SllllP MANUAL IMPORTANT SAFETY NOTICE Indicates a strong possibility of severe personal injury or deth if instructions are not followed. CAUTION: Indicates a possibility of equipment damage if instructions are not followed. NOTE Gives helpful information. Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. It is important to note that this manual contains some warnings and cautionsagainst some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand that those warnings could not cover all conceivable ways in‘which service, whether or not recommended by Honda, might be done or of the possibly hazardous consequences of'each conceivable way, nor could Honda investigate all such ways. Anyone using service procedures or tools, whether or not recommended by Honda, must satisfy himself thoraughlythat neither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected. TYPE CODE 0 Throughout this manual, the following abbreviations are used to identify individual model. CODE AREA TVPE CODE AREA TVPE EUROPEAN DIRECT SALES NETHERLANDS TYPE ll ED (haiy, Germany, Portugal, Norway; Finland, Ii H (Limited power/25 kw (34 PS); Denmark, Austria) ‘ Spain) EUROPEAN DIRECT SALES TVPE II E U. K. II ED (Limited power/37 kw (50 PS): Sweden, Germany) F FRANCE EUROPEAN DIRECT SALES TYPE III 6 GERMANY III ED (Limited power/25 kw (34 PSI; Germany, Portugal) SW SWITZERLAND H NETHERLANDS U AUSTRALIA (Belgium, Spain) HOW TO USE THIS MANUAL This service manual describes the service procedures for the CBGDOF. Follow the Maintenance Schedule (Section 3] recomr mendations to ensure that the vehicle is in peak oper ating condition. Perlorming the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Sections I and 3 apply to the whole motorcycle. Section 2 illustrates procedures for removal/ installation of components that may be required to perform service described in the following sections. Sections 4 through 19 describe parts of the motorcycle, grouped according to location. Find the section you wanton this page, then turn to the table of contents on the first page of the section Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent pages give detailed procedure. If you don't know the source of the trouble, go to section 21 Troubleshooting I ALL INFORMATION, ILLUSTRATIONS, DIREC- TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE I TIME OF APPROVAL FOR PRINTING HONDA I MOTOR CO, LTD. RESERVES THE RIGHT TO I MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANV OBLIGATION WHATEVER. NO PART OF THIS I PUBLICATION MAY BE REPRODUCED WITHOUT I WRITTEN PERMISSION THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON HONDA MOTORCYCLES, MOTOR SCOOTERS DRAWS. HONDA MOTOR 00.. LTD. SERVICE PUBLlCATION OFFICE CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE ENGINE AND DRIVE TRAIN LUBRICATION SYSTEM FUEL SYSTEM COOLING SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/VALVES CLUTCH/GEARSHIFT LINKAGE ALTERNATOR/STARTER CLUTCH CRANKCASE/PlSTON/CVLINDER CRANKSHAFI'ITRANSMISSION CHASSIS FRONT WHEEL/SUSPENSION/ STEERING REAR WHEEL/SUSPENSION HYDRAULIC BRAKE ELECTRICAL BATTERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER LIGHTS/METERS/SWITCHES WIRING DIAGRAMS TROUBLESHOOTING _A _| .3 .—A _L SYMBOLS The symbols used throughout this manual Show specific service procedures. If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols. £0? Replace the pa rt(sl With new onelsl before assembly. 7 ’7E Use recommended engine oil, unless otherwise soecified. ’73 Use molybdenum oil soiution (mixture of the engine oil and molybdenum grease in a ratio of1 : 1), fl Use multi-purpose grease [Lithium based multi-purpose grease NLGI at 2 or equivalentl. Use molybdenum disullide grease (containing more than 3 % molybdenum disulfide, NLGI #2 or @ equivalentl. Example: Molykote“ BR»2 plus manufactured by Dow Corning, U. S. A. Multi»purpose M—Z manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40 % molybdenum disulfide, NLGI 2: 2 or equivalent). (fix Example: Molykotew G»rI paste, manufactured by Dow Corning, U. S. A. Honda Moly GD (U. S. A. only) Rocol ASP manufactured by Rocol Limited, U. K. Rocol Paste manufactured by Sumico Lubricant. Japan fl Use silicone grease. QM Apply a locking agent. Use a middle strength locking agent unless otherwise specified. Jim! Apply sealant. % Use DDT 4 brake fluid. Use the reconmienoed brake fluid unless otherwise specified. a Use Fork or Suspension Fluid. 1. GENERAL INFORMATION GENERAL SAFETY 1-1 SERVICE RULES 1-2 MODEL IDENTIFICATION 1-3 SPECIFICATIONS 1-4 TORQUE VALUES 1-13 TOOLS 1-17 LUBRICATION 81 SEAL POINTS 1-19 CABLE & HARNESS ROUTING 1-22 EMISSION CONTROL SYSTEMS 1-32 GENERAL SAFETY CARBON MONOXIDE If the engine must be running to do some work, make sure the area Is well ventilated, Never run the engine in an enclosed area. ME The exhaust contains poisonous carbon monoxide gas that can cause lass of consciousness and may lead ta death. USED ENGINE OIL m_~__ 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 all on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used nil. KEEP DU T 0F REACH OF CHILDREN. Run the engine in an open area or with an exhaust evacuation system in an enclosed area. GASOLINE Work in a well ventilated area. Keep cigarettes, flames or sparks away from the work area or where gasoline is stored. %_ Gasaline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. HOT COMPONENTS M. Engine and exhaust system parts become very hot and remain hat for some time after the engine is run. Wear insulated gloves or wait until the engine and exhaust system have cooled before handling these parts, BRAKE DUST Never use an air hose or dry brush to clean the brake assemblies. MW— lnhaled asbestos fibers have been found to cause respiratory disease and cancer. BRAKE FLUID CAUTION' Spilling fluid on painted, plastic or rubber parts will damage them, Place a clean shop towel over these parts whenever the system is serviced. KEEP OUT OF REACH OF CHILDREN. 1-1 GENERAL INFORMATION COOLANT Under some condition, the ethylene glycol in engine coolant is combustible and its flame is not visible. If the ethylene glycol does ignite, you will not see any flame, but you can be burned. _WARNING 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. - Coolant {ethylene glycol) can cause some skin irritation and is uaisamms if swallowed. KEEP OUT OF REACH OF CHILDREN. 0 Do not remove the radiator cap when the engine is hot. The coolant is under pressure and could scald you, . Keep hands and clothing away from the cooling Ian, as it starts automatically. SERVICE RULES BATTERV HVDROGEN GAS & ELECTROLVTE MW - The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. - The battery contains sulfuric acid [electrolyte]. Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield. , If electrolyte gets on your skin, flush with water. —- If electrolyte gets in your eyes, flush with water for at least 15 minutes and calla physician immediately. - Electrolyte is poisonous. -il’ swallow-d, drink large quantities of water or milk and follow with milk a! magnesia or vegetable oil and call a physician. KEEP OUT OF REA CH OF CHILDREN. 1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents Parts that don't meet HONDA's design specifications may cause damage to the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners. 4. Install new gaskets, O-rlngsl cotter pins, and lock plates when reassembling. 5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassemblv. Lubricate any sliding surfaces before reassembly. 7. After reassembly. check all parts for proper installation and operation. 3. Route all electrical wire: as show on pages 1-22 through 1-31, Cable and Harness Routing. 1-2 MODEL IDENTIFICATION (1) The frame serial number is stamped on the right side ofthe steering head. CARBURETOR lDENTIFICATION NUMBER a (3| The carburetor idennfication number is stamped on the intake side of the carburetor body as shown. GENERAL INFORMATION (2i The engine serial number is stampad on the lower right side of the era nkcase‘ COLOR LABEL (4) The color label is anached as shown. When ordering color-coded pans, always specify the desiunated rnlnr l‘fil’IF SPECIFICATIONS . Displacement I Compression ratio Valve train Intake valve opens at1 mm closes (0.04 in) lift Exhaustvelve opens closes Lubrication system Oil pump type 1 Cooling system Air filtration Crankshaft type Engine dry weight Firing order Cylinder arrangement * GENERAL ITEM SPECIFICATIONS DIMENSIONS Overall length 2,080 mm (81.9 inl Overall width 740 mm (29.1 inl 1 Overall height 1,055 mm (41.5 in) Wheelbase 1,420 mm (55.9 in) 1 Seal height 795 mm (31.3 in) Footpeg height 344 mm (13.5 inl ‘ Ground clearance 135 mm (5.3 in) Dry weight 176 kg (388 lbsl 1 Curb Weight 195 kg (432 leI Maximum weight capacity 138 kg (414 lbs) FRAME Frame type Diamond ‘ Front suspension Telescopic fork Front wheel travel 112 mm (4.4 ml 1 Front axle travel 112 mm (4.4 in) Rear suspension Swingarm 1 Rearwheel travel 127 mm (5.0 in) Rear axle travel 127 mm (5. 0 in1 ( Rear damper Nitrogen gas filled damper 1 Front tire size 130/7OZR16 (61W) Radial 1 Rear tire size 180/552R17 (73W) Radial 1 Tire brand ‘ Bridgestone Front: BT-SOF RADIAL G /Flear: BT»50R RADIAL G I Michelin Front: TX11/Fiear: TX23 Front brake Hydraulic double disc brake Rear brake Hydraulic single disc brake Caster angle 25°40' Trail length 98 mm (3.9 in) 1 Fuel tank capacity 16.0 291.23 us gal , 3.521mp gal) Fuel reserve capacity 3.0 210.79 US gal . 