.1 kgl-m . 22 Ibf‘ttl Fill the crankcase with the recommended oil, OIL CAPAClTY: 3.6 ll (3.8 US qt , 3.2 Imp qt) at filter change 4.1 a (4.3 US qt , 3.6 Imp qt) at disassemny Reinstall the oil filler cap. Check the engine oil level (page 3—10). Make sure there are no oil leaks. Install the under cowl (page 2-7). CARBURETOR SYNCHRONIZATION NOTE: Perform this maintenance with the engine at normal operating temperature and transmission in neutral. Please the motorcycle on a level surface Start the engine, pinch the vacuum tube using a tube clamp, and stop the engine. Disconnect the maintenance vacuum tube from the air cleaner housing. 3-12 Disconnect the PAIR control valve vacuum tube from the PAIR control valve. Install the vacuum gauge attachment into the vacuum port. Connect the vacuum gauge to the maintenance vacuum tube and PAIR control valve vacuum tube, Start the engine and adjust the idle speed with the throttle stop control knob. IDLE SPPED: 1,200 i 50 min" (rpm) Check the difference between the front and rear carburetors. CARBURETOR VACUUM DIFFERENCE: 20 mm Hg (0.8 in Hg) NOTE. The base carburetor is front carburetor, Synchronize to specification by turning the synchro» nization adjusting screw. Rev the engine up several times Recheck the idle speed and synchronization. Remove the vacuum gauge. Connect the vacuum tubes to the air cleaner hous- ing and PAIR control valve. MAINTENANCE PAIR CONTROL VALVE VACUUM TUBE 3-13 MAINTENANCE ENGINE IDLE SPEED m“ If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area. NOTE: Olnspect and adiust the idle speed after all other engine maintenance items have been performed and are within specifications. 0 The engine must be warm for accurate idle speed inspection and adjustment. Warm up the engine, shift the transmission into neutral and place the motorcycle on its side stand on a level surface. Check the idle speed and adjust by turning the throttle stop control knob as required IDLE SPEED: 1,200 i 50 min" 1mm) RADIATOR COOLANT NEE—— I Avoid spilling engine coolant on the exhaust system or engine parts. They may be hot enough to cause the coolant to ignite and burn without a visible flame. 0 Coolant [ethylene glycol) can cause some skin irritation and is poisonous I! swallowed. KEEP OUT OF REACH OF CHILDREN 0 Do not remove the radiator cap when the engine ls hot. The coolant is under pressure and could scald you. 0 Keep hands and clothing away from the ooollng fan! as it start: automatically. Check the coolant level of the reserve tank with the engine running at normal operating temperature. The level should be been the “UPPER” and "LOWER" level lines with the motorcycle upright on a level surface, THROTTLE STOP CONTROL KNOB 3-14 MAINTENANCE ll the level is low, remove the reserve tank cap and till the tank to the "UPPER" level line with a 50/50 mixture of distilled water and antifreeze (coolant mixture preparation: page 64). RESERVE TALJK CAP / CAUTION: Using coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passages. Using tap water may cause engine damage. Check to see if there are any coolant leaks when the coolant level decrease very rapidly. If reserve tank becomes completely empw. there is a possibility of air getting into the cooling system. Be sure to remove all air from the cooling system (page 6-5it COOLING SYSTEM M“— To prevent injury, keep your hands and clothing away from the cooling Ian. It may start automati- cally, without warning. Remove the side cowl (page 2-5). 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. Remove the radiator grille. Check the radiator air passage for clogging 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 airflow is restricted over more than 20 % of the radiating surface. Install the radiator grille and side cowl (page 2-5). MAINTENANCE SECONDARY AIR SUPPLY SYSTEM Check the air supply hoses between the pulse secondary air injection (PAIR) control valve and PAIR check valves for damage or loose connections. Check the air supply hoses for cracks or deteriora» tion. NOTE: If the hoses show any signs of heat damage, inspect the PAIR check valves (page 5-22L Check the vacuum tubes between the rear cylinder head vacuum joint and PAIR control valve for deterioration, damage or loose connections. Also check that tubes are not kinked or pinched. For PAIR control valve inspection, see page 5-23. DRIVE CHAIN CHAIN SLACK INSPECTION W— Never Inspect and adjust the drive chain while the engine is running. Turn the ignition switch OFF, place the motorcycle on its side stand and shift the transmission into neutral. Check the slack in the drive chain lower run mid- way between the sprockets CHAIN SLACK235—45 mmll 313—1 3/4 in) ADJUSTMENT Loosen the axle nutl Turn both adjusting bolts an equal number at turn until the correct drive chain slack is obtained, Make sure the index marks on both adjusters are aligned with the index line of the swingarm. Tighten the rear axle nutt TORQUE: 93 N-m (9,5 kgf-m , 69 lbtrft) PAIR CONTROL VALVE AIR SUPPLV HOSES PAIR CHECK VALVE 3-16 Recheck the drive chain slack and free wheel rotation. Check the drive chain wear indicator label attached on the left drive chain adjuster. If the red zone of the indicator label reaches the index line on the swingarm, raplace the drive chain with a new one (page 348). CLEANING AND INSPECTION Clean the chain with a soft brush using a non- flammable or high flash point solvent and wipe it dry. Be sure the chain has dried completely before lubricating. Inspect the drive chain for possible damage or wear. Replace any chain that has damaged rollers, loose fitting links, or otherwise appears unserviceable. Installing a new chain on badly worn sprockets will cause the new chain to wear quickly. Inspect and replace the sprockem as necessary. LUBRICATION Lubricate the drive chain with 1380*90 gear oil or equivalent chain lubricant designed tor specifically for use on O-ring chains. Some commercially available chain lubricants may contain solvents which could damage the O-rings. Wipe off the excess chain lube. SPROCKET INSPECTION Inspect the drive and driven sprocket teeth for damage or wear. Replace if necessary. Never use a worn chain on new sprockets, Both chain and sprockets must be in good condition, or the new replacement parts will wear rapidly. Check the attachment bolt and nuts on the drive and driven sprockets. If any are loose. torque them. MAINTENANCE V ‘E‘vl HEDZONE / J CLEAN SOLVENT LUBRICATE GEAR OIL #80*90 DAMAGED NORMAL 3-17 MAINTENANCE REPLACEMENT This motorcycle uses a drive chain with a staked master link. Loosen the drive chain. Assemble the special tool. TOOL: Drive chain tool set 07HMH-MR10103 NOTE: When using the special tool, follow the manufac- turer’s instruction. Locate the crimped pin ends of the master link from the outside of the chain and remove the link with the drive chain tool set. Remove the drive chain. Remove the excessive drive chain links from the new drive chain with the drive chain tool set. NOTE: Include the master link when you count the drive chain links. SPECIFIED LINKS: 112 links REPLACEMENT CHAIN:DID§25 HV R K525 R021 Remove the drive sprocket cover (page 7-3). Install the new drive chain on the sprockets over the drive and driven sprockets. DRIVE CHAIN CUTI'ER ‘ DRIVE CHAIN CUTTER ‘— IIIIIIIIIII MASTER LINK 1 LINK imam LINK I I I<-————->‘ I SPECIFIED LINKS 3-18 Assemble the new master link, O-rings and master link plate with the drive chain tool set. NOTE: Insert the master link from the inside of the drive chain, and install the plate with the identification mark facing the outside. Measure the master link pin length projected from the plate. SPECIFIED LENGTH: DID:1.30—1.50 mm (0.051 -0.059 in) RK: 1203— 1.40 mm I0.047~0.055 in) Stake the master link pins with the drive chain tool set. Make sure that the master link pins are staked properly by measuring the diameter of the staked area, DIAMETER OF THE STAKED AREA: DID:5.50‘5.30 mm (0.217‘0228 in) RK: 5.45 - 5.85 mm (0115—0230 in) After staking, check the staked area of the master link for cracks. If there is any cracking, replace the master link, O-rings and plate. CAUTION: A drive chain with a clip-type master link must not ba used. Install the drive sprocket cover (page 7—12), MAINTENANCE MASTER LINK DRIVE CHAIN CUTTER MASTER LINK Z r in“ l _ 3 llillll ._ ’ DRIVE CHAIN CU'I'I'ER VERNIER CALIPERS CRACKS MAINTENANCE DRIVE CHAIN SLIDER Check the drive chain slider for wear, Replace the chain slider if it is worn to wear limit line. Refer to section 14 for drive chain slider replace- ment. BRAKE FLUID CAUTION: 0 Do not mix different types of fluid, as they are not compatible with other. 0 Do not allow foreign material to enter the system when filling the reservoir. - Avoid spilling fluid on painted, plastic or rubber parts. Place a rug aver these parts whenever the system is serviced. NOTE: When the full level is low. check the brake pads for wear (page 3-21lt A low fluid level may be due to wear of the brake pads. If the brake pads are worn, the caliper pistons are pushed out. and this accounts for a low reservoir level. It the brake pads are not worn and the fluid level is low, check entire system for leaks (page 3-21). FRONT BRAKE Turn the handlebar to the left side so that the reservoir is level and check the fluid level in the front brake reservoir. If the level is near the "LOWER" level line, 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 reservoir cap and tighten the cap screws to the specified torque. TORQUE: 1 N-m (0.15 kgrm , 1.1 lbf-lt) REAR BRAKE Place the motorcycle on a level suriace. and sup« port it upright. Check the fluid level in the rear brake reservoir. 3-20 MAINTENANCE It the level is near the “LOWER” level line, remove the reservoir cap. set plate and diaphragm, and till the reservoir with DOT 4 brake fluid from a sealed container to the upper level line. E EFlVlfl CAP SEY PLATE Install the diaphragm, set plate and reservoir cap, BRAKE PAD WEAR FRONT BRAKE PAD Check the brake pad for wear. Replace the brake pads if the wear limit groove of either pad is worn out. REAR BRAKE PAD Check the brake pad for wear by leaking from the rear side of the caliper. Replace the brake pads if either pad is worn to the bottom of the wear limit groove. Refer to page 15-10, 11 for brake pad replacement BRAKE SYSTEM Firmly apply the brake lever or pedal, and check that no air has entered the system It the lever or pedal feels soft or spongy when operated, bleed the air from the system. Refer to page 15-6 for air bleeding procedures. inspect the brake hoses, pipes and fittings lor deterioration, cracks, damage or signs ol leakage. Tlghlen any loose fittings. Replace hoses, pipes and fittings as required. .\‘/ > BRAKE POSEa ' 3-21 MAINTENANCE This model is equipped with a Dual Combined Brake System. Check the system as follows: Push the left front brake caliper upward by hand. Measure the stroke of the secondary master cylinder. The stroke should be less than 4 mm (0‘2 in). If stroke is 4 mm (0,2 in) or more, check for fol- Iowings: ~Air in hydraulic system —Ieaking hydraulic system BRAKE LEVER ADJUSTMENT The distance between the tip of the brake lever and the grip can be adjusted by turning the adjustert CAUTION: Align the arrow on the brake lever with the index mark on the adiuster. BRAKE PEDAL HEIGHT ADJUSTMENT Loosen the lock nut and turn the push rod until the correct pedal height is obtained. BRAKE LIGHT SWITCH NOTE: The brake light switch on the front brake master cylinder cannot be adjusted. If the front brake light switch actuation and brake engagement are off, either replace the switch unit or the malfunctioning parts of the system 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 proper time, Hold the switch body and turn the adjusting nut. Do not turn the switch body, 3-22 MAINTENANCE HEADLIGHT AIM M— An improperly adjusted headlight may blind » A oncoming drivm, or it may fail to light the road for a sale distance. NOTE: Adjust the headlight beam as specified by local laws and regulations. Adjust vertically by turning the vertical adjusting . sc rew‘ Adjust horizontally by turning the horizontal adjust— ing screw. HORIZONTAL ADJUSTING SCREW CLUTCH SYSTEM CLUTCH LEVER Measure the clutch free play at the end of the clutch leverr FREE PLAY: 10—20 mm (3/8—13/16 in) Adjust the next page: 10 20 mm {3:3 13/16 In) 3-23 MAINTENANCE Minor adjustment are made at the adjuster near the levert Loosen the look nut and turn the adjustert Tighten the lock nut securely. CAUTION: The adlustu may be damaged if it is positioned too far out, having minimal threads engagement. If the adjuster is threaded out near its limit and the correct free play cannot be obtained, turn the adjuster all the way in and back out one turn Tighten the look nut and make a major adjustment as described below Major adjustment is performed at the clutch armt Loosen the lock nut and turn the adjusting nut to adjust free play. Hold the adjusting nut securely while tightening the lock nut It proper free play cannot be obtained, or the clutch slips during the test ride, disassemble and inspect the clutch (see section 9). SIDE STAND Support the motorcycle on a level surface Check the side stand spring for damage or loss of tension, Check the side stand assembly (or freedom of movement and lubricate the side stand pivot if necessary. Check the side stand ignition cut-off system: *Sit astride the motorcycle and raise the side stand, *Startthe engine with the transmission in neutral, then shift the transmission into gear, while squeezing the clutch lever. *Fully lower the side stand. -The engine should stop as the side stand is lowered. it there is the problem with the system, check the side stand switch (page 19-20) SIDE STAND 3-24 MAINTENANCE SUSPENSION M— Loose, worn or damaged suspenslon parts impair motorcycle stability and control. Rapalr or replax any damaged components before ridingt Hiding a motorcycle with faulty suspension increase: your risk of an accident and possible iniury. FRONT SUSPENSION Check the action of the forks by operating the front brakes and compressing the front suspension several ti mes. Check the entire assembly for signs of leaks, damage or loose fasteners. Replace damaged components which cannot be repaired, Tighten all nuts and bolts. Refer to section 13 for fork service. REAR SUSPENSION Check the action of the shock absorber by com- pressing it several ti mes. Check the entire shock absorber assembly for signs of leaks, damage or loose fasteners Replace damaged components which cannot be repaired Tighten all nuts and bolts. Refer to section 14 for shock absorber service. Raise the rear wheel offthe ground and support the motorcycle securely. Check for worn swingarm bearings by grabbing the rear wheel and attempting to move the wheel side to side. Replace the bearings if any Iooseness is noted (section 14) NUTS, BOLTS, FASTENERS Check that all chassis nuts and bolts are tightened to their correct torque values (page 1-12). Check that the all cotter pins, safety clips, hose clips and cable stays are in place and properly secured. 3-25 MAINTENANCE WHEELS/TIRES NOTE: Tire pressure should be checked when the tires are COLD. Check the tire pressure with the tire pressure gauge. RECOMMENDED TIRE PRESSURE: Driver only: Font: 250 kPa (2‘50 kgf/cm2 , 36 psi) Roar: 250 kPa (2.50 kgt/em2 , 36 psi) Driver and passenger: Font: 250 kPa (2.50 kgf/cm2 , 36 psi) Rear: 280 kPa (2.80 kgf/cm‘ , 41 psi) Check the tires for cuts, embedded nails, or other damage Check the front and rear wheels for trueness (refer to section 13 and 14), Measure the tread depth at the center of the tires. Replace the tires when the tread depth reaches the following limits. MINIMUM TIRE DEPTH: Front: 1.5 mm (0.06 in) Rear: 20 mm (0.08 in) STEERING HEAD BEARING NOTE: Check that the control cables do not interfere with handlebar rotation. Raise the front wheel of! the ground and support the motorcycle securely. Check that the handlebar moves freely from side to side. If the handlebar moves unevenly, binds. or has vertical movement, inspect the steering head bearings (section 13). 3-26 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM CAM SHAFI’ OIL FILTER OIL PRESSURE RELIEF VALVE CONNECTING ROD CRANKSHAFT OIL PRESSURE SWITCH MAINSHAFT CLUTCH COUNTERSHAFT OIL PUMP OIL STRAINER 4. LUBRICATION SYSTEM OIL STRAINER/PRESSURE RELIEF VALVE 4-o LUBRICATION SYSTEM DIAGRAM SERVICE INFORMATION TROUBLESHOOTING 4.5 4—7 OIL PUMP 4-3 4-4 OIL PRESSURE INSPECTION 12 N‘m (1.2 kgf«m , 9 [bf-ft) 4-1 LU BRICATION SYSTEM SERVICE INFORMATION GENERAL AWARNlNG 0 II the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area. The exhaust contalns poisonous carbon monoxide gas that may cause loss 0! consciousness and lead to death. Hun the engine in an open area or wlth an exhaust evacuation system in an enclosed area. 0 Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. - The oil pump can be serviced with the engine installed in the frame. 0 The service procedures in this section must be performed with the engine oil drained. 0 When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine. 0 If any portion of the oil pump is worn beyond the specified service limits. replace the oil pump as an assembly. 0 After the oil pump has been installed, check that there are no oil leaks and that oil pressure is correct. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Engine oil capacity At draining 3.4 B (3.6 US qt , 3.0 Imp qt) At disassembly 4.1 0 (4.3 US qt , 3.6 Imp qt) 7 At oil filter change 3.6 I) (3.8 US qt , 3.2 Imp qt) 7 Recommended engine oil HONDA 4-stroke oil or equivalent motor 7 oil API service classification SE. SF or SG Viscosity: SAE 10W740 Oil pressure at oil pressure switch 588 kPa (6.0 kgflcmz , 85 psilat 7 5.000 rpm/(80 °CI176 °F) Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0008) Body clearance 0.157011 (000670.008) 0.35 (0.014) Side clearance 0.02_0.09(0.00170.004) 0.12 (0.005) TORQUE VALUES Oil pressure switch Oil pressure switch wire terminal screw 12 N-m (1.2 kgf‘m , 9 lbf-ft) Apply sealant to the threads 2 NM (0.2 kgf-m ,1.4Ibf~ft) Oil pump bolt 13 N~m (1.3 kgf-m,9lbf>ft1 Oil pump mounting bolt 12 N~m (1.2 kgf-m , 9 lbfrft) Oil drain bolt 30 N~m (3.1 kgf-m , 22 lbf-ft) Oil filter boss 18 Nm (1.8 kgf~m, 13 lbf-ft) Apply a locking agent to the threads Oil pump driven sprocket bolt Oil filter cartridge TOOLS 15 N-m (1.5 kgf-m. 11 IbI-ft) Apply slacking agent to the threads 10 N-m (1.0 kgf-m , 7 INT!) Apply clean engine oil to the O-ring Oil pressure gauge 07506-3000000 Oil pressure gauge attachment 07406-0030000 Oil filter wrench 07HAA-PJ70100 42 TROUBLESHOOTING Engine oil level too low 0 oil consumption 0 External oil leak o Worn piston ring or incorrect piston ring installation 0 Worn cylinder - Worn valve guide or seal Low or no oil pressure a Clogged oil orifice o Incorrea oil being used No oil pressure o Oil level too low 9 Oil pump drive sprocket broken 0 Oil pump damaged (pump shaft) 0 Internal oil leak LUBRICA'HON SYSTEM Low oil pressure 0 Clogged oil strainer screen 0 Oil pump worn or damaged a Internal oil leak o Incorrect oil being used 0 Low oil level High oil pressure n Plugged oil filter, gallery, or metering orifice o Incorrect oil being used LUBRICATION SYSTEM OIL PRESSURE INSPECTION NOTE: If the oil pressure indicator light remains on a few seconds. check the indicator system before check- ing the oil pressure. Check the oil level (page 3-10). Warm up the engine to normal operating tempera- ture (approximately 80 °C/176 °F). Stop the engine Remove the rubber cap and disconnect the oil pressure switch wire connector from the switch. Remove the bolt and washer. Remove the oil pressure switch. Connect an oil pressure gauge and attachment to the switch hole. TOOLS: Oil pressure gauge 07506-3000000 Oil pressure gauge attachment 07406-0030000 Start the engine and increase the rpm to 5,000 rpm and read the oil pressure. OIL PRESSURE: 538 kPa (6.0 kgf/cm2 , 85 psi) at 5,000 rpm (80 °Cl176 °FI Stop the engine and remove the tools. Apply sealant to the threads of the oil pressure switch. Install and tighten it to the specified torque. TORQUE: 12 N-m (1.2 kgf-m , 9 lbf-It) CAUTION: Tn prevent crankcase damage, do not over-tighten the switch. Install the bolt and washer. LU BRICATION SYSTEM Connect the oil pressure switch connector, tighten the terminal screw to the specified torque. TORQUE: 2 N-m (0.2 kgf~m , 1,4 Ibftft) Install the rubber cap. Start the engine and check the oil pressure indica- tor light gones out after a few seconds. If the oil pressure indicator light remains on a few seconds, stop the engine and check the indicator system (page 19—15). OIL STRAINER/ PRESSURE RELIEF VALVE OIL PAN REMOVAL Remove the under cowl (page 2-7). Remove the exhaust pipe (page 2-8). Drain the engine oil (page 3-11). Remove the oil pan flange bolts and under cowl stays. Remove the oil pan. Remove the dowel pins and O-rings. OIL STRAINER Remove the oil strainer and seal rubber from the oil pump. Clean the oil strainer screen. Coat the new seal rubber with a oil and install it onto the strainer. Install the strainer, aligning its groove with the pin on the oil pump. LU BRICATION SYSTEM OIL PRESSURE RELIEF VALVE RELIEF VALVE Remove the oil pressure relief valve from the oil pan. Remove the O-ring from the relief valve body. Remove the snap ring, spring seat, spring and piston from the valve body. VALVE BODY Check the piston for wear, sticking or other damage 0 Check the spring for fatigue or damage. SPRING 9 s \ ‘f'. SEAT \ ’ Check the operation of the pressure relief valve by 2 L3 pushing on the piston. PISTON SNAP nme/ Install the piston, spring and spring seat and secure them with the snap ring. Coat a new O-ring with oil and install it into the relief valve body groove. Install the relief valve into the oil pan. REIEF yALvE OIL PAN INSTALLATION . | Clean the oil pan mating surface thoroughly. J m Apply sealant to the oil pan mating surface. ...\":\ CAUTION: st“... Do not apply sealant more than necessary. -.\“.«..«\ 4-6 LUBRICATION SYSTEM Install the dowel pins to the oil pan, Coat new O-rings with oil and install them onto the dowel pins, Install the oil pan. install the under cowl stayst Install and tighten the flange bolts in a crisscross pattern in 2 — 3 steps Install the exhaust pipe (page 2-9). Install the under cowl (page In Fill the crankcase with recommended oil (page 3-11) NOTE: After installation, check that there are no oil leaks. OIL PUMP REMOVAL Remove the following: -Clutch and oil pump driven sprocket (page 9«3) —0il pan and strainer (page 4-5) Remove the three mounting bolts and oil pump assembly. Remove the dowel pins. DISASS EM BLY Remove the oil pump bolts. LUBRICATION SYSTEM Remove ‘he DII pump body and dowel pm: a“. PUMP BODY DOWEL PINS Remove the thrust washer, drive pin, oil pump INNER ROTOR PUMP SHAFT outer rotor and inner rotor. Remove the pump shaft. 961m ROTOR WASHER DRIVE PIN INSPECTION Temporarin install the oil pump shaft Install the outer and inner rotors into the oil pump COVGL Measure the tip clearance. SERVICE LIMIT: 0.20 mm (0.008 in) Measure the pump bndy clearance. SERVICE LIMIT: 0.35 mm (0.0” in) LU BRICATION SYSTEM Measure the side clearance a straight edge and feeler gauge, SERVICE LIMIT: 0‘12 mm (0005 in) ASSEM BLV 13 N-m (1‘3 kgfrm . 9 lbf-fl) DOWEL PIN WASHER OIL PUMP SHAFT OIL PUMP BODY OUTER ROTOR DRIVE PIN INNER ROTOR OIL PUMP COVER Install the outer rotor into the oil pump cover. Install the inner rotor into the oil pump cover. OUXEH noTon PUMP covsn Install the oil pump shaft through the oil pump cover and inner retort Install the drive pin into the hole in the pump shaft and align the pin with the groove in the inner rotor as shown. Install the thrust washer‘ PUMP SHAFT ’, DRIVE PIN LUBRICATION SYSTEM install the dowel pins. Install the oil pump body onto the oil pump coverl 0“- PUMP 300V DOWEL PINS Install and tighten the oil pump bolts to the speci- fied torque, OIL PUI‘W" BOLTS TORQUE: 13 NM (1.3 kgf-m , 9 lbfrft) INSTALLATION Install the dowel pins. Install the oil pump Install and tighten the mourning bolts to the speci- fied torque. TORQUE: 12 N-m (1,2 kgf‘m , 9 lbf-ft) Install the foIlowIng: —Oil strainer and oil pan (page 45) —Clutch and oil pump driven sprocket (page 9-8) After installation, fill the crankcase with recom- mended oil and check that there is no oil leaks. Check the oil pressure (page 4-4). 4-10 FUEL SYSTEM r ‘3 .® — 4 .g.'_.§~ gfi ’v. > 5-0 5. FUEL SYSTEM SERVICE INFORMATION 5-1 CARBURETOR ASSEMBLY 5-12 TROUBLESHOOTING 5-3 CARBURETOR COMBINATION 5-15 AIR CLEANER HOUSING 5-4 CARBURETOR INSTALLATION 5-18 CARBURETOR REMOVAL 5-5 PILOT SCREW ADJUSTMENT 5-20 CARBURETOR SEPARATION 5-7 SECONDARY AIR SUPPLY SYSTEM 5-22 DISASSEMBLY/ 59 FUEL FILTER 5-23 SERVICE INFORMATION GENERAL AWARNING o Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. 0 If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. Run the engine in an open area or with an exhaust evacuation sys1em in an enclosed area. 0 Bending or Misting the control cable will impair smooth operation and could cause the cable to stick or bind, resulting in loss of vehicle control. Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a lire or explosion. CAUTION: Be sure to remove the diaphrang before cleaning air and fuel passages with compressed air. The diaphragms might be damaged. o For fuel tank removal and installation, see page 2-10. 0 Before disassembling the carburetors, place an approved fuel container under the float chambers, loosen the drain screws and drain the carburetors. - After removing the carburetors, 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 reassembly. 0 The vacuum chamber and float chamber can be serviced with the carburetors combined. 0 For carburetor synchronization, see page 3-12. NOTE: If the vehicle is to be stored for more than one month, drain the float bowls. Fuel left in the float bowls may cause clogged jets, resulting in hard starting or poor driveability. FU EL SYSTEM SPECIFICATIONS ITEM SPECIFICA‘HONS Carburetor identification number VPJOA Mainjet Front: # 168 Rear: # 170 Slowjet #42 Jet needle number Front: 5510 Rear: 3513 Pilot screw initial opening See page 5-20 Float level 13.7 i 0.5 mm (054 i 0.02 in) Idle speed 1,200 i 50 min" (rpm) Throttle grip free play 2—6 mm (1/16—1/4ln) TORQUE VALUES Carburetor insulator band bolt Reed valve cover bolt TOOLS Float level gauge Pilot screw wrench 1 N-m (0.1 kgf‘m , 0.7 mm) 5 Mm (052 kgf~m , 3.8 Ibf-ft) Apply locking agent to the threads. 07401 -001 0000 079084730002 TROUBLESHOOTING Engine cranks but won't start 0 No fuel in tank 0 No fuel to carburetor - Clogged fuel strainer - Clogged fuel line 7C|ogged fuel valve vacuum tube - Clogged fuel tank breather tube 0 Too much fuel getting to the engine — Clogged air cleaner - Flooded carburetor - Intake air leak 0 Contaminated/deteriorated fuel o Improper choke operation 0 improper throttle operation 0 No spark at plug (faulty ignition system-section 17) Lean mixture 0 Clogged fuel jets 0 Faulty float valve 0 Float level too low - Restricted fuel line - Clogged carburetor air vent tube 0 Restricted fuel tank breather tube - Intake air leak 0 Faulty vacuum piston Rich mixture 0 Starting enrichment (SE) valve open 0 Clogged airjets 0 Faulty float valve 0 Float level too high 0 Dirty air cleaner 0 Faulty vacuum piston FUEL SYSTEM Engine stalls, hard to start, rough idling O Restricted fuel line 0 Fuel mixture too lean/rich - Contaminated/deteriorated fuel 0 intake air leak 0 Misadjusted idle speed 0 Misadiusted pilot screw 0 Restricted fuel tank breather tube 0 Clogged air cleaner 0 Clogged slow circuit O Starting enrichment valve open 0 Faulty ignition system (section 17) Afterburn when engine braking is used 0 Lean mixture in slow circuit 0 Faulty air cut-off valve 0 Faulty pulse secondary air iniection (PAIR) system - Faulty PAIR control valve - Faulty PAIR check valve *Clogged hose of the PAIR system I Faulty ignition system (section 17) Backfiring or misfiring during acceleration 0 Lean mixture - Faulty ignition system (section 17l Poor perfonnenoe (driveability) and poor fuel economy 0 Clogged fuel system 0 Faulty ignition system (section 17) FUEL SYSTEM AIR CLEANER HOUSING r- " Am HOSE / REMOVAL ‘ I ‘ NOTE: Refer to page 3-5 for air cleaner element replace— ment Remove the fuel tank (page 2-10). Remove the air cleaner element (page 3-5). Disconnect the maintenance vacuum vent tube, air hose and rear crankcase breather hose. Disconnect the air hose and front crankcase breather hose. Disconnect the pulse secondary ai vacuum tube and air supply hose, Remove the PAIR control valve from the air cleaner housing. njectioanAIR) AIRSUPPL WWW ‘\ ‘ , l-- l ‘\ . n ' / . x ‘ ’ COWF‘OL VALVE Remove the screws and airfunnels. FUEL SYSTEM Remove the screws and air cleaner housing. SCREWS Remove the O-rings. INSTALLATION Install new O»rings into the carburetor grooves Install the removed pans in the reverse order of removalt NOTE: 0 Install the wires and hoses properly (page 1-21) 0 install the air funnels with the “V” marks on the air funnel and air cleaner housing aligned, CARBURETOR REMOVAL m___ Gasollne is omen-rely flammable and is explosive under certain conditions. NOTE: When the carburetors will not be serviced, remove the carburetor assembly with the air cleaner hous- ing attached to prevent the threaded holes in the carburetor from damaging. Drain the coolant (page 66). Remove the air cleaner housing (page 54L Remove the throttle stop control knob from the clamp. FU EL SYSTEM Disconnect the throttle sensor 3P (Black) connector. Remove the throttle cables from the cable stay and disconnect the throttle cables from the throttle drum. Loosen the carburetor insulator band bolts and remove the carburetor assembly. NOTE: 0 After removing the carburetor assembly, do not place it up side down or the air intake might be deformed. I Seal the cylinder head intake ports with a shop towel or cover it with piece of tape to prevent any foreign material from dropping into the engine. Disconnect the carburetor heater hoses from the carburetor: ‘ .2 g. ACKl RONNECTDR 5-6 FUEL SYSTEM Loosen the starting enrichment (SE) valve nuts and disconnect the choke cables from the carburetors, SE VALVE NQTS Disconnect the fuel tube from the fuel joint ‘ CARBURETOR SEPARATION NOTE: The vacuum chamber and float chamber can be serviced without separating the carburetors. Disconnect the air vent tubes and drain tubest FUEL TUBES Disconnect the fuel tubes from the carburetors. Disconnect the carburetor heater joint hose from the carburetors Hf ATE I1 JOIN! HOSE EQfTERiPlflg'C'ONE WASHERS PLAN Remove the cotter pins, plastic cone washers, WASHERSf’MAllgws‘HERS plastic plain washers and metalic washers. " Remove the throttle link. CAUTION: Be careful not to bend or damage the throttle arm and link. H-IROVTLE LINK FUEL SYSTEM Remove the screws and throttle cable stay from the ’3 carburetor. . r Remove the nuts, bolts and the set plates. SE! PLATES \ CAUTION: Do not remove the throttle sensor from the set plate unless it requires replacement. it can cause the throttle sensor gettlng out of position resulting in improper ignition timing Remove the dowel pins from each carburetor. CAZBURETORS DOWEL PINS C RBURETOR HEAYER AIR VENT JOINT Remove the air joint, air vent joint and carburetor heater from each carburetor. ' AIR JOlNT FUEL SYSTEM CARBURETOR DISASSEMBLY/ . INSPECTION NOTE: Note the location of each carburetor part so they can be replaced in their original location; AIR CUT-OFF VALVE Disconnect the vacuum tube from the vacuum pipe. Remove the screw, washer and the air cut-off velvet / ‘ \ f SCREW‘WASHER " AIR CUTOFF VALVE Remove the air cut-off valve, air jet and O-rings. AIR CUT~0FF VALVE Apply vacuum to the vacuum tube of the valve. AIR CUT-OFF VALVE \ The vacuum should maintained. Air should not flow through the valve ports when the vacuum is applied, and should flow when the . vacuum is not appliedt names/l VACUUM CHAMBER VACUUM CHAMBER COVER Remove the screws and vacuum chamber cover. NOTE: As the compression spring is very long, i! will jump out of the carburetor when the cover is removed. FUEL SYSTEM Remove the diaphragm spring and diaphragm/ vacuum piston from the carburetor bodyt Temporarily install a 4 mm screw (example; vacu- um chamber cover screw) into the jet needle holder. Pull the screw and remove the jet needle holder. CAUTION: 0 Be careful not to damage the diaphragm, 0 Do nut remove the iet needle holder hy pushing the iot needle. Remove the spring, jet needle and washer from the vacuum piston. Check the jet needle for stepped wear. Check the vacuum piston for wear or damage. Check the diaphragm for pin hole, deterioration or damage. NOTE: Air leaks out of the vacuum chamber if the dia- phragm is damaged in any way, even a pin hole. FLOAT CHAMBER Remove the screws and float chamber and O-ring. 4 mm SCR EW DIAPHRAGM/VACUUM PISTON WASHER SPRING JETNEEDLE/ JET NEEDLE HOLDER / FOAT CHAMBER/ORING 5-10 Remove the float pin, float and float valve. Inspect the float for deformation or damage. Inspect the float valve seat for scores, scratches, clogging and damage Check the tip of the float valve where it contacts the valve seat for stepped wear or contamination. Replace the valve if the tip is worn or contaminated Check the operation of the float valve. Remove the following: *Main jet *Needle jet holder ’SIOWiet CAUTION: Handle the int: wlth care. They can easily be scored or scratched. Turn the pilot screw in and record the number of turns it makes before it seats lightly. Remove the pilot screw, spring, washer and O-ringt CAUTION: Damage to the pilot screw seat will occur if the pilot screw is tightened against the seat. Inspect each jet for wear or damage and replace if necessa ry. FLOAT VALVE FUEL SYSTEM FUEL SYSTEM CARBURETOR CLEANING Remove the followings: —Air cut-off valve — Diaphragm/vacuum piston — Main jet, needle iet holder and slowjet — Pilot screw/spring/washer/O-ring CAUTION: Cleaning the air and fuel passages with a piece of win will damage the carburetor body. Blow open all air and fuel passages in the carbure- tor body with compressed air‘ CARBURETOR ASSEMBLY AIR cumrr VALVE A'“ JET FLOAT VALVE COMPRESSION SPRING FLOAT PIN VACUUM CHAMBER COVER 9! I SPRING JET NEEDLE HOLDER FLOAT CHAM BER MAIN JET DIAPHRAGMNACUUM PISTON PILOT SCREW FLOAT CHAMBER Install the following: —S|ow jet *Needle jet holder *Main jet CAUTION: Handle alliets with care. They can easily be scored at scratched Install the pilot screw and return it to its original position as noted during removal. Perform the pilot screw adjustment procedure if a new pilot screw is installed (page 5-20). 5-12 FUEL SYSTEM Install the float and float valve in the carburetor body, then install the float pin through the body and float. FLOAT LEVEL INSPECTION With the float valve seated and the float arm just touching the valve, measure the float level with the special tool as shown. FLOAT LEVEL: 13.7 i 0.5 mm (0.54 :l: 0.02 in) TOOL: Carburetor float level gauge 07401 -001 0000 The float cannot be adjusted. Replace the float assembly if the float level is out of specification, Install a new Ovring in the float chamber. Install the float chamber. Install and tighten the three float chamber screws. FUEL SYSTEM VACUUM CHAMBER Check the condition of the O~ring on the jet needle holder, replace it necessary. Apply oil to the O-ring. Install the washer, jet needle, spring into the vacu- um piston. Press the iel needle holder into the vacuum piston until you feel a click indicating that the O-ring is seated into the groove in the vacuum piston. Install the diaphragm/vacuum piston in the carbure- tor body, aligning the diaphragm teb with the groove of the carburetor body. Hold the vacuum piston almost full open so the diaphragm is not pinched by the chamber cover. Install the chamber cover with the spring, being careful not to damage the springs Install and tighten the vacuum chamber cover screws. CAUTION: Do not plnch the diaphragm under the chamber cover. AIR CUT-OFF VALVE Install the 0-rings onto the air jet and air cut-off valve as shown. NOTE: Install the air jet with its small end facing the carburetor body. DIAPHRAGM'VACUUM PISTON WAS HE H _,I ORING / JET NEEDLE/ ‘ SPRING’” JET NEEDLE HOLDER ’ HAM BER COVER / AIR CUTDFF VALVE \ \ ’ O~R|NG / / :,' lé/ AIR JET / ,6 ,/ O-RINGS; FUEL SYSTEM Install the airjet and air cut-off valve onto the carbu— AIR CUT-OFF retor. Install and tighten the screw/washer. Connect the vacuum tube to the vacuum pipe of the carburetor body. CARBURETOR COMBINATION LEFT SET PLATE CABLE STAV FRONT CARBURETOR THROWLE LINK JOINT BOLTS 5-15 FUEL SYSTEM I AIR VENT JOINT/ 0 O-FIING v NOTE: Always replace the O-rings with onest Install the followings onto each carburetor: ~Carburetor heater with new O»rings —Air vent joint with a new O-ring —Airioint with a new O-ring " / CARBURHOR HEATER“ .. flrRlNG . 0 I Install the dowel pins to the each side of the carburetors. DOWEL PINS DOWEL PINS Install the right set plate onto the rear carburetor aligning the flat surfaces of the throttle sensor with the flat surfaces of the th rottla shaft. CAUTION: Do not remove the throttle sensor from the set plate unless it requires replacoment. It can cause the throttle sensor geftlng out of position resulting in improper ignition timing. THROTTLE SENSOR * 5-16 Install the left set plate and bolts. Install and tighten the nuts securely. Install the throttle cable stay onto the front carbure- a tor and tighten the screws securely. Install the followings onto the throttle arm pin: Front carburetor: 7 Plastic cone washer *Throttle link —Plastic washer —Metal|ic washer - New cotter pin Rear carburetor: \ *Plastic washer *Throttle link 7 Plastic cone washer ~Metallic washer ‘ New cotter pin NOTE: lnstall the plastic cone washer with the concave side facing to the throttle linkl FUEL SYSTEM LEFT SET PLATE maonfie LINK THRO‘ITLE LINK pLAs-nc CONE PLASTIC WASHER WASHER \ PLASTIC WASHER METALLIC WASHERS PLASTIC CONE WASHER 5-17 FUEL SYSTEM Move the throttle drum and check that throttle valves move smoothly and return automatically without binding, THROTTLE LINK Connect the carburetor heater joint hose to the carburetors. Connect the fuel tubes to the carburetorst Connect the airvent tubes and drain tubes. DRAIN USES CARBURETOR INSTALLATION Check the starting enrichment (SE) valve for scor- ing, scratches or wear. Check the seat at the tip of the SE valve for stepped weart Replace the SE valve if necessary. HEATER JOINT HOSE 5-18 FUEL SYSTEM Connect the fuel tube to the fuel ioint. 5E VALVE NUTS Connect the choke cables from the carburetors and "'\ tighten the starting enrichment (SE) valve nuts securelyt Connect the carburetor heater hoses to the carbure- tors. Coat the inside of the carburetor insulators with clean engine oil for ease of installations Install the carburetor assembly into the carburetor insulators and tighten the insulator band bolts. TORQUE: 1 N-m(0.1 kgftm,0t7lbf-h) Connect the throttle cables to the throttle drumt Install the throttle cables to the cable stay, FUEL SYSTEM Connect the throttle sensor 3F (Black) connector. '- I‘mfiiflsfim'figfixl ’Q . r 3‘ CONNE‘c‘ro’R' \ u 4 Install the throttle stop control knob to the clamp Install the aircleaner housing (page 5-5). Fill and bleed the cooling system (page 6-5). PILOT SCREW ADJUSTMENT IDLE DROP PROCEDURE m—. o I! the engine must be running to do some work, make sure the area I: well-ventilated. Never run the englm in an enclosed area. 0 The exhaust contains poisonous carbon monox- ide gas that may cause loss of consciousness and may lead to death. NOTE: I Make sure the carburetor synchronization is within specification before pilot screw adjust- ment (page 3-12). FUEL TANK o The pilot screws are factory ore-set, Adjustment " /’ is not necessary unless the carburetors are / overhauled or new pilot screws are installed. 0 Then engine must be warm for accurate adjust- ment. Ten minutes of stup-and-go riding is suff- cient. 0 Use a tachometer with graduations of 50 rpm or smaller that will accurately indicate 50 rpm change. Lift up the fuel tank using the maintenance bar (page 3-6). 5-20 1.Turn the pilot screw clockwise until it seats lightly, and then back it out to the specification given. CAUTION: Damage to the pilot screw seat will occur if the pilot screw is tightened against the seat. TOOLS: Pilot screw wrench 079084730002 INITIAL OPENING: 2 3/8 turns out 2.Warm the engine up to operating temperature. 3. Stop the engine and connect a tachometer according to the tachometer manufacturer’s in- structions. 4. Start the engine and adiust the idle speed with the throttle stop control knob. IDLE SPEED: 1,200 i 50 min" (rpm) 5.Turn the from carburetor pilot screw in or out slowly to obtain the highest engine speed. 6. Perform step 5 for the rear carburetor pilot screw. 7. Lightly open the throttle 273 times, adjust the idle speed with the throttle stop control knob. 8,Turn front carburetor pilot screw in gradually until the engine speed drops 50 rpm, 9. Then turn the front carburetor pilot screw coun- terclockwise to the final opening from the posi- tion in step 8. FINAL OPENING: 1/2 turns out 10.Adiust the idle speed with the throttle stop control knob. 11.Perform steps 8, 9 and 10 for the rear carburetor pilot screw. FUEL SYSTEM PILOT SCREW THROTTLE STOP CONTROL KNOB / 5-21 FU EL SYSTEM SECONDARY AIR SUPPLY SYSTEM SYSTEM INSPECTION Start the engine and warm it up to normal operat- ing temperature. Remove the air cleaner element (page 3-5). Check that the secondary air intake ports are clean and tree carbon deposits. It the ports are carbon fouled, check the pulse secondary air injection (PAIR) control valve, Disconnect the air cleaner housing-to-PAIR control valve tube (No. 15) from the air cleaner housing. Disconnect the PAIR control valve vacuum tube from the control valve and plug it to keep air from entering. Connect the vacuum pump to the PAIR control valve. Start the engine and open the throttle slightly to be certain that air is sucked in through the No. 15 vacuum tube. If the air is not drawn in, check the No. 15 tube for clogging. With the engine running, gradually apply vacuum to the PAIR control valve. Check that the air intake port stops drawing air, and that the vacuum does not bleed, SPECIFIED VACUUM: 40 mm Hg It the air drawn in, or if the specified vacuum is not maintained, install a new PAIR control valve, It afterburn occurs on deceleration, even when the secondary air supply system is normal, check the air cut-off valve. PAIR CONTROL VALVE AIR SUPPLY HOSE VACUUM PUMP VACUUM TUBE 5-22 FUEL SYSTEM PAIR CHECK VALVE INSPECTION For the rear cylinder PAIR check valve removal, remove the fuel tank (page 2-10)t Remove the bolts and PAIR check valve covert Remove the PAIR check valve from the cylinder head cover. Check the reed for damage or fatigue Replace if necessary. Replace the PAIR check valve if the seat rubber is cracked, deteriorated or damaged, or if there is clearance between the reed and seat. Install the PAIR check valve and cover onto the cylinder head cover. Apply locking agent to the cover bolt threads. Install and tighten the bolts to the specified torque TORQUE: 5 Nam (0.52 kgf-m , 3.8 Ibf-ft) FUEL FILTER REMOVAL/INSTALLATION Remove the under cowl (page 2-7). Disconnect the fuel tubes from the fuel filter. Remove the fuel filter/rubber cushion from the stay. Check the fuel filter for damage or contamination. Replace the fuel filler if necessary. Installation is in the reverse order of removal. COOLING SYSTEM SYSTEM FLOW PATTERN CAR BURETORS LE FT RADIATOR 6-0 6. COOLING SYSTEM SYSTEM FLOW PATTERN 6-0 RADIATOR 6-6 SERVICE INFORMAHON 6-1 RADIATOR RESERVE TANK 6-12 TROUBLESHOOTING 6-2 THERMOSTAT 6-12 SVSTEM TESTING 6-3 WATER PUMP 6-15 COOLANT REPLACEMENT 6-4 SERVICE INFORMATION GENERAL AWAHNlNG 0 Wait until the engine is cool before slowly removing the radiator cap. Removing the cap while the engine is hot and the coolant is under pressure may cause serious scalding. - Radiator coolant is toxic. Keep itaway from eyes, mouth, skin and clothes. -lf any coolant gets in your eyes, rinse them with water and consult a doctor immediately. — if any coolant is swallowed, induce vomiting, gargle and consult a physician immediately. — If any coolant gets on your skin or clothes, rinse thoroughly with plenty of water. 0 KEEP OUT OF REACH OF CHILDREN. CAUTION: Using Coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passages. Using tap water may cause engine damage. 0 Use only distilled water and ethylene glycol in the cooling system. A 50-50 mixture is recommended for maximum corrosion protection. Do not use alcohol«based antifreeze or an antifreeze with self-sealing properties. 0 Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system. 0 All cooling system service can be done with the engine in the frame. 0 Avoid spilling coolant on painted surfaces. 0 After servicing the system, check for leaks with a cooling system tester. . Refer to section 19 for coolant temperature indicator and fan motor switch. SPECIFICATIONS ITEM SPECIFICATIONS Coolant capacity Radiator and engine 2.8 l) (3.0 US qt , 2.5 Imp qt) Reserve tank 0.5 ii (0.5 US qt , 0.4 Imp qt) Radiator cap relief pressure 108— 137 kPa (1.1 -1.4 kgf/cm2 ,16-20 psi) Thermostat Beginto open 75—82 °C (167—180°F) Fully open 82 °C (180 °F) Valve lift 8 mm (0.3 in) minimum Standard coolant concentration 50% mixture with soft water TORQUE VALUES Thermo sensor 9 N-m (0‘9 kgf-m , 6.5 Ibf-ft) Apply sealant Engine coolant temperature (ECT) sensor 23 N-m (2.3 kgf-m, 17 Ith) Fan motor switch 17 N-m (1.7 kgf-m, 12 Ibf-ft) COOLING SYSTEM TOOLS Bea ring remover shaft 0793643500100 Bea ring remover, 10 mm 0793643500200 Sliding weight 07741—0010201 Driver 07749-0010000 Attachment, 28 X 30 mm 07946-137010!) Pilot, 10 mm 0774643040100 Mechanical seal driver attachment 079454150400 TROUBLESHOOTING Engine temperature too high I Faulty temperature gauge or thermosensor - Thermostat stuck closed 0 Faulty radiator cap 0 Insufficient coolant 0 Passages blocked in radiator, hoses or water jacket a Air in system O Faulty cooling fan motor 0 Faulty fan motor switch - Faulty water pump Engine temperature too low - Faulty temperature gauge or thermosensor - Thermostat stuck open - Faulty fan motor switch Coolant leaks o Faulty water pump mechanical seal 0 Deteriorated O-rings 0 Faulty radiator cap 0 Damaged or deteriorated cylinder head gasket 0 Loose hose connection or clamp o Damaged or deteriorated hoses COOLING SYSTEM SYSTEM TESTING MEN—— The engine must be cool before removing the radiator cap, or severe scalding may result. RAMA-70R COOLANT (HYDROM ETER TEST) Remove the side cowl (page 2-5L Remove the radiator cap. Tesl the coolant gravity using a hydrometer (refer to Section 5 of the Common Service Manual for “Coolant gravity chart”). For maximum corrosion protection, 8 5075093 solution of ethylene glycol and distilled water is recommended (page 6-4). Look for contamination and replace the coolant if necessary. Coolanllemperalure "F (“C1 ‘ 1 ‘ i" ' 3? M ‘ 50 59 68 77 86 95 lO4 113 122 1 Coolamvallo “,1. _ 1o» , 15) 1 110) V 1151 ‘ 120) 7125) 1301 . (351 1401 1‘45} 150) _ 7 77 5 V_V_V 1.009 1.0091 one 100: 1.007 1006 1.095 1093 199 9999 9937 | 7 11.013191? J «hereby; nonfigflmoosimoofltoos _ 102g M‘Logrogp 1.0241532110291013 1011510141012 4111351335 EH.on 71192511531102121.019 1.045 1.044_1.043 1,042 ._ V .933: 1031 1.0731025 jug 1,052 1.051 1.04sl1.047[1,9§§h.943h.o41[19331133511032 1.063 1.062 1.on Loss 1,055 1.9§4 1,053 1943 1045 1011- cap 06_4[1 06.2 1-Q59T1-05611.053l1-05'Jl1-047‘ o _. 73 1.9979 1,066 1.963 L060 1057 1,054} how .o71f1m41.071T1.oesli.oes[1.oaz{1.059; 6-3 COOLING SYSTEM RADIATOR CAP/SYSTEM PRESSURE INSPECTION Remove the radiator cap (page 6-3). NOTE: Before installing the cap in the tester, wet the sealing surfaces Pressure test the radiator cap, Replaee the radiator cap if it does not hold pressure, or if relief pressure is too high or too low, It must hold specified pressure for at least 6 seconds. RADIATOR CAP RELIEF PRESSURE: 108*137 kPa (1.1 —1.4 kgf/cm2 ,16*20 psi) Pressure the radiator, engine and hoses, and check for leaks. CAUTION: Excessive pressure can damage the tooling system components. Do not exceed 137 kPa {1.4 kgf/cmi 20 psi) Repair or replace components if the system will not hold specified pressure for at least 6 seconds. COOLANT REPLACEMENT RECOM. PREPARATION k‘fii‘fifié’gzg m—_—. . mm“ “mm mm Kw “mm”, ,m ETL'IEBEE‘EASE LOW MINERAL on mouth, skin and Garth”. SOLUTION DISTI LLED WATER ill any coolant gets In your eyes, rinse them with water and consult a doctor immedlately. ~lf any coolant Is swallowed, induce vomiting, gargle and consult a physician immediately. 7 If any coolant gets on your skin or clothes, COOLANT rinse thoroughly with plenty of water. 0 KEEP OUT OF REACH OF CHILDREN. CAUTION: Using coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passages. Ualng tap water may cause engine damage. NOTE: 'The effectiveness of coolant decreases with the accumulation of rust or if there is a change in the mixing proportion during usage. Therefore, for best performance change the coolant regularly as specified in the maintenance schedule. OMix only distilled, low mineral water with the anti-freeze. RECOMMENDED MIXTURE: 50*50 (Distilled water and antifreeze) REPLACEMENT/AIR BLEEDING M The engine must be cool before servicing the cooling system, or severe scalding may result NOTE: When filling the system or reserve tank with a coolant (checking coolant level). place the motor- cycle in a vertical position on a flat, level surface. Remove the side cowl (page 2-5). Remove the under cowl (page 2-7). Remove the radiator cap. Disconnect the lower radiator hose at the right radiator by loosening the hose band screw and drain the coolant from the system. Remove the drain bolt and drain the coolant from the front cylinder. Reinstall the drain bolt with the new sealing washer. Disconnect the siphon tube from the radiator. Drain the reserve tank coolant. Empty the coolant and rinse the inside of the reserve tank with water. Reinstall the radiator siphon tube. COOLING SYSTEM COOLING SYSTEM Fill the system with the recommended coolant through the filler opening up to tiller neckt Remove the radiator reserve tank cap and till the reserve tank to the upper level liner Bleed eirfrom the system as follow: 1. Shift the transmission into neutral Start the engine and let it idle for 2*3 minutes 2. Snap the throttle 374 times to bleed air from the system 3, Stop the engine and add coolant up to the proper level if necessary. Reinstall the radiator cap. 4. Check the level of coolant in the reserve tank and fill to the upper level if it is low. RADIATOR CAUTION: Be carelul not to damage the radiator care. REMOVAL/INSTALLATION Drain the coolant (page 6-4l Remove the fuel tank (page 24% RIGHT RADIATOR Disconnect the fan motor switch 2P (Black) connec- (or. Disconnect the siphon tube and upper radiator hose from the radiator. UPPER LEVEL \ RESERVE TANK L/ LOWER LEVEL nic'JNNrrron. 6-6 Disconnect the lower radiator hose. Remove the mounting bolts and washers. 01 n A Release the grommet on the radiator from the radia- tor bracket. Installation is in the reverse order of removal. Fill and bleed the conling system (page 6-5)t LEFT RADIAYOR Disconnect the upper radiator hose. COOLING SYSTEM COOLING SYSTEM Diswnnect the lower radiator hose. R , 9mm) , A \ Remove the mounting bolts and washers, Release the grommet on the radiator from the radia- tor bracket. Insiallation is in the reverse order of removal. Fill and bleed the cooling system (page 6-5l. HADIAYOR GRlLL r / DISASSEMBLY Remove the radiator grill from the radiator. H COOLING SYSTEM Remove the screws and right/left radiator covers. RADIAFOR COVERS LEFT RADIAFOR COVER COOLING FAN DISASSEMBLY Disconnect the fan molar swi‘ch connector‘ Remove the boks, ground eyelet and the fan motor/ shroud assembly. FAN MOTOR SWITCH CONNHI TOR 0 § . Remove the nu‘ and cooling fan. COOLING SYSTEM Remove the bolts and the fan motor from the shroud. For fan motor switch information, refer to page 19-14. ASSEM BLY RIGHT RADIATOR FAN MOTOR SHROUD COOLING FAN \ Install the fan motor onto the shroud with the drain & tube as shown Install and tighten the bolts. 6-10 COOLING SYSTEM Install the cooling fan onto the fan motor shaft by aligning the flat surfaces. Install and tighten the nut securely. Install the tan motor/shroud assembly onto the radiator, Route the fan motor switch wire and ground eyelet properly‘ Install and tighten the bolts Connect the fan motor switch wire to the fan motor switch. Install the right/left radiator covers and screws RADIATOR COVER COOLING SYSTEM RADIATOR RESERVE TANK THERMOSTAT Install the radiator grill to the radiator. RADIATOR GRILL / Install the radiator (page 6-7, at r REMOVAL Remove the right radiator (page 66). Remove the bolt. Remove the tab on the reserve tank from the stay, then remove the reserve tank INSTALLATION Installation is in the reverse order of removal. Install the right radiator (page 6-7). REMOVAL Remove the fuel tank (page 2-10). Drain the coolant (page 6-5), Loosen the hose band screw and disconnect the upper radiator hose from the thermostat housing cover. 6-12 COOLING SYSTEM Remove the bolts, ground terminal, thermostat housing cover and O-ring‘ Remove the thermostat and housing. Disconnect the thermo sensor connector (page 19-13) and engine coolant temperature sensor 2P (Green) connector (page 17-9). Loosen the hose band screws and disconnect the radiator hoses from the thermostat housing. Remove the thermostat housing. INSPECTION um_— I Wear insulated gloves and adequate eye protec- film 0 Keep flammable materials away from the elec- tric heating element. Visually inspect the thermostat for damage 6-13 COOLING SYSTEM Heat the water with an electric heating element to operating temperature for 5 minutes, Suspend the thermostat in heated water to check its operation. NOTE: Do not let the thermostat or thermometer touch the pan, or you will get Ialse reading, Replace the thermostat if the valve stays open at room temperature, or it it responds at temperatures other than those specified, THERMOSTAT BEGIN TO OPEN: 75—82 °C (167—180 “F) VALVE LIFT: 8 mm (03 in) minimum at 82 °C (180 "F) INSTALLATION Connect the radiator hoses to the thermostat housing and tighten the hose band screws securelyt Connect the thermo sensor connector (page 19-13) and engine coolant temperature sensor 2P (Green) connector (page 1740). Install the thermostat into the housing with its hole facing rearward. Install a new O-ring into the groove of the thermo- stat housing cover. THERMOMETER THERMOSTAT 6-14 COOLING SYSTEM InsLaII the thermostat housing cover and ground terminal. Install and tighten the housing cover bolts. housing cover and tighten the hose band screw securely. Fill the system with recommended coolant and bleed the air (page 6-5). Install the fuel tank (page 2-10). WATER PUMP RIGHT CRANKCASE COVER REMOVAL Drain the coolant (page 64). Remove the radiator reserve tank bolt Loosen the hose band screw and disconnect the lower radiator hose COOLING SYSTEM Disconnect the carburetor heater water outlet hose. Loosen the hose band screw and disconnect the bypass hose from the water pump cover, Remove the bolts and water pump cover. Remove the O-ring and dowel pins. Disconnect the ignition pulse generator 2P (Red) connector. Disconnect the drain tube from the right crankcase coven 6-16 COOLING SVSTEM Remove the bolts and the right crankcase cover. Remove the dowel pins and gasket. MECHANICAL SEAL REPLACEMENT Remove the waler pump shaft from the right crankcase cover. Remove ihe bearing using the special tools. TOOLS: Bearing remover shalt 07936-GE00100 B ng remover. 10 mm 07936-GE00200 Slldlng weight 07741 43010201 Remove the mechanical seal and oil seal from the right crankcase cover. WATER PUMP SHAFT \ OIL SEAL 6-17 COOLING SYSTEM Drive a new mechanical seal using the special tool. DRIVE R TOOLS: Driver 07749-0010000 Mechanical seal driver attachment 079454150400 Apply grease to a new oil seal lip and install the oil seal into the right crankcase cover. Drive a new bearing with the make side facing out, using the special tools. TOOLS: Driver 07749-0010000 Attachment. 28 X 30 mm 079464870100 Pilul, 10 mm 077460040100 Support the bearing inner race properly and install the water pump shaft. @ MECHANICAL v SEAL $.61 0| L SEAL RIGHT CRANKCASE COVER INSTALLATION Apply sealant to the crankcase mating surfaces as shown, 6-18 COOLING SYSTEM Install the dowel pins and a new gasket. Install the right crankcase cover, aligning the gear teeth of the water pump shaft and water pump driven sprocket and tighten the bolts securely‘ Route the ignition pulse generator wire and drain tube properly (page 1-21)‘ Connect the ignition pulse generator 2P (Red) con- nectar. Connect the drain tube from the right crankcase cover. NOTE: Route the wire and tubes correctly (page 1-21 ). Install the dowel pins and a new O-ring into the water pump cover groove. COOLING SYSTEM Install and tighten the bolts securely, Connect the carburetor heater water outlet hose and bypass hose from the water pump cover. Tighten the hose band screw securely‘ Connect the lower radiator hose Tighten the hose band screw securely. Install and tighten the radiator reserve tank bolt securely. Fill and bleed the cooling system (page 6-5). 6-20 ENGINE REMOVAL/INSTALLATION 39 Nm (4,0 kgf-m , 29 lbf-ft) 64 N-m (6‘5 kgfrm , 47 Ith) 64 N-m (6.5 kgf-m , 47 Ibf-ft) 39 N-m (4‘0 kgf-m , 29 lbf-fl) 3 Nvm (0.3 kgf-m , 2.2 MM Hg 0/ 54 N~m (5‘5 kgf-m , 4o Ibf-fl) \ 3 N‘m (0,3 kgf-m , 2.2 |th) 54 N-m (5,5 kgl-m , 4O Ibf-fl) 54 Nm (5‘5 kgf-m , 40 lbf-fl) 59 Nm (6‘0 kgfrm , 43 lbf-f!) 54 Nm (5.5 kgf‘m , 40 Ibf-fl) 7-0 7. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION 7-1 ENGINE INSTALLATION 7-6 ENGINE REMOVAL 7-3 SERVICE INFORMATION GENERAL 0 During engine removal and installation, support the motorcycle using a safety stand or a hoist. 0 Support the engine using a jack or other adjustable support to ease of engine hanger bolts removal. CAUTION: Do not use the oil filter as a jacking paint. 0 The following components can be serviced with the engine installed in the frame. *AIternator (Section 10) *Clutch (Section 9) ' 7 Cylinder head/valves (Section 8) *Gearshil‘t linkage (Section 9) *OiI pump (Section 4) *Waler pump (Section 6) 0 The following components require engine removal for service. *Crankcasytransmission (Section 11) *Crankshaft/piston/cylinder (Section 12) 'When installing the engine, be sure to tighten the engine mounting fasteners to the specified torque in the specified sequence. If you mistake the tightening torque or sequence, loosen all mounting fasteners, then tighten them again to the specified torque in the correct sequence. FRONT ENGINE HANGER BOLT/ADJUSTING BOLT/LOCK NUT CENTER ENGINE HANGER BOLT REAR ENGINE HANGER BOLT/ADJUSTING BOLT/LOCK NUT 7-1 ENGINE REMOVAL/INSTALLATION SPECIFICATIONS ITEM SPECIFICATIONS Engine dry weight 74.8 kg (164.9 lbs) Coolant capacity Radiator and engine 2.8 0 (3.0 US qt , 2.5 Imp qt) Engine oil capacity At disassembly 4.1 “4.3 US at 3.6 Imp qt) TORQUE VALUES Front engine hanger nut Front engine hanger adjusting bolt Front engine hanger lock nut Center engine hanger bolt Rear engine hanger nut Rear engine hanger adjusting bolt Rear engine hanger lock nut Shock link bracket bolt (12 mml (14 mm) Drive sprocket bolt TOOL Lock nu! wrench 54 N-m (6.5 kgf-m , 47 lbf-hl 3 Nrm (0.3 kgf-m , 2.2 Ibf-ft) 54 Nm (5.5 kgf-m , 40 mm) 39 N-m (4.0 kgf‘m , 29 mm) 04 N~m (0.5 kgf-m , 47 Ibf‘l‘t) a N-m (0.3 kgf-m , 2.2 let) 54 Nm (5.5 kgf-m , 40 Ibf-ftl 54 Nm (5.5 kgf-m , 40 mm) 59 N~m (6.0 kgf-m , 43 mm) 54 N-m (5,5 kgf-m , 40 Ibf-h) 07VMA-MBBO100 ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL DRIVE SPROCKET REMOVAL Disconnect the clutch cable from the clutch armt Remove the bolts, clamp and drive sprocket cover. Remove the drive chain guard and dowel pins, Loosen the rear axle nut and drive chain adjusters. Remove the drive sprocket bolt, washer and the drive sprocket with the drive chain from the coun- tershatt, ocxen.‘ .mt ENGINE REMOVAL Drain the engine oil (page 3-11). Drain the coolant (page 6-5) Remove the followings: — Exhaust system (page 2—8) - Left and right side radiators (page 645, 7) —Carburetor (page 5-5) —Fue| pump (page 1924) Disconnect the followings: — Alternator 3? (Black) connector —Side stand switch 3? (Green) connector ~ Ignition pulse generator 2P (Red) connector *Neulral switch/oil pressure switch 2P (Blue) con- hector " TNBTHMINAL *Speed sensor 2P (Blue) connector -‘ ' - T R HGSES" Remove the thermostat housing assembly by dis- connecting the followings: -Ground terminal -Engine coolant temperature (ECT) sensor connec- tor -Thermosensor connector -Water hoses from the cylinder head 7 Bypass hose from the water pump ENGINE REMOVAL/INSTALLATION Support the motorcycle securely using a safety stand or hoist. Remove followings: *Shock link plate (page 1442) -Shock absorber upper mounting bolt/nut (page 14-9) ASwingarm (page 1445) Remove the nut and starter motor cable. Remove the bolts and radiator stays. Disconnect the front PAIR check valve tube and front spark plug cap. Disconnect the rear PAIR check valve tube and rear spark plug cap. eminqwfirms ‘ WNUW 7-4 ENGINE REMOVAL/INSTALLATION Remove the drain tube and fuel tank breather tube from the stay on the left side of the engine. . FUEL TANK Remove the bolt and the battery ground cable from the engine Remove the shock link bracket nuts, bolts, collars and bracket with the side stand, Place a floor jack or other adjustable support under the engine. NOTE: The jack height must be continually adjusted to relieve stress for ease of bolt removal. Loosen and remove the front engine hanger nut and rear engine hanger nut from the right side Remove the right and left center engine hanger bolt/collar. ENGINE REMOVAL/INSTALLATION Hold each hanger bolt and loosen each lock nut using the special tool. TOOL: Lock nut wrench O7VMA-MBBOl 00 Remove the lock nuts. Remove the adjusting bolts, engine hanger bolts, collars and engine from the frame. ENGINE INSTALLATION ENGINE INSTALLATION NOTE: 0 Note the direction of the hanger bolts. oThe jack height must be continually adjusted to relieve stress from the mounting fasteners. 'When tightening the lock nut with the lock nut wrench, refer to torque wrench reading informa- tion on page 7-1 "SERVICE INFORMATION”. CAUTION: Be sure to tighten all engine mounting fasteners to * the specified torque in the specified sequence described below. I! ynu mistake the tightening torque or sequence, loosen all mounting fasteners, then tighten them again to the specified torque in the specified sequence. Install the adjusting bolts to the frame. 4‘. I“. LGGK‘ RENCH 7-6 ENGINE REMOVAL/INSTALLATION Install the engine in the frame Install the front engine hanger bolt collar. Install the front engine hanger bolt aligning the its flat surfaces to the cut-out of the adjusting bolt. Install the rear engine hanger bolt cullari Install the rear engine hanger bolt aligning the its llat surfaces tn the cut-out of the adjusting bolt. Install the right and left collars, Tighten the right center engine hanger bolt to the specified torque. TORQUE: 39 Nm (4.0 kgf'm , 29 lbf-fl) Tighten the left center engine hanger bolt to the specified torque. TORQUE: 39 Nm (4.0 kg?!