0.66 Imp gall ENGINE Bore and stroke 65.0 X 45.2 mm (2.56 X 1.78 in) 599 cm: (36,5 cu-in) 12.0 : 1 Silent muIti-link chain driven DOHC, 4 valves per cylinder 15“ BTDC 35" ABDC 33“ BBDC 7° ATDC Forced pressure and wet sump Trochoid Liquid cooled Oiled paper filter Unittype 61.9 kg (136.5 leI 1 - 2 — 4 - 3 Vertical 30° inline four GENERAL INFORMATION GENERAL c t’d ’— ( on )ITEM SPECIFICATIONS CAHBURETOR Type Constant velocity i Throttle bore ‘ 34 mml1.3 in) 7 DRIVE TRAIN Clutch system MultiAplate, wet Clutch operation system Cable operated type Transmission Constant mesh, 6-speed Primary reduction 1.863 (82/44) Final reduction 2.800(42/15I Gear ratio 1st 2.923 (41/14I 2nd 2,062 (33/16l 3rd 1.647(28/17I 4th 1.368 (26/19) 5th 1.200 (24/20) Gth 1.056 (25/23) Gearshift pattern Lah foot operated return system, 1 - N - 2 m 3 — 4 — 5 m 6 ELECTRICAL Ignition system Full transistorized ignition Starting system Electric starter motor Charging system Triple phase output alternator Regulator/rectifier SCR shorted/triple phase, full wave rectification fighting system Battery 1-5 GENERAL INFORMATION Unit1mm (in) — LUBRICATION SYSTEM ITEM STANDARD SERVICE LIMIT Engine oil capacity Atdraining 3.5 D (3.7 US qt, 3.1 Imp qt] , , 7 ‘ 7 At disessembly 112 ii (4.4 US qt, 3.7 imp qt) ‘ # At oil filter change 3.8 ll (4.0 US qt , 3.3 Imp qt) — Recommended engine oil HONDA 4rstroke oil or equivalent motor oil ~ API service classification SE, SF or 56 Viscosity: SAE 10 W—40 Oil pressure at oil pressure switch 490 kPa (5.0 kgf/cm1,71 psi) at ; — 6,000 min" (Nomi/(80 “C/176 °F) i Oil pump rotor "Tip clearance 7* __ 0.15 (0.006l max. i 0.20 (000% Body clearance 0.15—-0.22 (0006—0009) ' 0.35 (0.014) Side clearance 00270.07 (000170.003) 0.10 (9904) Oil pump drive sprocket collar 0. D. 34050734375(13405713415) 34.03 (1.340] Oil pump drive sprocket l. D. 35025-35075 (13789—13809) 35.10 (1.352] ,— FUEL SYSTEM ITEM SPECIFICATIONS Carburetor identification Except SW type VP49A number SW tyne VP4SB Main jet No.1/4; #100, No.2/3; #102 Slawjet #40 Jet needle 7 J7SL Pilot screw initial opening I Except SW type 1 3/4 thrns out W l SW type 2 1/8 turns out Float level 13.7 mm (0.54in) 1,300 i 100 min" (rpm) cuurn difference Within 30 mm Hg (1.2 in Hg) Base carburetor for synchronization No.3 carburetor GENERAL INFORMATION — COOLING SYSTEM ITEM SPECIFICATIONS Coolant capacity 7 Radiamr and engine Reserve (ank 2.0 lI(2.1US qt,1.8|mp qI) 0.20 B (0.21 US at , 0.18 Imp qt) Radiator cap relief pressure 108*137 ((P6 (1.1 ~14 kgf/crnz, 16*20 psi) Thermostal 7 Begin to open 80*84 ”C (176*183 °FI Fully open 95 r’C (203 6F) Valve lift 8 mm10.3in)minimum f CYLINDER HEAD/VALVES ITEM Unit: mmiin) STANDARD SERVICE LIMIT Cylinder compression 1,275i1,314 kPa (13.0‘ 13.4 kgf/cm1 , fii 185*191 psilaISOO rnin"(rpm) I Cylinder head warpaga , ‘ 0.10 {0.004) Valve, Valve clearance l IN 0.16 :l: 0.03 (0.006 1 0.001) A valve guide i EX 0.22 i 0.03 (0.009 t 0.001) . Valve stem 0. D. IN 1975—3390 (01565-01571) 3.965 (0.1561) EX ‘ 3365—3380 (0.1561 ~0.1567) 3.955 (0.1557) Valve guidel. D. IN 4.000i4.012I0.1575‘0.1580) l 4.0410155) EX 012(01575 0.1580) 4.0410159) Stem-to-gulde clearance IN .037 (0. 0004— 0. 001 5) _0.075 (0.0030) EX 0 020— 0.047 (00008—110019) 0.085 (0.0033) >7 Valve guide projection IN' 13.10—13 30 (0.516 0. 524) above c'vlinder’head EX 1130,1150 (0.445‘0.453) * Valve seat Width IN/EX 0.90—1.10I0.035*0.043) 1.5 (0.06) Valve spring free length INIEX 35.36 (1.392) 333611.333) Valve lifter Valve lifterO D. IN/EX 25.978*25.993(1.0228e1.0233) 25.37(1.0227)i Valve lifter bore I. D. IN/EX 26.010—26.026(1.0240‘10246) ( Camshafl Cam lobe height ( IN 36.140i36330 (14228—14323) . . ( EX 35.300“35.540 (1.3898" 1,3992) l 35.27(1.389] Journal 0. D. 5 23359—23380 (0.942.340.9441) l 24.955 (0.9825) Flunou! ¥ ‘ 0.05 (0.002) Oil clearance 0.020‘0.062 (0.0008i0.0024) l 0.10 (0.004) 7 GENERAL INFORMATION — CLUTCH/GEARSHIFT LINKAGE ( ”""' "‘m ""1 ITEM STANDARD SERVICE LIMIT Clutch Ieverfree play 10*20 (3/8s13/16) Clutch spring free length 49.7 (1.96) 48.3 (1.90) Clutch disc thickness 2§2*S.OB(0.115*0.121I 2.50 (0.102) Clutch plate warpage 0.30 (0.012) Clutch outer guide I. D. 21.994— 22.007 (0.56.507’03664) 21017013553] 0.70 34.975 — 34.991 (1.3770’13776) 34.985 (1.3756) Mainshaft O. D. at clutch outer guide 21980—21993 (0.8654’03659) 21.95 (0364' U II: I ALTERNATOR/STARTER CLUTCH ”' ”‘m ""’ i— ITEM STANDARD SERVICE LIMIT Starter driven gear 0. D. 51.699 s 51.718 (20354—20361) 51.664 (2.0348) — CRANKCASE/PISTON/CYLINDER ”""' '“m ""’ ITEM STANDARD SERVICE LIMIT Cylinder I. D. 65.000i65.015 (2.5581i2.5596) 65.10 (2.563l Out of round — 0.10 (0.004) g Taper 0.10 (0.004) Warpage 0.10 (0.004) Piston. Piston mark direction "IN“ mark facing toward the intake side - piston rings Piston 0. D. _ 64970-64390 (2.5579>Z.5587) 643012.555! Piston 0. D. measurement point 11 mm (0.4 in) from bottom cf skin ~ vPiston pin here I. D. 17002 ~17.006 (0.6594i0.6696) 17.02 (0.670] Piston pin 0. D. 16.994‘ 17.000 (0.6691 *0.6693) 16.98 (0.669I Pistonrto-pismn pin clearance 0.002 ~0.014(0.0001— 0.0006) 0.011(0002) Piston ring-to-ring Top 0.025i0.060 (00010—00024) 0.08 (0.003) 9 move clearance Second 0.015—0.050 (0.0006— 0.0020) 0.08 (0.003) Piston ring end Top 0.20—0.35 I0.008—0.014) 0.5 (0.02l gap Second 0.35fi0.50 I0.014‘0.020) 0.710.03I _ Oil (side rail) 0.20—0.70 (ODDS—0.028) 1.0 (0.04l Cylinder-to-piston clearance (1010,0045 (00004—00018) 0.10 (0.004) Connecting rod small and I. D. 17016—11034(06699—06706) 17.04 (0.671) Connecting rod—to-pislon pin clearance 0016—0040 (00006—00016) Crank pin oil clearance 0023-0052 (0.0011 *0.0020) 0.05 (0.002) 1-8 GENERAL INFORMATION ~ CRANKSHAFI'ITRANSMISSION U”"' m'“ ""‘ ITEM STANDARD SERVICE LIMIT Crankshah I Side clearang 0.10—0.25 (0004—0010) 0.30 (0.012) I Runoul 0.05 (0.002I ‘ Mainjoumal uil Clearance 11020—0045 (0.0008—0.0013I 0.05 (0.002I Transmission Gear I. D. M5, M5 28000—28021 (11024—11032) 728.04I1.104I C2, C3, C4 31.000’31025 (1.2205’12215) 31.04I1.222I Bushing 0. D. M5, M6 27.959’27980 (1.1007’11016) 27.94 (1.100) I C2 30.959’30380 (1.2139’11197) 3034(1218) I C3, C4 30350—30375 (12185—12195) 30.93 (1.218) Bushing I. D. I M5 24.985‘25006 (03837—03845) I 25.016 (0.9845) C2 ‘ 27385—28006 (1.1018—1.1026) I 28.021 (1.1032) i Gear—to-bushing M5, M6 0020—0062 (00003-00024) ’ cIearance C2, C3, C4 01120—0070 (0.DOOB*0.0028) v Mainshaft 0. D. M5 24367—24880 (03830—03835) 24.960 (0.9827) Clutch outer gulde 21.980i21893 (0.8654fi0.8659I 21.95 (0.864I Coumarshaft 0. D, C2 ' 27367—21930(LION—1.1015) 27.95I1.101I Bushingvto—shaft M5 mos—0.039 (o.oooz:o.oo15) , , , _ clearance C2 OBOE—0.039 (03002—00015) I Shifi fork, Shift fork Fork I. D. 12000—12021 (0.4724—0.4733) 12.030 (0.4735I fork Shaft Claw thickness 5.93’6110 (0.233’0236) 5.90 (0.232) I 11.957*11.963 (04707—04712) I 113510.470) Fork shaft 0. D, 1-9 GENERAL INFORMATION — FRONT WHEEL/SUSPENSION/STEERING W“ '"m “"’ ITEM STANDARD SERVICE LIMIT _lylinimum lire tread depth ‘ 1.5 (0.06) 250 kPa (2.50 kgf/an2 , 35 psi) Cold fire pressure Driver only i Driverand passenger 250 kPa (2.50 kgf/cm2 , 36 psi) Axle runout ‘ 0.20 (0.003) Wheel rim runoul Radial fl 2.0 (0.08) Axial 2.0 (0.08) Fork Spring free/length 309.2 (1217) 303.0 (11.93) Spring diracrion With the tapered end lacing down Tube runoui — 0.20 (0.008) Recommended fork fluid Forkfluid Fluid level 102 (4.0) Fluid capacity 486 i 2.5 cm“ (16.4 i 0.08 US 02, 17.1 i 0.09 Imp oz) Steering head bearing pra-load 038*) .47 N (0.10*0.15 kgf , 022*033 Ibf) — REAR WHEEL/SUSPENSION . . . ”n" '“'“ “"’ ITEM STANDARD SERVICE LIMIT Minimum tire tread dap‘h 7—. 2.0 (0.03) Cold tire pressure Driver only 290 kPa (2.90 kgf/cm‘ , 42 psi) Driver and passengar 290 kPa (2.90 kgf/cn'l2 , 42 psi) ‘ Axle runout 'f — 0.20 (0.008) Wheel rim runout Radial 2.0 (0.08) Axial 2.0 (0.08) Drive chain Size/link ' i DID 525VM2—1‘IOLE . FIK 525RO—110LE Slack 30—40 (1.2’1.6I 50 (2,0) Shock absorber pre-Ioad adjuster s1a'ndard poshion 2nd groove 1-10 GENERAL INFORMATION — HYDRAULIC BRAKE U""' ’“m “m ITEM STANDARD SERVICE LIMIT Front Specified brake fluid DOT4 Brake disc thickness 4.5 (0.18) _ W 3.5 (0.14) 7 # Brake disc runout 7 0.30 (0012) _Master cylinderl. D. 14.000‘14.043(0.5512*0.5529) 14.055 (0.5533) Master piston O. D. 13.957 ’13.984(0.5495~ 0.5506) 13.945 (0.5490) Caliper cylinder l. D. 27000-27050 (1.0630— 0650) 27.060 (1.0654) Caliper piston 0. D. 26335—26368(1.0604i10617) '26.910(1.0594) Rear Specified brake fluid DOT4 i M Brake pedal height 675 (2.66) Brake disc thickness 5.0 (0.20) 40 (0.16) Brake disc runout 7 0.30 (0.012) Master cylinder I. D. 14.000‘14043 (05512—05529) 14.055 (0.5533) Master piston O. D. 13.957‘13384 (0.5495i05506) 13.945 (0.5490) Calipe[cylinderl. D. 38.18—35.23(1.503m1.505) 3814(1506) l Caliper piston 0. D. 38.098i38.143 (14999715019) ‘ 38.09 (1.500) * BATTERY/CHARGHIQIVIG SYSTEM SPECIFICATIONS Battery ‘ Capacity 12V—6Ah 7 _ _ l Current leakage 1.2 mA max. .. Voltage (20“C/SE“F) Fullv chargfld 13.0—13.2V Needs charging Below 12.3V Charging current Normal 09 A/S— 10 L Quick , 40 N10 h Alternator Capacity 034 kW/5,000 min" (rpm) Charging coil resistance (NT/68°F) 0.1 -1.0 {2 13.0 #155 V/5,000 min“ (rpm) Regulator/rectifier regulated voltage 1“ IGNITION SYSTEM ITEM SPECIFICATIONS Spark plug CRSEH—S (NGK) U27FER9 (DENSO) Spark plug gap 0.8 —0.9 mm (0.03 *004 in) Ignition coil psakvoltaga IOOVrninirnum Ignition pulse generator peak voltage 0.7V minimum Ignition timing ("F” mark) 7" BTDC at idle U 't: ' ~ ELECTRIC STARTER "' "‘m “n’ ITEM STANDARD SERVICE LIMIT Starter motor brush lenath 120—130 (0.47 —0.51) 4.50113) 1-11 GENERAL INFORMATION — LIGHTS/ METERS/ SWITCHES ITEM SPECIFICATIONS Bulbs Head|ight [Hi/Lo) 12Vi60/55W PositiofllithExcept U type) 12Vi4W Brake/taillight 12V~ZII5W X 2 Turn signai light 12v—21w x 4 Instrument light 7 7 12V—1.7W X 3 Turn signai indicator 12V—1.7W X 2 77 High beam indicator 12Vi1.7W Neutrai indicator 12V—1.7W Oil pressure indicator 12V* 1 7W Fuse Main fuse 30 A Sub fuse 10 A X 4 Fan motor _ Stan to close (ON) 98* 102 “C (2084216 ”F) switch Stop to open 93—97 DC (199—207 °Fl Coolanttempera ure sensor at 80°C/176°F 45—60 (2 resistance at120°C/248°F 10720 9 1-12 GENERAL INFORMATION TORQUE VALUES TORQUE TORQUE FASTENER TYPE N-m (kgf-m, “1”” FASTENER TVPE N-m (kgf-m, Ibf-ft) 5mm hex bolt and nut 5(0.5,3.6) 5mm screw 4l0.4,2.9) 6mm hex bolt and nut 10(l.0,7) 6mm screw 9(0.9,6.5) 8mm hex boltand nut 22(2.2,‘|6) 6mmflange bolt (8 mm head: 10(1.D,7) 10 mm hex bolt and nut 3413.5 ,25) small flange) 12 mm hex bolt and nut 54155.40) Q Cm 6mm flange boit(10 mm head, 12112.9) large flange) and nut Q; Ellem 8 mm flange bolt and nut 26(17 '20) 10mm flange bolt and nut 39(4.0,29) - Torque specifications listed below are for important fasteners. I 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 grease to the threads. 