“ , 29 Ibf-fl) ENGINE REMOVAL/INSTALLATION Tighten the rear adjusting bolt with the rear engine hanger bolt to the specified torque and check that there is no clearanee between the collar and engine. TORQUE: 3 N-m (0.3 kgf-m , 2.2 lbf-h) Tighten the front adjusting bolt with the front engine hanger bolt to the specified torque and check that there is no clearance between the adjust- ing bolt and engine. TORQUE: 3 N‘m (0.3 kgf~m , 2.2 lbf-ft) 37. >31: . ’ 1‘ f 9*; AADJU§WG “0.19. A REAR ENGINE HANGER BOLT —>‘_ "0 CLEARANCE ADJUSTING BOLT FRONT ENGINE HANGER BOLT N0 CLEARANCE ADJUSTING BOLT ENGINE REMOVAL/INSTALLATION Hold the rear adjusting bolt with the rear engine hanger bolt and tighten the lock nut to the specified torque using the special tool. TOOL: Lock nut wrench 07VMA—M 330100 TORQUE: 54 N-m (5.5 kgf-m , 40 lbf‘ft) Hold the front adjusting bolt with the front engine hanger bait and tighten the lock nut to the specified torque using the special tool. TOOL: Lock nut wrench 07VMA-MBBO100 TOROUE: 54 N~m (5.5 kgf‘m , 4O Ibf-ft) Tighten the rear engine hanger nut to the specified torque. TORQUE: 64 N-m (6.5 kgf-m , 47 Ibf-tt) Tighten the front engine hanger nut to the specified torque. TORQUE: 64 N'm (6,5 kgf~m , 47 ibi-ft) ENGINE REMOVAL/INSTALLATION Install the shock link bracket with the side stand. Install the collars, bracket bolts and nuts. Tighten the bracket nuts to the specified torque, YOROUE: (12 mm ): 54 N-m (5.5 kgt-m , 40 Ibf-h) (14 mm): 59 N-m (6.0 kgfrm , 43 Ibf-tt) NOTE: Route the tubes, cables and wire harness properly Ipage1-21). Install the battery ground cable to the engine. Install and tighten the bolts securely. Install the drain tube and fuel tank breather tube to the stay on the left side of the engine. sr/w only mar: ’- _GéUNDCAaLE Connect the rear PAIR check valve tube and rear spark plug cap. Connect the front PAIR check valve tube and front spark plug cap. Install the radiator stays and bolts. Install the starter motor cable and tighten the nut. 7-10 ENGINE REMOVAL/INSTALLATION Install the followings: —Swingarm (page 14-20) -Shock absorber upper mounting bolt/nut (page 14-11) 7Shock link plate (Page 14-14) Install the mermostat housing assembly by con- necting the followings: — Bypass hose to the water pump 7Water hoses to the cylinder head _ Thermosensor connector — Engine coolant temperature (ECT) sensor connec- lOf 7Ground terminal Connect the followings: —Alternator 3P (Black) connector -Side stand switch 3P (Green) connector —Ignition pulse generator 2P (Red) connector —Neutral switclvoil pressure switch 2? (Blue) Cow "EC‘DY 7 Speed sensor 2P (Blue) connector Install the followings: 7 Exhaust system (page 2-9) 7 Left and right side radiators (page 6-18] 7Carburetor (Page 5-18) - Fuel pump (page 19-25) Fill the engine oil (page :HZ). Fill and bleed the cooling system (page 6-5). ENGINE REMOVAL/INSTALLATION DRIVE SPROCKET INSTALLATION Install the drive sprocket with the drive chain onto the countershaft. NOTE: Install the drive sprocket with its marking side facing out. Install the washer and bolt, then tighten the bolt to the specified torque. TORQUE: 54 N-m (5.5 kgfrm , 4O Ibf-ft) Install the drive chain guard and dowel pins. Install the drive sprocket cover, clamp and bolt. Tighten the bolts securely. Connect the clutch cable to the clutch arm. 7-12 CYLINDER HEAD/VALVES 10 Nm (1‘0 kgf-m , 7 lbf-fl) 20 N-m (2,0 kgf-m ,14lbf-ft) ‘ II" t 21 Nm (2.1 kgf‘m,15|bf-ft) " 3,4 ’2. 21 Nm (2.1 kgf‘m,15|bf>ft) \ 53 N-m (5‘4 kgl-m , 39 Ibf-ft) 8-0 8. CYLINDER HEAD/VALVES VALVE GUIDE REPLACEMENT VALVE SEAT INSPECT ION/REFACING CYLINDER HEAD ASSEMBLY CYLINDER HEAD INSTALLATION CAMSHAFI' INSTALLATION CYLINDER HEAD COVER ASSEMBLY CYLINDER HEAD COVER INSTALLATION CAM CHAIN TENSIONER LIFTER 8-14 3-15 8-19 8-20 3-21 8-26 8-27 8-28 SERVICE INFORMATION 8-1 TROUBLESHOOTING 3-3 CYLINDER COMPRESSION TEST 3-4 CYLINDER HEAD COVER REMOVAL s4 CYLINDER HEAD COVER DISASSEMBLY s-s CAMSHAFT REMOVAL 3-7 CYLINDER HEAD REMOVAL 8-10 CYLINDER HEAD DISASSEMBLY 3-11 cYLINDER HEAD INSPECTION 3-12 SERVICE INFORMATION GENERAL 0 This section covers service of the camshafts, cylinder head and valves. 0 The Camshafts, cylinder head and Valves can be serviced with the engine installed in the frame. 0 When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations. 0 Clean all disassembled pans with cleaning solvent and dry them by blowing them off with compressed air before inspection. 0 Camshaft lubricating oil is fed through oil passages in the cylinder head Clean the oil passages before assembling cylinder headv - Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head. 8-1 CYLINDER HEADNALVES SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cylinder compression 1.177 kPa (12.0 kgf/cm2 , 171 psi) — at 300 rpm Cylinder head warpage 7 0.10 (0.004) Valve, Valve clearance IN 0.16 (0.006) 7 valve guide EX 0.31 (0.012) 7 Valve stem CD. IN 5.975‘5390 (0.2352*0.2358) 5.965 (0.2348) EX 5.965m5.930 (0.2348*0.2354) 5.955 (0.2344) Valve guide LD. IN 6.000‘6.012(02362401367) 6.040 (0.2378) EX 6000—6012(0.2362‘02367) 6.040 (0.2378) Stem-to-guide clearance IN 0.010- 037 (00004-00015) 0.075 (0.0030) EX 0.020— .047 (00008—00019) 0035010033) Valve guide projection above IN 14.0— 14.2 (0.55—0.56) — cylinder head EX 14.0-14.2 (0.55—0.55) — Valve seat width IN/EX 1.1—1.3(0.04—0.05) 1.7 (0.07) Valve spring free length 43.3 (1 73) 42.9 (1.69) Valve lifter Valve lifter 0.D. lN/EX 33.978‘33393 (1.3377 *1.3383) 33.97 (1.337) Valve lifter bore l.D. lN/EX 34.010‘34026 (1.3390‘13396) 34.04 (1.340) Camshaft Cam lobe height IN 40.080*40.240 (1.5779*1.5842) 39.780 (1.5661) EX 40.230*40.390 (1.5839? 1.5902) 39.930 (1.5720) Runout —— 0.05 (0002) Oil clearance 0.020‘0362 (0.0008‘00024) 0.10 (0.004) TOROU E VALU ES Cylinder head cover bolt Cam sprocket bolt Camshalt holder bolt Cylinder head bolt (10 mm) Cam chain tensioner bolt Cam chain guide bolt Breather plate bolt Cylinder head sealing bolt Intake manifold vacuum port socket bolt Spark plug Carburetor insulator band bolt 10 N-m (1.0 kgfrm , 7 lbf-l‘t) 20 Nm (2.0 kgfrm , 1410M!) Applylocking agent to the threads 21 Nm (2.1 kgf-m , 15 Ibt-ft) Apply oil to the threads and seating surface 53 Nm (5.4 kgfrm ,391bf'ft) Apply oil to the threads and seating surface 23 N-m (2.3 kgfrm , 17 Ith) Apply locking agent to the threads 23 N-m (2.3 kgfrm , 17 Ith) Apply locking agent to the threads 12 N-m (1.2 kgf-m , 9 lbf-ft) Apply a locking agent to the threads 32 N-m (3,3 kgf-m , 24 lbf-ft) 3 N~m (0.34 kgt~m , 2.5 mm) 14 Nm (1,4 kgt-m,10|bt>ft) 1 Nrm (0.1 kgr-m,o,7 mm) TOOLS Valve spring compressor 07757—0010000 Valve guide remover 07742—0010100 Adjustable valve guide driver 07743-0020000 Valve guide reamer, 6,012 mm Valve seat cutter, 35 mm (EX 45“) 07780-0010400 Valve seat cutter 40 mm (IN 45“) 07780-0010500 Flat cutter, 38 mm (IN 32“) 077800012400 Flat cutter, 35 mm (EX 32°) 077800012300 Interior cutter, 3715 mm (Ex 60") 0778043014100 Interior cutter, 42 mm (IN 60“) 07780—001440!) Cutter holder, 6 mm TROUBLESHOOTING 07VM H-MBBOZOO 07VMH-MBBO100 CYLINDER HEAD/VALVES - 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 o lithe performance is poor at low speeds, check for white smoke in the crankcase breather tube. lithe tube is smoky, check for a seized piston ring (Section 12). Compression too low. hard starting or poor performance at low speed I Valves *lncorrect valve adjustment - Burned or bent valves —Incorrect valve timing - Broken valve spring — Uneven valve seating 0 Cylinder head *Leaking or damaged cylinder head gasket —Warped or cracked cylinder head - Loose spark plug 0 Cylinder/piston (section 12) Compression too high, overheating or knocking 0 Excessive carbon build-up on piston head or combus- tion cha mber Excessive smoke 0 Worn valve stem or valve guide I Damaged stern seal - Cylinder/piston (section 12) Excessive noise 0 Incorrect valve clearance 0 Sticking valve or broken valve spring 0 Worn or damaged camshaft - Worn or damaged valve lifter 0 Worn or damaged cam chain 0 Worn or damaged cam chain tensioner 0 Worn cam sprocket teeth a Cylinder/piston (section 12) Rough Idle 0 Low cylinder compression CYLINDER HEAD/VALVES CYLINDER COMPRESSION TEST Wh— II the engine must be running to do some work, make sure that the area is well-ventilated. Never run the engine in an enclosed area. The axhaum contains poisonous carbon monoxide gas that may cause loss of oansciousnass and may lead to death. SPARK PL UGvPLUG CAPS Warm up the engine to normal operating tempera- ture. Stop the engine and remove the all spark plug caps and remove the one spark plug at a time. NOTE: To measure the cylinder compression of each cylin- der, remove only one plug at a time. Install a compression gauge. 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 — 7 seconds. NOTE: To avoid discharging the battery, do not operate the starter motor for more than seven seconds. Compression pressure: 1,177 kPa (12.0 kgf/cm‘, 171 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 FRONT: Remove the lower heat guard (page 17-6). Remove the spark plug cap from the spark plug. Disconnect the crankcase breather hose and PAlR check valve tube from the cylinder head cover. 8-4 CYLINDER HEAD/VALVES Remove the cylinder head cover bolts and special Washers CYLINDER HE ao‘covsn GUSSPECIAL Remove the cylinder head covert WASHER ‘6 -‘ Remove the O-ring and dowel pin. REAR: Remove the fuel tank (page 2-10). Remove the spark plug cap from the spark plug, Disconnect the crankcase breather hose and PAIR check valve tube from the cylinder head cover. awn/mew 5 Remove the cylinder head cover bolts and special Slaléu'ggfiiflgAD'QDVER-BOUS SPECW- washers. r s \ H Remove the cylinder head covert fl .5 I CYLINDER HEAD/VALVES Remove the O-ring and dowel pin. A. CYLINDER HEAD COVER meme DISASSEMBLY Remove the wlinder head cover packing‘ Remove bolts and breather plate and gasket Check the PAIR check valve for wear of damage. Replace if necessary‘ 8-6 CYLINDER HEAD/VALVES CAMSHAFT REMOVAL For front cylinder, remove the following: -air cleaner housing (page 54) " - radiator (page 66) SEALlNG BOLT \ Remove the cylinder head cover (page 8-4)‘ Remove the cam chain tensioner lifter sealing bolt and sealing washer, / ’ A I Turn the tensioner lifter shaft fully in (clockwise) SE L Ngwastfl and secure it using the stopper tool. This tool can easily be made from a thin (1 mm thickness) piece of steel. $1 STOPPER TOOL 4.5 mm MATERRIAL THICKNESS: 1.0 mm Remove the bolts and the cam chain guide plate from the camshaft holders. Remove the crankshaft hole cap. 8-7 CYLINDER HEAD/VALVES NOTE: Be careful not to drop the cam sprocket bolts into the crankcase Remove the cam sprocket bolts from the intake and exhaust camshaft. Turn the crankshaft counterclockwise one turn, and remove the other cam sprocket bolts. Remove the cam sprockets from the camshafts, and suspend the cam chain with a piece of wire to prevent it from falling into the crankcase. Loosen and remove the camshaft holder bolts, then remove the camshaft holders, dowel pins and camshafts. NOTE: It is not necessary to remove the dowel pins from the camshaft holderst Remove the valve lifters and shims. NOTE: 0 Be careful not to damage the valve lifter bore. - Shim may stick to the inside of the valve liftert Do not allow the shims to fell into the crankcase, a Mark all valve lifters and shims to ensure correct reassembly in their original locations, oThe valve lifter can be easily removed with a valve lapping too or magnet. IThe shims can be easily removed with a tweezers or magneto INSPECTION CAMSHAFI’ HOLDER Inspect the camshaft journal surface of the cam- shaft holder for scoring, scratches, or evidence of insufficient lubrication, CAM SFROCKETS v\ \ \\\. CYLINDER HEAD/VALVES CAMSHAFI' RUNOUT Support both ends of the camshaft with V-blocks ,_\ OIL HOLES and check the camshaft runout with a dial gauge‘ senvuce LIMIT: 005 mm (0.002 in) \‘/ J \t \ CAM LOBE HEIGHY Using a micrometer, measure each cam lobe height. SERVICE LIMITS: IN: 39.780 mm (15661 in) EX: 39.930 mm (1.5720 in) CAMSHAFI' OIL CLEARANCE Wipe any oil from the journals of the camshaft, cyl- inder head and camshaft holders Lay a strip of plastigauge lengthwise on top of each camshaft journalt Install the camshaft holders and tighten the bolts in a crisscross pattern in 2-3 steps. NOTE: Do not rotate the camshaft when using plastigauget TORQUE: 21 N-m(2.1 kgf-m,15|bf‘ftI CYLINDER HEAD/VALVES Remove the camshaft holders and measure the width of each plastigauge. The widest thickness determines the oil clearance. SERVICE LIMIT: 0.10 mm (0.004 in) When the service limits are exceeded, replace the camshaft and recheck the oil clearance. Replace the cylinder head and camshaft holders as a set if the clearance still exceeds the service limit. CYLINDER HEAD REMOVAL Remove the carburetor assembly (page 5-5). Remove the camshaft (page 8-7). Remove the bolts and cam chain tensioner lifter. Remove the bolts and water hose joint. Remove the carburetor insulator. "30$. ‘GARBURETOH wagomon Remove the two 6 mm cylinder head bolts. HEAD BOLTS (10 mm) '1 Loosen and remove the six 10 mm cylinder head '. ' bolts. NOTE: Loosen the 10 mm belts in a crisscross pattern in 273 steps. Remove the cylinder head. 8-10 CYLINDER HEADNALVES Remove the dowel pins and cylinder head gasket, DOWELPlNS ' ' CYLINDER HEAD DISASSEMBLY LIFTER BORE PROTECTOR /\\ // \\ )l Remove the spark plug from the cylinder head. Make a lifter bore protector from a plastic 35 mm film container by cutting the bottom of the contain» er. Install the protector into the valve lifter borer Remove the valve spring cotters using the special VALVE SPRING COMPRESSOR tools as shown. ‘ it; . TOOL: Valve spring compressor 07757-0010000 CAUTION: To prevent loss of tension, do not compress the valve spring more than necessary to remove the panels. Remove the following: *Spring retainer ivalve spring VALVE SPRING *Valve ,‘ AStem seal —Valve spring seat \ SPRING \ REYAINER NOTE: t f Mark all parts during disassembly so they can be Pf, '/ placed back Inthelr original locations VALVE SPRING SEN / / STEM SEAL CYLINDER HEAD/ VALVES CYLINDER HEAD INSPECTION CYLINDER HEAD Remove carbon deposits from the combustion chambers. Check the spark plug hole and valve areas for cracks, NOTE: Avoid damaging the gasket surface: Check the cylinder head for warpage with a straight edge and feelar gauge. SERVICE LIMIT: 0.10 mm (0.004 in) VALVE SPRING Measure the free length of the valve springs. SERVICE LIMIT: 423 mm (169 in) Replace the springs if they are shorter than the service limits. VALVE LIFI'ER VALVE mun I \ Inspect each valve litter for scratches or abnormal \ wear: Measure the each valve lifter O‘D. SERVICE LIMIT: 33.97 mm (1,337 in) 8-12 CYLINDER HEAD/VALVES VALVE LIFTER BORE Inspect each valve lifter bore for scratches or abnormal wear. Measure the each valve lifter bore LD. SERVICE LIMIT: 34.04 mm (1.340 in) VALVENALVE GUIDE Inspect each valve for bending, burning or abnor- mal stem wear. Check valve movement in the guide, measure and _, record each valve stem 0.D. SERVICE LIMITS: _’ IN: 5.965 mm (0.2348 in) EX: 5.955 mm (0.2344 in) Ream the guides to remove any carbon deposits VALVE GUIDE REAMER before checking clearances. Insert the reamer from the camshaft side of the head and always rotate the reamer clockwise. TOOL: Valve guide reamer, 6.012 mm 07VMH-MBBOZOO Measure and record each valve guide I.D. SERVICE LIMIT: IN/EX: 6.040 mm (0.2378 in) Subtract each valve stem OD. from the correspond- ing guide ID. to obtain the stem-to-guide clearance, STANDARDS: IN: 0010 — 0.037 mm (0.0004— 0.0015 in) EX: 0.020 A 0.047 mm I0.0008*0.0019 in) If the stem-to-guide clearance is out of standard, determine if a new guide with standard dimensions would bring the clearance within tolerance If so, replace any guides as necessary and ream to fit If the stem-to-guide clearance is out of standard with the new guides, replace the valves and guides. NOTE: Reface the valve seats whenever the valve guides are replaced (page 844). CYLINDER HEAD/VALVES CAM CHAIN TENSIONER/CAM CHAIN GUIDE CAM CHAIN GUIDE Inspect the cam chain tensioner and guide for ex- cessive wear or damage, replace if necessary To remove the cam chain tensioner and guide: From cylinder: Remove the flywheel (page 103). Rear cylinder: Remove the primary drive gear (page 9-14). Remove the bolts, cam chain tensioner and guide Apply locking agent to the bolt threadsr Install the cam chain tensioner and guide, and tight- en the bolts to the specified torque. YORCIUE: 23 N~m (2.3 kgf‘m, I7 lbf-h) Install the primary drive gear (page 9-15). Install the flywheel (page 10—6). VALVE GUIDE REPLACEMENT Chill the replacement valve guides in the freezer section of a refrigerator for about an hour. Heat the cylinder head to 130-140 °C (275—290 °F) with a hot plate or oven. m____ To avoid bums, weer heavy gloves when handling the heated cylinder head. CAUTION: Do not use a torch to heat the cylinder head,- it may cause warping. Support the cylinder head and drive out the valve guides from combustion chamber side of the cylin- der head. TOOL: Valve gulde remover 07742-0010100 8-14 CYLINDER HEAD/VALVES While the cylinder head is still heated, drive new valve guides in the cylinder head from the cam- V Ab‘au’srAaLE VALVE GUIDE DRIVER shaft side until the exposed height is 14.07 14.2 mm (0.55*0.56 in). TOOL: Adiustahle valve guide driver 0774343020000 Let the cylinder head cool to room temperature. Ream the new valve guide after installation, Insert the reamer from the camshaft side of the head and also always rotate the reamer clockwise. TOOL: Valve guide reamer, 6.012 mm 07VMH-MBBOZOO NOTE: OTake care not to tilt or lean the reamer in the guide while reaming. 0 Use cutting oil on the reamer during this opera- tion. Clean the cylinder head thoroughly to remove any metal particles. Reface the valve seat (see below). VALVE SEAT INSPECTION/REFACING mews TOOL ‘ ’ Clean the intake and exhaust valves thoroughly to remove carbon deposits. Apply a light coating of Prussian Blue to the valve seats, Lap the valves and seats using a rubber hose or other handJapping tool. Remove and inspect the valves, CAUTION: The valves cannot be ground. If a valve face is burned or badly worn or if it contacts the seat unevenly, replace the valve. Inspect the width of each valve seat. SYANDARDS: * * IN: 1.1-1.3 mm (0.04~0.05 in) f Ex: 13 —1.5 mm (0.05 — 0.06 in) SERVICE LIMI IN: 1,7 mm (0.07 in) EX: 1,7 mm (0.07 in) SEAT WIDTH It the seat is too wide, too narrow or has low spots, the seat must be ground. 8-15 CYLINDER HEADNALVES Inspect the valve seat face for: - Uneven seat width: — Replace the valve and reface the valve seat. 0 Damaged face: — Replace the valve and refece the valve seat. - Contact area (too high or too low): - Reiece the valve seat. NOTE: The valve cannot be ground. If the valve face is burned or badly worn or if it contacts the seat unevenly, replace the valve. VALVE SEAT REFACING Valve seat cutters/grinders or equivalent valve seat refacing equipment are recommended to correct worn valve seatsr NOTE: Follow the reIacing manufacturer’s operating in» structions. If the contact area is too high on the valve, the seat must be lowered using a 32“ flat cutter. If the contact area is too low on the valve, the seat must be lowered using a 60° interior cutter. A J DAMAGED FACE UNEVEN SEAT WIDTH TOO LOW TOO HIGH 45° 32° CONTACT TOO HIGH OLD SEAT WIDTH \ CONTACT T00 LOW OLD SEAT WIDTH f» r 60 32° 8-16 Use a 45-degree cutter to remove any roughness or irregularities from the seat. NOTE: Reface the seat with a 45-degree cutter whenever a valve guide is replaced. Use a 32-degree cutter to remove the top 1/4 of the existing valve seat material Use a (SO-degree cutter to remove the bottom 1/4 of the old seat. Remove the cutter and inspect the area you have retacedr Install a 45-degree finish cutter and cut the seat to the proper width. Make sure that all pitting and irregularities are removed Refinish if necessary, CYLINDER HEAD/VALVES ROUGHNESS OLD SEAT WIDTH OLD SEAT WIDTH VAT WIDTH \ mg 8-17 CYLINDER HEAD/VALVES Apply a thin coating of Prussian Blue to the valve seat. Press the valve through the valve guide and onto the seat to make a clear pattern. NOTE; The location of the valve seal in relation to the valve face is very important for good sealing. It the contact area is too high on the valve, the seat must be lowered using a 32 degrees flat cutter. It the contact area is too low on the valve. the seat must be raised using a (SO-degree inner cutter. Refinish the seat to specifications, using a 45- degree finish cutter. After cutting the seat, apply lapping compound to the valve face, and lap the valve using light pres- sure. After lapping, wash all residual compound off the cylinder head and valve. NOTE: Do not allow lapping compound to enter the guides. CONTACT T00 HIGH T-fie OLD SEAT WIDTH CONTACT TOO LOW OLD SEAT WIDTH T3; LAPPING TOOL 8-18 CYLINDER HEAD/VALVES CYLINDER HEAD ASSEMBLY VALVE LIFTER SHIM A VALVE SPRING \ COTTERS 92 SPRING RETAINER - } g , .. ‘ ~ 9 VALVE GUIDE INTAKE VALVE EXHAU ST VALVE Clean the cylinder head assembly with solvent and as F qua blow through all oil passages with compressed air. . VALVE 5" ING SEAT yt‘ \\ Install the valve spring seats. Install the new stern seals. T: VALVE SPRING \ ‘I SPRlNG Lubricate the valve stems with molybdenum disul- w ‘ it RUNNER fide oil and insert the valve into the valve guide. \ ‘l\ l , ‘ {l To avoid damage to the stem seal, turn the valve : l slowly when inserting VALVE ‘ , ’ O V STEM SEAL Install the valve springs with the tightly wound VALVE SPR‘NG coils facing the combustion chamber. \ \ l COMBUSTION CHAMBER SIDE 8-19 CYLINDER HEAD/VALVES Install the tappet hole protector into the valve litter bore. Install the valve spring retainert Install the valve cutters using the special tool as shown. To prevent loss of tension, do not compress the valve spring more than necessary. TOOL: Valve spring compressor 07757-0010000 CAUTION: To prevent loss «I tensinn, dn not compress the valve spring more than necessary tn install the cotton Tap the valve stems gently with two plastic ham- mers as shown to seat the cutters lirmly. CAUTION: Support the cylinder head above the work bench surface to prevent possible valve damage, Install and tighten the spark plug to the specified torquet TORQUE: 14 N~m (1‘4 kgf-m , 10 lbf-fll CYLINDER HEAD INSTALLATION Install the dowel pins and a new cylinder head gasket as shown. LIFTER BORE PROTECTOR . \ y GASKET 8-20 CYLINDER HEADNALVES Install the cylinder head. HEAD'BOLTS (Io mm) ’ ’7. . .l y t 1 1 ‘ Apply oil to the threads and seating surface of the 10 mm cylinder head bolts and install them. Install the two 6 mm flange bolts. Tighten the 10 mm cylinder head bolts in a criss- cross pattern in 2 — 3 steps to the specified torque. TORQUE: 53 N-m (5.4 kgf-m , 39 lbf-ft) Install and tighten the 6 mm bolts. Install a new O-ring into the water hose joint 1 WATER HOSE JOINT groove. Install the water hose joint and tighten the bolts. Install the carburetor insulator with the "CARB UP” “CARS up" MARK INSULAIUR mark facing out and up so that the tab is positioned " / ’ as shown. ' Tighten the carburetor insulator band screw to the specified torque. YOROUE: 1 NAm (0.1 kgf-m , 0.7 Ibf-ft) CAMSHAFT INSTALLATION Apply molybdenum disulfide oil to the outer sur» face of the each valve lifter. Install the shims and valve lifters into the valve lift- er bores 8-21 CYLINDER HEAD/VALVES Apply molybdenum disulfide oil to the camshaft IDENTIFICATION MARKS journals and cam lobes. NOTE: The camshafts have the following identification markst “F W": Front cylinder intake camshaft "F EX": Front cylinder exhaust camshaft "R IN”: Rear cylinder intake camshaft "R EX": Rear cylinder exhaust camshaft {9‘ \ \V lnstall the camshaft in their proper location NOTE: "IN" MARK Install the each camshaft holder to the correct loca- . tions with the identification markst . "IN": Intake camshaft holder 1 . "EX": Exhaust camshaft holder . ‘ < —-—— Q a .\ i’ . ' / ‘4 "E X“ MARK CAMSHAFT HOLDER Install the dowel pins. Install the camshaft holders onto the camshafts. . DOWEL PINS A ‘ Apply oil to the threads and seating surfaces of the camshaft holder bolts‘ Install the bolts and tighten them in a crisscross pat» tern in 2 or 3 steps. YOROUE: 21 N-m(2.l kgf‘m,15lbf>ft) 8-22 CAM SPROCKET INSTALLATION NOTE: 0 If both front and rear camshafts were serviced, install the front cam sprocket first, then install the rearcam sprocket. oEven if you are servicing either the front or rear cylinder head, the other cylinder head cover must be removed and the other cam sprocket position must be checked. Remove the crankshaft hole cap and timing hole cap. FRONT CAM SPROCKETS: If the rear cylinder has not been serviced, remove the rear cylinder head cover and check the rear cam sprocket position as follows: Turn the crankshaft counterclockwise and align "RT" mark on the flywheel with the index mark on the left crankcase cover. Check the timing marks ("Rtl” for intake and "RE" for exhaust) on the rear cylinder cam sprockets If the timing marks are facing outward. turn the crankshaft counterclockwise 1-1/4 turn (450°) and align the “FT” mark with the index mark. If the timing marks are facing inward, turn the crank- shaft counterclockwise 1/4 turn (90°) and align the "FT" mark with the index mark. CYLINDER HEAD/VALVES CYLINDER HEAD/VALVES Install the cam sprockets onto the cam chain and cam sprocket flanges so that the timing marks (“F.l" for intake and "F.E" for exhaust) on the sprockets are flush with the cylinder head surface and facing outward as shown. Make sure that both intake and exhaust cam lobes are facing up, align the bolt holes in the cam sprockets and camshafts. Clean and apply locking agent to the cam sprocket bolt threads. Install the cam sprockets bolts‘ Turn the crankshaft counterclockwise one turn and install the remaining cam sprocket bolts. Tighten the cam sprocket bolts to the specified torque. TORQUE: 20 N-m (2.0 kgf-m , 14 |bf~ft) Turn the crankshaft counterclockwise one turn and tighten the other sprocket bolts to the same torque. Apply oil to the threads and seating surfaces of the camshaft holder bolts. Install the cam chain guide plate‘ Tighten the camshaft holder bolts to the specified torque. TORQUE: 21 N-m (2.1 kgf-m , 15 (bf-ft) Tighten the 6 mm bolt securely‘ Remove the stopper tool from the cam chain ten- sioner litter and install the sealing bolt with a new sealing washer. If the rear cylinder has been serviced, install the rear cylinder cam sprockets (see next page). Install the crankshaft hole cap and timing hole cap (page 3-10). Install the following: — Cylinder head cover (page 8-27l *Radiator (page 6-7, 8) —Air cleaner housing (page 5-5) “F I" MARK . ' \\ \ I ' CAME'PRQGKHS” ‘3“ CAM SPROCisiT sous fifm‘gfixw‘ne 'n: 7! v as 8-24 REAR CAM SPROCKET: If the front cylinder has not been serviced, remove the front cylinder head cover and check the front cam sprocket position as follows: Turn the crankshaft counterclockwise and align “FI'” mark on the flywheel with the index mark on the left crankcase cover. Check the timing marks (“F.I” for intake and “F.E” for exhaust) on the front cylinder cam sprockets. If the timing marks are facing outward, turn the crankshaft counterclockwise 3/4 turn (270°) and align the “RT” mark with the index mark. If the timing marks are facing inward, turn the crank- shaft counterclockwise 1-3/4 turn (630°) and align the "RT" mark with the index mark. Install the cam sprockets onto the cam chain and cam sprocket flanges so that the timing marks ("R.l" for intake and “R.E” for exhaust) on the sprockets are flush with the cylinder head surface and facing outward as shown. Install the camsprocket bolts and cam chain guide plate in the same procedures as for the front cylin» der. CYLINDER HEAD/VALVES ‘F I" MARK _ ’ a ‘ fififlfigzfiMARK "R I" MARK CYLINDER HEAD/VALVES CYLINDER HEAD COVER ASSEMBLY Install the new gasket and crankcase breather plate to the cylinder head cover. Apply a locking agent to the crankcase breather plate bolt threads‘ Tighten the bolts to the specified torque. TORQUE: 12 NT“ (1.2 kgf‘m , 9 |bf‘h) Install the FAIR check valves into the cylinder head cover. Apply sealant to the cylinder head cover side of a new packing. Install the cylinder head packing into the groove of the cylinder head cover. v PACKING 8-26 CYLINDER HEAD/VALVES CYLINDER HEAD COVER INSTALLATION dam Apply sealant to the cylinder head semi-circular cut-outs as shown CYLINDER HEAD Install the dowel pin and new O-ringl Install the cylinder head cover onto the cylinder CVLINDER HEAD coves head‘ Install the special washers with their "UP" mark "UP" MARK facing up \ l, / I / SPECIAL WASHER 8-27 CYLINDER HEAD/VALVES Install anti tighten the cylinder head cover bolts to CYLINDER HEAojaV/E US the specified torque. ; TORQUE: 1o N-m (1.0 kgtm , 7 Ibf‘ft) ' FRONT: Install the spark plug cap onto the plug‘ Connect the breather hose to the cylinder head covert Connect the PAIR check valve tube to the PAIR check valve Install the lower heat guard (page 17-6). REAR: Install the spark plug cap onto the plug, Connect the breather hose to the cylinder head coven Connect the PAIR check valve tube to the PAIR check valve. Install the fuel tank (page 2-10)‘ CAM CHAIN TENSIONER LIFTER REMOVAL Remove the carburetor (page 5-5). Remove the cam chain tensioner sealing bolt and sealing washert 8-28 CYLINDER HEADNALVES Turn the tensioner shaft fully in (clockwise) and secure it using the stopper tool to prevent damag- ing the cam chain. See page 8—7 for detail of the toolt BOLTS Remove the bolts and cam chain tensioner lifter. Remove the gasket. GASKET CAM CHAIN TENSIONER LIFTER INSTALLATION CAM CHAIN TENSIDNER LIFYER Turn the cam chain tensioner lifter shaft clockwise fully to retract the tensioner litter and secure it with a stopper tool. Install the new gasket onto the cam chain tensioner CAM CHAIN TENSIUNER llFTFR lifter. NOTE: Note the direction of the gasket, Install the cam chain tensioner lifter into the cylin- der head block. 8-29 CYLINDER HEADNALVES Install and tighten the bolts securely. SEALING BOLT 1' r Remove the stopper tool, y Install a new sealing washer and tighten the sealing boll securely. Install the carburetor (page 54 3)‘ 8-30 CLUTCH/GEARSHIFI' LINKAGE 23 N‘m (2,3 kgf-m ,17Ibf-ft) 127 Mm (130 kgf-m , 94 “#40 9-0 9. CLUTCH/GEARSHIFT LINKAGE SERVICE INFORMATION 9-1 GEARSHIFT LINKAGE 9-12 TROUBLESHOOflNG 9-2 PRIMARY DRIVE GEAR 9-14 RIGHT CRANKCASE COVER RIGHT CRANKCASE COVER REMOVAL 9-3 INSTALLATION 9-16 CLUTCH 9-3 cLUTCH LIFTER ARM 9-17 SERVICE INFORMATION GENERAL 0 This section covers service of the clutch. This service can be done with the engine installed in the frame. 0 Clean Off any gasket material from the right crankcase cover surface. 0 Be careful not to damage the crankcase cover mating surface when servicing. 0 When removing or servicing the clutch, use care not to allow the dust or dirt to enter the engine. 0 Transmission oil viscosity and level have an effect on clutch disengagement, When the clutch does not disengage or the motorcycle creeps with clutch disengaged, inspect the transmission oil level before servicing the clutch system. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Clutch leverfree play 10-20 (3/8—13/16) Clutch spring free length 49.6 (1.95) 46.6 (1.83) Clutch disc thickness 3.72i3.33 (0146—0153) 3.5 (0.14) Clutch plate warpage 0.30 (0.012) Clutch outer guide LD. 28.000*23.021 (I.1024*1.1032) 28.031 (1.1036) 0.0. 34375—34391 (1.3770* 1.3776) 34.965 (1.3766) Mainshaft CD. at clutch outer guide 27380—27393(1.1016*1.1021) 27.970(1.1012) TORQUE VALUES Clutch center lock nut Clutch spring bolt Oil pump driven sprocket bolt Gearshift cam bolt Gearshift spindle return spring pin Primary drive gear bolt TOOLS Clutch center holder Driver Attachment, 32 X 35 mm Attachment, 37 X 40 mm Attachment, 42 X 47 mm Pilot, 17 mm Pilot, 35 mm Gear holder 127 Mm (13.0 kgf-rrI . 941nm) 12 NM (1.2 kgf-m , 9 Ibf-ft) 15 N-m (1.5 kgf-m , 11 lbt-ft) 23 N-m (2.3 kgf-m ,17Ibf'ft) 23 N-m (2.3 kgf-m ,17Ibf'fl) 33 N-m (9.0 kgf-m , 65 Ibf'fl) 07724—0050002 07749-0010000 07746-0010100 07746-0010200 07746-0010300 07746-004040!) 07746-0040800 07724-0010100 Apply oil to the threads Stake the nut Apply a locking agent to the threads Apply a locking agent to the threads Apply oil to the threads CLUTCH/GEARSHIFT LINKAGE TROUBLESHOOTING clutch lever too hard to pull in 0 Damaged, kinked or dirty clutch cable 0 Faulty clutch lifter bearing 0 Damaged clutch lifter mechanism 0 Improperly routed clutch cable Clutch slips when accelerating 0 Clutch lifter sticking 0 Worn clutch discs 0 Weak clutch springs 0 No clutch lever free play 0 Transmission oil mixed with molybdenum or graphite additive Clutch will not disengage or motorcycle creeps with clutch disengaged 0 Too much clutch lever free play 0 Clutch plate warped 0 Loose clutch center lock nut 0 Improper oil viscosity 0 Engine oil too high, improper oil viscosity 0 Damaged clutch lifter mechanism 0 Clutch lifter piece installed improperly Hard to shift 0 Improper clutch operation 0 Improper oil viscosity 0 Bent shift fork 0 Bent shift fork shaft ' Bent fork claw 0 Damaged shift drum cam groove 0 Loose stopper plate bolt 0 Damaged stopper plate and pin 0 Damaged gearshift spindle Yranslnission jumps out of gear 0 Worn shift drum stopper arm 0 Weak or broken shift arm return spring 0 Loose stopper plate bolt 0 Bent shift fork shaft 0 Damaged shift drum cam groove - Damaged or bent shift forks 0 Worn gear engagement dogs or slots Gearshift pedal will not return 0 Week or broken gearshift spindle return spring O Bent gearshift spindle 9-2 CLUTCH/GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL Drain the engine oil (page 3—1 1) Drain the coolant (page 6-5), Remove the water pump cover (page 6—15). Disconnect the igniiion pulse generator 2F (Red) connector. Remove the bol‘s and right crankcase coveri Disconnect the drain ‘ube from ‘he right crankcase coveri Remove the gasket and dowel pins. CLUTCH REMOVAL Remove the clutch spring bolis, springs and pressure plate. Remove the cluich liner piece Remove the liner rod from ihe mainshaft. Remove the following: *Ten clutch discs ANine clutch plates -Judder spring —Spring seat CLUTCH/GEARSHIFT LINKAGE Unsta ke the clutch center lock nutt CAUTION: Be careful not to damage the mainshah‘ threads. Hold the clutch center with the clutch center holder, then remove the lock nuL YOOL: Clutch center holder 0772M050002 Discard the lock nut. Remove the lock washer and clutch center. Remove the washer. 9-4 CLUTCH/GEARSHIFT LINKAGE Align the primary drive gear and sub-gear teeth with a screwdriver as shown. Pull out the clutch outer. NOTE: When the oil pump driven sprocket will be re- moved, loosen the driven sprocket bolt with the clutch outer still installedt Remove the oil pump driven sprocket bolt/washer. Remove the oil pump drive/driven sprocket and drive chain as an assembly. Remove the clutch outer guide INSPECTION Clutch Iifur boaran Turn the inner race of the lifter bearing with your finger. The beaan should turn smoothly and lreely with- out excessive play. ll necessary replace the bearing. Drive the bearing out of the pressure plate. Drive a new bearing into the plate with its mark side facing out. TOOLS: Driver 07749—0010000 Attachment 32 X 35 mm 07746—0010100 Pilo‘, 17 mm 077450040400 Clutch spring Measure the clutch spring free length. SERVICE LIMIT: 4&6 mm (1.83 in) NOTE: Replace the clutch springs as a sett .— CLUTCH/GEARSHIFI' LINKAGE Clutch center Check the grooves of the clutch center for damage or wear caused by the clutch plates. Replace if necessary. Clutch disc Replace the clutch discs if they show signs of scar- ing or discoloration Measure the disc thickness of each disc, SERVICE LIMIT: 35 mm {0.14 in) NOTE: Replace the clutch discs and plates as a set Clutch plate Check each disc plate for warpage on a surface plate using a feeler gauge. SERVICE LIMIT: 030 mm (0.012 in) NOTE: Replace the clutch discs and plates as a set. Judder spring/spring seat Check the spring and seat for damage or warpage. CLUTCH CENTER SPRlNG SEAT JUDDER SPRING CLUTCH/GEARSHIFI' LINKAGE Clutch outer/clutch outer gulde Check the slots of the clutch outer for damage or wear caused by the clutch discs. Replace if necessary, Check the needle bearing lor wear or damage, Replace the needle bearing if necessary (page 9-8), CLUTCH OUTER Measure the 0D. and ID. of the clutch outer guide. SERVICE LIMITS: O‘DJ 34.965 mm (1.3766 in) I.D.: 28.031mml1.1036in) Mainshah Measure the mainshaft CD. at clutch outer guide sliding surface SERVICE LIMIT: 27.970 mm (1.1012 in) Clutch lifter rod LIF YER FlOD l Check the clutch litter rod for wear and lrueness. ‘, ~ / CLUTCH/GEARSHIFT LINKAGE CLUTCH OUTER NEEDLE BEARING REPLACEMENT DRIVER i - ' NEEDLE BEARING Press the needle bearing out of the clutch outer using the special too|st TOOLS: Driver 077490010000 . Attachment, 37 X 40 mm 07746—0010200 ’ Pilot, 35 mm 07746—0040800 ' P|L01 Press a new needle bearing into the clutch outer so DRIVER that the casing of the needle bearing is flush with the clutch outer surface as shown, a NEEDLE V BEARING 1 NOTE: Press the needle bearing into the clutch outer with the marked side facing up. TOOLS: Driver o7749—oo1oooo Attachment-12 X 47 mm 07746-0010300 Pilot, 35 mm 07746-0040800 INSTALLATION CLUTCH LIFTER non JUDDER SPRING CLUTCH DISC / SPRING SEAT PLATE B CLUTCH PLATE A CLUTCH OUTER GUIDE OIL PUMP DRIVE 12 N>m SPROCKET (1.2 kgf-m, » . . ' OIL PUMP DRIVEN 9 Ibf-ft) ; - SPROCKET LOCK ' ' 15 N-m (1.5 kgf‘m. 11 mm) WASHER // CLUTCH OUTER / WASHER g EbglcfiugENTER CLUTCH CENTER 127 Mm (130 kgf-m , 94 Ibf‘ft) Coat the clutch outer guide with molybdenum disulfide oil and install it onto the mainshal‘t with the flange side facing the crankcase. Install the oil pump drive/driven sprocket and drive chain as an assembly. NOTE: Install the oil pump driven sprocket with its index mark facing crankcase Apply a locking agent to the threads of the oil pump driven sprocket bolt. Install the oil pump driven sprocket bolt and wash- er, NOTE: Tighten the oil pump driven sprocket to the speci- fied torque after clutch outer installation, Align the primary drive gear and sub-gear teeth with a screwdriver as shown‘ Install the clutch outer to the meinshaft aligning the holes on the clutch outer and pins on the oil pump drive sprocket by turning the oil pump drive sprock- BL Tighten the oil pump driven sprocket bolt to the specified torque. TORQUE: 15 N-m (1.5 kgfrm , 11 Ibf‘ft) CLUTCH/GEARSHIFI' LINKAGE ‘ — INDEX MARK ‘ , "7HV9U1ER ' nnwt SPROCKETS. -— 6010:“ ’I ‘ v . LiTth‘lgUTIER -- |_ -. CLUTCH/GEARSHIFT LINKAGE Install the washer onto the clutch outer. Install the clutch center and lock washer. Apply oil to the threads and seating surface of a new clutch center lock nut and install it to the mainshaft. Hold the clutch center with the clutch center holder, then tighten the lock nut to the specified torque, TOOL: clutch center holder 07724—0050002 TORQUE: 127 Mm (13.0 kgf-m , 94 Ibf‘ft) Stake luck nut into the mainshaft groove with a punch‘ CAUTION: Be careful not to damage the mainshaft threads. 9-10 Install the spring seat and judder spring onto the clutch center as shown. Coat the clutch discs and plates with clean engine oil. Stack the ten clutch discs and nine plates (A: 8, B: 1) alternately, starting with the disc. NOT Clutch plate B has different surface as compared with clutch plate A. Install clutch plate B original position (as shown). NOTE: Install the outer clutch disc in the shallow slot on the clutch outer. Apply grease to the tip of the lifter rod and install it into the mainshal‘t. CLUTCH/GEARSHIFI' LINKAGE SPRING SEAT CLUTCH CENTER JUDDER SPRING 7E CLUTCH PLATE B LlFTER PIECE SIDE fl CLUTCH ARM SIDE 9-11 CLUTCH/GEARSHIFT LINKAGE Apply molybdenum disulfide oil to the clutch liner piece and install it into the mainshaft, Install the pressure plate. Install the clutch springs and spring bolts. Tighten the bolts in a crisscross pattern in 2*3 steps to the specified torque. TORQUE: 12 N-m (1,2 kgf-m , 9 lbf~fll Install the right crankcase cover (page 9-16), GEARSHIFI' LINKAGE REMOVAL Remove the clutch assembly (page 9-3). Remove the bolt and gearshift arm. Pull the gearshift spindle assembly and thrust wash- ‘ . t u GEA HIFT SPINDLE ASSEM er out at the crankcase, ' ' * ' \ _ \ Remove the following: . Fifi-figs MlfiIWA§HER —Gearshift cam bolt RN ‘ mg. ' ‘ *Gearshift cam —Dowel pin — Stopper arm bolt *Stopper arm —Washer *Return spring 9-12 CLUTCH/GEARSHIFI' LINKAGE INSPECTION RETURN SPRING Check the gearshift spindle for wear, damage or / bending. Check the return spring for fatigue or damage, INSTALLATION Install the following: *Washer *Return spring *Stopper arm Tighten the stopper arm bolt securely, Install the dowel pin onto the shift drum, . l' 3‘ " ' b'Ewét PIN‘I Lift the stopper arm with a screwdriver and insmll the gearshift cam by aligning the pin groove in the cam with the dowel pin. Apply a locking agent to the gearshift cam bolt threads. Install and tighten the gearshift cam bolt to the specified torque. TORQUE: 23 NM (23 kgf~m. 17 lbfll) CLUTCH/GEARSHIFT LINKAGE Install the thrust washer and gearshift spindle r assembly into the crankcase while aligning the spring ends with the gearshift spindle return spring pin. Install the gearshift arm aligning the punch marks on the gearshift spindlet Install and tighten the pinch bolt securely. Install the clutch assembly (page 9-8). PRIMARY DRIVE GEAR REMOVAL Remove the clutch (page 9-3)r Temporarily install the clutch outer. Install the special tool between the primary drive and driven gears as shown, loosen the primary drive gear bolt, and remove the bolt and special washer. TOOL: Gear holder 07724-0010100 Remove the clutch outer (page 96). Remove the ignition pulse generator rotor and primary drive gear assembly. J IG‘NITI‘mLfi GENEHWTORj 9-14 CLUTCH/GEARSHIFI' LINKAGE Remove the water pump driven sprocket and drive chain. INSTALLATION Apply molybdenum disultide oil to the water pump driven sprocket shaft. Install the water pump drive chain ever the drive and driven sprockets. Install the driven sprocket shaft into the crankcase Install the damper springs into the primary drive gear grooves. Apply molybdenum disulfide grease to the primary drive gear and sub-gear sliding surfaces, Install the sub-gear onto the primary drive gear boss so that the subgear tabs are positioned against the damper spring and holes see aligned. PHIMARV DRIVE GEAR SUE GEAR DAMPER SPRING HOLES TAB Install the primary drive gear assembly and ignition pulse generator rotor, aligning the wide grooves with the wide teeth. Bni VBRIVE '23 ' Apply oil to the threads and seating surface of the k . primary drive gear bolt. 1 Install the special washer and primary drive gear boltt Install the clutch outer (page 9-8)t Install the special tool between the primary drive and driven gears as shown Tighten the primary drive gear bolt to the specified torquet TOOL: Gear holder 07724-0010100 TORQUE: 88 Nm (9‘0 kgfrm , 65 Ibfrft) Install the clutch (page 9-8)t CLUTCH/GEARSHIFI' LINKAGE RIGHT CRANKCASE COVER INSTALLATION Apply a sealant to the mating surfaces of the crank- case as shown. Install the dowel pins and a new gasket onto the right crankcase cover‘ Install the right crankcase cover, aligning the gear teeth of the water pump shaft and water pump driven sprocket Install and tighten the right crankcase cover bolts securely‘ NOTE: Route the wire and tube currectIy (page 1-21). Connect the drain tube to the right crankcase cover. Connect the ignition pulse generator 2P (Red) con- nectar. Install the water pump cover (page 64% Pour the recommended engine oil (page 3-12). Fill and bleed the cooling system (page 6-5). 9-16 CLUTCH/GEARSHIFI' LINKAGE CLUTCH LIFTER ARM CLUTCH 1mm macs REMOVAL Remove the drive sprocket cover (page 7-3)‘ Remove the clutch lifter piece by turning the clutch lifter arm clockwise. Remove the clutch lifter arm, spring and washer. INSPECTION Check the dust seal for fatigue or damage. Check the needle bearing for wear, damage or loose fit. Replace these parts it necessarvr NOTE: If the dust seal replacement is required, press the dust seal to the case surface. NEEDLE BEARING Check the clutch lifter arm for damage or bending. Check the spring for fatigue or damage, Replace these pans if necessary. SPRING CLUTCH LIFTER ARM 9-17 CLUTCH/GEARSHIFI' LINKAGE Check the clutch lifter piece for damage or bending. Check the dust see! for fatigue or damage CLUTCH LIFTER PIECE / DUST SEAL INSTALLATION Apply grease to the dust seal lips and needle bear- ing. Apply grease to the clutch lifter arm sliding surface ‘ and slit. Install the washer, spring and clutch lifter arm. SleG/WASHER Align the clutch lifter arm slit and hole on the right CLUTCH LIFTER ARM crankcase cover by turning the clutch lifter arm clockwise. Apply grease to the clutch lifter piece. Install the clutch lifter piece Install the drive sprocket cover (page 742). 9-18 ALTERNATOR/STARTER CLUTCH 157 Nm (16.0 kgf-m,116lbf-fl) 12 NM (12 kngm ,9 lbflt) N 15 N-m(115 kgf-m,11|bf‘ffi 10 N-m (1.0 kgf‘m , 7 |th) 1 0-0 10. ALTERNATOR/STARTER CLUTCH SERVICE INFORMA110N 10-1 FLYWHEEL REMOVAL 1o-3 TROUBLESHOOTING 1o-1 STARTER CLUTCH 10—4 ALTERNATOR cOVER REMOVAL 10.2 FLYWHEEL INSTALLATION 1o-s STATOR 1o-2 ALTERNATOR COVER INSTALLATION 1o-7 SERVICE INFORMATION GENERAL 0 This section covers service of the alternator stator, flywheel and starter clutch. These parts can be removed with the engine installed in the frame. 0 The front cylinder cam sprockets must be removed to remove the starter reduction gear. 0 Refer to section 16 for alternator stator inspection, 0 Refer to section 18 for starter motor servicing. SPECIFICATION Unit: mm (in) ITEM STANDARD SERVICE LIMIT Starter driven gear boss O.D. 57‘749— 57768 (212736* 2.2743) 571539 (22692) TORQUE VALUES Flywheel bolt 157 N-m (16.0 kgf-rTI , 116 Ibfrft) Starter one-way clutch socket bolt 23 Nam (23 kgf~m , 17 lbf-ft) Stator socket bolt 12 Nam (12 kgf‘m , 9 lot-ft) Cam chain guide bolt 23 N-m (2,3 kngm, 17 lbf-ft) TOOLS Flywheel holder 077250040000 Rotor puller 077330020001 TROUBLESHOOTING Engine does not turn 0 Faulty starter clutch 0 Damaged starter reduction gear/shaft Apply oil to the threads and seating surface. Apply a locking agent to the threads. Apply a locking agent to the threads 10—1 ALTERNATOR/STARTER CLUTCH ALTERNATOR COVER REMOVAL STATOR Remove the fuel tank (page 2-10). Disconnect the alternator 3F (Black) connector. Remove the alternator cover bolts and alternator memfil' \\ cover. "‘ CAUTION: The alternator cover {stator} is magnetically at- tached to the flywheel, be careful during removal. NOTE: The engine oil will run out when the alternator cover is removed. Set a clean oil pan under the engine and add the recommended oil to the specified level after installation. Remove the gasket and dowel pins. SOCKET BOLTS wmr HROMMET REMOVAL Remove the alternator wire grommet from the alter- nator cover. Remove the socket bolt and stator wire holder. Remove the socket bolts and stator. 1 0-2 ALTERNATOR/STARTER CLUTCH 'NSTALLATION soch sons J WIREGROMMET . i Install the stator into the alternator cover. Apply sealant to the wire grommet, then install the wire grommet into the alternator cover groove se- curely‘ Install and tighten the socket bolts to the specified torque, TORQUE: 12 Nm (1.2 kgfrm , 9 lbf-ft) Install the wire holder and tighten the socket bolt securely. FLYWHEEL REMOVAL Flemove the alternator cover (page 10-2). Hold the flywheel using the flywheel holder, then remove the flywheel bolt. TOOL’ Flywhul holder 077250040000 Remove the washert Remove the flywheel using the special tool. TOOL: Rotor puller 07733—0020001 Remove the woodruff key, ALTERNATOR/STARTER CLUTCH Remove the from cylinder cam sprockels (page 8-7). Remove the boll and cam chain guide Pull the starter reduction gear shaft and remove the reduction gear. Check the starter reduction gear and shaft for wear or damage. STARTER CLUTCH STARTER DRIVEN GEAR INSPECTION Check the operation of the one-way cluich by turn- ing the driven gear. You should be able to tum the driven gear counier- clockwise smoothly, but the gear should not turn clockwise. DISASSEMBLY STARTER DRIVEN GEAR Remove the siarter driven gear by turning it coun- ierclockwise. 1 0-4 Hold the flywheel with a flywheel holder, and re- move the starter one-way clutch socket boltsl TOOL: Flywheel holder 07725-0040000 Remove the starter one-way clutch assembly. Remove the starter one0‘0022 in) Calculate the taper and out of round at three levels in X and Y axis Take the maximum reading to determine them. SERVICE LIMITS: Taper: 0.10 mm (0004 in) Out of round: 010 mm (0004 in) MIDDLE PISTON ASSEMBLY Clean the piston ring grooves thoroughly and in- stall the piston rings, NOTE: 0 Apply oil to the piston rings 0 Avoid piston and piston ring damage during installation 0 Install the piston rings with the marking (R) fac- ing up. 0 Do not mix the top and second rings; the top ring is narrower than the second ring in width, 12-12 Space the piston ring and gaps 180 degrees apart Do not align the gaps in the oil rings (side rails). After installation, the rings should rotate freely in the ring grooves. PISTON INSTALLATION Apply molybdenum disulfide oil to the connecting rod small end, Assemble the piston and connecting rod. Front cylinder piston: Note that the connecting rod has "MBB" mark. Install the piston on the connecting rod so that the "F-IN" mark is facing the same direction as the oil hole in the rod. Rear cylinder piston: Rearcylinder piston has "R" mark, Note that the connecting rod has “MBB” mark. Install the piston on the connecting rod so that the "IN" mark is opposite the oil hole in the rod. CRANKSHAFI'[PISTON/CYLINDER MARK TOP RING —> SECOND RING *m OIL RING SIDE RAILS SPACER r ‘\ \ 20 mm or more PISTON OIL HOLE "MBB" MARK "F-lN" MARK “IN” MARK "R" MARK OIL HOI£ 12-13 CRANKSHAFI'IPISTON/CYLINDER Apply molybdenum disultide oil to the piston pin outer surface. Install the piston pin, and secure it using a new piston pin clips. NOTE: Do not align the piston pin clips end gap with the piston cut-out. Coat the piston and piston rings with the engine oil. Install the piston/connecting rod assembly in the cylinder with the “IN” mark toward the intake side, using a commercially available piston ring oom- pressor tool. Apply molybdenum disultide oil to the main journal bearing sliding surfaces on the upper crankcase, and erankpin bearing sliding surfaces on the con- necting rods and bearing caps. Install the crankshaft onto the upper crankcase. Set the connecting rods onto the era nkpin. Install the bearing caps, aligning the dowel pins with the holes in the connecting rods. Apply oil to new connecting bolt threads and seat- ing surfaces and install the bolts. CAUTION: The oannectlng rod bolts cannot be reused. Once the connecting rod bol'ts have been loosened re- place them with new ones. Tighten the bolts in 2 or 3 steps alternately. TORQUE: 29 Nm (3.0 kgf-m , 22 lbf-fl) i 120“ Assemble the crankcase halves (page 11-10), PISTON PIN 12-14 FRONT WHEEL/SUSPENSION/STEERING 27 N-m (2‘8 kgf-m , 20 lbf-fl) g 31 Nm (3.2 kgf‘m , 23 lbfrfl) \ ,- \ 27 N-m (2,8 kngm , 20 IN“) a 31 N-m (3.2 kgfrm . §f 23 Ibf-fl) L' s: 59 N-m (6‘0 kgf-m, 43 Ibf-h) . / 22 N-m (2‘2 kgf-m ,16lbf-ft) “as / 22 him (22 kgf>m,16|bf-ft) 0 v 31 NM (3.2 kgf-m , 23 lbf-ft) 13-0 13. FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMAHON 13-1 TROUBLESHOOTING 13-2 HANDLEBAR 13-3 FRONT WHEEL FORK STEERING STEM 13-12 13-18 13-30 SERVICE INFORMATION GENERAL ‘ “WARNING - Riding on damaged rims impairs safe operation of the vehicle. - A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. 0 A hoist or equivalent is required to support the motorcycle when servicing the Iront wheel, fork and steering stem. 0 Refer to section 15 for brake system service. 0 Use only tires marked “TUBELESS” and tubeless valves on rim marked “TUBELESS TIRE APPLICABLE”. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Minimum tire tread depth 1.5 (0.06) Cold tire pressure Driver only 250 kPa (2,50 kgf/cmz , 36 psi) Driver and passenger 250 kPa (2.50 kgf/cm2 , 36 psi) Axle runout 0.20 (0.008) Wheel rim runout Radial 7 2.0 (0.08) Axial 7 2.0 (0.03) Wheel balance weight — 60 g (2.1 climax. Fork Spring free length 428.8 (16.88) 420.2 (16.54) Tube runout — 0.20 (0008) Recommended fluid Fork fluid Fluid level 114 (4.5) 7 Fluid capacity 529 i 2.5 cm“ (17.9 :r 0.08 US oz, 7 18.7 t 0.09 Imp Dz) Steering head bearing preload 1.0*1.5 kgf (2.2*3.3 lbf) — 13-1 FRONT WHEEL/SUSPENSION/STEERING TOROUE VALUES Handiebarweight mounting screw Throttle housing screw Front axle bolt Front axle holder bolt From brake disc bolt Right front caliper mounting bolt Fork cap Fork socket bolt Fork top bridge pinch bolt Fork bottom bridge pinch bolt Front brake hose clamp bolt (fork side) Steering stem nut Steering stern bearing adjusting nut Bystarter lever pivot bolt Handlebar upper holder bolt Handlebar lower holder nut Left front caliper pivot bolt Left front caliper bolt (secondary masteriointi TOOLS Bearing remover shaft Bearing remover head, 20 mm Driver Attachment. 42 X 47 mm Attachment, 52 X 55 mm Pilot, 20 mm Slider weight Oil seal driver Steering stern socket Ball race remover Ball race remover Driver amchment Driver handle Needle bearing remover Steering stem driver TROUBLESHOOTING Hard steering 0 Steering bearing adjustment nut too tight 0 Worn of damaged steering head bearings 0 Bent steering stem I insufficient tire pressure Steers one side or does not track straight e Damaged or loose steering head bearings 0 Bent forks 0 Bent axle oWheel installed incorrectly 0 Bent frame - Worn or damaged wheel bearings 0 Worn or damaged swingarm pivot bearings Front wheel wobbling ' Bent rim O Worn or damaged front wheel bearings 0 Faulty front tire - Unbalanced front tire and wheel 10 N-m (1.0 kgf‘m , 7 lbf-ft) ALOC screw 4 N-m (0.42 kgf‘m , 3.0 in-fti 59 N-m (6.0 kgf‘m , 43 Ibf-ft) 22 N-m (2.2 ngm ,16Ibf-ft) 20 N-m (2.0 kgf~m , 14 lbf‘ft) ALOC bolt 31 Nm (3.2 kgf-m , 23 Ibf-ft) ALOC bolt 22 N-m (2.2 kgf-m ,16Ibf-ft) 20 N-m (2.0 kgf-m ,14Ibf-ft) 22 N~m (2.2 kgf'm ,16Ibf‘ft) 27 N-m (2.8 kgf'm , 20 W0“) 12 N~m (1,2 kgfrm , 9 Ibfrft) 103 N-m (10.5 kgf‘m , 75 WM!) 25 N~m (2,5 kgf-m ,18Ibf‘fli 9 N-m (0.9 kgf'm , 6,5 lbf‘ft) 27 N-m (2.8 kgf~m , 20 Ibf-m 27 Nm (2.8 kgf~m , 20 mini 31 N'm (3.2 kgf‘m , 23 lbf'fli 31 Nm (3.2 kgf-m , 23 lbf~ffi ALOC bolt ALOC bolt 07746-0050 1 00 077400050600 077490010000 077460010300 077460010400 077460040500 07947-KA501 00 07947-KA40200 07916—3710101 07946371 0500 07953-MJ 10000 07953-MJ10100 07953-MJ10200 07946-KA50000 07946-M300000 Front wheel turns hard 0 Faulty front wheel bearings 0 Bent front axle 0 Front brake drag Soft suspension 0 insufficient fluid in fork - incorrect fork fluid weight 0 Weak fork springs - Insufficient tire pressure Hard suspension 0 Bent fork tubes 0 Too much fluid in fork 0 Incorrect fork fluid weight 0 Clogged fork fluid passage Front suspension noise 0 Insufficient fluid in fork 0 Loose fork fasteners 13-2 Apply locking agent to the threads FRONT WHEEL/SUSPENSION/STEERING HAN DLEBAR wiggle? REMOVAL / Remove the wire bands and rearview mirrors. memos Disconnect the clutch switch connectors from the EFY HANDLEBAR SWITCH clutch lever bracket. Remove the screws and left handlebar switch from the handlebar, Remove the haltv nutv collar and knuckle guard. BOLT KNUCKLE GUARD NUTI‘COLLAR Remove the byslarter lever/clutch lever pivot bolt. T V Disconnect the clutch cable and choke cable from CROKE CABLE PWOT BOLT BVSTAR ER LE ER the clutch lever and bystaner lever. Remove the bystaner lever and clutch levert C TCH CABLE CLUTCH LEVER 13-3 FRONT WHEEL/SUSPENSION/STEERING Remove the set plate, Remove the screws and clutch lever bracket holder from the handlebar. Remove the clutch lever bracket from the handle- bar‘ Remove the screw, handlebar weight and the hen- dlebar gripfrom the handlebar. Remove the master cylinder from the handlebar (page 15-13)t CAUTION: Do not disconnect the hydraulic line. NOTE: Keep the master cylinder upright to prevent air 'from entering the hydraulic system. CLUTCH LEVER BRACKET HANDLEBAR WEIGHT MASTER CYLINDER BRACKET HOLDER / 13-4 FRONT WHEEL/SUSPENSION/STEERING Remove the screws and throttle housing cover from the handlebar. SCREWS / THROTYLE HOUSING COVER throttle cables from the throttle pipe. mm“ L: CABLES THROI M "OUS'M‘ Remove the throttle cable guide and disconnect the \ Remove the throttle housing from the handlebarl \ mm 11,; PIPE CABLE GUIDE Remove the screws and engine stop switch from ENGINE STOP SWITCH the handlebar. ,-’ A \L SCREWS W R | T Remove the screw, handlebar weight and throttle K L E? WF 6H grip from the handlebar, 13-5 FRONT WHEEL/SUSPENSION/STEERING NOTE: If the handlebar lower holders will be removed, loosen the lower holder nuts before removing the upper holders. Loosen the handlebar lower holder nuts, NOTE: Do not remove the handlebar lower holder nuts yet Remove the handlebar upper holder bolt caps. Remove the handlebar upper holder bolts and upper holders, Remove the handlebar. Remove the handlebar lower holder nuts/washers and lower holders. Check the bushings for wear or damage. Replace the bushing if necessary. 13-6 FRONT WHEEL/SUSPENSION/STEERING INSTALLATION mm [513145111121 4’ "“x Install the handlebar lower holders/washers and handlebar lower holder nuts/washers. NOTE: Do not tighten the lower holder nuts yeti Install the handlebar and handlebar upper holderst NOTE: Install the handlebar upper holder with its punch mark facing toward. Install and tighten the handlebar upper holder bolts to the specified torque. NOTE: At handlebar upper holder bolts installation, tight- en the forward bolts first, then tighten the rear boltst TORQUE: 27 Nm (2.8 kgf‘m , 20 Ibf-ft) Install the handlebar upper holder bolt caps. Tighten the handlebar lower holder nuts to the spec ified torque. TORQUE: 27 N-m (2.8 kgf-m , 20 lbfth) FRONT WHEEL/SUSPENSION/STEERING Clean the inside surface of the left handlebar grip and the outside surface of the handlebar. Apply Honda Band A or equivalent to the inside surface of the left handlebar grip and outside sur- face ofthe handlebar. Wait 3—5 minutes and install the grip. Rotate the grip for even application of adhesive. NOTE: Allow the adhesive to dry for an hour before using. Install the handlebar weight to the handlebar align- HANDLES“ WE'GHT ing the tab on the handlebar weight with the slit of the handlebar. Install and tighten the new screw to the specified torque. TORQUE: 10 N-m (1.0 kgf-m , 7 lbf-ft) ¢,\ v Install the clutch lever bracket and holder, aligning mating surface of the holder with the punch mark on the handlebar. Tighten the forward screw first, then tighten the rear screw. CLUTCH LEVER BRACKET \ PUNCH MARK BRACKET HOLDER SCREWS Install the set plate to the clutch lever bracket. aligning the tab on the set plate with the hole on the clutch lever bracket. SET PLATE 13-8 FRONT WHEEL/SUSPENSION/STEERING Install the clutch lever and bystarter levert Apply grease to the bystarter lever/clutch lever BVSYARTER CAELE “STARTER LEVER l I pivot be“ \ PIVOT BOLT I Install and tighten the bystarter lever/clutch lever pivot bolt to the specified torque. TORQUE: 9 N‘m (0‘9 kgfrm , 6.5 Ibf-ftl Connect the clutch cable and choke cable to the clutch lever and bystarter lever. CLUTCH CABLE CLUTCH LEVER Install the knuckle guard, collar, bolt and nut, Install the dust cover over the clutch lever bracket. DUST COVER 30” / NUT/COLLAR Connect the clutch switch connectors Install the left handlebar switch, aligning the pin on the switch with the hole in the handlebar, LEFT HANDLEBAR SWITCH Tighten the forward screw first, then tighten the rear screw. 13-9 FRONT WHEEL/SUSPENSION/STEERING Apply grease to the throttle pipe inner surface and handlebar sliding outer surface Install the throttle pipe. 3‘ YHROHLE PIPE Install the handlebar weight to the handlebar align- ing the tab on the handlebar weight with the slit of the handlebart Install and tighten the new screw to the specified torque. TORQUE: 10 NM (1.0 kgf‘m , 7 lbl-l‘t) ENGINE STOP SWlTCN HOLE \ /’ Install the engine stop switch, aligning the pin on the switch with the hole in the handlebari 13-10 FRONT WHEEL/SUSPENSION/STEERING Tighten the forward screw first, then tighten the rear screw. \ \ A SCREWS Apply grease to the throttle cable ends and connect them to the throttle grip. E—fim maoms CABLES Apply grease to the throttle cable guide sliding sur- ' '3. face. ‘ ‘ Install the Ihrottle cable guide to the throttle hous- ing. 1 ‘mep .fim CABLE GUIDE Install the throttle housing to the handlebar. THRO "LE HOUSING LINER Install the throttle housing cover to the throttle ’ housing aligning its mating surface with the punch mark on the handlebar. T HROT iLE HOUSING Install and tighten the throttle housing cover SCREWS screws to the specified torque ( TORQUE: 4 N‘m (0‘42 kgtrm , 3.0 Ibi‘ft) Install the master cylinder (page 15-18). Install the wire bands and reerview mirrors, NOTE: Route the cables, wires and harness properly (page 1-21). FRONT WHEEL/SUSPENSION/STEERING FRONT WHEEL REMOVAL m.— A oontamlnated brake disc or pad reduces stopplng power. Discard contaminated pads and olnn a eontaminatod disc with a high quality brake degmslng agent. Support the motorcycle securely using a safety stand or a hoist. Loosen the right axle holder bolts. Remove the axle bolt. Loosen the left axle holder bolts. Remove the mounting bolts and right brake caliper. CAUTION: Support the brake caliper with a piece of wire so that is does not hang from the brake hose. Do not twist the brake hose. NOTE: Do not operate the brake lever or pedal after the brake caliper is removed. Remove the axle and the front wheel. 13-12 FRONT WHEEL/SUSPENSION/STEERING INSPECTION Axle Set the axle in V-block and measure the runout: Actual runout is 1/2 the total indicator reading. SERVICE LIMIT: 020 mm (0.008 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 lits tightly in the hub. Remove and discard the bearings il they do not turn smoothly, quietly, or if they fit loosely in the hub. NOTE: Replace the bearings in pairs. Install the new bearings into the hub using the special tools (page 13-15). Wheel rim runout Check the rim runout by placing the wheel in a turning stand. Spin the wheel by hand, 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 balance CAUTION: Wheel balance directly affects the stability, handling and over all safety of the motorcycle Always check balance when the tire has been removed from the rim. NOTE: For optimum balance, the tire balance mark (a point dot on the side wall) must be located next to the valve stem. Remount the tire it necessary. FRONT AXLE INSPECTION STAND 13-13 FRONT WHEEL/SUSPENSION/STEERING NOTE: Note the rotating direction marks on the wheel and tire. Remove the dust seals from the wheel. Mount the wheel, tire and brake discs assembly in an inspection stand. Spin the wheel, allow it to stop, and mark the low est (heaviest) point of the wheel with a chalk. Do this two or three times to verify the heaviest area if the wheel is balanced, it will not stop consistently in the same position To balance the wheel, install wheel weights on the highest side of the rim, the side opposite the chalk marks, Add just enough weight so the wheel will no longer stop in the same position when it is spun‘ Do not add more than 60 grams to the wheeL DISASSEMBLY Remove the side collars Remove the dust seals. Remove the bolts and brake discs 13-14 FRONT WHEEL/SUSPENSION/STEERING Install the bearing remover head into the bearing. From the opposite side, install the bearing remover shaft and drive the bearing out of the wheel hubt Remove the distance collar and drive out the other bearing, TOOLS: Bearing remover held, 20 mm 07746-0050600 Boaran remover shaft 07746-0050100 ASSEMBLY $0 NM (2.0 kgf-m,14lbf-h) FRONT WHEEL RIGHT BRAKE DISC LEFT WHEEL BEARING LEFT DUST SEAL LEFT BRAKE DISC CAUTION: Never install the old bearings. Once the bearings has been rcmovcd, the bearing must be replaced with new ones. Drive in a new right bearing squarely. Install the distance collar, then drive in the left bearing using the special tool. TOOLS: Driver 07749-0010000 Attachment, 42 X 47 mm 077460010300 Pilot 20 mm 0774641040500 FRONT WHEEL/SUSPENSION/STEERING m___— Do not get grease on the brake discs or stopping power will be reduced. Install the brake discs on the wheel hub with its rotating direction mark (a) facing out Install and lighten the new brake disc bolts to the specified torquet TORQUE: 20 N«m (2,0 kgf'm , 14 Ibt-I‘t) INSTALLATION Apply grease to the dust seal lips, then install the dust seals into the wheel hub. Install the side collars. Apply thin layer of grease to the front axle surface. Install the front axle from the left side. Install the right brake caliper and tighten the new mounting bolts to the specified turque‘ YOROUE: 31 NJ?! (3.2 kgf-m , 23 lbf-ftl 13-16 FRONT WHEEL/SUSPENSION/STEERING Hold the axle and tighten the axle bolt to the speci- fied torque, TORQUE: 59 N-m (6,0 kgf-m , 43 Ibf-l‘t) Tighten the right axle holder bolts to the specified torque, TORQUE: 22 N-m (2.2 kgf-m, 16 "3"!) with the front brake applied, pump the fork up and down several times to seat the axle, D check the brake operation by applying the brake lever and pedal. Tighten the left axle holder bolts to the specified torque. TORQUE: 22 N-m (2‘2 kgf-m,16lbf-ftl Check the clearance between the brake disc and BRA pm caliper bracket on each side after installation V The clearance should be at least 0.7 mm (0.03 in), I ‘ kt I a 9 ' n“ ‘ ' FRONT WHEEL/SUSPENSION/STEERING FORK REMOVAL Remove front wheel (page 13-12). For the left fork leg removal, remove the following: PIVOT 50” 7 Left brake caliper pivot bolt ASecondary master cylinder joint bolt Remove the brake pipe/hose clamp bolts. Remove the socket bolts and bolt‘ Remove the bolt, front fender and front fender bracket. 