4. Stake. 5. Apply oil to the threads and flange surface. 6. Apply clean engine oil to the O-ring. 7. U-nut 8. ALOC bolt: replace with a new one. 9. CT bolt 7 ENGINE THREAD TORQUE ”EM °TV DIA. (mm) N-m (kgf-m, mm) REMARKS MAINTENANCE: Spark plug 4 10 12l1.2,9) Timing hole cap 1 45 18(1.8,13) NOTE3 Oil drain bolt 1 12 29 (3.0 , 22) Oilfilter cartridge 1 20 10l'l.0,7) NOTES LUBRICATION SVSTEM: Oilfilter boss 1 20 18(13, 13) NOTE: Oil pump driven sprocket bolt 1 6 15 (1.5 , 11) NOTE 2 Oil pump assembly bolt 1 6 8 (0.8 , 58) NOTE 9 Oil cooler sealing bolt 1 1S 49 (5.0 , 36) NOTE 2 FUEL SVSTEM: Carburetor assembly bolt/nut, 5 mm 1 5 5 (0.5 , 3.6) 6 mm 1 6 10 (1.0 , 7) Boost joint for synchronization 3 5 2 (0.25 ,1.8) Insulator band screw 8 5 See page 1-14 COOLING SYSTEM: Water pump cover bolt 2 6 1311.3,9) NOTE 9 Coolant temperature sensor unit 1 PT 1/8 10 [1.0 , 7) NOTE 1 Water hosejoint 1 12 29 (3.0 , 22) Sealingspecialbolt 1 10 ‘lZl1.2,9I GENERAL INFORMATION 7' ENGINE (Cont’d) ‘ THREAD TORQUE 'TEM QTY DiA. (mm) N-m (kgrm, le't) REMARKS CVLINDER HEADNALVES: Cylinder head sealing bolt 1 18 32 (3.3 , 24l NOTE 2 Cylinder head socket bolt 10 9 47 (4.8 , 35) NOTE 5 No.1 Intake vacuum port plug 1 5 3(O.3,2.2) Cylinder head cover bolt 5 6 1011.0,71 Camshaft holder (Iange bolt 20 6 12 (1.2 , 9i NOTE 5 Breather plate flange bolt 2 6 12 (1.2 , 9i NOTE 2 Cam sprocket bolt 4 7 20 (2.0 , 14) NOTE 2 Cylinder head stud bolt 8 13 See below Cam chain tensioner cap nut 1 G 12(1.2,91 Cam chain lifter sealing bolt 1 6 10(1.0,7l CLUTCH/GEARSHIFI' LINKAGE: Clutch center lock nut 1 20 108 (11.0 , 80) NOTE 4, 5 Clutch spring bolt 4 6 12(1.2,9l Shift drum center socket bolt 1 B 23 (2.3 , 17) NOTE 2 Shift drum stopper pivot bolt 1 6 12 (1.2 , 9) Gearshift return spring pin 1 8 23(2.3,17) ENGINE REMOVAL/INSTALLATION: Drive sprocket special bolt 1 10 54 (5.5 , 40) CRANKCASE/PISTDN/CVLINDER: Main journal bolt 10 8 25 (2,6 .19) NOTE 5 Crankcase boltl10 mm 1 10 39 (4.0 , 29) 8mm 1 8 24(2.4,17) Lower crankcase sealing bolt, 20 mm 1 20 29 (3.0 , 22) NOTE 2 Lower crankcase sealing bolt, 14 mm 1 14 25 (2,5, 18) NOTE 2 Connecting rod nut 8 7 25 (2.6 .19) NOTE 5 ALTERNATOR; Flywheel flange bolt 1 10 103 (10.5 , 76) NOTE 5 Stator mounting socket bolt 4 6 12 (1.2 , 9i Alternator wire clamp socket bolt 1 6, 10 (1.0 , 7) Starter clutch outer socket bolt 6 ‘5 1611.6,121 NOTE 2 IGNITION SVSTEM: Ignition pulse generator rotor special bolt 1 10 59 (6.0 , 43l ELECTRIC STARTER/STARTER CLUTCH: Starter motorterminai nut 1 6 1D (1.0 , 7) LlGHTS/METERS/SWITCHES: Oil pressure switch 1 PT1/E 12 (1.2 , 9) NOTE 1 Oil pressure switch terminal screw 1 4 2 (0.2 ,1.4l Neutralswitch 1 10 12(1.2,9l Cylinder hand stud bolt: Connecting tube clamp: 10 i 1 mm (0.4 :t 0.04m) N H; (0. 03 03 Insulator clamp: 4 inl 1-14 GENERAL INFORMATION i FRAME , THREAD TORQUE ITEM 0 TV DIA. (mm) N-m (kgt-m, lbf-ftI REMARKS FRAME BODY PANELS/EXHAUST SVSTEM: Sidestand pivot bolt 1 10 15(1.5,11) Side stand pivot lock nut 1 10 39 (4.0 , 29) Footpeg holder bolt 4 8 26 (2.7 , 20) Exhaust pipejoint nut 6 7 20 (2.0 , 14) See page 1—16 Muffler/exhaust pipe stay bolt 2 8 22 (2.2 , 16) Muffler protector bolt 1 6 12 (1.2 . 9) Muffler band bolt 2 8 22(Z.2, 16) Grab rail mounting bolt 4 B 26 (2.7 , 20) Front fender mounting bolt 2 6 12 (1.2.9) Rean/iew mirror mounting nut 2 10 34l3.5 .25) Rear reflector mounting nut 1 5 5 (0.5 , 3.6) Side Cover upper mounting bolt 2 5 1 (015,1.1) Side cover lower mounting bolt 2 5 4 (0.4 , 2.9) Hearturn signal unit mounting nut 2 10 5 (0.5 , 3.6) Taillight mounting nut 2 6 7(0.7,5.1) Fuel valve nut 1 22 34 (3.5 , 25) Fuel tank stay bolt 2 6 12(1.2,9) COOLING SYSTEM: Coolant temperature sensor 1 PT 1/8 9 (0.9,6.5) Fan motor switch 1 16 18 (1.8 .13) NOTE 1 Fan motor mounting nut 3 6 5 (0.5 , 3.6) Cooling fan motor nut 1 6 3 (0.28 , 2.0) NOTE 2 ENGINE MOUNTING: Front engine hanger nut 2 10 54 (5.5 , 40) Engine hanger bracket bolt 2 B 22 (2.2 , 16) Rear engine hanger nut (upper) 1 10 54 (5.5 , 40) Rear engine hanger nut (lower) 1 10 54 (5.5 , 40) GEARSHIFT LINKAGE: Gearshift pedal link bolt (gearshift pedal side) 1 8 26 (2.7 , 20) Gearshift pedal link bolt (gearshift spindle side) 6 20 (2.0.14) FRONT WHEEL/5USPENSION/STEERING: Handlebar holder bolt 4 8 26 (2.7 , 20) Steering stem nut 1 24 103 (10.5 , 76) 7 See page 1330 Top thread A 1 26 37 Top thread B 1 26 7 Fork top bridge pinch bolt 2 8 23 (2.3 , 17) Fork bottom bridge pinch bolt 2 10 ”(4.019) Front axle bolt 1 14 5916.0 , 43) Front axle holder bolt 2 8 22 (2.2 .16) Front brake disc mounting bolt 12 6 20 (2.0 , 14) NOTE 5 Fork cap 2 37 23 (2.3 , 17) Fork socket bolt 2 E 20 (2.0 , 14) NOTE 2 REAR WHEEL/SUSPENSION: Rear axle nut 1 16 88 (9.0 , 65) NOTE 7 Rear brake disc mounting nut 4 E 42(4.3,31) NOTES Final driven sprocket nut 5 12 103l11.0 , 30) NOTE 7 Swingarm pivot nut 1 14 88 (9.0 . 65) NOTE 7 Drive chain case bolt 2 6 12 (1.2 , 9) Drive chain slider bolt 2 6 9 (0.9 , 6.5) Drive chain adjuster lock nut 2 S 21 (2.1 .15) Rear shock absorber upper mounting nut 1 10 37 (3.8 , 27) NOTE 7 Rear shock absorber lower mounting nut 1 10 37 (3.8 , 27) NOTE 7 '7‘ p—A UI GENERAL INFORMATION — FRAME lCont'd) , THREAD TORQUE "EM ° " DlA. (mm) N-m 1kgf-m.lhf-ftl REMARKS HYDRAULIC BRAKE: Front brake master cylinder holder bolt 2 6 1211.2,9) Front brake master cylindercap screw 2 4 1 (0.15,1.1) Brake lever pivot bolt 1 6 1 [0.1 , 0.7) Brake lever pivot nut 1 6 610.6. 4.3) From brake switch screw 1 4 1 10.12 , 0.9) Front brake caliper mounting bolt 4 8 3013.1 , 22) NOTE 8 Front brake caliperslide pin (main) 2 12 2312.3,17) NOTE2 From brake caliper slide pin (sub) 2 S 13 (1.3,9) NOTE 2 Fad pin 3 1D 1811.8,13) Pad pin p1ug 3 1D 21025.18) Front brake hose clamp bolt 2 E 12 11.2 , 9) NOTE 8 Brake caliper bleeder 3 8 610.6 , 4.3) Rear master cylinder mounting bolt 2 6 1211.2,9) Hear master cylinder hose joint screw 1 4 1 (0.15,1.1) NOTE2 Rear master cylinder push rod nut 1 8 1811.13.13) Rear brake caliper slide pin (main) 2 12 2712.8,20) NOTEZ Rear brake cal1perslide pin (sub) 1 8 2312.3,17) NOTEE Rear brake hose clamp bolt 1 6 9103,65) NOTE 8 Brake hose oil bolt 5 10 34 (3.5 , 25) LlGHTS/METEfiS/SWITCHES: Ignition switch mounting bolt 2 8 25 (2.5 , 18) NOTE 2 Exhaust pipe iolnt nut tightening sequence: 1—16 TOOLS NOTES: 1. Equivalent commercially available. 2. Alternative tooll 3. SW type only. GENERAL INFORMATION DESCRIPTION TOOL NUMBER REMARKS REF. SEC. Float level gauge 07401-0010000 5 Oil pressure gauge attachment 07406—0030000 NOTE 1 4 Oil pressure gauge 07506-3000000 NOTE 1 4 Flywheel holder 07725-0040000 NOTE 1 10 Rotor puller 07733—0020001 NOTE 2: 07933-3950000 10 Adjustable valve guide driver 07743-0020000 8 Attachment, 32 X 35 mm 07746-0010100 14 Attachment, 37 X 40 mm 07746-0010200 9 Attachment, 42 X 47 mm 07746-0010300 9, 13, 14 Attachment, 52 X 55 mm 07746-0010400 13, 14 Attachment, 28 X 30 mm 077464870100 14 Driver 40 mm l. D. 07746-0030100 12 Attachment, 25 mm (IN) 07746-0030200 12 Attachment, 30 mm (IN) 0774643030300 12 Pilot, 15 mm 077460040300 14 Film, 17 mm 07746-0040400 14 Pilot, 20 mm 07746-0040500 14 Pilot, 35 mm 077460040300 9 Pilot, 22 mm , 0774643041000 14 Bearing remover shaft 07746-0050100 13, 14 Bearing remover head, 17 mm 07746-0050500 14 Bearing remover head, 20 mm 07746-0050600 13 Driver 07749—0010000 9, 13, 14 Valve spring compressor 07757—0010000 8 Valve seat cutter NOTE 1 8 Seat cutter, 27.5 mm (45° IN) 07780-0010100 Seat cutter, 245 mm (45‘1 EX) 07780-0010200 Flat cutter, 27 mm [32" lNl 07780-001330!) Flat cutter, 24 mm [32“ EX) 0778070012500 interior cutter, 26 mm (60" IN) 0778041014500 Interior cutter, 22 mm (60" EX) 0778043014202 Cutter holder, 4.0 mm 07781-0010500 Pilot screw wrench 079084730002 5 Snap ring pliers O7914-SA50001 NOTE 2: 07914-3230001 15 Steering stern socket 0791645710101 13 Driver attachment, 28 X 30 mm 07946-1870100 14 Bearing race remover 07946-3710500 13 Steering stern driver 07946-M500000 13 Driver shaft 07946-MJ00100 14 Slider weight 079477KA50100 13 Oil seal driver attachment 07947-KF00100 13 Driver attachment 079537MJ10100 13 Driver handle 07953-MJ10200 13 Valve spring compressor attachment 07959-KM30101 B Valve guide driver 07GMDVK170100 8 Needle bearing