13-18 FRONT WHEEL/SUSPENSION/STEERING Loosen the top bridge pinch bolt. When the fork leg will be disassembled, loosen the fork cap, but do not remove it yet, Loosen the fork bottom pinch bolt and remove the fork tube from the fork top bridge. DISASSEMBLY FORK ICAP ,\> CAUTION: \ Be careful not to scratch the fork tube or damage \ the dust seal. _ Remove the fork cap from the fork tube. Remove the fork spring collar and spring spacer SPR'NG COELAR from the fork tubet Remove the fork spring from the fork tube. FORK SPRING 13-19 FRONT WHEEL/SUSPENSION/STEERING Pour out the fork oil from the fork leg by pumping the fork 8— 10 times. Hold the fork slider in a vice with soft jaws or a shop toweli Remove the fork socket bolt with a hex wrench. NOTE: If the fork piston turns together with the socket bolt, temporarily install the fork spring, spring spacer, fork spring collar and fork cape Remove the fork piston and rebound spring. FORK p’sYoN NOTE: Do not remove the fork piston ring, unless it is _ necessary to replace with a new one. \ REBOUND SPRING FORK PISY‘ON RING R . emove the dust seal DUST SEAL 13-20 FRONT WHEEL/SUSPENSION/STEERING Remove the stopper ringt STOPPER RING CAUTION: Do not scratch the fork tub: sliding surface. NOTE: Check that the fork tube moves smoothly in the fork slidert If it does not, check the fork tube for bending or damage, and bushings for wear or damage Pull the fork tube out until you feel resistance from the slider bushingt Then move it in and out, tapping the bushing lightly until the fork tube separates from the fork slider, The slider bushing will be forced out by the fork tube bushingt Remove the oil lock piece from the fork slidert V / FORK TUBE FORK SLIDE“ l l l l N / / OIL LOCK PIECE Remove the oil seal, back-up ring and slider bushing from the fork tuber OIL SEAL BACK UP RING \\ FORK TUBE SLIDER BUSHING 13-21 FRONT WHEEL/SUSPENSION/STEERING NOTE: Do not remove the fork tube bushing unless it is necessary to replace it with a new one Carefully remove the fork tube bushing by prying the slot with a screwdriver until the bushing can be pulled off by hand‘ INSPECTION Fork spring Measure the fork spring free length. SERVICE LIMIT: Fork sprlng: 420.2 mm (16.54 in) Fork tube/slider/piston Check the fork tube and fork slider for score marks, scratches, or excessive or abnormal wear, Replace any components which are worn or dam- aged, Check the fork piston ring for wear or damage. Check the rebound spring for fatigue or damage. Replace the component if necessary, FORK TUBE BUSHING \ / FORK SLIDER FORK PISTON RING REBOUND SPRING FORK TUBE FORK PISTON / / / 13-22 FRONT WHEEL/SUSPENSION/STEERING Place the fork tube in V-block and measure the runoutt DIAL INDICATOR Actual runout is 1/2 the total indicator reading, SERVICE LIMIT: 0.20 mm (0.008 ml FORK TUBE Fork tube bushing Visually inspect the slider and fork tube bushings BUSHING Replace the bushings it there is excessive scoring or scratching, or if the teflon is worn so that the BACK'UPR'NG copper surface appears on more than 3/4 of the entire surface. Check the back-up ring; replace it if there is any distortion at the poinfi shown‘ CHECK POINTS COPPER SURFACE BRAKE CAMPER PIVOT BEARINGS REPLACEMENT Remove the dust seals and pivot collar‘ Q , ,_\\/ DUST SEALS I Press out the pivot bearings using the special tool. NEEDLE BEARING HEM TIER TOOL: Needle bearing remover O7946-KA50000 1 3-23 FRONT WHEEL/SUSPENSION/STEERING Apply grease to the pivot bearings. Press the needle bearings into the lurk slider using q the same tool, NEEDLE B ARING NOTE: . ‘3,5mrn ‘0.1‘Il’ll Install the bearings so that the bearing cage below ‘ 3.5 mm (0.14 in) from the pivot surface, TOOL: Needle bearing remover 07946-KA50000 Apply grease to the new dust seal lips‘ Install the dust seals and pivot collar. \ / S! & Distsuts Check the pivot collar and bushing for wear or dam- age ‘BU Replace the component if necessary. \\ PWOT COLLAR 13-24 FRONT WHEEL/SUSPENSION/STEERING ASSEMBLY Before assembly, wash all parts with a high flash or non-flammable solvent and wipe them dry. 2? FORK PISTON RING g OIL SEAL STOPPER RING DUST SEAL '* r Wfi SPRING COLLAR / I FORK CAP OIL LOCK PIECE // / I / 9/ 4‘! FORK SLIDER / I , [4‘ SPRING SPACER FORK TUBE I FORK SPRING BACK—UP RING 4‘! SEALING WASHER GUIDE BUSHING/ FORK PISTON REBOUND SPRING FORK SOCKET BOLT 20 Nm (2.0 kgf‘m ,14lbf-ft) g FORK TUBE BUSHING Install a new fork tube bushing if the bushing has been removed, CAUTION: 0 Be careful not to damage the fork tube bushing coating. 0 Do not open the fork tube bushing more than necessary NOTE: Remove the burrs from the bushing mating surface, being cereiul not to peel off the coating. \ . I Apply fork oil to the new oil seal lip. v a ou‘ SEAL EACK UP RING Install the slider bushing, back-up ring and a new oil seaL NOTE: lnstelI the oil seal with its marked side facing up. SLIDER BUSHING 13-25 FRONT WHEEL/SUSPENSION/STEERING Install the oil lock piece to the fork tube. r _ OIL LOCK PIECE Install the fork lube into the fork slider‘ ‘ /" FORK TUBE FORK SLIDER Drive the oil seal in using the special tools SLIDER WEIEHT STOWER RWG i "- OIL SEAL TOOLS: \\ (I, Slider weight D7947-KA50100 \ r. , Oil seal driver 07947-KA40200 ‘ / t / BACKUP \ ‘ RING \ GUlDE BUSHING Install the stopper ring into the fork slider groove securely. Install the dust seal. DUST SEAL , 13-26 FRONT WHEEL/SUSPENSION/STEERING Install the rebound spring to the fork piston. Install the fork piston into the fork tuber FORK TUBE REBOUND SPRING FORK PISTON Hold the fork slider in a vise with soft jaws or a $"°P‘°‘”e'- 0 SEALING WASHE Clean and apply a locking agent to the fork socket my 4* boltthreadsi Install the socket bolt with a new sealing washer. Tighten the bolt to the specified torque FORK SOCKET BOLT NOTE: If the fork piston turns together with the socket bolt, temporarily install the fork spring, spring spacer, fork spring collar and fork cap, TORQUE: 20 N-m (2.0 kgf‘m , 14 lbf'fl) Pour the specified amount of recommended fork fluid into the fork tube. RECOMMENDED FORK FLUID: Fork fluid FORK FLUID CAPACITY: 529 t 2,5 cm3 (17.9 i: 0.03 US oz, 18.7 1 009 Imp oz) Pump the fork tube several ti mesi 13-27 FRONT WHEEL/SUSPENSION/STEERING Measure the oil level from the top of the fork tube while compressing the tube all the way after stroking the fork tube slowly more than 5 times and the damper rod more than lotimes, NOTE OIL LEVEL Be sure the oil level is the same in the both forkst FORK OIL LEVEL:114 mm (4.5 in) Pull the fork tube up and install the fork spring with the tightly would end facing down, « TlGHTLY WOULD END WMMAMNWVWWVWN Install the spring spacert SPRING COLLAR Install the fork spring collart spams SPACER Install new O—rings onto the fork cap. Apply fork fluid to the new O-rings. FORK CAP Install the fork cap into the fork tube. NOTE: Tighten the fork cap after installing the fork tube into the fork bridge. 13-28 FRONT WHEEL/SUSPENSION/STEERING INSTALLATION Install the fork legs into the steering stern and fork top bridge. Align the top end of the fork tube with the upper surface of the top bridge as shown. Tighten the bottom bridge pinch bolt to the speci- fied torque. TORQUE: 27 Nm (2.8 kgfrm , 20 lbf‘fi) Tighten the fork cap to the specified torque (if it was removed). TORQUE: 22 N-m (2.2 kgf~m. 16 |le) Tighten the top bridge pinch bolt to the specified torque. TORQUE: 22 Nm (2.2 kgf‘m,16|bf‘ft) Install the front fender bracket and front fender. Install the bolt. Install the bolt and socket bolts. 13-29 FRONT WHEEL/SUSPENSION/STEEHING Install and tighten the brake pipe/hose clamp bolts securely. Install the following: - New secondary master cylinder mounting bolts TORQUE: 31 N Lower bearing Check the steering bearings, inner and outer races for wear or damage BEARING REPLACEMENT NOTE: Always replace the bearings and races as a set. Remove the lower bearing outer races using the following tool. TOOL: Bearing race remover 079468710500 FRONT WHEEL/SUSPENSION/STEERING Remove the upper bearing outer races using the following tool. TOOLS: Ball race remover 07953-MJ 10000 Driver attachment O7953-MJ 10100 Driver handle 07953-MJ10200 Temporarily insmll the steering stem nut onto the stem to prevent the threads from being damaged when removing the lower bearing inner race from the stem. Remove the lower bearing inner race with a chisel or equivalent tool, being careful not to damage the stem. Remove the dust seal, Apply grease to new dust seal lips and install it over the steering stem: Install a new lower bearing inner race using a special tool and a hydraulic press. TOOL: Steering stem driver 07946-M 300000 Drive the new upper bearing outer race into the head pipe using the following tools‘ TOOLS: Driver 07749-0010000 Driver attachment, 42 X 41 mm 07746-0010300 Drive the new lower bearing outer race into the head pipe using the following tools‘ TOOLS: Driver 07749-0010000 Driver attachment, 52 X 55 mm 07746-0010400 STEERING STEM NUT /! STEERING STEM DRI‘ ' 9,6» DUST SEAL / 13-32 FRONT WHEEL/8USPENSION/STEERING INSTALLATION STEERING STEM NUT gLOCK WASHER 103 Nrml1o.5 kgrm , 7s Ibt-ft) , ‘ Q3 STEM BEARING Top BRIDGE ADJUSTING NUT LOCK NUT 25 N-m (2.5 kgt-m, i" 18 Ibf-ft) / / /// 12 N-m (1.2 kgt-m . 9 Ibf-l‘t) // ~fi DUST SEAL IQ UPPER BEARING INNER RACE m UPPER BEARING E '3 ®‘\ UPPER BEARING LOWER BEARING \ OUTER RACE LOWER BEARING INNER RACE ® LOWER BEARING OUTER RACE STEERING STEM Apply grease to the lower bearing and bearing race. Install the lower bearing onto the steering stern. Insert the steering stem into the steering head pipe. Apply grease to the upper bearing and bearing race. Install upper bearing, inner race and dust seal. Install and tighten the stem bearing adjusting nut to the initial torque. TOOL: Steering stem socket 07916—371010] TORQUE: 25 N‘m (2.5 kgf‘my18lbf‘fti Move the steering stern right and left, lock-to-Iock, five times to seat the bearings. Make sure that the steering stern moves smoothly, without play or binding; then loosen the bearing I adjusting nut. Retighten the bearing adjusting nut to the specified torque. TORQUE: 25 N-m (2.5 kgf>m , 18 lbI-ft) FRONT WHEEL/SUSPENSION/STEERING Recheck that the steering stem moves smoothly without play or binding. Install the new lock washer onto the steering stem. Align the tabs of the lock washer with the grooves in the adiusting nut and bend two opposite tabs (shorter) down into the adjusting nut groove. Install and finger tighten the lock nut. Hold the lock nut and further tighten the lock nut within 1/4 turn (90°) enough to align its grooves with the lock washer tabs. Bend the lock washer tabs up into the lock nut groove. Install the top bridge. Install the fork legs (page 13-29). Connect the ignition switch 3P connector (page 19-16). Install the steering stern nut. Tighten the steering stem nut to the specified torque. TORQUE: 103 Nm (10.5 kgf~m ,761bf‘h) Install the delay valve and tighten the bolts to the specified torque. TORQUE: 12 N-m (1.2 kgf‘m , 9 Ibf-ft) Install the steering stem cover and tighten the bolts securely. Install the front wheel (page 13-16). 1 3-34 FRONT WHEEL/SUSPENSIONISTEERING STEERING HEAD BEARING PRE-LOAD Remove the upper cowl (page 2-6)t Jack»up the motorcycle to raise the front wheel off the ground, Position the steering stem to the straight ahead position. Hook a spring scale to the fork tube and measure the steering head bearing preload. NOTE: Make sure that there is no cable or wire harness interference. The pre-load should be within 10— 1.5 kg! (22* 3.3 Ibf). It the readings do not fall within the limits, lower the front wheel to the ground and adjust the steer- ing bearing adjusting nut. 13-35 REAR WHEEL/SUSPENSION 93 N-m19,5 kngm , 69 lbf-ft) 59 Nm (6‘0 kgfrm , 43 Ibf-ft) ' A 35 Nm (3‘6 kgf-m , 26 WM!) 88 N-m (9‘0 kgf‘m , 65 IN“) 35 Nm (3.6 kgfrm , 26 let) 59 N‘m (6.0 kgf‘m, 43lbf-fl) 44 Nm (4.5 kgf~m , 33 lbf-fl) 12 Nm (1‘2 kgf-m , 9 Ibi-fl) 93 Nm (9.5 kgf‘m , 69 “DH” 14-0 14. REAR WHEEL/SUSPENSION SERVICE INFORMATION 14-1 SHOCK ABSORBER 14—9 TROUBLESHOOTING 14.2 SUSPENSION LINKAGE 14-12 REAR WHEEL 14.3 SWINGARM 1415 SERVICE INFORMATION GENERAL RWARNIIIG 0 Riding on damaged rims impairs safe operation of the vehicle. 0 A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake dagreasing agent. 0 The shock absorber contains nitrogen gas under high pressure. Do not allow fire or heat near the shock absorber. 0 Before disposal of the shock absorber, release the nitrogen. 0 The damper unit is filled with nitrogen gas under high pressure, do not try to disassemble. O A hoist or equivalent is required to support the motorcycle when servicing the rear wheel and suspension. O Use genuine Honda replacement bolts and nuts for all suspension pivots and mounting points. 0 Use only tires marked "TUBELESS" and tubeless valves on rim marked "TUBE LESS TIRE APPLICABLE". 0 Refer to section 15 for brake system service. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Minimum tire tread depth 2.0 (0.08) Cold tire pressure Driver only 250 kPa (2.50 kgf/cm‘, 36 psi) 7 Driver and passenger 280 kPa (2.80 kgf/cm2 , 41 psi) g Axle runout 0.20 (0.008) Wheel rim runout Radial ~ 2.00108) Axial — 2.0 (0.08) Wheel balance weight — 60 g (2.1 ozlmax. Drive chain Size/link DID D|D525 HV/112 LE RK RK525 ROZ1/112 LE 7 Slack 35*45 (1 318—1 3/4) 7 TORQUE VALUES Rear axle nut 93 N-m (9.5 kgf-m , 69 Ibf'ft) U-nut Rear brake disc bolt 42 N-m (4.3 kgf-m , 31 IN“) ALOC bolt Final driven sprocket bolt 108 N-m (11.0 kgfrm , 80 Ibf-I‘t) Shock absorber upper mounting nut 59 Nm (6.0 kgf—m ,43 IbI-ft) U-nut Shock absorber lower mounting nut 44 Nm (4.5 kgf-m , 33 lbf-ft) U-nut Swingarm—to—shock link plate nut 88 Nm (9.0 kgf-m , 65 IbI-It) U-nut Shock link-to-shock link plate nut 44 N-m (4.5 kgI-m , 33 INT!) U-nut Shock link-to-bracket nut 59 Mr" (60 kgf-m , 43 Ibf-fl) U-nut Swingarm pivot nut 93 Nm (9.5 kgI-m , 69 Ibf-fll U-nut Drive chain slider screw 4 N-m (0.42 kgf~rn , 3.0 Ibf-ft) Apply a locking agent to the threads Rear brake hose guide bolt 12 Nm (1.2 kgf-rn , 9 lbf-ft) Shock link bracket bolt (12 mm) 54 Nm (5.5 kgt-m , 40 Ibf‘ftl (14 mm) 59 N~m (6.0 kgI-m , 43 Ibf‘ft) 14-1 REAR WHEEL/SUSPENSION TOOLS Bearing remover shaft 07746-0050100 Bearing remover head, 20 mm 07746-0050600 Driver 07749-0010000 Attach merit, 32 X 35 mm 07746-0010100 Attachment, 37 X 40 mm 07746-0010200 Attachment, 42 X 47 mm 07746-0010300 Attachment, 52 X 55 mm 077460010400 Attach merit, 62 X 68 mm 07746-0010500 Driver handle attachment 07949-3710001 Attachment, 24 X 26 mm 07746-0010700 Attachment, 22 X 24 mm 07746-0010800 Pilot, 17 mm 07746-0040400 Pilot, 20 mm 07746-0040500 Pilot, 25 mm 07746-0040600 Pilot, 28 mm 07746-0041100 Needle bearing remover 07LMC~KV30100 TROUBLESHOOTING Soft suspension 0 Weak shock absorber spring 0 Incorrect suspension adjustment - Oil leakage from damper unit 0 Insufficient tire pressure Hard suspension 0 Incorrect suspension adjustment - Damaged rear suspension pivot bearings o Bent damper rod I Tire pressure too high Rear wheel wobhling - Bent rim 0 Worn or damaged rear wheel bearings 0 Faulty rear tire 0 Unbalanced reartire and wheel 0 Insufficient rear tire pressure 0 Faulty swingarm pivot bearings Rear wheel turns hard 0 Faulty rear wheel bearings 0 Bent rear axle 0 Rear brake drag 0 Drive chain too tight Rear suspension noise 0 Faulty rear shock absorber - Loose rear suspension fasteners 0 Worn rear suspension pivot bearings 1 4-2 REAR WHEEL/SUSPENSION REAR WHEEL REMOVAL Loosen the drive chain adjusters and rear axle nut. Support the motorcycle securely using a hoist or equivalent. Remove the axle nut and washer. Push the rear wheel forward. Derail the drive chain from the driven sprocket. Remove the axle from the left side and remove the rear wheel. INSPECTION REAR AXLE Axle Place the axle in valocks and measure the runout. Actual runout is 1/2 the total indicator reading. SERVICE LIMIT: 0.20 mm (0.008 in) Wheel bearing WHEEL A Turn the inner race of each bearing with yourfinger. BE RING Bearings should turn smoothly and quietly. Also check that the hearing 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. NOTE: Replace the wheel hearings in pairs. 14-3 REAR WHEEL/SUSPENSION Wheel rim runout Check the rim runout by placing the wheel in a turn- 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: Ra Ax : 2.0 mm (0.08 in) 2.0 mm (0.08 in) Driven sprocket Check the condition of the final driven sprocket teeth. Replace the sprocket if worn or damaged. NOTE: - It the final driven sprocket requires replacement, inspect the drive chain and drive sprocket. 0 Never install a new drive chain on a worn sprock- et or a worn chain on new sprockets. Both chain and sprocket must be in good condition or the replacement chain or sprocket will wear rapidly. Wheel balance See page 13-13 for wheel balance. DISASSEMBLY Remove the side collars and dust seals. Remove the bolts and brake disc. OK No GOOD O x 1 4-4 REAR WHEEL/SUSPENSION Remove the driven flange assembly from the left wheel hub. NOTE: If you will be disassemble the driven flange, loosen the driven sprocket nuls before removing the driv- en flange from the wheel hub. Remove the wheel damper rubbers. Remove the O-ring‘ Driven flange bearing removal Loosen the driven sprocket nutst Remove the driven flange lrorn the wheel hub, then remove the driven sprocket nuts and sprocket. Remove the driven flange collar. Drive out the driven flange bearing. \ vulva: COL‘ 1 4-5 REAR WHEEL/SUSPENSION Wheel bearing removal Install the bearing remover head into the bearing. From the opposite side install the bearing remover shaft and drive rhe bearing out of the wheel hub. Remove the distance collar and drive out the other bearing. TOOLS: Bearing remover head, 20 mm 077460050600 Bearing romovor Shift 077450050100 ASS EM BLY gaz N‘m (4.3 kgI-m , 31 mm) BRAKE DISC RIGHT WHEEL BEARING I / REAR WHEEL LEFI’ WHEEL BEARING COLLAR DRIVEN FLANGE BEARING DUST SEAL O-RING DAMPER RUBBER DRIVEN FLANGE FINAL DRIVEN SPROCKET 108 N‘m(11I0 kgf‘m , 80 lbf-ft) Wheel hearing installation CAUTION: Never install the old bearings, once the bearings has been removed, the bearing must be replaced with new ones. Drive in a new right bearing squarely‘ TOOLS: Driver 07749-0010000 Attachment. 52 X 55 mm 07746-0010400 Pilot, 20 mm 07746-0040500 1 4-6 Install the dismnce collar, then drive in the left side bearing, TOOLS: DIN-r 07749-0010000 Attachment. 42 X 47 mm 07746-0010300 Pilot, 20 mm 0774643040500 Driven flange bearing installation Drive the new driven flange bearing into the driven flange using the special tools. TOOLS: Driver ' 07749-0010000 Attachment, 62 X 68 mm 07746-0010500 PiIot, 15 mm 07746—004060!) Apply grease and install the driven flange collar. Install the wheel damper rubbers into the wheel hubt Apply oil to the new O-ring and install it into the groove of the wheel hubt REAR WHEEL/SUSPENSION REAR WHEEL/SUSPENSION Install the driven flange assembly into the left wheel hub. If the driven sprocket was removed, install the driv- en sprocket and tighten the nuts. TORQUE: 108 N-m (11.0 kgi‘m , 80 Ith) Install the brake disc with its “->" mark facing out. Install and tighten the new bolts to the specified torque. TORQUE: 42 N-m (4‘3 kgf-m , 31 Ibfrft) Apply grease to the dust seal lips, then install it into the driven flange. Apply grease to the side collar inside. Install the side collars. INSTALLATION Install the rear brake caliper bracket onto the guide ofthe swingarm. 1 4-8 REAR WHEEL/SUSPENSION Place the rear wheel into the swingarm. Install the drive chain over the driven sprocket Install the axle from the left side. install the washer and loosely install the axle nut. Adiust the drive chain slack (page 3-16). Tighten the axle nut to the specified torque. TORQUE: 93 Nm (5.5 kgf‘m , 69 lbf-ft) SHOCK ABSORBER REMOVAL Support the motorcycle securely using a hoist or equivalent. Remove the side cover (page 2-th Remove the shock absorber lower mounting bolt/ "UL Remove the upper mounting bolt/nut and shock absorber. REAR WHEEL/SUSPENSION INSPECTION Visually inspect the damper unit for damage. Busumc Check for the: *Damper rod for bend or damage — Damper unit for deformation or oil leaks - Upper mounting bushing for wear or damage . ‘ Inspect all the other parts for wear or damage. Q“ DAM PE H Remove the lowerjoint pivot collar and dust seals. Check the dust seals and needle bearing for wear or damage. Replace them if necessary. PIVOT COLLAR NEEDLE BEARING SHOCK ABSORBER DISPOSAL PROCEDURE Center punch the damper to mark the drilling point. Wrap the damper unit inside a plastic bag. Support the damper in a vise as shown. Through the open end of the bag, insert a drill motor with a sharp 30 mm (1.2 in) drill bit. m— 0 Do not use a dull drlll blt which could cause a buIId-up of excessive heat and pressure inslde the damper, leading to explosion and severe personal injury. 0 The shock absorber contalns nitrogen gas and oil under high pressure. Do not drill any farther down the damper case than the measurement given above, or you may drill into the oil cham- ber-,- oil escaping under high pressure may cause serious personal lniuryt oAIways wear eye protection to avoid getting metal shavlng In your eyes when the gas pres- sure ls released. The plas1ic bag is only intended no shield you from the escaping gas 30 mmi1.2 in) Hold the bag around the drill motor and briefly run the drill motor inside the bag; this will inflate the bag with air from the motor and help keep the bag lrorn getting caught in the bit when you start. SHOCK ABSORBER 14-10 REAR WHEEL/SUSPENSION LOWER JOINT NEEDLE BEARING REPLACEMENT Remove the pivot collar and dust seals, Set the damper in a hydraulic press. CAUTION: Place the damper with the rebound damping adluster facing up. Press the needle bearing out from the Iowerjointu TOOLS: Driver handle attachment 07949-3710001 Attachment, 22 X 24 mm 07746-0010800 Pilot, 17 mm 077460040400 Pack a new needle bearing with multi-purpose grease Press the needle bearing into the lower joint until the depth (tom the lower joint outer surface is 73*82 mm (031-032 in), using the special tools. TOOLS: Driver 077490010000 Attachment 24 X 26 mm 0774643010700 Pilot, 11 mm 07746—0040400 Apply grease to the new dust seal lips Install the dust seals and pivot collar. INSTALLATION Install the shock absorber into the frame with the rebound damping adjuster facing to the right. Install the upper mounting bolt and nut and tighten the upper mounting nut to the specified torque. TORQUE: 59 N-m16u0 kgf-m ,431bf‘ft) DRIVER HANDLE ATTAEIRMENT \ ’\\ ATTACHMENT/PILOT / 7 s 52 mm 103i 332ml I" v ,1; I 14-11 REAR WHEEL/SUSPENSION Install the lower mounting bolt and nut and tighten the lower mounting nut to the specified torque YOROUE: 44 NW! (4.5 kgf‘m , 33 |th) Install the side cover (page 2-2). SUSPENSION LINKAGE SWINGARM-TO . REMOVAL/DISASSEMBLY LINK HATE BOW ,. _ Support the motorcycle securely using a hoist or ' equivalent. Remove the side cover (page 2-2). Remove the following: —Shock absorber lower mounting boltJnut *Swingarm-to-shock link plate boll/nut *Shock link-to-shock link plate bolt/nut *Shock link plates *Shock link-to-brecket bolt/nut —Shock link DUST SEALS Remove the pivot collar and dust seals from the shocklinkt ~ 5.; ' V, w o PIVOT COLLAHS SHOCK LINK 14-12 REAR WHEEL/SUSPENSION INSPECTION snocx LINK PLATES Check the shock link plates for damage or fatigue. Check the dust seals and collars for wear, damage DUST SEALS or fatigue. Check the needle bearings for damage or loose fit. lithe needle bearings are damaged, replace them. NEEDLE BEARINGS SHOCK LINK NEEDLE BEARING HEPLACEMENY DRIVER HANDLE ATTAgl-MENT Press the needle bearing out of the shock link using special tools and a hydraulic press. TOOLS: Drlver handle attachment 07949-3710001 Attachment, 2 X 24 mm 07746-0010800 Pilot, 17 mm 07746-0040400 I. lr‘lflflbl “ ' Pack a new needle bearing with multi-purpose grease. ATT ENT’ Press a new needle bearing into the shock link so PILO that the needle bearing surface is lower 53* DRWEH 5.7 mm (0.21—0.22 in) from the end of the shock link surface. NOTE: 3 5.7 mm (0.21 0.22 inl Press the needle bearing into the shock link with the marked side facing outt YOOLS: Driver 07749-0010000 Attachment. 24 X 26 mm 07746-0010700 Pilot, 17 mm 07746-0040400 14-13 REAR WHEEL/SUSPENSION 14-14 ASSEMBLY/INSTALLATION E DUST SEALS Apply grease to the dust seal lips, then install the dust seals and pivot collars. SHOCK LINK Install the following: *Shock link 7 Shock Iink-to-bracket boll/nul vShoek link plates with their “FR” mark facing to the from. *Swingarm-to-shock link plate bolrJnut *Shock absorber lower mounting bolt/nut *Shock Iink-to-shock link plate bolt/nut Tighten all nuts to the specified torque. TORQUE: Swingam-‘o-shock Ilnk plate nut: 88 N-m (9‘0 kgf-m . 65 IN“) shock absorber lower mounting nut: 44 Nrm (4.5 kgf-m 1 33 lbf-h) shock link-terbracket nut: 59 N-m (6‘0 kgf-m , 43 lbfrft) Shock link-to-shack link plate nut: 44 N-m (4.5 kgf‘m , 33 lbf-ft) Install the side cover (page 2-2)‘ , PIVOT COLLARS SWINGARMJOAS‘FEDT , LINK PlATE BOLT/NIB REAR WHEEL/SUSPENSION SWINGARM ‘ ‘ BOLTS/NUTS REMOVAL ‘ / Remove the rear wheel (page 14-3L Remove the shock link plates. Remove the bolts and drive chain cover, Remove ‘he bolts and brake hose guides. Remove the rear brake caliper/bracket assembly from the swingarm. Remove the right and left swingarm pivot caps, REAR WHEEL/SUSPENSION Loosen the swingarm pivot nut. Remove the muffler mounting bolt and nut. Remove the socket bolt, swingarm pivot nut and left footpeg bracket. Remove the socket bolt. Remove the muffler mounting bolt and nut. Remove the swingarm pivot bolt and right foot peg bracket. Remove the swingarm. DISASSEMBLV/INSPECTION Check the drive chain slider for wear or damage. DRNEEHNN LlDER Remove the screws and drive chain slider. Remove the pivot collars and dust seals from the swingarm pivot. Check the dust seals and collar for damage or fa- tigue. Turn the inner race of right pivot bearings with your finger. Check the left needle bearing for damage. The bearings should turn smoothly and quietly. Also check that the bearing outer race (its tightly in the hub. Remove and discard the bearings if the races do not turn smoothly and quietly, or if they lit loosely in the pivot. RIGHT PIVOT COLLARS / LEFT PIVOT COLLAR 14-16 REAR WHEEL/SUSPENSION PIVOT BEARING REPLACEMENT Remove the snap ring. SNAP RING Remove the right pivot bearings (radial ball bear- ings) from the swingarm pivot. Remove the diste rice collar. BEARINGS/DISTANCE @LLAR Press the left pivot bearing (needle bearing) out of . , I ‘ ATTACHMENT the swmgarm pivot using the specual tools. TOOLS: Driver 07749-0010000 Attachment, 32 X 35 mm 07746-0010100 Pilot, 28 mm 07746-0041100 NEEDLE BEARING - Press a new left pivot bearing (needle bearing) into the swingarm pivot so that the needle bearing sur— DRIVER HAMDLE face is lower 14715 mrn (0.55—0.59 in) from the ATTACHMENT end of the swingarm pivot surface using the special tools. NOTE: Press the needle bearing into the swingarm with the marked side facing out. ~14 lamm “155 059m) TOOLS: Driver handle attachment 07949-3710001 Amchment, 37 X 40 mm 07746-0010200 Pilot, 28 mm 07746-0041100 Install the distance collar, Press new right pivot bearings (radial ball bearing) into the swingarm pivot one at a time using the spe» cial tools. TOOLS: Drlver 07749-0010000 Attachment, 37 X 40 mm 07746-0010200 Pilot, 20 mm 07746-0040500 14-17 REAR WHEEL/SUSPENSION Install the snap ring into the swingarm pivot groove securely, SNAP‘nIN‘G LINK PLAYE PIVOT BEARING REPLACE- DUST SE Remove the pivot collar and dust seals from the swingarm. Check the dust seals and collar for damage or ta- tigue, Remove the needle bearing out of the swingarm us- ing special tool. TOOL: Needle bearing remover O7LMC-KV30100 Pack a new needle bearing with mum-purpose ’ EDLE BEANNG grease, OVER Install a new needle bearing into the swingarm so " that the needle bearing surface is lower 8‘0— 9.0 mm (o.31~o.35 in) from the end of the swing- arm surface, 8,0 3.0 mm (0.3! 035 in) 1,. YOOL: Needle bearing remover 07LMC-KV30100 l l 14-18 REAR WHEEL/SUSPENSION Apply grease to the dust seal lips, then install the E DUST SEALV dust seals and pivot collar into the swingarm. ASSEMBLY RIGHT DUSTSEAL SWINGARM RIGHT PIVOT COLLAR PIVOT COLLAR NEEDLE BEARING / l DUST SEAL ‘ SNAP RING /@ OUTER BALL BEARING DRIVE CHAIN SLIDER DISTANCE COLLAR INNER BALL BEARING % \ \\\ RIGHT DUST SEAL RIGHT PIVOT COLLAR LEFT PIVOT COLLAR LEFT DUST SEAL EFT DUST SEAL 4 N-m (0.42 kgf—m , 3.0 lbf-ft) NEEDLE BEARING Apply grease to the dus1 seal lips, then install the dust seals and pivot collars into the swingarm pivot. l RIGHT PIVOT COLLARS LEFT PIVOT COLLAR 14-19 REAR WHEEL/SUSPENSION Install the drive chain slider, aligning the hole with DRIVE CHAIN SLIDER the boss on the swingarmr Apply a locking agent to the drive chain slider screwthreads. Install the collars and screws, then tighten the screws to the specified torque. TORQUE: 4 N‘m (0.42 kgf-m , 3.0 Ibf-ft) INSTALLATION Apply thin coat of grease to the swingarm pivot bolt surface. Install the swingarm in the frame and insert pivot bolt through the right footpeg bracket, swingarm, engine and left footpeg bracket Install and tighten the socket bolt TORQUE: 35 N-m (3.6 kgf-m , 26 Ibf-ft) Install the muffler mount boll/nut securelyt Install the swingarm pivot nut. Install and tighten the socket bolt. TORQUE: 35 Nm (3.6 kgf‘m , 26 letI Install the muffler mount bolt/nut securely. Tighten the swingarm pivot nut to the specified torque, TORQUE: 93 N~m (9,5 kgf-m , 69 Ibf-ft) 14-20 REAR WHEEL/SUSPENSION Inslall Ihe left and right swingarm pivm caps. SWINGAMJVI m I \ A Route the brake hose properly, lighlen the brake ‘ hose guide bolts to the specified torque, YOROUE: 12 N~m (1‘2 kgf-m , 9 Ibf-ft) InsIall the drive chain cover aligning the lab with the lab on the swingarm. Install and tighten the bolts‘ Install the shock link plate (page 14-14), Install the rear wheel (page 148). HYDRAULIC BRAKE 35 Nm (3.6 kgf-m , 26 let) 35 N-m (3‘6 kgf‘m , 26 Ibf-f!) 35 N-m (3‘6 kgfrm , a 31 N-m (3‘2 kgfvm , 23 IN“) 26 let) I 4‘! 31 Mm 132 kgf-m , 23 lbf-h) 15-0 15. HYDRAULIC BRAKE SERVICE INFORMATION 15-2 REAR MASTER CYLINDER 15-21 TROUBLESHOOTING 15-4 PROPORTIONAL CONTROL VALVE 15-25 BRAKE FLUID REPLACEMENT] DELAY VALVE 15-26 AIR BLEEDING 15-5 FRONT BRAKE CALIPER 15-27 BRAKE PAD/ DISC 15-10 REAR BRAKE CALIPER 15-32 FRONT MASTER CYLINDER 15-13 BRAKE PEDAL 1 5-37 SECONDARY MASTER CYLINDER 15-19 35 Nm (3‘6 kgf-m , 26 lbf‘ffl 12 N-m (1.2 kgf‘m , 9 H364!) frm , 9 “WM 12 N-m(1‘2k 1N>m (0.15 kgf‘m ,1,1lbf-ft) 35 Nm (3.6 kg“?! , 26 Ibf-ft) 12 N-rn (1‘2 kgf-m , 9 IbI-ft) 15-1 HYDRAUUCBRAKE SERVICE INFORMATION GENERAL AWARNING o A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. 