remover attachment 07GMD-K170200 14 Inspection adaptor 07GMJ—MLBO1OO 17 Oil filter wrench 07HAA—PJ70100 4 Peak voltage adaptor 07HGJ-0020100 NOTE 2: 17, 19 lmrie diagnostic tester (model 6251 Tappet hole protector 07HMGAMR70002 8 Drive chain tool set 07HMH—MR10103 3 Clutch center holder 07JMB-MN50301 9 1-17 GENERAL INFORMATION DESCRIPTION TOOL NUMBER REMARKS REF. SEC. Pilot screw wrench D7KMA-MSGD101 NOTE 3 5 - Needle bearing remover U7LMC-KV301DD 14 VaIve guide reamer, 4.008 mm 07MMH-MV90100 8 Pilot screw wrench elbo D7PMA7M220110 NOTE 3 5 Compressiongauge attachment 07RMJ-MY50100 NOTE 1 S 1-18 LUBRICATION & SEAL POINTS GENERAL INFORMATION * ENGINE LOCATION Crankcase mating surface 5? Eco. mo llr 2:; Liquid sealant (Three Bond 1207B l or equivalent) ‘ MATERIAL l l l REMARKS 10—15 mm [CIA—0.6m) 10'15 mm (0‘440.6ln) 10*15 mm (0.440.6in) Oil pressure switch threads Do nut apply to the thread head +1 ‘ 374mm(0.170.2in). —<— Ignition pulse generator grommet Thermosensor threads Lower crankcase sealing bolt threads Cylinder head sealing bolt threads Alternator grommet Sealant "A” marked bolts Crankcase mating surface Crankcase mating surface 1-19 GENERAL INFORMATION l0.2*0.4inl — ENGINE (Cont’d) LOCATION MATERIAL REMARKS Cylinder head semi-circular cut-out Sealant 5 e 10 mm (0.2i0.4inl 5*10mrn Camshaft lobes/ journals Valve lifter outer sliding surface Valve stern [valve guide sliding surfacel Connecting rod small and bore Main journal bearing surface Connecting rod bearing surface MEI/4, CS, C6 shifter gear (shift fork grooves) Cylinder head bolt threads and seating surface Crankshaft thrust surface Clutch outer sliding surface Starter idle gearshaft sliding surface Molybdenum disul- fide oil (a mixture of 1/2 engine oii and 1/2 molybdenum disul- fide grease) Clean enti~rust oil and apply to the threads and seating surface. Clutch center lock nut threads Starter clutch sliding surface Piston surface Piston pin bore Piston ring grooves Piston pin surface Piston ring surface Mainjournal 8 mm bolt threads and seating surface Connecting rod bolt/nut threads Camshaft holder bolt threads and seating surface Flywheel bolt threads Cam chain tensioner collar sliding surface Cam chain tensioner and slipper surface Each gearteeth and rotating surface Oil seal lip (without dust lipl Each O-ring Each bearing Clutch friction disc lining surface Oil filter cartridge threads and mating surface Other rotating area and sliding surface Engine oil Timing hole cap threads Each oil seal'lips (with dust lip) Multi~ purpose grease Cylinder head cover breather plate bolt threads Cam sprocket bolt threads Oil pump driven sprocket bolt threads Shift drum bearing set plate bolt threads Starter clutch outer torx bolt threads Shift drum center bolt threads Mainshaft bearing set plate bolt threads Gearshift spindle oil seal set plate bolt threads Oil filter boss threads Oil cooler sealing bolt threads Locking agent T LLUELL * Coating width 6.5 i 1 mm 1-20 GENERAL INFORMATION — FRAME LOCATION MATERIAL REMARKS Steering head bearing sliding surface Sfeering head dust seal lips Swingarm pivot needle bearing Rear wheel sleeve sliding surface Rear wheel hub O~ring Side stand pivot sliding surface Clutch lever pivot sliding surface Throttle pipe sliding area Footpeg pivot sliding area Gearshift pedal link sliding area Swingarm dust seal lips Rear brake pedal sliding surface Each Oil seal lips Each dust seal lips Mum-purpose grease Steering stern top thread Driven sprocket nut threads and seating surface Engine oil Drive chain #80—-SD gear oil Brake master cylinder cups Brake caliper piston seals DOT 4 brake fluid Speedometer gearbox pinion gear Molybdenum disulfide Grease Brake caliper dust seals From brake lever pivot and piston lips Rear master cylinder bout inside and push rod tips Brake caliper slide pin surface Silicone grease Brake lever adjuster stopper bolt threads Fork socket half threads Brake caliper slide pin threads Locking agem Fork oil seal lips Fan motor switch threads and O~ring Sealant Handle grip rubber inside Honda Bond A Fork cap O-ring Fork fluid 1—21 GENERAL INFORMATION CABLE & HARNESS ROUTING FRONT BRAKE HOSE CLUTCH CABLE CHOKE CABLE THROTTLE CABLES LEFT HANDLEBAR SWITCH WIRE fg‘ “\ RIGHT HANDLEBAH SWITCH WIHE 7- / SPEEDOMETER CABLE LEFT TURN SIGNAL WIRE 1-22 GENERAL INFORMATION IGNITION SWITCH 4P (NATURAL) CONNECTOR RIGHT HANDLEBAR SWITCH 9P (BROWN) CONNECTOR WIRE CLAMP COMBINATION METER 5F INATURALI CONNECTOR LEFT HANDLEBAR SWITCH 6P IBLUEI CONNECTOR COMBINATION METER SP IREDI CONNECTOR LEFT HANDLEBAR SWITCH 6P (BLACK) CONNECTOR WIRE CLAMPS POSITION LIGHT CONNECTORS HEADLIGHT SOCKET 1-23 GENERAL INFORMATION CHOKE CABLE FRONT BRAKE HOSE THROTI’LE CABLES '- i /\ /, // «. «fig: Mm? /Wfl/y/A\ J/ /§§//,/ A . G y/w‘oe CLUTCH CABLE 1-24 GENERAL INFORMATION THROTTLE CABLES FUEL TANK AIR VENT TUBE CHOKE CABLE PAIR (PULSE SECONDARY AIR INJECTION) CONTROL VALVE AIR SUPPLY TUBE cLUTCH CABLE SUE-AIR CLEANER TUBE REGULATOR/RECTIFIER SIFHON TUBE F ii». 7 , Q "rm/I I 2—:\ ' Q®\\+\? V17E V — ANTS? «I \-/>g,. EL y I/ / / 5V / / ,_/e z 7 % WIRE CLAMP / PAIR CONTROL VALVE VACUUM TUBE IGNITION PULSE GENERATOR WIRE OIL PRESSURE SWITCH CRAN KCASE BREATHER TUBE WATER TEMPERATURE SENSOR 1-25 GENERAL INFORMATION SPEEDOMETER CABLE FRONT BRAKE HOSE RADIATOR SUE-HARNESS 1-26 GENERAL INFORMATION RADIATOR SUBVHAHNESS SPEEDOMETER CABLE MAIN WIFIE HARNESS No. 1/4 IGNITION COIL 1_27 CRANKCASE BREATHEH TUBE GENERAL INFORMATION RADIATOR SIPHON TUBE BATTERY NEGATIVE (- I CABLE BATTERY POSITIVE (+) CABLE RADIATOR RESERVE TANK OVERFLOW TUBE STARTER MOTOR CABLE STARTER RELAY SWITCH STARTER MOTOR GROUND CABLE REAR BRAKE LIGHT SWITCH WIRE RADIATOR RESERVE TANK OVERFLOW TUBE 1-28 GENERAL INFORMATION WIRE CLAMP MAIN WIRE HARNESS FUSE BOX OIL PRESSURE SWITCH IGNITION CONTROL MODULE RADIATOR SIPHON TUBE ALTERNATOR WIRE FUEL TANK AIR VENT TUBE CONNECTOR COVER: v ALTERNATOR 3P (WHITE) NEUTRAL SWITCH - IGNITION PULSE GENERATOR 2P (BLUE) - SIDE STAND SWITCH 3P (GREEN‘IN TE) - REAR BRAKE LIGHT SWITCH 2? HI 3'95 STAND SWITCH - ENGINE SUB-HARNESS 3P (RED) 1-29 GENERAL INFORMATION PAIR CONTROL VALVE AIR SUPPLY TUBE PAIR CONTROL VALVE VACUUM TUBE PAIR CONTROL VALVE PAIR CONTROL VALVE VACUUM TUBE 1 30 GENERAL INFORMATION RIGHTTURN SIGNAL WIRE TAIL/BRAKE LIGHT SUB-HARNESS IGNITION CONTROL MODULE ”‘47 LEFT TURN SIGNAL WIRE ,// MAIN WIRE HARNESS TURN SIGNAL RELAY REAR BRAKE RESERVOIR HOSE REAR BRAKE HOSE REAR BRAKE CALIFER 1-31 REAR MASTER CYLINDER GENERAL INFORMATION EMISSION CONTROL SYSTEMS SOURCE OF EMISSIONS The combustion process produces carbon monoxide and hydrocarbons. Control of hydrocarbons is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic. Honda Motor C0,, Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydrocarbons. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow—by gas is returned to the combustion chamber through the air cleaner and carburetor. AIR CLEANER HOUSING CARBURETOR <3: FRESH AIR 4—; BLOW-BY GAS 1-32 GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (SECONDARY AIR SUPPLY SYSTEM) The exhaust emission control system is composed of a lean carburetor setting. and no adjustments should be made except idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcase emission control system. The exhaust emission control system consists of a secondary air supply system which introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn into the exhaust port by the function of the PAIR (Pulse secondary air injection) control valve. This charge of fresh air promotes burning of tho 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; it consists of check valves built into the PAIR control valve, A PAIR check valve prevents reverse air flow through the system. The PAIR control valve reacts to high intake manifold vacuum pressure will cut off the supply of fresh air during engine deceleration, thereby preventing afterburn in the exhaust system. No adjustments to the secondary air supply system should be made, although periodic inspection of the components is recommended, PAIR CONTROLVALVE AlFl CLEANER HOUSlNG PAIR CHECK VALVE EXHAUST PORT 1-33 GENERAL INFORMATION NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Local law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control priorto its sale or delivery to the ultimate purchaser or while it is in use; (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMFERING ARE THE ACTS LISTED BELOW: 1. Removal of, or puncturing of the muffler, baffles, header pipes or any other component which conducts exhaust gases. 2 Removal of, or puncturing of any part of the intake system. 3. Lack of proper maintenance. 4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with pans other than those specified by the manufacturer. 1—34 FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS FUELTANK . L‘ REAR COWL ' , SEAT GRAB RAIL FRONT FENDER SIDE COVER \ REAR FENDER 2—0 2. FRAME/ BODY PANELS/ EXHAUST SYSTEM BODY PANEL LOCATIONS 2.0 REAR COWL ‘ 2.3 SERVICE INFORMATION 24 FUEL TANK 24 TROUBLESHOOTING 2-1 FRONT FENDER 24 a SEAT 2-2 REAR FENDER 2-5 SIDE COVER 2-2 MUFFLER/EXHAUST PIPE 2-5 SERVICE INFORMATION GENERAL AWARNING 0 Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. I Serious burns may result if the exhaust system is not allowed to cool belore componentsare removed Or serviced . 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. o This section covers removal and installation of the body panels, fuel tank and exhaust system. I Always replace the exhaust pipe gaskets after removing the exhaust pipe from the engine. 