0 Check the brake system by applying the brake lever and pedal after the air bleeding. CAUTION: o This model equipped with a Linked Braking System. Must be follow the system eir bleeding procedure {Page 15-5! i! you disconnect or service any part of the brake hydraulic system. a Do not disassemble the secondary master cylinder push rod or the correct brake performance will not be obtained. - Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber parts. Be careful whenever you remove the reservoir cap; make sure the front reservoir is horizontal first. 0 Never allow contaminates (dirt, water, etc.) to get into an open reservoir. 0 Once the hydraulic system has been opened, or it the brake feels spongy, the system must be bled. - Always use fresh DOT 4 brake fluid from a sealed container when servicing the system, Do not mix different types of fluid they may not be compatible, 0 Always check brake operation before riding the motorcycle. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Front Specified brake fluid DOT 4 Brake disc thickness 4474.6 (0.17-0.18) 3.5 (0.14) Brake disc runout 0.30 (0012) Master cylinder LD. 12.700—12.743 (0.5000*0.5017) 12.755 (0.5022) Master piston O.D. 12.657— 12.684 (0.4983*0.4994) 12.645 (0.4978) Secondary master cylinder LD. 12.700-12.743 (0.5000*0.5017) 12.755 (0.5022) Secondary master piston 0.D. 12,657'12.684(0.4983 — 0.4994) 12.645 (0.4978) Caliper cylinder |.D. Right Upper 27,000*27.050 (1,0630 -1,0650) 27.060 (1.0654) Middle 22550—21700 (0.8917*0.8937) 22.710 (0.3941) Lower 27.000 — 27.050 (1.0630*1.0650) 27.060 (1.0654) Left Upper 25.400 — 25.450 (1,0000*1.0020) 25.460 (1.0024) Middle 22550-22100 (0,8917*0.3937) 22.710 (0.8941) Lower 25.400 — 25.450 (1.0000*1.0020) 25.460 (1.0024) Caliper piston OD. Right Upper 26335—26968 (1,0604*1.0617) 26.910 (1.0584) Middle 22585—22618(0.8892*0.8905) 22.560 (0.8882) Lower 26335—26368 (1.0604* 1.0617) 26.910 (1.0594) Left Upper 25335—25368 (0.9974*0.9987) 25.310 (0.9965) Middle 22535—22618(0.8892#0.8905) 22.560 (0.8882) Lower 25335—25368 (03974—03987) 25.310 (0.9965) 15-2 HYDRAULIC BRAKE Unit: mm (in) ITEM STANDARD SERVICE LIMIT Rear Specified brake fluid DOT 4 Brake pedal height 82.5-84.5 (3.25-3.33) Brake disc thickness 4.8* 5.2 (0.19*0,20l 4.0 (016) Brake disc runout 0.30 (0.012) Master cylinder |.D. 17.460*17.503(0.6874‘068911 17.515 (0.6896) Master piston OD. 17.417*17,444(0.6857‘0.6868l 17.405 (0.6852) Caliper cylinder (D. From 22650-22100 (0.8917*0.8937) 22.710 (0.8941) Center 27000—21050 (1.0630~1.0650) 27.060 (1.0654) Rear 22.650~22.700 (0.8917*0.8937) 22.710 (0.8941) Caliper piston CD. Front 22585—221513(03892—03905) 22.560 (0.8882) Center 26335—26368 (1,0604- 1.0617) 26.910 (1.0594l Rear 22585-22613 (03892—03905) 22.560 (0.8882) TORQUE VALUES Front brake master cylinder holder bolt Front brake master cylinder cap screw Brake lever pivot bolt Brake lever pivot nut Brake lever adjuster Front brake light switch screw Right from caliper mounting bolt Left (ront caliper pivot bolt Left front caliper bolt (secondary masterjoint) Caliper body B bolt Front brake caliper slide pin (main) Front brake caliper slide pin (sub) Pad pin Brake caliper bleed valve Secondary master cylinder push rod lock nut Secondary master cylinder connector Rear master cylinder mounting bolt Rear master cylinder reservoir mounting bolt Rear master cylinder push rod nut Rear master cylinder hose joint screw Brake hose oil bolt Brake pipe joint Brake pipe 2/3 way joint Brake hose guide bolt Delay valve mounting bolt Proportioning control valve (PCV) mounting bolt 12 N-m (1.2 kgf-m , 9 lbi-(t) 1N‘m (0.15 kgi-m ,1.1|bf-ft) 1 Nam (0.1 kgf~m , 07 IN“) 6 N-m (0.6 kgf-m , 4.3 Ibf-fl) 4 N-m (0.4 kgf‘m , 2.9 Ibf-ftl 1 NH! (012 kgf-m , 0.9 “7140 31 N-m (3.2 kgf-m , 23 lbf-ft) ALOC bolt 31 Mm (312 kgf-m , 23 lbf~ftl ALOC bolt 31 Nm (3.2 kgf-m , 23 Ibi‘ft) ALOC bolt 32 N-m (3.3 kgf-m . 24 (MR) ALOC bolt 23 N-m (2.3 kgf-m ,17Ibfrit) 13 N-m (1.3 kgl-m , 9 lbf‘hl 1S N-rn (1.8 kgl-m, 131M") 6 Nam (0.6 kgf-m , 4.3 mil!) 18 Nm (1.8 kgf‘m,131bf‘hl 10 N«m (1.0 kngm , 7 (bf-ft) 12 N~m (1.2 kgf‘m , 9 (bf-ft) 12 N-m (1,2 kgf‘m , 9 (bf-ft) 18 N-m (1.8 kgf‘m,13|bf‘ft) 1 N-m (0.15 kgfm , 1.1 lbf‘ftl Apply a locking agent to the threads 35 Nm (3.6 kgf-m , 26|bf1ftl 17 N-m (1.7 kgf-m ,1Zlbt-ft) Apply oil to the threads and flange surface 12 Nm (1.2 kgfrm , 9 lbf-ftl 12 N-m (1.2 kgl-m , 3 112m) 12 N-m (1.2 kgi-m , 9 (but) 12 NM (1.2 kgf-m , 9 1mm 15-3 HYDRAULIC BRAKE TOOL Snap ring pliers 07914-SA50001 TROUBLESHOOTING Brake lever/pedal soft or spongy o Air in hydraulic system c Leaking hydraulic system - Contaminated brake pad/disc o Worn caliper piston seal 0 Worn master cylinder piston cups 0 Worn brake pad/disc 0 Contaminated caliper I Caliper not sliding properly 0 Low brake fluid level - Clogged fluid passage 0 Warped/deformed brake disc 0 Sticking/worn caliper piston o Sticking/worn master cylinder piston o Contaminated master cylinder 0 Bent brake lever/pedal Above items are normal but the brake system still has poor performance, check for nose dive during making It the nose dive excessive, check for secondary master cylinder hydraulic system. Brake lever/pedal hard 0 Clogged/restricted brake system 0 Sticking/worn caliper piston o Caliper not sliding properly o Clogged/restricted fluid passage 0 Worn caliper piston seal 0 Sticking/worn master cylinder piston o Bent brake lever/pedal Brake drags o Contaminated brake pad/disc - Misaligned wheel - Clogged/restricted brake hose joint 0 Warped/deformed brake disc I Caliper not sliding properly I Improper secondary master cylinder installed length 0 Clogged/restricted brake hydraulic system c Sticking/worn caliper piston o Clogged master cylinder port Rear wheel locks when only the brake lever is applied! Front wheel locks when only the brake pedal is applled (In die case that all items are normal in "Poor lever/pedal brake performance") olmproper secondary master cylinder push rod installed length 0 Faulty proportional control valve (PCV) 15-4 HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/ AIR BLEEDING m____ A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. CAUTION: - Do not allow foreign material to enter the system when filling the reservoir. 0 Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is sorvloed. NOTE; 0 The lever brake line air bleeding procedure is performed in the same manner as in the ordinal air bleeding procedure. 0 Once the hydraulic system has been opened. or if the brake feels spOI'IQV, the system must be bled. 0 When using a commercially available brake bleeder, follow the manufacturer’s operating in- structions. BRAKE FLUID DRAINING Lever brake line Support the motorcycle on its side stand. Turn the handlebar to the left until the reservoir is parallel to the ground, before removing the reser- voir cap. Remove the screws, reservoir cap. set plate and diaphragm. Connect a commercially available brake bleeder to the front brake caliper outer bleed valve. Loosen the bleed valve and pump the brake bleed- er. Stop pumping the bleeder when no more fluid flows out of the bleed valve. \ \ anAigaLgngfifl 1 5-5 HYDRAULIC BRAKE Pedal brake line Connect a commercially available brake bleeder to the front brake caliper center bleed valve Loosen the bleed valve and pump the brake bleed- er. Stop pumping the bleeder when no more fluid llows out of the bleed valve. Connect a commercially available brake bleeder to the rear brake caliper outer bleed valve. Loosen the bleed valve and pump the brake bleed- er. Stop pumping the bleeder when no more fluid flows out of the bleed valve Connect a commercially available brake bleeder to the rear brake caliper center bleed valve Loosen the bleed valve and pump the brake bleed» er. Stop pumping the bleeder when no more fluid flows out of the bleed valve BRAKE FLUID FILLING/AIR BLEEDING Lever brake line Fill the reservoir with DOT 4 brake fluid from a sealed containert CAUTION: 0 Use only DOT4 brake fluid from a sealed contain- or. 0 Do not mix different types of fluid. They are not compatible. Operate the brake lever several times to bleed air from the master cylinder. 15-6 HYDRAULIC BRAKE Connect a commercially available brake bleeder to the bleed valve Pump the brake bleeder and loosen the bleed valve, adding fluid when the fluid level in the master cylinder reservoir is low. NOTE: oCheok the fluid level often while bleeding the brakes to prevent air from being pumped into the system oWhen using a brake bleeding tool, follow the manufacturer’s operating instructions Repeat the above step procedures until air bubbles do not appear in the plastic hose. NOTE: It air is entering the bleeder from around the bleed valve threads, seal the threads with teflon ta pe, Close the bleed valve. Operate the brake lever and check brake operation. If it still feels spongy, bleed the lever system againt BRAKf‘BLEE ER‘ If a brake bleeder is not available, use the following procedure: Connect a transparent bleed hose to the bleed ' valve and place the outer end of the hose in a containsrt Loosen the bleed valve 1/4 turn and pump the brake lever until the brake fluid flows out from the bleed valve. 1. Pump the brake lever several times, then squeeze the brake lever all the way and loosen the bleed valve 1/4 turn. Wait several seconds and close the bleed valve. NOTE: Do not release the brake lever until the bleed valve has been closed. 1 Release the brake lever slowly until the bleed valve has been closed. 3. Repeat the steps 172 until there are no air , bubbles in the bleed hoset After bleeding air completely and tighten the bleed valves to the specified torquet TORQUE: 6 Nam (0.6 kgf‘m , 4.3 lbf-ft) HYDRAULIC BRAKE Fill the reservoir to the casting ledge with DOT 4 brake fluid from a sealed container. SCREWS Install the diaphragm, set plate and reservoir cap. ‘ Tighten the reservoir cap screws to the specified torque. TORQUE: 1 N-m(0.15kgf-m.1r1 lbf-ft) Check the front brake operation (page 3-21). Pedal brake line NOTE: 0 Before performing this service, prepare the brake fluid 500 cm“ (16.9 US oz, 14.1 Imp 02) or more, because the brake line is long 0 Fluid filling and bleed air from the brake pedal line in the sequence as follow: 1 . Right from caliper center bleed valve 2. Left front caliper center bleed valve 3. Rear caliper center bleed valve 4. Rear caliper outer bleed valve Remove the reerfender (page 2-3). - RESERVOIR CAP ' \ Remove the reservoir cap, set plate and diaphragm. - ‘ Fill the reservoir with DOT 4 brake fluid. I /. I, DIAPHR :M Pump the brake pedal while filling the brake fluid and feed fluid into the master cylinder. 15-8 HYDRAULIC BRAKE LConnect a commercially available brake bleeder to the right front brake caliper center bleed valve. NOTE: When using a brake bleeder, follow the manufac- turer's operating instructions Pump the brake bleeder and loosen the bleed valve. Operate the brake bleeder and feed the brake fluid until fluid flow out from the bleeder valve. Close the bleeder valve. 2. Feed the brake fluid at the lelt front brake caliper center bleeder valve as same procedure in step 1. 3. Feed the brake fluid at the rear brake caliper center bleeder valve as same procedure in step 1. 4. Feed the brake fluid at the rear brake caliper outer bleeder valve as same procedure in step 1. 5‘ Repeat step 1 *4 until the pedal resistance is felt. Next bleed the air from the system without using a brake bleeder tool. Connect the transparent bleeder tube to the bleed valve and place the outer end of the hose in a container. .Pump the brake pedal 5-10 times, then release the pedal. Loosen the bleed valve, then pushing down the brake pedal all the way. NOTE: Do not release the brake pedal while opening the bleed valve. Close the bleed valve. 2. Release the brake pedal slowly and wait several seconds after it reaches the end of its travel. 3. Repeat above step 1 and 2 until bubbles cease to appear in the fluid at the end of the bleed tube and pedal resistance is felt. NOTE: 'After the bubbles cease to appear in the fluid, repeat air bleeding procedure about 2—3 times. OEIaborately bleed the air from the rear brake caliper outer bleeder valve (from secondary master cylinder-to-PCV-to-rear brake caliper line). Tighten the each bleed valve to the specified torque. TORQUE: 6 N-m (0‘6 kgf-m , 4.3 let) HYDRAULIC BRAKE Fill the reservoir up to the “UPPER” level, Specified brake fluid: DOT 4 brake fluid Install the diaphragm, set plate and reservoir cap. BRAKE PAD/ DISC FRONT BRAKE PAD REPLACEMENT m__—__ After the brake pad replacement, check the brake operation by applylng the brake lever and pedal. NOTE: Always replace the brake pads in pairs to assure even disc pressure, Push the caliper pistons all the way in to allow . installation of new brake pads. NOTE: Check the brake fluid level in the brake master cylinder reservoir as this operation causes the level to rise Remove the pad pin plug and loosen the pad pint Remove the pad pin and brake pads. 15-10 HYDRAULIC BRAKE Clean the inside of the caliper especially around the caliper pistons. Make sure the brake pad spring is in place Install the new brake pads. Push the brake pads against the pad spring, then i install the pad pin. Tighten the pad pin to the specified torque. TORQUE: 1B N-m(1t8 kgfrm ,13Ibf‘ft) Install and tighten the pad pin plug securely. REAR BRAKE PAD REPLACEMENT MEN—— After the brake pad replacement, check the brake operation by applying the brake lever and pedal. NOTE: Always replace the brake pads in pairs to assure even disc pressure Push the caliper pistons all the way in by pushing the caliper body inward to allow installation of new brake pads. NOTE: Check the brake fluid level in the brake master cylinder reservoir as this operation causes the level to rise 15-11 HYDRAULIC BRAKE Remove the pad pin plug and loosen the pad pin. Remove the pad pin and brake padsl Clean the inside of the caliper especially around the caliper pistons Make sure the brake pad spring is in place. Install the new brake pads and pad pine Tighten the pad pin to the specified torque TORQUE: 18 N-m (1.8 kgfrm ,13Ibf‘ftl 15-12 HYDRAULIC BRAKE Install and tighten the pad pin plug securely. BRAKE DISC INSPECTION Visually inspect the brake disc for damage or cracks. Measure the brake disc thickness with a microme- ter. SERVICE LIMITS: FRONT: 3.5 mm (0.14 in) REAR: 40 mm (0.16 in) Replace the brake disc it the smallest measurement is less than the service limit. Measure the brake disc warpage with a dial indica- ‘Ort SERVICE LIMIT: 0.30 mm (0,012 in) Check the wheel bearings for excessive play, if the warpage exceeds the service limit, Replace the brake disc if the wheel bearings are normaL FRONT MASTER CYLINDER Em was on W REMOVAL Drain the lever brake hydraulic system (page 155). Remove the brake hose oil bolt, sealing washers and brake hose eyelet. CAUTION: Avoid spllllng fluid on painted, plastic, or rubber pans. Place a rag over these parts whenever the system is serviced 15-13 HYDRAULIC BRAKE Disconnect the brake light switch wire connectors. SWITCH CONNECT Remove the bolts from the master cylinder holder MASTER CVLINDER ASSEMBLV and remove the master cylinder assemblvt DISASSEMBLY Remove the pivot bolt/nut and knuckle guardt PIVOT BOL'F‘NUT Remove the brake lever assembly and push rod. PUSH “OD BRAKE LEVER ASSEMBLY 15-14 HYDRAULIC BRAKE Remove the screw and brake light switch. Remove the boot. Remove the snap ring from the master cylinder body using the special tool as shown. TOOL: Snap ring pliers 07914-SA50001 Remove the master piston and spring, Clean the inside of the cylinder and reservoir with brake fluid. INSPECTION Check the piston boot, primary cup and secondary cup for fatigue or damage. Check the master cylinder and piston for abnormal scratches Measure the master cylinder LD. SERVICE LIMIT: 12.755 mm (0.5022 in) Measure the master cylinder piston 0,Dt SERVICE LIMIT: 12.645 mm (0.4978 in) SCREW BRAKE LJGHT SWITCH ‘ i BOOT SNAPRING SNAP RING PLIERS 15-15 HYDRAULIC BRAKE ASSEMBLY 1 N‘m (0.15 kngm , 1‘1 lbl-ftl BOOT PUSH ROD RESERVOIR CAP SET PLATE DIAPHRAGM SNAP RING BRAKE LEVER ASSEMBLY ‘I FRONT MASTER CYLINDER ROM 1 N-m (0.1 kgf‘rn , 0.7 lbf-ft) BRAKE LIGHT SWITCH KNUCKLE GUARD 1 N'm (0.12 kgfrm , 0.9 Ibf-f!) 6 Mn! (0.6 kgf‘m , 4‘3 lbf-l‘t) CAUTION: SPRWG Keep tho piston, cups, spring, snap ring and boat as a sat; do not substitute individual parts. Coat all parts with clean brake fluid beforé assembly. Dip the piston in brake fluid. Install the spring to the piston. 5"!) Install the piston assembly into the master cylinder, 4' CAUTION: {7 —-—— MASTER PISTON When installing the cups, do not allow the lips to turn insida out. SNAP RING Install the snap ring using the special tool, CAUTION: Be certain the snap ring is firmly seated in the groove. TOOL: Snap ring pliers 07914-SA50001 SNAP RING PLIERS 15-16 HYDRAULIC BRAKE ,fil BOO‘l Apva silicone grease to the inside of the boot. Install the boot. Install the brake light switch and tighten lhe screw to the specified torque TORQUE: 1 N-m (0.12 kgf-m ,0.9 lbf-ft) K LIGHT SWIYCH Apply silicone grease to the tip of the push rod, then install it to master cylinder as shown PUSH ROD Apply silicone grease to the tip of the push rod, then install the brake lever assembly. BRAKE LEVER ASSEMBLY 15-17 HYDRAULIC BRAKE Install the knuckle guard to the master cylindert Install and tighten the pivot bolt to the specified torque. PIVIOT BOLT TORQUE: 1 Nam (0.1 ngm , 0‘7 lbfrft) Hold the pivot bolt and tighten the pivot nut to the specified torque. TORQUE: 6 N-m (0.6 kgfrm , 4.3 lbi‘ft) KNUCKLE GUARD PIVOTNUT INSTALLATION MASTER CVLINDER ASSEMELV Place the master cylinder assembly on the handle- bar. HOLDER Align the end of the master cylinder with the punch m k h h dl b ‘ ar ont e an e ar PUNCH MA L. Install the master cylinder holder with the "UP" mark facing up Tighten the upper boltfirst, then the lower bolt TORQUE: 12 NW (12 kgf-m , 9 lbf-l‘t) Connect the brake light switch wire connectors, * LING WASHERS Install the brake hose eyelet with the oil bolt and new sealing washers Align the brake hose eyelet with the stopper on the master cylinder, then tighten the oil bolt to the specified torque. DIL BOLT TORQUE: 35 Nm (3‘6 kgf‘m , 26 Ibf‘ft) Fill the reservoir to the upper level and bleed the brake system (page 156). .q ~l-‘M BRAKE H0 15-18 HYDRAULIC BRAKE SECONDARY MASTER CYLINDER EIL BOLTS! REMOVAL EALING WASH Drain the pedal brake hydraulic system (page 15-5). Remove the left front brake caliper (page 15-27lt Remove the brake hose oil bolts, sealing washers and brake hose evelets and left caliper bracket] secondary master cylinder assemblvt CAUTION: h. _ _ . CALIFER BACKST/SECONElARY Avoid splllllly fluid on painted, plastic, in rubber MASTER CY‘HNDER fiaEMBLY parts. Plane a rag over these parts whenever the ' ‘ ' system is serviced. SNAP RING FLIERS BOOT Remove the boot. / Remove the snap ring from the master cylinder body using the special tool as shown, TOOL: Snap ring pliers 079143450001 Remove the push rod, master piston and spring. Clean the inside of the cylinder with brake fluid. MINE—— Do not disassemble the secondary master cylinder push rad or the correct brake performance is not no obtained. I. — — x 4, (.0 INSPECTION . i .7 I Check the piston boot, primary cup and secondary cup for fatigue or damage. Check the master cylinder and piston for abnormal (19" " scratches, Measure the master cylinder |.Dt SERVICE LIMIT: 127.55 mm (05022 in) Measure the master cylinder piston ODI SERVICE LIMIT: 12345 mm (0.4978 in) 15-19 HYDRAULIC BRAKE ASSEMBLY BOOT PUSH ROD ASSEMBLY SNAP RING SPRING CAUTION: Keep the piston, cups, spring, snap ring and boat as a set; do not substitute lndivldual parts. Coat all parts with clean brake fluid before assem- bly, Dip the piston in brake fluid. Install the spring to the piston. Install the piston assembly. Apply silicone grease to the piston contact area of the push rod, CAUTION: When installing the nups, do not allow the lips to turn inside out Install the push rod into the master cylinder. Install the snap ring using the special tool, CAUTION: Be certain the snap ring ls firmly seated in the groove. YOOL: Snap ring pliers 07914-SA50001 MASTER PISTON SECONDARY MASTER CVLINDER BODY » SPRING MASTER PISTON l // / I M " / (1/ "an / / PUSH ROD ASSEMBLY 2-5. SNAP RlNG PLIEHS 15-20 HYDRAULIC BRAKE Install the boot securely. Install the brake hose eyelet with the oil bolt and new sealing washers. Tighten the oil bolts to the specified torque. TORQUE: 35 N-m (3.6 kgf-rn , Z6 lbf‘ft) Install the left front brake caliper (page 15-32) Bleed the air from pedal brake line (page 15-8). REAR MASTER CYLINDER REMOVAL Drain the pedal brake hydraulic system (page 15-6l‘ Remove the brake hose oil bolt, sealing washers, brake hose and pipe. CAUTION: Avoid spilling fluid on painted, plastic, or rube parts. Place a ran over these pans whenever the system is serviced Remove the right footpeg bracket (page 14—15). Remove and discard the brake pedal joint cotter pin. Remove the joint pin. JOINT PIN 15-21 HYDRAULIC BRAKE Remove the screw and reservoir hole joint and O-ring Irom the master cylinder. Loosen the rear master cylinder mounting bolts and rear master cylindert DISASSEMBLY Remove the bout. Remove the snap ring from the master cylinder body using the special tool as shown. TOOL: Snap ring pliers 07914»SA50001 Remove the push rod, master piston and spring. Clean the inside of the cylinder with brake fluid. INSPECTION Check the piston boot, primary cup and secondary cup for fatigue or damage. Check the master cylinder and piston for abnormal scratches. Measure the master cylinder LD. SERVICE LIMIT: 17.515 mm (016896 in) SNAP RING PLlERS 15-22 Measure the master cylinder piston 0.Dt SERVICE LIMIT: 174405 mm (0.6852 in) ASSEMBLY ~, O-RING RESERVOIR HOSE JOINT PRIMARY CUP CAUTION: Keep the piston, cups, spring, snap ring and boat as a set: do not substmmv lndlvidual parts. Coat all parts with clean brake fluid before assem- blyt Dip the piston in brake fluid. Install the spring to the piston Install the piston/push rod assemblyt CAUTION: When installing the cups, do nm‘ allow the lips to turn Inside out HYDRAULIC BRAKE REAR MASTER CYLINDER BODY MASTER PISTON/PUSH ROD ASSEMBLY SNAP RING 18 N-m (1‘8 kgf-m,13lbf~f!l SPRING . PRIMARYCUP (“be I ,fi‘é MASTER PISTON/PUSH HOD ASSEMBLY 1 5-23 HYDRAULIC BRAKE Be certain the snap ring I: firmly seated in the Install the snap ring using the special tool. CAUTION: SNAP RING groove. TOOL: Snap ring pliers 07914-SA50001 Install the boot. SNAP RING FLIERS If the push rod is disassembled, adiust the push rod length as shown. After adjustment. tighten the lock nut to the speci- fied torque, 83.5 i 1 mm (329 i 0.04 in) O TORQUE: 13 Nm (1‘8 kgf-m ,13lbf‘ftl l _J U ll ll ll ll LOCK NUT LOWER JOINT INSTALLATION Place the master cylinder onto the main footpeg and tighten the mounting bolts TORQUE: 12 N-m (1.2 kglrm , 9 lbflt) Apply brake fluid to a new O-ring and install it onto the reservoir hose joint, Install the reservoirjoint into the master cylinder, 15-24 HYDRAULIC BRAKE Apply a locking agent to the rear master cylinder joint screw threads. install and tighten the screw to the specified torque. TORQUE: 1 N-m (0.15 kgf-m ,1,1 lbf-l‘t) Connect the brake pedal to the push rod lower joint. install the joint pin and secure it with a new cotter pin, JOINT FIN Install the brake hose with the oil bolt and new sealing washers, Push the eyelet joint against the stoppers, then tighten the oil bolt to the specified torque, TORQUE: 35 N-m (3‘6 kgf-m , 26 lbf‘fil Fill the reservoir to the upper level and bleed the pedal brake line (page 15-8lt ‘ PROPORTIONAL CONTROL VALVE REMOVAL/INSTALLATION Remove the oil bolt, sealing washers and brake pipe eyelet from the PCV (Proportional Control Valve), 1 5-25 HYDRAULIC BRAKE Loosen the oil pipe nut and remove the oil pipe. Remove the two mounting bolts and PCV‘ Installation is in the reverse order of removalt Tighten the PCV mounting bolts to the specified torque. TORQUE: 12 N-m (1‘2 kgf-m , 9 let) DELAY VALVE REMOVAL Remove the steering stem cover (page 13-30). Remove the oil bolts, sealing washers and brake hose eyelets from the delay velvet Remove the mounting bolts and delay valve‘ INSTALLATION Install the delay valve onto the steering stern. Install and tighten the delay valve mounting bolts to the specified torque. TORQUE: 12 Nm (1.2 kgf-m , 9 lbl-ft) Install the brake hoses with the oil bolts and new sealing washers. Push the eyelet joints against the stoppers, then tighten the oil bolts to the specified torque TORQUE: 35 Nrm (3.6 kgf‘m , 26 lbf-ftl Fill the reservoir to the upper level and bleed the pedal brake line (page 15-8). 15-26 HYDRAULIC BRAKE FRONT BRAKE CALIPER m1— ' V LEFT CALIPER REMOVAL ‘ sfig-gg/EEAUNG I CAUTION: Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag aver these parts whenever the system is serviced. Drain the lever and pedal brake line hydraulic sys- temlpage15-5L Remove the oil bolts, sealing washers and brake hose eyelet joints. Remove the secondary master cylinder joint bolt and caliper pivot bolt, then remove the caliper from the bracket RIGHT CALIPER REMOVAL Remove the oil bolts, sealing washers and brake hose eyeletjointst Remove the caliper bracket mounting bolts and then remove the caliper/bracket assembly. DISASSEMBLV Remove the brake pads (page 15-10), Remove the caliper bracket from the caliper body. \ CALIFER BODY 1 5-27 HYDRAULIC BRAKE Remove the brake pad spring from the caliper body. Remove the brake pad retainer from the caliper bracket. Remove the boots from the caliper body and brack- BL Remove the bolts and caliper body B. Place the piece of wood sheet under the caliper pistons. Apply small squirts of air pressure to the fluid inlet to remove the pistons. m____ Do not use high pressure air or bring the nozzle too close to the inlet. NOTE: Mark the pistons to ensure correct reassembly. Push the dust seals and piston seals in and lift them DUL CAUTION: Be careful not to damage the piston sliding surface. Clean the seal grooves with clean brake fluid PAD RETAINER CAMPER BRACKET BOOT FAD SPRING CALlPEH BODV BOOT CALIPER EODV 8 \ PISTON SEAL \ DUST SEAL 15-28 HYDRAULIC BRAKE INSPECTION Check the caliper cylinder for scoring or other dam- age‘ Measure the caliper cylinder I.D‘ SERVICE LIMITS: Right: Upper: 2706!) mm (1.06541n) Middle: 221710 mm (0.8941 in) Lower: 27.060 mm (1.0654 in) Left: Upper: 25.460 mm (1.0024 in) Middle: 22.710 mm (0.3941 in) Lower: 25.460 mm (1.0024 in) Check the caliper pistons for scratches, scoring or other damage. Measure the caliper piston 01D. SERVICE UMITS: Right: Upper: 261910 mm (1.0594 in) Middle: 22.560 mm (0.8882 in) Lower: 261910 mm (1.0594 in) Left: Upper: 251310 mm (0.9965 in) Mlddle: 22.560 mm (0.8882 in) Lower: 25.310 mm (019965 in) ASSEMBLY CALIPER BRACKET Right: BOOT PAD SPRING CALlPER sonv B PAD RETAINER 13 Nm (1,3 kgf-m , 9 lbf‘ft) BOOT CALIPER BODY BRAKE PADS 18 Nm (118 kgf-m , 13 |bf~ft) 15-29 HYDRAULIC BRAKE Left: BOOT CALIPER BRACKET/ SECON DARY MASTER Y B CYLINDER CALIPER BOD PAD SPRING PAD RETAINER w v DUST SEALS 23 N-m12.3kgf‘m, 17 lbf‘l‘t) 13 Nm (1.3 kgfrm, SIM-ft) BOOT d v 32 N-m (3.3 kgf-m , 24 lbf-ft) CALIPER PISTONS 2!! PISTON SEALS BRAKE PADS 18 Nrm (1.8 kgf-rn ,13Ibf~ft) PISTON SEALS Coat the new dust seals with silicone grease. y Coat the new piston seals with clean brake fluid‘ .69 . Install the pistons and dust seals into the groove of the caliper body. Coat the caliper pistons with clean brake fluid and install them into the caliper cylinder with their opening ends toward the pad. 1/ Dust SEALS\\U ¥ \’ NOTE: \ Install the each piston seal, dust seal and caliper . / \' piston in their proper locations. CAL'PER PISTONS Install the caliper body B and tighten the new bolts CALIPER BODY a to the specified torquet TORQUE: 32 Nm (33 kgi-m , 24 lbf‘fll 15-30 Install the brake pad retainer onto the caliper brack- et. Install the pad spring into the caliper body. NOTE: Note the installation direction of the pad springt Apply silicone grease to the boots inside then in- stall them. Assemble the caliper and bracket RIGHT CALIPER INSTALLATION Install the right brake caliper/bracket assembly over the brake disc, install and tighten the new caliper mounting bolts‘ TORQUE: 31 N-m (3‘2 kgf-m , 23 Ibf‘ft) Install the brake hose eyelets to the caliper body with new sealing washers and oil bolt Push the brake hose eyelet stoppers against the caliper body, then tighten the oil bolt to the speci- fied torque TORQUE: 35 NM (3,6 kgf~rn , 26 lbf-flI Install the brake pads (page 15-11). CALIPER BODY / PAD SPRING CALIPER BRACKET HYDRAULIC BRAKE CAMPER BRACKET / , ,. I \ PAD RETAINER CALIPER BODY HYDRAULIC BRAKE LEFI' CALIPER INSTALLATION Install the left brake caliper onto the bracket. Install the left brake caliper/bracket assembly over the brake disc. Install the new caliper pivot bolt and secondary master cylinderjoint bolt. Tighten the bolts to the specified torque. TORQUE: Pivot bolt: 31 Nm (3,2 kgf-m , 23 Ibi-ft) Joint bolt: 31 N-m (3,2 kgf-m , 23 Ibi‘ft) Install the brake hose eyelets to the caliper body with new sealing washers and oil bolt. Push the brake hose eyelet to the stopper on the caliper, then tighten the oil bolt to the specified torque. TORQUE: 35 Nm (3.6 kgi-m , 26 Ibf‘h) Install the brake pads (page 15-11). Fill and bleed the lever and pedal line brake hydrau- lic system (page 15-3). REAR BRAKE CALIPER REMOVAL Drain the pedal line brake hydraulic system (page 15-5). Loosen the oil bolts, then remove the rear wheel lpage14-3i. Remove the oil bolts, sealing washers and brake hose eyeletioints. CAUTION: Avoid spilling fluid on painted, plan/G, or rubber parts. Place a reg over those parts whenever the system is serviced. 15-32 HYDRAULIC BRAKE DISASSEMBLV CALIPEH BODV Remove the rear brake pads (page 15-11). Remove the caliper bracket from the caliper body, CALIPEH BRACKET Remove the brake pad spring from the caliper body. PAD RETAINER CAMPER BRACKET Remove the brake pad retainer lrom the caliper \ 4 J bracket. . Remove the boots from the caliper body and PAD SPRING brackeL // 1/ BOOT \ CALIPER aoov / \ BOOT Remove the bolts and caliper body B. CAUPER 300v a Place the piece of wood sheet under the caliper pistons. Apply smell squirts of air pressure to the fluid inlet to remove the pistons. m_— Do not use hlgh pressure air or bring the nozzle too close to the inlet. NOTE: Mark the pistons to ensure correct reassembly. 1 5-33 HYDRAULIC BRAKE Push the dust seals and piston seals in and lift rhem out. PISTON SEALS o. CAUTION: Be careful not to damage the piston sliding surface. Clean the seal grooves with clean brake fluid, DUST SEALS INSPECTION Check the caliper cylinder for scoring or other dam- age. Measure the caliper cylinder l.D, SERVICE LIMIYS: Front: 22.710 mm (0.8941 in) Center: 7.060 mm (1 .0654 in) Rear: 22.710 mm (08941 in) Check lhe caliper pistons for scratches, scoring or other damage. Measure the caliper piston O.D. SERVICE LIMITS: Front: 22,560 mm (03882 in) Center: 26910 mm (1.0594 in) Rear: 22.560 mm (0.8882 in) 15-34 HYDRAULIC BRAKE ASSEMBLY PAD RETAINER Q’sz NM (3.3 kgf—m , 24 Ibm) PAD SPRING BRAKE PADS CALIPER PISTONS CALIPER BRACKET CALIPER BODY B g DUST SEALS 18 N~m (L8 kgf-m ,13lbf-ft) Coat the new piston seals with clean brake fluid. a PiSTON SEALS Coat the new dust seals with silicone grease. v \ Coat the caliper pistons with clean brake fluid and 0 Install the piston and dust seals into the groove of the caliper body, install them into the caliper cylinder with their opening ends toward the pad. g a 0 V3/ DUST SEA 5/“) L NOTE: Install the each piston seal, dust seal and caliper CAUPE“ P'STONS piston in their proper locations. CALIPER BODY 8 Install the caliper body B and tighten the new bolts to the specified torque, TORQUE: 32 N-m (3.3 kgf-m , 24 Ibf-ft) 15-35 HYDRAUUCBRAKE Install the brake pad retainer onto the caliper brack- CALIPER BRACKET PAD SPRING et. Install the pad spring into the caliper body. \ ’ NOTE Note the installation direction of the pad spring. \ PAD RETAINER CALIFER BODY Apply silicone grease to the boot inside then install CALIPEH BRACKET them. Assemble the caliper and bracket r I rfil BOOTS Install the rear brake pads (page 15-12). I CALIPER BODY INSTALLAflON , OIL nous Temporarin install the brake hose eyelets to the caliper body with new sealing washers and oil bolts Install the caliper/bracket assembly unto the swingarm aligning the bracket groove with the swingarm boss. Install the rear wheelipage14rslr Push the brake hose eyelet stoppers to the caliper. then tighten the oil bolts to the specified torque TORQUE: 35 Nam (36 kgf‘m , 26 Ibt‘fl) Fill and bleed the pedal brake line hydraulic system (page 158). 15-36 HYDRAULIC BRAKE BRAKE PEDAL REMOVAL Remove the right lootpeg bracket (page 14-15) Remove and discard the brake pedal joint cotter pin. Remove the joint pin. Unhook the brake pedal return spring. Remove the snap ring, washer and brake pedal from the footpeg, INSTALLATION Apply grease to the sliding surface of the brake pedal and the bracket. Assemble the brake pedal to the footpeg bracket Install the washer and snap ringt Hook the brake pedal return spring‘ Install the brake pedal joint and secure it with a new cotter pin‘ Install the right footpeg bracket (page 14-20). JOINT PIN RETURNVSPRING 15-37 BATI'ERY/ CHARGING SYSTEM SYSTEM DIAGRAM REGULATOR/RECTIFIER ALTERNATOR BATTERY e r\ MAIN FUSE 30A v v G W BATTERY I I I I I l—l REGULATOR] RECTIFIER ALTERNATOR T T v . c. R . w . 16-0 16. BATTERY/CHARGING SYSTEM SYSTEM DIAGRAM 16-0 CHARGING SYSTEM INSPEC‘HON 1845 SERVICE INFORMATION 16-1 ALTERNATOR CHARGING COIL 16-7 TROUBLESHOO'HNG 16-3 REGULATOR/ RECTIFIER 16-8 BA'I'I'ERY 16-5 SERVICE INFORMATION GENERAL [AWARHH - The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. 0 The battery contains sulfuric acid {electrolyte}. Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield. —lf electrolyte gas on your skin, flush with water. — lf electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately. 0 Electrolyte is poisonous. —lf swallowed, drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and call a physician. KEEP OUT OF REACH OF CHILDREN. - Always turn off the ignition switch before disconnecting any electrical component. CAUTION: Some electrical components may be damaged If terminals or connectors are connected or disconnected while the ignition switch is ON and current is present. o For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space. For maximum service life, charge the stored battery every two weeks. 0 For a battery remaining in a stored motorcycle, disconnect the negative battery cable from the battery terminal NOTE: The maintenance free battery must be replaced when it reaches the end of its service life. CAUTION: The battery caps should not be removed. Attempting to remove the sealing caps from the cells may damage the battery. o The battery can be damaged of overcharged or undercharged, or of left to discharge for long period. These same conditions contribute to shortening the "life span" of the battery, Even under normal use, the performance of the battery deteriorates after 2 *3 years. 0 Battery voltage may recover after battery charging, but under heavy load, battery voltage will drop quickly and eventually die out. For this reason, the charging system is often suspected as the problem Battery overcharge often results from problems in the battery itself, which may appear to be an overcharging symptom, If one of the battery cells is shorted and battery voltage does not increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte level goes down quickly, , 0 Before troubleshooting the charging system, check for proper use and maintenance of the battery, Check if the battery is frequently under heavy load, such as having the headlight and taillight UN for long periods of time without riding the motorcycle. 16-1 BATTERY/ CHARGING SYSTEM 0 The battery will self»discharge when the motorcycle is not in use For this reason, charge the battery every two weeks to prevent sulfation from occurring. 0 Filling a new battery with electrolyte will produce some voltage, but in order to achieve its maximum performance, always charge the battery. Also, the battery life is lengthened when it is initially charged I When checking the charging system, always follow the steps in the troubleshooting flow chart (page 16-3). Battery charging This model comes with a maintenance-tree (MF) battery. Remember the following about MF batteries. - Use only the electrolyte that comes with the battery 7 Use all of the electrolyte *Seal the battery properly -Never open the seals again CAUTION: For battery charging, do not exceed the charging current and time specified an the battery. Use of excessive current or charging time may damage the battery. Battery testing Refer to the instruction is in the Operation Manual for the recommended battery tester for details about battery testing. The recommended battery tester puts a “load” on the battery so that the actual battery condition can be measured. Recommended battery tester BM-z1o-AH or BM-Zlo or BAYTERV MATE or equivalent SPECIFICATIONS ITEM SPECIFICAHONS Battery Capacity 12V712AH Current leakage 0.1 mA max. Voltage (20 “0/68 °Fi Fully charged 13.0 —13.2 V Needs charging Below 12.3 V Charging current Normal 12 N57 10h Quick 5.0 No.5 h Alternator Capacity 0.315 kW/ 5,000 min" (rpm) Charging coil resistance (20 °C168 °Fi 0.3 i 05 £2 1 6-2 BATTERV/ CHARGING SYSTEM TROUBLESHOOTING 1. Battery undercharging (Voltage not ralsed to regulated voltage). Remove the battery (page 165). Check the battery condition using the recom- mended battery tester. RECOMMENDED BATTERV TESTER: BM-Zl O or BATTERY MATE or equivalent Correct Install the battery (page 16-5). Check the battery current leakage (Leak test; page16-7i. STANDARD: 0.1 mA max, —|ncorrect —> 0 Faulty battery —|ncorrect ——> Disconnect the regulator/rectifier connector and recheck the battery current leakage. Correct Check the alternator charging coil (page 16-7). STANDARD:O‘3 — 0.5 $2 Correct Remove the battery (page 16-5). Measure and record the battery voltage using a digital multimeter (page 16-5). lnsta|l the battery (page 16—5). Stan the engine. Measure the charging voltage (page 16-6). Compare the measurement to result of the follow- ing calculation. STANDARD: MEASURED BATTERY VOLTAGE < MEA» SURED CHARGING VOLTAGE < 15.5 V Incorrect Correct 0 Shorted wire harness o Faulty ignition switch 0 Faulty regulator/recti- tier — lncorrect—> 0 Faulty charging coil — Correct —> 0 Charging system is normal Incorrect 1 6-3 BATTERY/CHARGING SYSTEM Incorrect Check the regulator/rectifier connector voltage Correct—> - Open circuit in related wire and resistance (page 16—8). 0 Loose or poor contacts of related terminal - Shortad wire harness Correm ._———> o Faulty regulator/rectifiEI’ 16-4 BATTERY REMOVAL/INSTALLATION Remove the seat (page 2-2). Remove the battery holder band. Disconnect the negative cable and then the positive cable, and remove the battery. Install the battery in the reverse order ol removal with the proper wiring as shown. NOTE: Connect the positive terminal first and then the negative cable. After installing the battery, coat the terminals with clean grease. Reinstall the removed parts. VOLTAGE INSPEC'HON Measure the battery voltage using a digital multi- meter. VOLTAGE: Fullv charged: 13.07132 V Under charged: Below 12.3 V TOOL: Digital multimeter Commercially available BATTERY CHARGING mm— 0 The battery gives off exploslve gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. 0 Turn power ON/OFF at the charger, not at the battery terminal. Remove the battery (see above). BATI'ERY/ CHARGING SYSTEM POSITIVE CABLE BA1TERY/ CHARGING SYSTEM Connect the charger positive (+) cable to the battery positive (+) terminal. Connect the charger negative l-l cable to the battery negative (7) terminal. CAUTION : 0 Quick-charging should only be done in an emer- gency: slow charging is preferred. 0 For battery charging, do not exceed the charging current and time specified on the battery. Using excessive current or extending the charging time may damage the battery. CHARGING SYSTEM INSPECTION NOTE: 0When inspecting the charging system, check the system components and lines step-by-step according to the troubleshooting on page 1&3. ' Measuring circuis with a large capacity that exceeds the capacity of the tester may cause damage to the tester. Before starting each test. set the tester at the highest capacity range first, then gradually lower the capacity ranges until you have the correct range. 0 When measuring small capacity circuits, keep the ignition switch off. It the switch is suddenly turned on during a test, the tester fuse may blow, CHARGING VOLTAGE INSPECTION m—._ If the engine must be running to do some work, make sum the area is well-ventilated. Never run the engine in an enclosed area. The exhaust contalns poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death. NOTE: Be sure the battery is in good condition before performing this test. Remove the seat (page 2-2). Warm up the engine to normal operating tempera- ture. BATTERY 16-6 BATTERY/ CHARGING SYSTEM Stop the engine, and connect the multimeter as shown. CAUTION: c To prevent a short, make absolutely certain which are the positive and negatlve terminals or cable. 9 Do not disconnect the battery or any cable in the charging symm without first switching all the Ignition switch. Failure to lollow this precaution can damage the tester or electrical components. Restart the engine. With the headlight on Hi beam, measure the voltage on the multimeter when the engine runs at 5,000 rpm. Standard: Mnsured battery voltage (page 165) < Measured charging voltage (see above) < 15.5 V at 5.000 rpm CURRENT LEAKAGE INSPECTION Turn the ignition switch oft and disconnect the negative battery cable from the battery. Connect the ammeter (+) probe to the ground cable and the ammater (ml probe to the battery (7) terminal. With the ignition switch off, check for current leak- age. GROUND CABLE NOTE: 0 When measuring current using a tester, set it to a high range. and then bring the range down to an appropriate levelt Current flow higher than the range selected may blow out the fuse in the ISSLGL 0 While measuring current, do not turn the ignition on. A sudden surge of current may blow out the fuse in the tester. SPECIFIED CURRENT LEAKAGE: 0.1 mA max. If current leakage exceeds the specified value, a shorted circuit is likely. Locate the short by disconnecting connections one by one and measuring the current. ALTERNATOR CHARGING COIL NOTE: It is not necessary to remove the stator coil to make this test INSPECTION Remove the fuel tank (page 240). Disconnect the alternator 3P (Black) connector. 1 6-7 BATTERY/ CHARGING SYSTEM Check the resistance between all three Yellow terminals. STANDARD:0.3 — 0.5 Q (at 20 °C/68 °F) Check for continuity between all three Yellow terminals and Ground. There should be no continuity. If readings are still far beyond the standard, or if any wire has continuity to ground, replace the alternator stator. Refer to section 10 for stator removal. REGULATOR/ RECTIFIER SYSTEM INSPECTION Remove the reartender (page 2-3)4 Disconnect the regulator/rectifier 6P connector, and check it for loose contact or corroded terminals. It the charging voltage reading (see page 16-6) is out of the specification, measure the voltage between 6P connector terminals (wire harness side) as follows: Item Terminal Specification Battery RedNVhite (+) Battery voltage charging and should register line ground (—l Charging coil Yellow and 03 - 05 S2 line Yellow (at 20 °Cl68 °F) Ground line Green and Continuity ground should exist If all components of the charging system are normal and there are no loose connections at the regulator/rectifier connectors, replace the regulator [rectifier unit. 16-8 REMOVAL/ INSTALLATION Remove the raarfender (page 2-3). Disconnect the 6P connector. Remove rhe regulator/rectifier unit mounting bolts, ground cable and regulator/rectifier‘ Install the regulator/rectifier unit in the reverse order of removal. BATTERY/CHARGING SYSTEM GROUND CABLE REGULATOR/RECTIFIER 6P CONNECTOR 1 6-9 IGNITION SYSTEM SYSTEM DIAGRAM ENGINE STOP SWITCH IGNITION SWITCH O IGNITION CONTROL THRO‘I'I'LE SENSOR MODULE (ICM) MAIN FUSE 30 A ENGINE COOLANT ' TEMPERATURE g (ECT) SENSOR IGNITION PULSE GENERATOR ELISE 10A REAR IGNITION COIL NEUTRAL SWITCH SIDE STAND SWITCH P M “ wume 59mm m IGNIW comm um: Luca) 17-0 17. IGNITION SYSTEM SVSTEM DIAGRAM 17-0 IGNITION PULSE GENERATOR 17-7 SERVICE INFORMATION 17-1 THROTTLE SENSOR 17-7 TROUBLESHOOTING 17-3 ENGINE COOLANT TEMPERATURE IECT) SENSOR 17-9 IGNITION SYSTEM INSPECTION 17—4 IGNITION TIMING 17-10 IGNITION COIL 17-6 SERVICE INFORMATION GENERAL AWARIHNG When the engine must be running to do some work, make sure the area ls well ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death, Run the engine in an open area or with an exhaust evacuation system in an enclosed area. CAUTION: Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is ON and current is present, 0 When servicing the ignition system, always follow the steps in the troubleshooting sequence on page 173. e The transistorized ignition system uses an electrically controlled ignition timing system. No adjustment can be made to the ignition timing. 0 The ignition control module (ICMi varies ignition timing according to the engine speed. The engine coolant temperature (ECT) sensor and throttle sensor signal the ICM to compensate the ignition timing according to the coolant temperature and throttle opening. 0 The ICM may be damaged if dropped. Also, if the connector is disconnected when current is flowing, the excessive voltage may damage the ICM. Always turn off the ignition switch before servicing. - A faulty ignition system is often related to poor connections, Check those connections before proceeding. 0 Make sure the battery is adequately chargedt Using the starter motor with a weak battery results in a slower engine cranking speed as well as no spark at the spark plugs. 0 This motorcycle's spark plug is equipped with platinum type electrodes. Do not use spark plugs other than specified. 3 For spark plug inspection, see section 3. 0 See section 19 for following components: —Ignition switch —Engine stop switch *Neutral switch *Side stand switch *CIutch switch 17-1 IGNITION SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Spark plug DPRSEVX—Q (NGK) Spark plug gap 0.807030 mm (0.031 ~0.035 in) Ignition coil peak voltage 100 V minimum _Ignition pulse generator peak voltage 0.7 V minimum Ignition timing ("F” mark) 15° BTDC at idle Engine coolant temperature At 20 “C (68 °Fl 2-3 H; (ECT) sensor resistance At 80 “C (176 °F) 200—400 9 Throttle sensor Resista rice (20 °Cl68 °F) 4— 6 k Q Input voltage 47— 5.3 V TORQUE VALUES Timing hole cap 10 N-m (1‘0 kgI-m , 7 lbf-ft) Apply grease to the threads Primary drive gear bolt 88 N-m (9‘0 kgI-m , 65 Ibf-ft) Apply oil to the threads and flange surfaces Spark plug 14 N-m (1.4 kgf-m,10|bf~ft) Ignition pulse generator mounting bolt 12 N-m (1.2 kgf-m , 9 lbf~ftl Apply a locking agent to the threads Rear ignition coil mounting bolt 12 N-m (1.2 kgI-m , 9 Ibf~ft) Engine coolant temperature (ECT) sensor 23 N-m (2‘3 kgt~m , 17lbt-1t) TOOLS Peak voltage adaptor 07HGJ-0020100 with commercially available digital multimeter (impedance 10 M Q/DCV minimum) 17-2 TROUBLESHOOTING - Inspect the following before diagnosing the system, *Faulty spark plug *Loose spark plug cap or spark plug wire connection *Water got into the spark plug cap (leaking the ignition coil secondary voltage) 0 "initial voltage” of the ignition primary coil is the battery voltage with the ignition switch 0N and engine stop switch at RUN (The engine is not cranked by the staner motor), No spark at all plugs IGNITION SYSTEM Unusual condition Probable cause (Check in numerical order) Ignition coil primary voltage No initial voltage with ignition and engine stop switches 0N. (Other electri- cal components are normal) 1. Faulty engine stop switch. Z.An open circuit in Black/White wire between the igni- tion coil and engine stop switch. 3. Faulty ICM (in case when the initial voltage is normal while disconnecting ICM connector. Initial voltage is normal, but it drops down to 2-4 V while cranking the engine. 1. Incorrect peak voltage adaptor connections. 2. Undercherged battery. 3. No voltage between the BlackNl/hite (+) and Body ground (7) at the ICM multi-connector or loosen ICM connection. 4.An open circuit or loose connection in Green wire. 5. An open circuit or loose connection in Vellow/Blue and Blue/Yellow wires between the ignition coils and ICM. 6. Short circuit in ignition primary coil. 7. Faulty side stand switch or neutral switch. 8,An open circuit or loose connection in No. 7 related circuit wires. 0 Side stand switch line: Green/White wire 0 Neutral switch line: Light Green and Light Green/ Red wire 9. Faulty ignition pulse generator (measure the peak volt» age) 10, Faulty ICM (in case when above No. 179 are normal). Initial voltage is normal, but no peak voltage while cranking the engine, 1. Faulty peak voltage adaptor connections, 2. Faulty peak voltage adaptor. 3. Faulty ICM (in case when above No. 1, 2 are normal). Initial voltage is normal, but peak voltage is lower than standard value. 1.The multimeter impedance is too low; below 10 M52/ DCV. 2. Cranking speed is too low (battery under—charged). 3.The sampling timing of the tester and measured pulse were not synchronised (system is normal it measured voltage is over the standard voltage at least once). 4. Faulty ICM (in case when above No.1-3 are normal). Initial and peak voltage are normal. but does not spark, 1.Fau|ty spark plug or leaking ignition coil secondary currentampere, 2. Faulty ignition coil. lgnition pulse generator Peak voltage is lower than standard value. 1.The multimeter impedance is too low; below 10 MQ/ DCV. 2. Cranking speed is too low (battery under charged). 3. The sampling timing of the tester and measured pulse were not synchronised (system is normal if measured voltage is over the standard voltage at least once). 4. Faulty ICM (in case when above No. 1—3 are normal). No peak voltage. 1. Faulty peak voltage adaptor, 2. Faulty ignition pulse generator. 17-3 IGNITION SYSTEM IGNITION SYSTEM INSPECTION NOTE: DIGITAL MULTIMETER 0 If there is no spark at any plug, check all connec- tions for loose or poor contact before measuring each peak voltage, 0 Use recommended digital multimeter or commer- cially available digital multimeter with an impedance of 10 M Q/DCV minimum, O The display value differs depending upon the internal impedance of the multimeter. o If using lmrie diagnostic tester (model 625). follow the manufacturer’s instructions. PEAK VOLTAGE ADAPTOR Connect the peak voltage adaptor to the digital multimeter, or use the Imrie diagnostic tester, TOOLS: lmrie diagnostic tester (model 625) or Peak voltage adaptor 07HGJ-0020100 with Commercially available digital multimeter (impedance 10 M Q /DCV minlmum) IGNITION COIL PRIMARY PEAK VOLTAGE coon KNOWN SPARK PLUG m—__ Avoid touching the spark plugs and tester probes to prevent electric shock. NOTE: 0 Check all system connections before inspection If the system is disconnected. incorrect peak voltage might be measured, 0 Check cylinder compression and check that the spark plugs are installed correctly. Shift the transmission into neutral and disconnect the all spark plug caps from the spark plugs Connect a known good spark plugs to the spark plug caps and ground the spark plugs to the cylin- der as done in a spark test. Front: Remove the lower heat guard (page 17-6). Rear: Remove the left side cover (page 2-2). IGNITION SYSTEM connect the peak voltage adaptor or Imrie tester to the ignition coiL With the ignition coil primary wire connected, IGNITION COIL CONNECTION: Front: Blue/Yellow terminal (+) 7 Body ground (—) Rear: Yellow/Blue terminal (+) -Body ground (~l Turn the ignition switch “ON” and engine stop switch to “RUN”. Check for initial voltage at this time ' .\ The battery voltage should be measured. PEAK VOLTAGE ADAPTOR If the initial voltage cannot be measured, check the power supply circuit (refer to the troubleshooting, page 17-3). Shift the transmission into neutral. Crank the engine with the starter motor and read ignition coil primary peak voltage. PEAK VOLTAGE: 100 V minimum If the peak voltage is abnormal, check for an open circuit or poor connection in Yellow/Blue and Blue/Yellow wires. If not defects are found in the harness, refer to the ‘troubleshooting chart on page 17-3, IGNITION PULSE GENERATOR PEAK VOLTAGE NOTE: Check cylinder compression and check that the spark plugs are installed correctly. Remove the seat (page 2-2). Disconnect the ICM connector from the ICM. Connect the peak voltage adaptor or Imrie tester probes to the connector terminals of the wire harness side. TOOLS: Imrie diagnostic tenor (model 625) or Peek voltage adaptor 07HGJ<0020100 with Commercially avallablo digital multimeter [impedance 10 M £2 IDCV mlnlmum) CONNEC‘HON: Yellow terminal (+) —White/Ye|low terminal (m) Crank the engine with the starter motor and read the peak voltage. PEAK VOLTAGE: 0.7 V minimum PEAK VOLTAGE ADAPTOR IGNITION SYSTEM If the peak voltage measured at ICM connector is abnormal, measure the peak voltage at the pulse generator 2P (Red) connector. Lift and support the fuel tank (page 3-6). Disconnect the ignition pulse generator 2P (Red) connector and connect the tester probes to the terminal (Yellow and White/Yellow). In the same manner as at the ICM connector, measure the peak voltage and compare it to the voltage measured at the ICM connector‘ 0 If the peak voltage measured at the ICM is abnormal and the one measured at the ignition pulse generator is normal, the wire harness has an open circuit or loose connection elf both peak voltages measure are abnormal, check each item in the troubleshooting chart. If all items are normal, the ignition pulse generator is faulty. See page 17-7 for ignition pulse generator re— placement. IGNITION COIL REMOVAL/INSTALLATION FRONT: Disconnect the spark plug cap from the plug (page 3-6I‘ Remove the quick screws and lower heat guard, Disconnect the primary wires from the ignition coil terminals Remove the mounting bolts and ignition coil assemblyt Installation is in the reverse order of removal. 1 7-6 IGNITION SYSTEM REAR: Remove the left side cover (page 2-21 Disconnect the spark plug cap from the plug (page 3-6), Disconnect the primary wires from the ignition coil terminals Remove the mounting bolts and ignition coil assembly. Installation is in the reverse order of removalt Tighten the mounting bolts to the specified torque. TORQUE: 12 N-m (1‘2 kgf-m , 9 Ibf-ft) IGNITION PULSE GENERATOR REMOVAL/INSTALLATION Remove the right crankcase cover (page 6-16) Remove the wire grommet from the cover. Remove the mounting bolts and ignition pulse gen- erator. Install the ignition pulse generator into the cover. Appr sealant to the wire grommet, then install it into the groove of the covert Clean and apply a locking agent to the mounting bolt threadst Install and tighten the ignition pulse generator bolts to the specified torque. TORQUE: 12 Nm (1.2 kgf‘m , 9 Ibisft) Install the removed parts in the reverse order of removalt THROTTLE SENSOR SYSTEM INSPECTION Remove the seat (page 2-2I‘ Disconnect the ICM (ignition control module) con- nector (page 17-5), Measure the resistance between the Yellow/Red and Green/Black wire terminals of the wire harness side connector. STANDARD: 4—6 It £2 (20 °Cl68 “FI ICM CONNECTOR IGNITION SYSTEM Check that the resistance between the Red/Yellow and Blue/Green wire terminals varies with the throttle position while operating the throttle grip. r mmsigm .1 refit K . I Q \N , \ Fully open—Fully closed position: Resistance decreases Fully closed—Fully open position: Resistance increases II the correct measurements cannot be obtained, disconnect the throttle sensor 3F (Black) connector and perform the same inspections at the sensor terminals 0 If the measurement at the lCM is abnormal and the one at the throttle sensor is normal, check for open or short circuit, or loose or poor connec- tions in the wire harness. 0 If both measurements are abnormal, replace the throttle sensor. Connect the ICM connector. Turn the engine stop switch to RUN and the ignition switch ON. Measure the input voltage between the Yellow/Red (+) and Blue/Green wire terminals of the wire harness side throttle sensor 3P (Black) connector, STANDARD: 4.7—5.3 V lithe input voltage is ebnormal, or if there is no input voltage, check for open or short circuit in the wire harness, or loose or poor ICM connector contact. REPLACEMENT Remove the carburetors from the insulators (page 5-5lt Remove the torx screws and throttle sensort YHRQTTLE SENSOR 1 7-8 IGNITION SYSTEM Install the throttle sensor so that the cut out of the throttle sensor is positioned on the flat surfaces of the throttle shalt. Apply locking agent to the torx screw threads and loosely install the screws. CAUTION: Install the throttle sensor properly Improper installation can cause damage to the throttle sensor, Adjust the throttle sensor position so that the resis- tance between terminals A and B is 490*510 £2, and tighten the torx screws Connect the throttle sensor connector. install the removed parts in the reverse order of removalt ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION Remove the side oowl (page 2-5). Disconnect the ICM connector (page 17-5). Disconnect the ECT sensor con nectorr Check for continuity between the ECT sensor connector and ICM connector. There should be continuity between the same color wires, and no continuity between different color WIISS, Drain the coolant (page 6—5)t Remove the ECT sensor and sealing washer from the thermostat housing IGNITION SYSTEM Suspend the sensor in cold water. Heat the water slowly, using an electric heating element MM— Keep all Ilammable materiel: away from the electric heating element. Wear protective clothing, insulated gloves and eye protection. Measure the resistance between the sensor termi- rials. STANDARD: 2 —3 k Q 120 “C168 °Fi 200*400 Q (80 °C/176 °Fi if the resistance is out of above range, replace the ECTsensor. Install the ECT sensor with a new sealing washer and tighten it. TORQUE: 23 Nm (2.3 kgf-m. 17 lbf-ft) Install the removed parts in the reverse order of removal. Fill and bleed the cooling system (page 6-5). IGNITION TIMING m.— - If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area. 0 The exhaust contains poisonous carbon monox- ide gas that may cause loss of consciousness and may lead to death. NOTE: Read the instructions for timing light operation. Warm up the engine. Stop the engine and remove the timing hole cap. 17-10 IGNITION SYSTEM Connect the timing light to the front cylinder spark plug wire. Stanthe engine and let it idle, IDLE SPEED: 1,200 i 50 min" (rpm) The ignition timing is correct if the "F" mark aligns with the index mark on the alternator covert Increase the engine speed by turning the throttle stop screw and make sure the "F" mark begins to move counterclockwise when the engine speed at approximately 1,500 rpm Coat a new O-ring with grease and install and tighten the timing hole cap to the specified torquet YOROUE: 10 N«m (1.0 kgf‘m , 7 lief-ft) 17-11 ELECTRIC STARTER SYSTEM DIAGRAM ENGINE STOP SWITCH IGNITION SWITCH O STARTER SWITCH STARTER RELAY SWITCH/MAIN FUSE 30 A STARTER MOTOR BATTERY NEUTRAL SWITCH CLUTCH DIODE/FUSE ID A SIDE STAND SWITCH STARTER RELAY SWITCH a w G W W MAIN FUSE M “A - CLUTCH SWITCH I IGNITION SWITCH m BI: BLACK ""' " ‘ Br: BROWN Nam“ ”'°”E G: GREEN swncn 2mm) W _0_ L9: LIGHT GREEN RI RED T STARTER SWITCH w: WHITE v: YELLOW f HI I @ STARTER moron m m |——— w—> To Maillot/Reamer an sInE sum cut—é 9— am FUSE IIIA unpozzoA) Swnc" n —O—— ml —o\o(— 18-0 18. ELECTRIC STARTER SYSTEM DIAGRAM Is-o STARTER MOTOR 18-4 SERVIcE INFORMATION 13-1 STARTER RELAv SWITCH 13-11 TROUBLESHOOTING 13-2 DIODE 13-12 SERVICE INFORMATION GENERAL AWARNIIIG Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing serious injury. 0 The starter motor can be serviced with the engine in the frame. 0 When checking the starter system, always follow the steps in the troubleshooting flow chart (page 18—2), 0 A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current. 0 If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may be damaged. 0 See section 10 for starter clutch servicing. 0 See section 19 for following components: — Ignition switch *Engina stop switch *Starter switch -Neutral switch ‘Side stand switch *Clutch switch SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Starter motor brush length 12.0- 13.0 (0.477051) 6.50316) TORQUE VALUES Starter motor terminal nut 10 N-m (1.0 kgfrm , 7 lbf-ft) 18-1 ELECTRIC STARTER TROUBLESHOOTING Starter motor does not turn - Check for a blown main or sub fuses before servicing. 0 Make sure the battery is fully charged and in good condition. Check the starter relay switch operation. You should hear the relay “CLICK” when the starter switch button is depressed. Apply battery voltage to the starter motor —“CL|CK"heard-> directly and check the operation. "CLICK”not heard Normal Abnormal 0 Poorly connected starter motor cable 0 Faulty starter relay switch (page 18—10) 0 Faulty starter motor (page 18—4) Disconnect the starter relay switch connector. and check the relay coil ground wire lines as below for continuity: 1.Green/Red terminal-clutch switch diode-neu- tral switch line (with the transmission in neu- tral and clutch lever released). 2,Green/Red terminal—clutch switch-side stand switch line (in any gear except neutral, and with the clutch lever pulled in and the side stand up. —Abnormal —> 0 Faulty neutral switch (page 19-19) 0 Faulty neutral diode o Faulty clutch switch - Faulty clutch/side stand diode 0 Faulty side stand switch . Loose or poor contact connector 0 Open circuit in wire harness Normal Connect the starter relay switch connector. With the ignition switch ON and the starter switch pushed, measure the starter relay voltage at the starter switch connector (between Vellow/ Red (+)and ground 1’). -—No voltage» - Faulty ignition switch 0 Faulty starter switch 0 Blown out main or sub—fuse o Loose or poor contact of connector 0 Open circuit in wire harness Battery voltage registered Check the starter relay switch operation. — Normal '—> 0 Loose or poor contact starter relay switch connec- Abnormal tor 0 Faulty starter relay switch 1 8-2 ELECTRIC STARTER The shatter motor turns when the transmission is in neutral, but does not turn with the transmission in any position except neutral, with the side stand up and the clutch lever pulled in Check the clutch switch operation. Normal Check the side stand switcht Normal |_—_, Starter motor tum: engine slowly 0 Low battery voltage 0 Poorly connected battery terminal cable 0 Poorly connected starter motor cable 0 Faulty starter motor 0 Poor connected battery ground cable Starter motor turns, but snglne does not turn 0 Starter motor is running backwards - Case assembled improperly -Terminals connected improperly 0 Faulty starter clutch 0 Damaged or faulty starter drive gear Starter relay switch "clicks", but engine does not turn over 0 Crankshaft does not turn due to engine problems ~ Normal —> 0 Faulty clutch switch — Normal —> 0 Faulty clutch switch Open circuit in wire harness 0 Loose or poor contact connector 1 8-3 ELECTRIC STARTER STARTER MOTOR REMOVAL @— With the ignition switch OFF, remove the negative cable at the battery before servicing the starter motor. Remove the under cowl (page 2-7). Remove the rubber cap, terminal nut and the starter motor cable from the starter motor. Remove the starter motor mounting bolts, slay and the starter motor from the crankcase. Remove the O-ring from the starter motor, O’RING DISASSEMBLY Remove the starter motor case bolts. 