0 When installing the exhaust system, loosely install all of the exhaust pipe 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 prop- erly. 0 Always inspect the exhaust system for leaks after installation. TORQUE VALUES Side Stand pivot bolt Side stand pivot lock nut Footoeg holder bolt Exhaust pipe joint nut Muffler/exhaust pipe stay bolt Muffler protector bolt Muffler band bolt Grab rail mounting bolt FrOnl fender mounting bolt Front brake hose clamp bolt Rearview mirror mounting nut Rear reflector mounting nut Side cover upper mounting bolt Side cover lower mounting bolt Raarturn signal mounting nut Taillight mounting nut Fuel valve nut Fuel tank stay bolt TROUBLESHOOTING Excessive exhaust noise - Broken exhaust system ' Exhaust gas leak 15 N-m (1.5 kgl-rn ,11Ibf-ft) as N-m 14.0 kgf-m , 29 lbf-ft] 26 Nvm (2.7 kgf-m , 20 lbf'ftl 20 Nvm (2.0 kgf-m ,14lbf'fll 22 N-rn (2.2 kgf~m ,16Ibf-ftl 12 N-m (1.2 kgf‘m , 9 Ibftft) 22 N-m (2.2 kgf-m , 16 Ibf-ft) 26 Nrm (2.7 kgi~m , 20 Ibf-ftl 12 Nrm (1.2 kgf-m , 9 Ibf‘ft) 12 Nm (1.2 kgf-m,9 lbf-ftl 34 N-m (3.5 kgi-m , 25 Ital-ft) 5 N-m (0.5 kgf-m , 3.6 Ibf-ftl 1N>m (0.15 kgf‘m,1.1lbftft) 4 N-m (0.4 kgf-m , 2.9 Ibf-ft) 5 N-m (0.5 kgf‘rn , 3.6 lbI-fll 7 N-m (0.7 kgf-m , 5.1 WHO 34 N-m (3.5 kgf‘m , 25 lbf'ftl 12 N4“ (1.2 kgf-m , 9 Ibf‘fll Poor performance - Deformed exhaust system - Exhaust gas leak G Clogged muffler 2-1 FRAME/BODY PANELS/EXHAUST SYSTEM SEAT REMOVAL Unlock the seat lack using the ignition key. Remove the seat backward while releasing the seat hooks from the frame hooks. INSTALLATION install the seat while aligning its hooks with the frame hooks, Push the seat forward, lock it securely. CAUTION: . Be careful nut to damage the wire harness. I After installation, make sure that the seat is installed properly by moving the seat. SIDE COVER REMOVAL Remove the seat (see above). Remove the two side cover mounting screws. NOTE. The upper mounting bolt is screwed into the rubber nut. If the rubber nut is turn together with the mounting bolt, hold the rubber nut with your finger, Release the rear tabs from the rear cowl grooves, then remove the side cover. INSTALLATION Install the side cover aligning its tabs with the grooves in the rear cowl. Install and tighten the upper mounting screw to the specified torque. TORQUE: 1 Nam (0,15 kgI-m , 1.1 Ibf-ft) Install and tighten the lower mounting screw to the specified torque. TORQUE: 4 N-m l0.4 kgf‘m , 2.9 IbI-Ftl IGNITION KEY GROOVES SCREWS TABS ‘ SCREWS LEFT SIDE COVER FRAME/BODY PANELS/EXHAUST SYSTEM REAR COWL 2-3 TRIM CLIP REMOVAL/INSTALLATION Remove the trim clip. Raise the center pin by pushing the retaining tabs back, Install the trim clip. Push the center pin until the pin flush with the outer casing. REMOVAL Remove the seat and side covers (see previous Pagel‘ Remove the tour caps from the grab rail. Remove the four socket bolts and grab rail, Remove the two trim clips‘ Remove the two rubber plugs. Remove the rear cowl mounting bolts, Release the left side of the rear cowl from the frame, then remeve the right side of the rear cowl between the muffler and frame. INSTALLATION Installation is in the reverse order of remeval. NOTE! Always install the trim clips first. TORQUE: Grab rail mounting bolt: 26 N-m (2.7 kgf-m , 20 Ibf-ft) CAPS SOCKET BOLTS GRAB RAIL RUBBER PLUGS TRIM CLIPS FRAME/BODY PANELS/EXHAUST SYSTEM FUEL TANK WW 0 Gasoline is extremely flammable and is explosive under certain conditions, I Wipe up spilled gasoline at nnce. REMOVAL Remove the seal and side covers (page 2—2). Turn the fuel valve OFFt Remove the fuel tank mounting bolt and nut. Disconnect the fuel valve vacuum tube from the intake port Swing the rear end of the fuel tank and disconnect the fuel tube from the fuel valve. Disconnect the fuel tank air vent tube. Release the fuel tank from the mounting rubbers, then remove the fuel tank upwardt NOTE‘ Be careful not to damage the No.1 carburetor vacuum chamber by the fuel valve. INSTALLATION Install the fuel tank in the reverse order of removal. Tighten the fuel tank bracket bolt to the specified torque TORQUE: 12 N-m (1.2 kgf-m , 9 lbfrftl NOTE: After fuel tank installation, turn the fuel valve ON and make sure there is no fuel leaks. FRONT FENDER REMOVAL] INSTALLATION Remove the front brake hose clamp bolts. Remove the front fender mounting bolts and front fender. Installation is in the reverse order of removal. Tighten the front fender mounting bolts and brake hose clamp bolt to the specified torque. TORQUE: 12 N-rn (1,2 kgf-m . 9 lbf-ft) FUEL TANK AlR VENTTUBE FUEL TUBE VACUU M TUBE MOUNTING BOLTS CRAMF‘ BOLTS FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER REMOVAL Remove the rear cowl (page 24). Remove the muffler (see below). Remove the turn signal relay and ICM (Ignition Control Module) from the rearfender. Disconnect the brake/tail light connectors. Remove the rear fender mounting bolts and rear fender from the frame. INSTALLATION Installation is in the reverse order of removal. MUFFLER/EXHAUST PIPE 2-5 MUFFLER REMOVAL/lNSTALLATION m—__ Do not service the exhaust system while it is hot: Remove the rear cowl (page 2-3). Loosen the exhaust pipe clamp bolt: Remove the mounting bolt/nut and muffler. Remove the muffler packing. Remove the bolt' collar and muffler protector from the muffler, Install the muffler in the reverse order of removal. NOTE: Alwavs replace the muffler packing with a new one. TORQUE: Muffler mounting bolt/nut: 22 N!“ (2.2 kgf-m ,16lbf-fl) Exhaust band bolt: 22 N-m (2.2 kgf-m ,16Ibf'fll BOLTS TURN SIGNAL RELAY REAR FENDER CONNECTORS MOUNTING BOLT/NUT MUFFLER ‘ CLAMP BOLT BOLT PROTECTOR FRAME/ BODY PANELS/ EXHAUST SYSTEM 2-6 EXHAUST PIPE REMOVAL/INSTALLA- TION Remove the muffler. For ease of exhaust pipe removal, remove the radiator mounting bolts. Remove the exhaust pipe joint nuts. Remove the exhaust pipe mounting boldnut, wash- er and exhaust pipe, Remove the exhaust pipe gaskets. lnstall the new exhaust pipe gaskets into the ex» haust ports of the cylinder head. NOTE. -Always replace the exhaust pipe gaskets and exhaust pipe Joint gaskets with new ones. - Prevent failing the gasket, apply grease to the exhaust pipe gaskets. Install the exhaust pipe, and temporarily install exhaust pipe joint nuts and muffler mounting bolt/ nut. RADIATOR BOLT BOLT JOINTNUTS MOUNTING BOLT EXHAUST PIPE £9" GASKET JOINT NUTS FRAME/BODY PANELS/EXHAUST SYSTEM First tighten the exhaust pipe joint nuts to the specifiedtorque. NOTE: Tighten the exhaust pipe joint nuts in numerical order shown in the illustration. TORQUE: 20 N-m i2‘0 kgi-m,14lbf-ft) install the exhaust pipe mounting boltJnut and tighten the nut to the specified torque, TORQUE: 22 N-m (2.2 kgf-m,16lbf-ftl Install the muffler, Install the radiator and tighten the mounting boltst Install the removed parts in the reverse order of removal. 2-7 EXHAUST PIPE RADIATOR BOLT BOLT 3. MAINTENANCE SERVICE INFORMATION 3—1 DRIVE CHAIN 3-17 MAINTENANCE SCHEDULE 3-3 DRIVE CHAIN SLIDER 3-22 FUEL LINE 3-4 BRAKE FLUID 3-22 THROTTLE OPERATION 3-4 BRAKE PAD WEAR 3-23 B CARBURETOR CHOKE 3-5 BRAKE SYSTEM 3-23 AIR CLEANER 3-5 BRAKE LIGHT SWITCH 3-24 SPARK PLUG 3-5 HEADLIGHT AIM 3-24 VALVE CLEARANCE 3-7 CLUTCH SYSTEM 3-25 ENGINE OIL/OIL FILTER 3-12 SIDE STAND 3-25 CARBURETOR SYNCHRONIZATION 3-14 SUSPENSION 3—26 ENGINE IDLE SPEED 3-15 NUTS, BOLTS, FASTENERS 3-27 RADIATOR COOLANT 3-16 WHEELS/TIRES 3-27 COOLING SYSTEM 3-16 STEERING HEAD BEARINGS 3-28 SECONDARY AIR SUPPLY SYSTEM 3-17 SERVICE INFORMATION GENERAL AWARNING - Gasoline is extremsly 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. I If the engine must be running to do soma work, maka sure tho arms 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 systsm in an enclosed area. I Place the motorcycle on a levei ground before starting any work. SPECIFICATIONS ITEM SPECIFICATIONS Throttle grip free pla Spark plug kSpark plug gap Valve clearance IN I \ EX I 2*6mm(1/16~1/4inh CR9EHi9INGK) U27FERS (DENSO) 0.8—0.9 mm (0.03‘004 in} 0.16 rt 0.03 mm 10.006 : 0.001 in) 0.22 i 0.03 mm (0.009 t 0.001 in) MAINTENANCE ITEM SPECIFICATIONS Engine oil capacity ( At draining 3.5 ll (3.7 US qt , 3.1 Imp qt) At oil filter changer Recommended engine oil 7 3.8fl(4.0 US qt,3.3lmp qt) HONDA 4—stroke oil or equivalent motor oil API service classification 5E, SF or SG Viscosity: SAE 1OWi40 Engine idle speed 1,300 i 100 min" (rpm) Drive chain slack 30*40 mm (1.2 - 1.6 in) Recommended brake fluid DOT4 Tire size Front 130/7OZR1G (61W) _‘ , , Hear 180/552R17 (73w) Tire brand ' Bridgestone Front 7 BT-SOF RADIAL G Rear BT—50Fl RADIAL G Michelin Front TX11 . Hear TX23 Tire air pressure Driver only Front 250 kPa (2.50 kgi/cmz , 36 psi) Hear 290 kPa (2.90 kgt/cm2 42 psi) Driver and passenger Front 250 kPa (2.50 kgf/cm‘ . 