1 8-4 ELECTRIC STARTER NOTE: SEAL RING REAR COVER ASSEMBLV Record the location and number of shims. Remove the following: — Rear cover assembly “‘ 'Seal ring *Shims SHIMS — grorln gover assembly [SEAL RING mom COVER ASSEMBLV — ea rll’lg — Lock washer - Insulated washer I ‘fl LOCK WASHER -Shims —Armature INSULATED WASHER INSPECTION eusmns Check the bushing of the rear cover for wear or damages Check the from cover oil seal for fatigue or other OIL SEAL NEEDLE BEANNG damage, Check the needle bearing for damage. FRONT COVER 18-5 ELECTRIC STARTER Inspect the commutator bars for discoloration, Bars discolored in pairs indicate grounded arme- ture coils, in which case the starter motor must be replaced. NOTE: Do not use emery or sand paper on the commuta- tor. Check for continuity between individual commuta- tor bars; there should be continuity. Also, check for continuity between individual com— mutator bars and the armature shaft; (here should be no continuity. Check for continuity between the cable terminal and the brush wire (the indigo colored wire or the insulated brush holder). There should be continuity. Check for continuity between the motor case and the cable terminal. There should be no continuity. ARMATUHE COMMUTATOR BARS BRUSH CABLE TERMINAL 1 8-6 ELECTRIC STARTER Inspect the brushes for damage and measure the brush length. SERVICE LIMIT: 6.5 mm (0.26 in) Remove the following: WASHER O~R|NG *Nu! *Washer 7 Insulator washers * O-ri ng NUT ,7. ‘4 INSULATOR WASHERS ~Brush holder assembly BRUSH HOLDER ASSEMBL *Brushlterminal - Insulalor INSULATOR _BHUSHITERMINAL BRUSH HOLDER ASSMBLY TERMINAL ‘ INSULATOR 18-7 ELECTRIC STARTER ASS EM BLY SHIMS REAR COVER SHIMS INSULATOR WASHERS @ @/ LOCK WASHER @/ FRONT covER BRUSH HOLDER ASSEMBLV INSULATOR INSULATED WASHER \ Q \ NUT W TE @ v O-RING WASHER MOTOR CASE Install The following: -lnsulator anus’ newts/{swan — Brush/terminal — Brush holder assembly INSULATOR .ERUSH/TERMINAL —New O-ring —lnsula‘or washers WASHER 0 O-RING —Washer v —Nut NUT INSULATOR WASHERS 18-8 ELECTRIC STARTER Install the brush holder, aligning the holder tab with the case groove, and the holder grooves with the insulated brush wires. Push and hold the brushes inside the brush holder, and install the armature through the motor case and brush holder. When installing the armature into the motor case, hold the armature tightly to keep the magnet of the case from pulling the armature against it. CAUTION: The call may be damaged pulls the armature agalnstthe use. Install the brush springs properly‘ Install the shims and insulated washer onto the armature shafts NOTE: Install the shims properly as noted during removal. Install a new seal ring onto the motor case. Apply grease to the oil seal lip and needle bearing in the front cover‘ Install the lock washer onto the front covert Install the front cover. BRUSH HOL ARMATURE BRUSH SPRINGS rs! siAL RING SHIMS LOCK WASHER FRONT COVER ELECTRIC STARTER Install the shims onto the armature shaft. o SEAL RING AUGN v NOTE: Install the shims properly as noted during removal. Install a new seal ring onto the motor case. Apply thin coat of grease to the armature shaft end. Install the rear cover aligning its groove with the brush holder tab. mg ,6. REAR COVER Install and tighten the case bolts securely, INSTALLATION Apply clean engine oil to the new O-ring, Install a new O-ring onto the starter motor groove. Install the starter motor into the crankcase, Install the stay. Install and tighten the starter motor mounting bolts. 18-10 ELECTRIC STARTER Route the starter motor cable. Install and tighten the terminal nut to the specified torque. TORQUE: 10 Nlm (1.0 kgfm , 7 |th) Install the rubber cap securely. Install the under cowl (page 2-7). STARTER RELAY SWITCH OPERATION INSPECTION Remove the seat (page 2-2). Shift the transmission into neutral. Turn the ignition switch ON and depress the starter switch button, The coil is normal it the starter relay switch clicks. If the switch "CLICK" is not heard, inspect the relay switch using the procedure below. GROUND LINE INSPECTION Disconnect the starter relay switch 4P connector. Check for continuity between the Green/Red wire and ground. If there is continuity when the transmission is in neutral or when the clutch is disengaged and the side stand switch is up, the ground circuit is normal (in neutral, there is a slight resistance due to the diode). VOLTAGE INSPECTION Connect the starter relay switch 4P connector. Shift the transmission into neutral. Measure the voltage between the Vellow/Red wire (+) and ground at the starter relay switch connec- tor. There should be battery voltage only when the starter switch button is depressed with the ignition switch is ON. ELECTRIC STARTER DIODE CONTINUITV INSPECTION Disconnect the starter relay switch 4P connector and cables. Connect an ohmmeter to the starter relay switch large terminals, Connect a fully charged 12V battery to the starter relay switch connector terminals (Yellow/Red and Green/Red). Check for continuity between the starter relay switch terminals. There should be continuity while 12V battery is connected to the starter relay switch connector terminals and should be no continuity when the battery is disconnected REMOVAL Remove the seat (page 2-2). Open the fuse box and remove the diode. INSPECTION Check for continuity with an ohmmeter between the diode terminals. When there is continuity, a small resistance value will register. If there is continuity in one direction. the diode is normal. INSTALLATION Install the diode in the reverse order of removal. 18-12 LIGHTS/METERS/SWITCHES SYSTEM DIAGRAM FRONT BRAKE LIGHT SWITCH IGNITION SWITCH RIGHT HANDLEEAR SWITCH FUEL CUT RELAY Q COOLING FAN MOTOR SWITCH HEADLIGHT RELAY/ j FUEL RESERVE SENSOR TURN SIGNAL RELAY / r ' X -' . I / , REAR BRAKE LIGHT SWITCH SPEED SENSOR / .a “b L ; CLUTCH SWITCH ’/ LEFT HANDLEBAR “ SWITCH ( / \ ENGINE COOLANT ‘ \ TEMPERATURE '. ' IECT) SENSOR \\ THERMO SENSOR v 3 FUEL PUMP OIL PRESSURE SWITCH SIDE STAND SWITCH NEUTRAL SWITCH 19-0 19. LIG HTS/ M ETERS/ SWITCH ES SYSTEM DIAGRAM 19-0 COOLING FAN MOTOR SWITCH 19-14 SERVICE INFORMATION 19-1 OIL PRESSURE SWITCH 19-15 TROUBLESHOOTING 19-3 IGNI110N SWITCH 19-16 HEADLIGHT 19-4 HANDLEBAR SWITCHES 19-16 POSITION LIGHT 19-4 BRAKE LIGHT SWITCH 19-18 TURN SIGNAL 19-5 CLUTCH SWITCH 19-19 LICENSE LIGHT 19-6 NEUTRAL SWITCH 19-19 TAIL/BRAKE LIGHT 19-6 SIDE STAND SWITCH 19-20 COMBINATION METER 19-7 LOW FUEL INDICATOR/ FUEL RESERVE SENSOR 19-21 SPEEDOMETER/SPEED SENSOR 19-10 HORN 1 9-22 TACHOMETER 19-12 TURN SIGNAL RELAY 19-22 COOLANT TEMPERATURE GAUGE/ THERMO SENSOR 19—12 FUEL PUMP/ FUEL CUT RELAY 19-23 SERVICE INFORMATION GENERAL “WARNING 0 A halogen headlight bulb becomes very hot while the headlight is ON, and remains hot for a while after it is turned OFF. Be sure to let it cool down before servicing. 0 Use an electric heating element to heat the water/coolant mixture for the fan motor switch inspection. Keep all flammable materials away Iron-i the electric heating element. Wear protective clothing, insulated gloves and eye protection, 0 Note the following when replacing the halogen headlight bulb. *Wear clean gloves while replacing the bulb. Do not put finger prints on the headlight bulb, as they may create hot spots on the bulb and cause it to tail. — It you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early failure. — Be sure to install the dust cover after replacing the bulb. - Check the battery condition before performing any inspection that requires proper battery voltage. 0 A continuity test can be made with the switches installed on the motorcycle. 0 The lollowing color codes used are indicated throughout this section. Bu: Blue G: Green Lg: Light Green R: Red BI: Black Gr: Gray 0: Orange W: White Br: Brown Lb: Light Blue P: Pink V: Yellow 19-1 LlGHTS/MFI’ERS/SWITCHES SPECIFICATIONS ITEM SPECIFICATIONS Bulbs Headlight l High/Low 12V—60/55W X2 Position light 12V75W Brake/tail light 12Vi21/5W X2 Front turn signal light 12V‘21W Rear turn signal light 12V~21W License light 12V‘5W Instrument light 12V—1.7W,12V—3.4W ><2 Turn signal indicator 12V*3.4W X2 High beam indicator 12V—1.7W Neutral indicator 12V—3‘4W Oil pressure indicator 12VV3AW Fuel indicator 12V73.4W Fuse Main fuse 30 A Subfuse 20A><1 10A><5 Fan motor Startto close (ON) 98—102 “C (208-216°Fl switch Stop to open 93*97 “C (199*207 “Fl Coolant temperature sensor resistance at 80 “CH 76 °F 47 *57 S7. at120°C/248°F 14‘189 Fuel pump flow capacity Minimum700 cm3 (23.7 US oz , 24.6 imp ozilminute at 13V TORQUE VALUES 23 Nm (2‘3 kgf‘m , 17 Ith) 12 Nm (1.2 kgf‘m , 9 Ibf-ft) 10 N~m (1.0 kgf-rn , 7 lbf‘fti 10 N«m (1.0 kgf-m , 7 WP“) 29 Nm (3.0 kgf-m , 22 Ibf'") 9 N-m (0‘9 kgf—m , 6.5 lbf-It) Fuel level sensor Neutral switch Side stand switch bolt Side stand pivot bolt Side stand pivot lock nut Thermo sensor Apply sealant to the threads 19-2 TROUBLESHOOTING SPEED SENSOR/SPEEDOMETER LlGHTS/MEI'ERS/SWITCHES The odometer/trip meter operate normally, but the speedometer does not operate 0 Faulty speedometer The speedometer operate normally, but the odometer/trip meter does not operate 0 Faulty odometer/trip meter The speedometer operate is abnormal 0 Check for the lollowing before diagnosingr 7 Blown main or sub fuses 7 Loose or corroded terminals of the connectors *Discharged battery Check for loose or poor contact of the speed sen- sor 3P (Black) connector. With the ignition switch 0N and measure the volt- age at the speed sensor connectort —AbnormaI—— - Loose or poor contact of related terminals 0 Open circuit in Black/Brown or Green/Black wires between the battery and speed sensor Normal Check for loose or poor contact of the combina- tion meter 9P (Black), 6? connectors. With the ignition switch 0N and measure the volt- age at the bottom of the speedometer terminalst ——AbnormaI—>- Loose or poor contact of related terminals 0 Open circuit in Black/Brown or Green/Black wires between the battery and speedometer Normal With the ignition switch OFF, check for continuity between the Pink/Green wire of the speed sensor and Black/Red terminal of the speedometer. —Abnormal—>~ Open circuit or loose connection in Pink/Green wire Normal Support the motorcycle using a hoist or other support to rise the rearwheel off the ground. Measure the output voltage (sensor signal) at the speedometer with the ignition switch is ON while slowly turning the rearwheel by your hand. —AbnormaI—>. Faulty speed sensor 0 Loose speed sensor mounting bolts Normal 5—, o Faulty speed sensor 1 9-3 LlGHTS/METERS/SWITCHES HEADLIGHT POSITION BULB REPLACEMENT M— A halogen headlight bulb becomes very hot while the headlight is ON. and remains hot for a while after it is turned OFF. Be sure to let it cool down before servicing. Remove the headlight bulb sockets. Remove the dust cover. Unhook the bulb retainer and remove the headlight bulb/socket. CAUTION: Avoid touching halogen headlight bulbs. Finger print: can create hot spots that cause a bulb to break. If you touch the bulb with your bare hands, clean it with cloth moistened with denatured alcohol to pre~ vent early bulb failure. Remove the headlight bulb from the socket. Install a new bulb into the socket. Install the headlight bulb/socket aligning its tabs with the grooves in the headlight unit. Install the dust cover tightly against the headlight with its "TOP" mark facing up Connect the headlight sockets. LIGHT BULB REPLACEMENT Remove the steering stem cover (page 13-30). Remove the bulb socket and bulb. Install the front turn signal bulb in the reverse order of removal, "TOP" MARK RETAINER BULB BULB SOCKET 19-4 LIGHTS/METERS/SWITCHES TURN SIGNAL BULB REPLACEMENT Front Remove the inner side cowl (page 2-5). Turn the bulb socket counterclockwise and remove it While pushing in, turn the bulb counterclockwise to remove it and replace with a new one. Install the front turn signal bulb in the reverse order of removal. BULB SOCKET Rear Remove the screw and turn signal lens. While pushing in, turn the bulb counterclockwise to remove it and replace with a new one Install the rear turn signal bulb in the reverse order of removal‘ LENS SCREW BULB 19-5 LIGHTS/METERS/SWITCHES LICENSE LIGHT BULB REPLACEMENT Remove the license light bracket socket bolts and the license light assembly Remove the nuts, license light case and lens. While pushing in, turn the bulb counterclockwise to remove it and replace with a new one. Install the license light bulb in the reverse order of removal. TAIL/ BRAKE LIGHT BULB REPLACEMENT Remove the seat (page 2-2), Turn the bulb socket counterclockwise and remove it While pushing in, turn the bulbs counterclockwise to remove it and replace with new ones. Install the tail/brake light bulb in the reverse order of removal. Install the seat (page 2»2l. SOCKET BOLTS BULB SOCKET 1 9-6 LIGHTS/METERS/SWITCHES COMBINATION METER BULB REPLACEMENT Remove the upper cowl (page 26L METER LIGHT METER LIGHY BULB Pull the meter light bulb socket out of the combina- tion meter. Remove the bulb from the socket and replace it with a new one. mm L ocxer ' INDICATOR/PILOT BULB Remove the tab on the combination meter from the grommet on the meter stay. Swing the combination meter assembly uplight. Pull the indicator/pilot bulb socket out of the combi- nation melert Remove the bulb from the socket and replace it with a new one. REMOVAL/INSTALLATION Remove the upper cowl (page 2-6). Disconnect the combination meter 9? (Black) eon- nector and SP connectorr Remove the combination meter wire from the clamp. LIGHTS/METERS/SWITCHES Remove the tab on the combination meter from the grommet on the meter stay‘ Remove the mounting bolts and combination me- ter assembly. Installation is in the reverse order of removal. NOTE: Route the combination meter wire properly (page 1-21) DISASSEMBLV scnsws Remove the screws and upper case UPPER CASE Remove the O-rings. O-fllNGS Remove the meter light bulb sockets and indicator/ pilot bulb sockets from the lower case (page 19-7). 19-8 Remove the screws, speedometer, tachometer, coolant temperature gauge and clock switcht Remove the screw, damp and meter wi re. ASSEMBLY Assemble the combination meter in the reverse order of removal. NOTE: Connect the wire terminals and install the bulb sockets according to the collar codes on the lower case. SPEEDOMETER SCREWS CLAMP CLOCK SWITCH METER WIRE LIGHTS/METERS/SWITCHES TACHOMETER SCREWS SPEEDOMETER CLAMP .\ r’ ' . ‘0 — 0 CLOCK SWITCH METER me C00%‘ TEMPERATURE GAUGE TACHOMETER UPPER CASE COOLANT TEMPERATURE GAUGE 1 9-9 LlGHTS/METERS/SWITCHES SPEEDOMETER/SPEED SENSOR VOLTAGE INSPECTION Remove the right side cover (page 2-2). Disconnect the speed sensor 3P (Blue) connector and check for loose or poor contact of the connec- tort With the ignition switch is ON and measure the volt- age at the 3P (Blue) connector of the wire harness side Connection: Black/Brown (+) * Green/Black (—) standard: Battery voltage If there is no voltage, replace and repair the wire harness. Remove the upper cowl (page 245)‘ Check for loose or poor connection of the combinav tion meter 9P (Black) connector and SP connector. With the ignition switch is ON and measure the volt- age at the bottom of the combination meter termi- nal. Connection: Black/Brown (H 7 Green/Black (-) Standard: Battery voltage If there is no voltage. replace and repair the wire harness. OUTPUT SIGNAL INSPECTION Remove the upper cowl (page 2-6L With the ignition switch is OFF, check for continuity of the Pink/Green wire between the speed sensor 3P (Blue) connector and combination meter termi- nal. There should be continuity. If there is no continuity, replace and repair the wire harness 19-10 LlGHTS/METERS/SWITCHES Support the motorcycle securely with a hoist or PINKJGREE equivalent. Connect the speed sensor 3P (Blue) connector, Measure the voltage at the combination meter ter- minals with the ignition switch is ON while slowly turning the rear wheel by hand, OONNECTION: Pink/Green H) - Green/Black ii) STANDARD: Repeat 0 to 5V if the measurement is out of specification, inspect the open circuit in wire harness. SPEED SENSOR REMOVAL/ INSTALLAATION Remove the fuel tank (page 2-10)- Disconnect the speed sensor 3P (Blue) connectort Remove the bolts, battery ground cable and speed SSI'ISOIX Check the O—ring is in good condition, replace if nec» 0 mm; essary. \ Install the speed sensor into the upper crankcase. t\ Install the battery ground cable, ‘ Install and tighten the mounting bolts securely. NOTE: Route the speed sensor wire and battery ground - '- cable properly (page 1»21). /‘ l f Connect the speed sensor 3P (Blue) connectort SPEED SENSOR 19-11 LIGHTS/MHERS/SWITCHES TACHOMETER INSPEC'I10N Remove the upper cowl (page 2—6)‘ Check for loose or poor contact terminals of the combination meter. Connect the peak voltage adaptor to the tachome- ter Yellow/Green terminal and ground. TOOLS: lmrio diagnostic tester (model 625) or Peak voltage adaptor 07HGJ-0020100 with Commercially available digital multimeter (impedance 10 M (2 IDCV minimum) counecnou: Vellow/Green (H and Ground (Al Start the engine and measure the tachometer input voltage. PEAK VOLYAGE: 105 V minimum If the value is normal, replace the tachometer‘ If the measured value is below 10.5 V, replace the ignition control module (ICM). If the value is 0 V, perform the following: Remove the seat (page 2-2) and disconnect the ICM connector. Check for continuity between the tachometer termi» nal and the ICM connector Yellow/Green terminal. If there is no continuity, check the wire harness for an open circuit If there is continuity, replace the tachometer unit. For tachometer replacement, see 19-8; combination meter disassembly and assembly. COOLANT TEMPERATUREGAUGE/ THERMO SENSOR INSPECTION Remove the fuel tank (page 2-10). Disconnect the thermo sensor wire connector from , the sensor. Ground the thermo sensor wire with a jumper wire. D GITAL MULTIMETER 19-12 LIGHTS/METERS/SWITCHES Turn the ignition switch 0N and check the coolant temperature gauge. Disconnect the thermo sensor wire connector from the ground immediately if the gauge needle moves fully to H, CAUTION' Immediater disconnect the sensor wire connector from the ground when the needle moves to H (hot) to prevent damage to the gauge. If the needle moves, check the thermo sensor unit. If the needle does not move, check for open circuit in GreemBIue wire. Turn the ignition switch 0N and measure the volt- age between the Black/Brown and Green/Black wira terminals There should be battery voltage, If there is no voltage between the terminal, check the wire harness. If a voltage is measured, faulty coolant temperature gauge unit is faulty. THERMO SENSOR UNIT INSPECTION m__ 0 Wear insulated gloves and adequate eye protec- tion. 0 Keep flammable materials away from the elec- tric heating element. Drain the coolant (page 65). Disconnect the wire connector from the thermo sen- sor and remove the sensor. Suspend the thermo sensor in a pan of coolant (50—50 mixture) an electric heating element and measure the resistance through the sensor as the coolant heats up. NOTE: oSoak the thermo sensor in coolant up to its threads with at least 40 mm (1.57 in) from the bottom of the pan to the bottom of the sensor. IKeep the temperature constant for 3 minutes before testing. A sudden change of temperature will result in incorrect readings. Do not let the thermometer or thermo sensor touch the pan. COOL ANT TEMPERATURE GAUGE i THERMO SENSOR 80 °C (176 “H 120 °C (248 °F) 47—57Q 14‘189 Temperature Resists nce THERMO METER 19-13 LIGHTS/METERS/SWITCHES Replace the sensor it it is out of specification by more than 10 % at any temperature listed. Apply sealant to the thermo sensor threads. Do not apply sealant to the sensor head. Install and tighten the thermo sensor. YORQUE: 9 N-m (0.9 ngm , 6.5 Ibf-ft) Connect the thermo sensor connector. Fill the system and bleed the air (page 65). COOLING FAN MOTOR SWITCH INSPECTION Check for a blown fuse before inspection. Remove the side cowl (page 2-5). Fen motor does not stop Turn the ignition switch OFF, disconnect the con- nector from the fan motor switch and turn the igni- tion switch 0N again If the fan motor does not stop. check for a shorted wi re between the fan motor and switch. If the fan motor stops, replace the fan motor switch. Fan motor does not start Before testing, warm up the engine to operating temperature Disconnect the connector from the fan motor switch and ground the connector to the body with a jumperwire, Turn the ignition switch 0N and check the fan motor, If the motor starts, check the connection at the fan motor switch terminal. It is OK, replace the fan motor switch If the motor does not start, check for voltage be— tween the fan motor switch connector and ground, If battery voltage is measured, replace fan motor. If there is no battery voltage, check for poor connec- tion of the fan motor 2P (Black) connector or broken wire harness. 19-14 LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION Disconnect the fan motor switch connector and remove the switch. Install a new O—ring onto the fan motor switcht Install and tighten the fan motor switch securely. Connect the fan motor switch connector‘ OIL PRESSURE SWITCH INSPECTION If the oil pressure warning indicator stays on while the engine running, check the engine oil level before inspection. Make sure that the oil pressure warning indicator come on with the ignition switch ON. it the indicator does not come on, inspect as follow: Remove the under cowl (page 2-7) Remove the dust cover. Remove the screw and oil pressure switch terminal, Short the oil pressure switch wire terminal with the ground using a jumper wire. The oil pressure warning indicator comes on with the ignition switch is ON. If the light does not comes on, check the sub 0 Clogged fuel line and strainer 0 Clogged fuel tank breather tube Reaching carburetor 2. Perform spark test —— Weak or no spark 0 Faulty spark plug - Fouled spark plug Good spark 0 Loose or disconnected ignition system wires 0 Broken or shorted spark plug wire 0 Faulty ignition pulse generator ' Faulty ignition coil 0 Faulty engine stop switch 0 Faulty ignition control module (ICM) o Faulty ignition switch 3. Remove and inspect spark plugs — Wet plug ——> 0 Flooded carburetor 0 Starting enrichment (SE) valve ON Good condition position (open) 0 Throttle valve open 0 Dirty air cleaner 4, Start by following normal procedure Engine starts but stops —> o Improper choke operation 0 Incorrectly adjusted carburetor Engine does not start - Leaking carburetor insulator o Improper ignition timing (Faulty ICM or ignition pulse generator) 0 Contaminated fuel 5‘ Test cylinder compression —- Low compression —-——> 0 Valve stuck open a Worn cylinder and piston rings 9 Damaged cylinder head gasket 0 Seized valve o Improper valve timing 21-1 TROUBLESHOOTING ENGINE LACKS POWER 1. Raise wheel off the ground and spin by hand Wheel spins freely Possible cause Wheel does not spin —-> 0 Brake dragging freely 0 Worn or damaged wheel bearings 0 Drive chain too tight 2. Check tire pressure Pressure normal 3. Accelerate rapidly low to second Engine speed reduced when clutch 5 released 4, Accelerate lightly E ngi ne speed increase Pressure low 0 Faulty tire valve 0 Punctured tire Engine speed doesn‘t —' 0 Clutch slipping change accordingly when 0 Worn clutch discs/plates clutch is released 0 Warped clutch discs/plates 0 Weak clutch spring 0 Additive in engine oil Engine speed does not —> 0 Starting .enrichment (SE) valve 0N increase position (open) 0 Clogged aircleaner 0 Restricted fuel flow 0 Clogged muffler 0 Restricted fuel tank breather tube 5. Check ignition timing Correct 6. Test cylinder compression Normal compression 7t Check carburetor for clogging Not clogged 8. Remove and inspect spark plugs Not fouled or discolored 9. Check oil level and condition Correct To page 21-3 Incorrect I Faulty ignition control module (ICM) 0 Faulty ignition pulse generator Low compression —> 0 Valve clearance too small 0 Worn cylinder and piston rings 0 Damaged cylinder head gasket 0 Improper valve timing Clogged ——>OCarburetor not serviced frequently enough Fouled or discolored—> I Plugs not serviced frequently enough 0 Incorrect spark plug used Incorrect —-——> 0 Oil level too high 0 Oil level too low 0 Contaminated oil 21-2 TROUBLESHOOTING From page 21»2 Possible cause 10. Remove cylinder head cover and Valve train not lubricated—>0 Clogged oil passage 'nspect lubrication properly 0 Clogged oil orifice Valve train lubricated properly 11. Check for engine overheating — Overheating—> o Coolant level too low 0 Fan motor not working lFautly fan motor or fan motor switch) Not overheating o Thermostat stuck closed 0 Excessive carbon build-up in combus- tion chamber 0 Use of poor quality fuel 0 Clutch slipping I Lean fuel mixture 0 Wrong type of luel 12c Accelerate or run at high speed— Engine knocks -—> o Worn piston and cylinder 0 Wrong type of fuel 9 Excessive carbon build-up in combus- Engine does not knock tion chamber 0 Ignition timing too advance (Faulty ICMl 0 Lean fuel mixture POOR PERFORMANCE AT LOW AND IDLE SPEED Possible cause 1. Check carburetor pilot screw adjustment — Incorrect 0 See section 5 Correct 2, Check lor leaking carburetor insulator Leaking — 0 Loose carburetor insulator bands 0 Damaged carburetor insulator No leak 3. Perform spark test — Weak or intermittent spark —> 0 Faulty spark plug 0 Fouled spark plug 0 Loose or disconnected ignition system Good spark wirgs 0 Broken or shorted spark plug wire 0 Faulty ignition pulse generator 0 Faulty ignition coil 0 Faulty engine stop switch 0 Faulty ignition control module (ICMl 0 Faulty ignition switch 4‘ Check i nition timin Incorrect ' Faulty ignition control module (ICM) 9 9 ' Faulty ignition pulse generator 21-3 TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED Possible cause 1‘ Disconnect fuel tube at carburetor — Fuel flow restricted—> 0 Restricted fuel tube and pump the vacuum line 0 Restricted fuel tank breather tube 0 Faulty fuel valve Fuel flows freely o Clogged fuel strainer 2‘ Check carburetor for clogging— CIogged——> o Carburetor not serviced frequently enough Not clogged 3‘ Check valve timing—— Incorrect —> 0 Cam sprockets not installed properly Correct 4. Check ignition timing—— Incorrect o Faulty ignition control module (ICM) 0 Faulty ignition pulse generator Correct 5‘ Check valve spring —Weak —> - Faulty valve spring Not weak POOR HANDLING Poulblo cause 1. If steering is heavy 0 Steering stem adjustment nut too tight 0 Damaged steering head bearings 2‘ If either wheel is wobbling 0 Excessive wheel bearing play 0 Bent rim . Improperly installed wheel hub o Excessively worn swingarm pivot bearings o Bent frame 3‘ If motorcycle pulls to one side———————> - Front and rear wheels not aligned - Bent fork 0 Bent swingarm - Bent axle - Bent frame 21-4 AIR CLEANER AIR CLEANER HOUSING ALTERNATOR CHARGING COIL ALTERNATOR COVER INSTALLATION REMOVAL BATTERY BODY PANEL LOCATIONS BRAKE FLUID BRAKE FLUID REPLACEMENT/AIR BLEEDING BRAKE LIGHT SWITCH ILIGHTS/METERS/SWITCHES) (MAINTENANCE) BRAKE PAD WEAR BRAKE PAD/DISC BRAKE PEDAL BRAKE SYSTEM CABLE & HARNESS ROUTING CAM CHAIN TENSIONER LIFTER CAMSHAFT INSTALLA'HON REMOVAL CARBURETOR CHOKE CARBURETOR ASSEMBLY COMBINATION DISASSEMBLY/INSPECTION INSTALLATION REMOVAL SEPARATION CARBURETOR SYNCHRONIZATION CHARGING SYSTEM INSPECTION CLUTCH CLUTCH LIFTER ARM CLUTCH SYSTEM CLUTCH SWITCH COMBINATION METER COOLANT REPLACEMENT COOLANT TEMPERATURE GAUGE/THERMOSENSOR COOLING FAN MOTOR SWITCH COOLING SYSTEM CRANKCASE ASSEMBLY SEPARATION CRANK PIN BEARING CRANKSHAFT CYLINDER COMPRESSION TEST CYLINDER HEAD COVER ASSEMBLY DISASSEMBLY INSTALLATION REMOVAL CYLINDER HEAD ASSEMBLY DISASSEMBLY INSPECTION INSTALLATION REMOVAL DELAY VALVE DIODE DRIVE CHAIN DRIVE CHAIN SLIDER EMISSION CONTROL SYSTEMS ENGINE COOLANT TEMPERATURE (ECT) SENSOR ENGINE DOES NOT START OR IS HARD TO START ENGINE IDLE SPEED INDEX 3-5 54 1 6-7 10-7 10-2 1 6-5 2-0 3-20 1 5-5 19-18 3-22 3-21 1 5-10 1 5-37 3-21 1 >21 $28 8-2 1 5-7 3-5 5-12 5-15 5-9 5-1 B 5-5 5-7 3-1 2 166 9-3 9-1 7 3-23 1 9-1 9 19-7 64 19-1 2 19-14 3-1 5 1 1-10 1 1 -3 1 2-6 I 2-3 8-4 8-26 8-6 8-27 8—4 8-19 8-1 1 84 2 3-20 8-1 0 1 5-26 18-12 3-1 6 3-20 1 -28 1 7-9 2 1 -1 3-14 ENGINE LACKS POWER ENGINE OIL ENGINE OIL FILTER ENGINE INSTALLATION REMOVAL FLYWHEEL INSTALLATION REMOVAL FORK FRONT BRAKE CALIPER FRONT WHEEL FRONT MASTER CYLINDER FUEL FILTER FUEL LINE FUEL PUMP/FUEL CUT RELAY FUEL TANK GEARSHIFT LINKAGE GENERAL SAFETY HANDLEBAR HANDLEBAR SWITCHES HEADLIGHT HEADLIGHT AIM HORN IGNITION COIL IGNITION PULSE GENERATOR IGNITION SYSTEM INSPECTION IGNITION SWITCH IGNITION TIMING LICENSE LIGHT LOW FUEL INDICATOR/FUEL RESERVE SENSOR LUBRICATIONS & SEAL POINTS LUBRICATION SYSTEM DIAGRAM MAIN JOURNAL BEARING MAINTENANCE SCHEDULE MODEL IDENTIFICATION MUFFLER/EXHAUST PIPE NEUTRAL SWITCH NUMBER PLATE BRACKET NUTS. BOLTS, FASTENERS OIL PRESSURE INSPECTION OIL PRESSURE SWITCH OIL PUMP OIL STRAINER/PRESSURE RELIEF VALVE PILOT SCREW ADJUSTMENT PISTON/CYLINDER POOR HANDLING POOR PERFORMANCE AT HIGH SPEED POOR PERFORMANCE AT LOW AND IDLE SPEED POSITION LIGHT PRIMARY DRIVE GEAR PROPORTIONAL CONTROL VALVE RADIATOR RADIATOR COOLANT RADIATOR RESERVE TANK REAR BRAKE CALIPER REAR CARRIER REAR FENDER REAR FENDER B REAR MASTER CYLINDER REAR WHEEL REGULATOR/RECTIFIER 21-3 1 5-25 6-6 3-14 6-12 1 5-32 2-3 23 1 5-21 14-3 1 6—8 RIGHT CRANKCASE COVER INSTALLATION REMOVAL SEAT SECONDARY AIR SUPPLY SYSTEM (MAINTENANCE) (FUEL SYSTEM) SECONDARY MASTER CYLINDER SERVICE RULES SERVICE INFORMATION (ALTERNATOR/STARTER CLUTCH) (BATTERY/CHARGING SYSTEM) (CLUTCH/GEARSHIFT LINKAGE) (COOLING SYSTEM) (CRANKCASE/TRANSMISSION) (CRANKSHAFT/PISTON/CYLINDER) (CYLINDER HEADNALVES) (ELECTRIC STARTER) (ENGINE REMOVAUINSTALLATION) (FRAME/BODY PANELS/EXHAUST SYSTEM) (FRONT WHEEL/SUSPENSION/STEERING) (FUEL SYSTEM) (HVDRAULIC BRAKE) (IGNITION SYSTEM) (LIGHTS/METERS/SWITCHES) (LUBRICATION SYSTEM) (MAINTENANCE) (REAR WHEEL/SUSPENSION) SHIFT FORK/SHIFT DRUM SHOCK ABSORBER SIDE COVER SIDE COWL SIDE STAND SIDE STAND SWITCH SPARK PLUG SPECIFICATIONS SPEEDOMETER/SPEEDO SENSOR STARTER CLUTCH STARTER MOTOR STARTER RELAY SWITCH STATOR STEERING HEAD BEARING STEERING STEM SUSPENSION SUSPENSION LINKAGE SWINGARM SYSTEM DIAGRAM (BATTERY/CHARGING SYSTEM) (ELECTRIC STARTER) (LIGHTS/METERS/SWITCHES) (IGNITION SYSTEM) SYSTEM FLOW PA‘I'I'ERN SYSTEM TESTING TACHOMETER TAIL/BRAKE LIGHT THERMOSTAT THROTTLE OPERATION THROTTLE SENSOR TOOLS TORQUE VALUES TRANSMISSION 9-16 9-3 2-2 3—16 5-22 1549 I-2 104 16-1 94 6'1 11-1 12-1 18-1 7-1 2-1 134 154 17-1 19-1 TROUBLESHOOTING (ALTERNATOR/STARTER CLUTCH) (BATTERY/CHARGING SYSTEM) (CLUTCH/GEARSHIFT LINKAGE) (COOLING SYSTEM) (CRANKCASE/TRANSMISSION) (CRANKSHAFT/PlSTON/CYLINDER) (CYLINDER HEAD/VALVES) (ELECTRIC STARTER) (FRAME/BODY PANELS/EXHAUST SYSTEM) (FRONT WHEEL/SUSPENSIONISTEERING) (FUEL SYSTEM) (HYDRAULIC BRAKE) (IGNITION SYSTEM) (LIGHTS/MEIERS/SWITCHES) (LUBRICATION SYSTEM) (REAR WHEEL/SUSPENSION) TURN SIGNAL TURN SIGNAL RELAY UNDER COWL UPPER COWL VALVE CLEARANCE VALVE GUIDE REPLACEMENT VALVE SEAT INSPECTION/REFACING WATER PUMP WHEELS/TIRES WIRING DIAGRAMS 10-1 1 6-3 9-2 6-2 1 1 —2 12—2 8-3 13-2 2«1 1 3-2 1 5-4 1 7-3 1 9-3 4-3 1 4—2 19-5 19-22 2-7 2-6 3-8 84 4 (H 5 6—1 5 3-26 20-1 To print chapters, click on the printer icon and fill in the page range. 1. General Information 4 - 32 2. Frame/Body panels/Exhaust 33 - 43 3. Maintenance 44 - 69 4. Lubrication system 70 - 80 5. Fuel system 81 - 104 6. Cooling system 105 - 126 7. Engine removal/Installation 126 - 138 8. Cylinder headNalves 139 - 169 9. Clutch/Gearshift linkage 170 - 188 10. Alternator/Starter clutch 189 - 197 11. CrankcaselTransmission 198 - 210 12. CrankshafflPiston/Cylinder 211 - 206 13. Front wheel/Suspension/Steering 226 - 261 14. Rear wheel/Suspension 262 - 283 15. Hydraulic brake 284 - 321 16. Battery/Charging system 322 - 331 17. Ignition system 332 - 343 18. Electric Starter 344 - 356 19. Lights/MetersISwitches 357 - 382 20. Wiring diagrams 383 21. Troubleshooting 384 - 387 22. Index 388 - 389 Note: Make sure to select ‘1 Shrink to fit in the printer dialog box when printing wiring diagrams.