36 psi) 7 ,, Rearir fl 7 __ 290 kPa (2.90 )(gf/cm2 , 42 psi) Minimum tire tread depth Front _ 1.5 mm (0.06_in) Rear 2.0 mm (0.08”!) TORQUE VALUES Spark plug Timing hole cap Oil drain bolt Oil filter cartridge Cylinder head cover bolt Camshaft holderflange bolt Rear axle nut Drive chain adjuster lock nut TOOL Oil filter wrench 12 Nvm (1,2 kgf-m , 9 lbf‘ft) 13 N-m (1.8 kgf-m ,13lbf-fl) 29 ern (3.0 kgf-m , 22 Ibf'fl) 10 Nvm (1.0 kgf-m , 7 Ibf‘ft) 10 N-m (1.0 kgf-m,7 lbf‘ft) 12 N-m (1.2 kgf‘rn,9 lbf-ft) Apply grease to the threads Apply clean engine oil to the Orring surface 88 N-m (9.0 kgf-m , 65 lbfrft) U—nut 21 N-m(2.1 kgf-m,15|bf-ft) D7HAA»F'J70100 3-2 Apply oil to the threads and seating MAINTENANCE MAINTENANCE SCHEDULE Perform the Pie-ride inspection in the Owner’s Manual at each scheduled maintenance period. I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate. The following items require some mechanical knowledge. Certain items (particularly those marked * and “) may require more technical information and tools, Consult their authorized HONDA dealert FREQUENCY IWHICHEV- 12> ODOMETERREADINGlNOTE‘l) \ ‘EgggMES X‘I,000km 1 5112 18I24 30 as REFER ITEMS \\ I U X1,000mi 0.5 4 s 12l16 20 24 TOPAGE ‘ Months 5 12 18 24 30 36 r l FUELLINE | . I l | 3-4 I I THRO'I'I’LE OPERATION I I I I I 3-4 CARRURETORCHOKE . I I I I I 3-5 w CLEANER _ NOTEZ . __ ‘ R i R 3-5 SPARK PLUG I I R I 35 r VALVE CLEARANCE . L 3-7 ENGINE OIL R R R . R 3-12 . ENGINEOILFILTER 747 R R R R 3-12 CARBURETOR SYNCHRONIZATION I I I 3-14 * ENGINEIDLESPEED I I I I I I 1‘ I 3-15 7 RADIATOR COOLANT NOTE 3 I I H 3-1 s * COOLING SYSTEM I I I I 3-16 - SECONDARYAIRSUPPLYSYSTEM I I I I l I 3-17 ____DR|VE#CH_N_N ‘ : EVERY 1,000 km 1600 mi) |,L 3-17 DRIVECHAIN SLIDER I I i I 3-22 BHAKEFLUID NOTEa I I ‘ R I i I R 322 BRAKE PAowEAR I I ‘ l I I I i 3-23 BRAKE SYSTEM I I I I I 3-23 4+ BRAKE LIGHTSWITCH I I I I 3-24 * HEADLIGHTAIM I I I I 3-24 CLUTCH SYSTEM 1 I I i 3-25 SIDE STAND I I I I I 3-25 * SUSPENSION I i I . I 3-26 * NUTS,BOLTS,FASTENERS I I ll I 327 ** WHEELS/TIRES I I I 3-27 H STEERING HEADBEARINGS I I I I I 3-28 * Should be serviced by an authorized HONDA dealer, unless the owner has proper tools and service data and is mechanically qualified. x >1: In the interest of safety, we recommend these items be serviced only by an authorized HONDA dealer. NOTES: 1. At higher odometer reading, repeat at the frequency interval established here. 2. Service more frequently when riding in unusually wet or dusty areas. 3. Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires mechanical skill. 3-3 MAINTENANCE FUEL LINE Check the fuel lines for deterioration, damage or leakage. Replace the fuel line if necessary. Also check the fuel line fittings for leakage. Check the fuel valve vacuum tube for damage or pinched tube. THROTTLE OPERATION Check for smooth throttle grip full opening and automatic full closmg in all steering positions. Check the throttle cables and replace them if they are deteriorated, kinked or damaged. Lubricate the throttle cables, if throttle operation is not smooth. Measure the free play at the throttle grip flange. FREE PLAY: 276 mm (1/16—1/4 in) Throttle grip free play can be adjusted at either end of the throttle cable. Minor adjustment are made with the upper adjuster. Adjust the free play by loosening the lock nut and turning the adjuster. Major adjustments are made with the lower adjuster on the carburetort Adjust the free play by loosening the lock nut and turning the adjuster. After adjustment, tighten the lock nut securelyt Recheck the throttle operation. Replace any damaged parts, if necessary. 3-4 LOCK NUT MAINTENANCE CARBURETOR CHOKE Check for smooth operation of the choke lever. Lubricale the choke cable if the operation is not smooth. \ CHOKE LEVER AIR CLEANER Remove the left side cover (page 2A2). Remove the three screws and air cleaner housing coven Remove and discard the air cleaner element in accordance with the maintenance schedule (page 3.3). Also replace the air cleaner element any time it is excessively dirty or damage. Install the removed parts in the reverse order of removai. SPARK PLUG REMOVAL Remove the radiator mounting bolts, then release the radiator from the grommet. i’\ ,m MAINTENANCE Always use spool/led spark plugs on this motorcycle. Remove the seat and side covers lpage 2-2). Remove the fuel tank mounting bolt/nut and remove the fuel tank from the frame grommets. Place the fuel tank brackets onto the frame grommets as shown, Remove the spark plug caps‘ NOTE. Clean around the spark plug bases wtth compressed air before removing, and be sure that no debris is allowed to enter the combustion chamber. Remove the spark plugs using a equipped spark plug wrench or an equivalent. Inspect or replace as described in the maintenance schedule (page 3-3). INSPECTION Check the following and replace if necessary lrecommended spark plug: page 3-1) 7 Insulator for damage -E|ectrodes for wear , Burning condition, coloration; *dark to light brown indicates good condition, —excessive lightness indicates malfunctioning ignition system or lean mixture. *wet or black sooty deposit indicates over-rich mixture. 3-6 INSULATOR SIDE ELECTRODE MAINTENANCE REUSING A SPARK PLUG Clean the spark plug electrodes with a wire brush or special plug cleaner. Check the gap between the center and side electrodes with a wire-type feeler gauge. If necessary, adjust the gap by bending the side electrodes carefully‘ SPARK PLUG GAP: 0.8i0.9 mm (0.03*0.04 in) CAUTION: To prevent damage to the cylinder head, hand- tighten the spark plug before using a wrench in tighten to the specified torque. Reinstall the spark plugs in the cylinder head and hand tighten, then torque to specification. TORQUE: I2 N-m (1,2 kgf-m , 9 mm) REPLACING A SPARK PLUG Set the plug gap to specification with a wire-type feeler gauge (see above), CAUTION: Do nat avertighten the plug‘ Install and hand tighten the new spark plug, then tighten it about 1/2 tum alter the sealing washer contacts the seat of the plug hole. Install the spark plug caps. VALVE CLEARANCE INSPECTION BOLT/ STOPPER TOOL NOTE' WASHER TENSIONER LIFTER Inspect and adjust the valve clearance while the engine is cold (below 35 ”C/95 “Fl. Remove the cylinder head cover (page 8-4). Remove the cam chain tensioner lifter sealing bolt and washer. Turn the cam chain tensioner lifter shaft clockwise fully and secure it using the mechanic’s tensioner stopper tooi (page 8-5). /‘\'1 3-7 MAINTENANCE Record the clearance far each Vii/V5 [or reference in shim salsctinn if adjustment l5 required. Remove the timing hole cap and O-ring. Turn the crankshaft clockwise, align the "T" mark on the ignition pulse generator rotor with the index mark on the ignition pulse generator rotor cover. The timing marks (“IN" and “EX"l on the cam sprockets must be flush with the cylinder head surface and facing outward as shown. If the timing marks on the cam sprocket facing inward. turn the crankshaft clockwise one full turn (360°) and realign the timing marks with the cylinder head surface so they are facing outward. Insert the feeler gauge between the valve lifter and the cam lobe. Check the valve clearance for the No.1 and No.3 cylinder intake valves using a feeler gauge, VALVE CLEARANCE: IN: 0.16 i 0.03 mm (0.006 1: 0.001 in) NOTE: Record the clearance for each valve far reference in shim selection if adjustment is required. 3-8 TIMING MARKS Turn the crankshaft clockwise 1/2 turn (180°), align the index line on the ignition pulse generator rutor so that it is facing up as shown. Check the valve clearance for the N02 and No.4 cylinder exhaust valves using a Ieeler gauge. VALVE CLEARANCE: EX: 0.22 :r 0.03 mm (0.009 t 0.001 in) NOTE Record the clearance for each valve for reference in shim selection if adjustment is required. MAINTENANCE INDEX LINE Turn the crankshaft clockwise 1/2 turn (180°), align the "T" mark on the ignition pulse generator rotor with the index mark on the ignition pulse generator rotorcover. Check the valve clearance far the N02 and No.4 cylinder intake valves using Iaeler gauge. VALVE CLEARANCE: IN: 0.16 t 0.03 mm 10.006 1 0.001 in) No.2/4 EXHAUST VALVE "T" MARK INDEX MARK No.2/4 INTAKE VALVE MAINTENANCE Turn the crankshaft clockwise 1/2 turn (180°), align lNDEX LINE the index line on the ignition pulse generator rotor . facing up as shown. Check the valve clearance for the No.1 and N03 cylinder exhaust valves using a feeler gauge. VALVE CLEARANCE: EX: 0.22 :l‘ 0.03 mm (0,009 i 0.001 in) ADJUSTMENT Remove the camshaft (page 8-6). Remove the valve lifters and shims. NOTE. - Shim mav stick to the inside of the valve lifter. Do not allow the shims to fall into the crankcase. - Mark all valve lifters and shims to ensure correct reassembly in their original locations. 0 The valve lifter can be easily removed with a valve lapping tool or magnet. - The shims can be easily removed with a tweezers or magnet. Clean the valve shim contact area in the valve lifter with compressed air. 3-10 MAINTENANCE Install the shims and Valve lifters in their original locations. Measure the shim thickness and record it. NOTE: Sixty-five different thickness shims are available from the thinness 1.200 mm thickness shim to the thickest 2.800 mm thickness shim 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: ' Make sure of the correct shim thickness by measuring the shim by micrometer. I Heface the valve seat if carbon deposit result in a calculated dimension of over 2.800 mm. Install the newly selected shim on the valve retainer. Apply molybdenum disulfide oil to the valve lifters. Install the valve lifters into the valve lifter holes. Install the camshaft (page 8-20). Rotate the camshafts by rotating the crankshaft clockwise several times. Recheck the valve clearance. Remove the cam chain tensioner stopper tool. Install the new sealing washer and cam chain tensioner sealing bolt. Tighten the bolt securely. Check that the timing hole cap O-ring is in good condition. replace it necessary. Apply grease to the timing hole cap threads. Install and tighten the timing hole cap to the specified torque. TORQUE: 18 N'm (1.8 kgf-m ,13lbf-ft) Install the removed pans in the reverse order of removal. 3-11 BO LT @ SEALING WASHER v MAINTENANCE ENGINE OIL/OIL FILTER must/mm OIL LEVELINSPECTION . ‘ ‘"" K. We Start the engine and let it idle for 2*3 minutes. Stop the engine and wait3 minutes. Remove the oil level dipstick and wipe the oil from the dipstick with a clean cloth. With the motorcycle upright on level ground, insert the dipstick into the stick hole without screwing it in. Remove the dipstick and check for the oil level. If the level is below the lower line, fill the crankcase with recommended oil up to the upper level line. RECOMMENDED ENGINE OIL: OIL VISCOSITIES HONDA 4-stroke oil or equivalent motor oil APl service classification: SE, SF or SG Viscosity: 10W—40 NOTE: Other viscosities shown in the chart may be used when the average temperature in your riding area is within the indicated range. Reinstall the oil level dipstick. ENGINE OIL & FILTER CHANGE NEW—— A warm—up engine and the oil in it are hat, be careful not to burn yourself. NOTE: Change the engine oil with the engine warm and the motorcycle on level ground Io assure complete draining. Remove the oil level dipstick. Place a oil drain pan under the engine to catch the oil, then remove the oil drain bolt and sealing washer. Drain the oil completely, CAUTION: Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. 3—12 MAINTENANCE Loosen the oil filter cartridge using the special tool. TOOL: Oil filter wrench 07HAA-PJ70100 Pull the oil filter cartridge forward, then remove from the right side and discard it. Check that the sealing washer on the drain bolt is in good condition, replace if necessary, Install and tighten the drain bolt. TORQUE: 29 N‘m (3.0 kgfvm . 22 lbf-ft) Apply oil to the new oil filter cartridge O»ring. install the new oil filter cartridge and tighten it to the specified torque. TOOL: Oil filter wrench D7HAA-PJ70100 TORQUE: 10 NW" 110 kgf—m . 7 lbf-fi) Fill the crankcase with recommended engine oil. OIL CAPACITV: 3.5 D [3.7 US qt , 3.1 Imp qt) atdraining 3.8 E [4.0 US at , 3.3 Imp qt) at oil filter change Install the oil level dipstick. Stamhe engine and let it idle for 2 to 3 minutes. Stop the engine and recheck the oil level. Make sure there are nu oil leaks. MAINTENANCE CARBURETOR SYNCHRONIZATION _WARNING If the engine must be running ta do same work, make sure the area is well ventilated. Never run the engine in en enclneed area. NOTE Synchronize the carburetors with the engine at normal operating temperature, transmission is in neutral and the motorcycle supported securely on a level surface. Remove the fuel tank (page 2-3). Remove the plug and washer from the No.1 intake port, Remove the rubber cap from No.4 intake ports, Install the 3—way joint to the fuel valve vacuum tube (No.2 vacuum tube). Connect the fuel tube and vacuum tube to the fuel valve. Disconnect the No.3 vacuum tube from the PAIR (Pulse secondary air injectioni control valve, Screw the adaptor into the No.1 intake port. Connect the vacuum gauge tubes to the adaptors and 3-way joint. Start the engine and adjust the idle turning the throttle stop screw. speed by IDLE SPEED: 1,300 .+ 100 min"(rpm) 3-14 PLUG/WASHER RUBBER CAP No.2 VACUUM TUBE { ADAii'rOR \\ No.3 VACU UM TUBE MAINTENANCE Check the each carburetor intake vacuum pressure is within 30 rn 1.2 in H ofthe base carburetor. , \ m ( ) g i i ‘ »€\z\ \ l NOTE' / \ 'The No.3 carburetor cannot be adjusted; it is the ‘ . base carburetor. V r l \ 0The No.3 cylinder intake vacuum pressure is the base vacuum pressure. # / . \ L N \ l VACUUM GAUGE Synchronize to specification by turning the ADJUSTING SCREW adjusting screw with the philips screwdriver. Recheck the idle speed and each cylinder intake vacuum pressure so it is within 30 mm (1.2 in) Hg of the base carburetor reading after snapping the throttle grip 3'4 times. Remove the vacuum gauge tubes. Connect the fuel valve vacuum tube and PAIR Control valve tube. Install the rubber capto the No.4 intake port. Install the vacuum plug into the No.1 intake port, and tighten it securely. ENGINE IDLE SPEED M If the engine must be running to do some work, make sure the area Is weII‘ventiIated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss a! consciousness and lead to death. Run the engine in an epen area or with an exhaust evacuation system in an enclosed area. , . \ NOTE. . ‘ mmeenew 0 Inspect and adjust 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 and shiftthe transmission into neutralt Turn the throttle stop screw as required to obtain the specified idle speed. IDLE SPEED: 1,300 a 100 min“ (rpm) 3—15 MAINTENANCE RADIATOR COOLANT Check the coolant level of the reserve tank with the engine running at normal operating temperature. The level should be between the "UPPER” and "LOWER" level lines. If necessary, add recommended cuolant. Remove the seat (page 272i Remove the reserve tank filler cap and fill to the “UPPER" level line with 50/50 mixture of distilled water and antifreeze Reinstall the filler cap, COOLING SYSTEM Check the radiator air passages for clogging or dam- age. Straighten bend fins, and remove Insects, mud or other obstructions with compressed air or low water pressure Replace the radiator ifthe airflow is restricted over more than 20% of the radiating surface Inspect the radiator hoses for cracks or deterioration, and replace if necessary. Check the tightness of all hose clamps and fasten- ers. 3-16 MAINTENANCE SECONDARY AIR SUPPLY SYSTEM NOTE: The secondary air supply system introduces filtered air into exhaust gases in the exhaust port. The secondary air is drawn into the exhaust port whenever there is negative pressure pulse in the exhaust system. This charged secondary 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. Check the air injection hoses between the PAIR lpulse secondary air injection] control valve and cylinder head for deterioration, damage or loose connections. Make sure that the hoses are not cracked. NOTE; If the hoses show any signs of heat damage. inspect the PAIR check valve for damage. Check the airsuction hose between the airfilter and PAiR control valve for deterioration, damage or loose connections. Make sure that the hoses are PAIFl CONTROL VALVE not kinked, pinched or cracked. DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION WEE—— Never inspect and adlust the drive chain while the engine is running. Turn the ignition switch OFF, support the motorcycle on its side stand and shift the transmission into neutral. Check the slack in the drive chain lower run midway between the sprockets. CHAIN SLACK: 30—40 mm (1.Z*1.6 in) CAUTION: Excessive chain slack, 50 mm (2.0 in) or more, ma y damage the frame. Lubricete the drive chain with #80 7 #90 gear oil or drive chain lubricant designed specifically for use with O-ring chains. Wipe off excess oil or chain lubricant. 3-17 MAINTENANCE ADJUSTMENT Loosen the rear axle nut and adjuster lock nuts. lurn both adjusting nuts until the correct drive chain slack is obtained. Make sure the index marks on the both axle washers are aligned with the index marks on the swingarm. After adjustment, check the drive chain wear indicer ter label attached on the swingarm. If the red zone of the indicator label reaches the index mark on the rear axle washer. replace the drive chain with a new one (page 3—19). Tighten the both drive chain adjuster lock nuts. TORQUE: 21 N4“ (21 kgf-m , 15 Ibf-fti Tighten the rear axle nut to the specified torque. TORQUE: 88 N»m (9.0 kgf-m , 65 IbI-fll Recheck the drive chain slack and free wheel rota- tion. Lubricate the drive chain. CLEANING AND LUBRICATION NON—FLAMMABLE 0R HIGH FLASH POINT SOLVENT Clean the chain with non-flammable or high flash point solvent and wipe it dry. Be sure the chain has dried completely before lubricating. Effie Inspect the drive Chain tor possible damage or CLEAN wear. Replace any chain that has damaged rollers, loose fitting links, or otherwise appears unserviceable. WIPE AND Installing a new chain on badly worn sprockets will DRY cause the new chain to wear quickly. Inspect and replace sprocket as necessary. Lubricate the drive chain with $80 7 90 gear oil or LUBRICATE drive chain lubricant designed specifically for use with O-ring chains. Wipe off the excess oil or chain lubricant. #80 SO GEAR OIL OR 3'18 DRlVE CHAlN LUBRICANT MAINTENANCE SPROCKETS INSPECTION lnspectthe drive and driven sprocket teeth for wear or damage, replace if necessary. Never use a new drive chain on worn sprockets. Both chain and sprockets must be in good condition, or the new replacement chain WIII wear rapidly. Check the attaching bolts and nuts on the drive and driven sprockets. If any are loose, torque them. TORQUE: Drive sprocket bolt: 54 N-m (5.5 kgrm , 40 lbfrft) Driven sprocket nut: 108 Mm 111.0 kgI-m , 30 lell REPLACEMENT This motorcycle uses a drive chain with a staked master link. Loosen the drive chain (page 3—18). Assemble the special tool as shown. TOOL: Drive chain tool set 07HMH-MR10103 NOTE When using the special follow the manufacturer’s instruction. tool. 3-19 DAMAGE NI": DRIVE CHAIN TOOL SET MAINTENANCE Locate the crimped pin ends of the master link from the outside of the chain, and remove the link with —> 4— MASTER LINK the drive chain tool set. TOOL: Drive chain tool set 07HMH—MR10103 llll l Remove the drive chain. DRIVE CHAIN TOOL SET Remove the excess drive chain links from the new drive chain with the drive chain tool set. MASTER LINK NOTE: Include the master link when you count the drive chain linksl l l STANDARD LINKS: 110 llnks mt l REPLACEMENT CHAIN: l DID: DID525VM2a12OZB <————d BK: RK525R0~120LJiFZ 110 LINKS CAUTION: DRIVE CHAIN TOOL SET Never reuse the aid drive chain, master link, master link plate and Dvrings. Assemble the new master link, O-rings and plate. CAUTION: Insert the master link tram the inside of the drive chain, and install the plate with the identification mark facing the nutsidav MASTER LINK Assemble and set the drive chain tool set. TOOL: Drive chain tool set 07HMH-MR10103 & Make sure that the master link pins are installed properly. Measure the master link pin length projected from the plate, STANDARD LENGTH: DID: 1 15*155 mm(0.045—D.06l in) RK: 1.271.4mrn(D.05—0.06inl Stake the master link pinsr 3_20 Make sure that the pins are staked properly by measuring the diameter of the staked area using is slide caliper. DIAMETER OF THE STAKED AREA: DID: 550*5480 mm lO,217—0.228in) RK: 5.507580 mm (0117*0228 in) After staking, check the staked area of the master link for cracks. If there is any cracking, replace the master link, O-rings end plate. CAUTION: A drive chain with a clip—type master link must not be used. DRIVE CHAIN GUIDE PLATE INSPECTION Remove the screw and speedometer cable. Remove the belts, drive sprocket cover and drive chain guide plate. Check the drive chain guide plate for wear or damage. If the drive chain guide plate is excessively wear or damage, replace it with a new one. CAUTION; Avnid damaging the crankcase, periodically inspect the drive chain guide plate, replace if HHL‘BSSII’Y. 3-21 MAINTENANCE GOOD NO GOOD f3 :\ CRACKED ‘ , WSPRO—‘qlgETCOVER DRIVE CHAIN GUIDE PLATE MAINTENANCE DRIVE CHAIN SLIDER DRIVE CHAIN SLlDER Inspect the drive chain slider for excessive wear or damage ll it is worn to the wear indicator, replace the drive chain slider. BRAKE FLUID CAUTION’ I 012 not mix dilferant types of fluid, as they are not compatible with each other. - Do not allow foreign material to enter the system when filling the reservoir. 0 Avoid spilllng fluid on painted, plastic ar rubber parts. Place a rag over these parts whenever the system is serviced. NOTE When the fluid level is low, check the brake pads for wear (see next page). A low fluid level may be due to wear ofthe brake pads, If the brake pads are worn, the caliper piston is pushed out, and this accounts for a low reservoir level. If the brake pads are not worn and the fluid level is low, check entire system for leaks lpage 3-23l. FRONT BRAKE Turn the handlebar to the left so that the reservoir is level and check the front brake fluid reservoir levelthrough the sightglass. If the level is near the lower level line, check the brake pad wear (see next page). REAR BRAKE Place the motorcycle on level surface, and support it upright position, Remove the seat [page 2v2l. Check the rear brake fluid reservoir level. If the level is near the lower level line, check the brake pad wear (see next page). 3-22 BRAKE PAD WEAR BRAKE SYSTEM 3-23 MAINTENANCE FRONT BRAKE PADS Check the brake pads fpr wear. Replace the brake pads if either pad is worn t0 the bottom of wear limit groove. Refer to page 15-6 tor brake pad replacement. WEAR INDICATOR REAR BRAKE PADS Check the brake pads for wear. Replace the brake pads if either pad is worn to the bottom of wear limit groove. Referto page 15-7 for brake pad replacement. INSPECTION Firmly apply the brake lever or pedal, and check that no air has entered the system. If the lever or pedal feels soft or spongy when operated, bleed the air item the system, Inspect the brake hose and fittings for deterioration, ‘ cracks and signs of leakage. Tighten any loose fittings. Replace hoses and fittings as required, Reler to page 154 for brake bleeding procedures. BRAKE LEVER ADJUSTMENT The distance between the tip of the brake lever and the grip can be adjusted by turning the adjuster. DIRECTION A: Brake lever turther away from the grlp DIRECTION B: Brake lever closer to the grip CAUTION: Align the allowance an the brake lever with the index mark an the adjuster. MAINTENANCE 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 front brake light switch does not require adjust ment. Adjust the rear brake light switch so that the brake light comes on just prior to the brake actually being engaged. If the light fails to come on, adjust the switch so that the light comes on at the proper time. Hold the switch body and turn the adjuster. Do not turn the switch body. HEADLIGHT AIM 3-24 m— An improperly adjusted headlight may blind an- caming drivers, or it may fall to light the mad for a safe distance. NOTE: Adjust the headlight beam as specified by local laws and regulations Place the motorcycle on a level su rface. Adjust the headlight beam horizontally beam adjust- ment are made using the horizontal beam adjusting SCTBW. . A clockwise rotation moves the beam toward the right side of the rider. Adjust the headlight beam vertically by move the headlight case assembly. Remove the rubber plugs from the headlight case mounting bolts. Loosen the headlight case mounting bolts and adjust the vertical beam by moving the headlight case assembly. HEADLIGHT CASE ASSEMBLY MAINTENANCE CLUTCH SYSTEM Measure the clutch free play at the end of the clutch lever. FREE PLAV: 10*20 mm (3/8A13/16 inl Minor adjustment are made with the upper adjuster at the clutch lever, Loosen the lock nut and turn the adjuster, CAUTION: The adjuster may be damaged if it is pasitianad tau far out, leaving minimal thread engagement. lithe adjuster is threaded out near its limit and the correct free play cannot be obtained, turn the adjuster all the way in and back out one turn, Tighten the lock nut and make a major adjustment as described below. Major adjustment is performed at the clutch arm. Loosen the lock nut and turn the adjusting nut to adjust free play. Hold the adjusting nut securely while tightening the lock nutl li proper free play cannot be obtained, or the clutch slips during the test ride, disassemble and inspect the clutch (see section Bl. SIDE STAND Supportthe motorcycle on a level surface. Check the side stand spring for damage or loss of tension, Check the side stand assembly for freedom of movement and lubricate the side stand pivot it necessary. 3-25 SIDE STAND MAINTENANCE Check the side stand ignition cut-off system: Sit estride the motorcycle and raise the side stand *Start the engine with the transmission in neutral, then shift the transmission into gear, with the clutch leversqueezed. 7 Move the side stand full down. *The engine should stop as the side stand is lowered. lfthere IS a problem with the system, check the side stand switch isection 19). SUSPENSION mam—w Loose, worn or damaged suspension parts impair motorcycle stability and control. Repair or replace any damaged components before riding. Riding a motorcycle with faulty suspension increases your risk of an accident and possible injury. FRONT SUSPENSION INSPECTION Check the action of the forks by operating the front brakes and compressing the front suspension several times. 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 sen/ice, REAR SUSPENSION INSPECTION Support the motorcycle using a hoist or equivalent and raise the rear wheel off the ground. Hold the swingarm and move the rear wheel sideways with force to see if the axle bearings are worn. Check for worn swingarm bearings by grabbing the rear swingarm and attempting to move the swingarrn side to side. Replace the bearings if any looseness is noted. 3-26 MAINTENANCE Check the action of the shock absorber by compressing it several times. Check the entire shock absorber assembly for signs of leaks, damage or loose fasteners. Replace damaged components which cannot be repaired. Tighten all nuts and bolts. Refer to section 14 for shock absorber service. NUTS, BOLTS, FASTENERS Check that all chassis nuts and bolts are tightened to their correct torque values (page 1-13). Check that all safety clips, hose clamps and cable stays are in place and properly secured. WHEELS/TIRES NOTE. Tire pressure should be checked when the tires are COLDr RECOMMENDED TIRE PRESSURE AND TIRE SIZE: \ 1 FRONT REAR Tire pressure ‘250 (2.50 , 36) 290 (230,42) kF’a lkgl/cm‘, psil Tire size 130/7OZR16 180/552R17 (61W) i7awi Tire Bridgeslone BT—SOF BT-EOR bland l RADIAL G RADIAL G l Michelin TX11 sza 3-27 MAINTENANCE 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 Iollowing limitst MINIMUM TREAD DEPTH: FRONT: 1.5 mm (0.06 in) REAR: 2.0 mm (0.08 in) STEERING HEAD BEARINGS Check ma! the Support the motorcycle securely and raise the front control cables do wheel off the ground, nor interfere with Check that the handlebar moves freely from side to handlebar relation. Sidet If the handlebar moves uneven iv, binds, or has vertical movement, inspecI the steering head bearings (Section 15”. 3-28 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM EXHAUST CAMSHAFT INTAKE CAMSHAFT PISTON CONNECTING ROD OIL PRESSURE SWITCH 4— fiF’ —> -—§ —> CRANKSHAFT OIL OHIFICE MAINSHAFT OILC OLER ,i i! i! H COUNTERSHAFT /( OIL PUMP OIL FILTER PRESSURE RELlEF VALVE OIL STRAINER 4. LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM 4-0 OIL STRAINER/PRESSURE RELIEF VALVE 4—4 SERVICE INFORMATION 4-1 OIL PUMP 4-6 TROUBLESHOOTING 4-2 OIL COOLER 4-10 OIL PRESSURE INSPECTION 4-3 SERVICE INFORMATION I GENERAL AWARNING I if the engine must be running to da same work, make sure the area is well-ventilated Never run the engine in an enclosed area. The exhaust contains paisonuus carbon monaxide gas that may cause loss of cansciausness and load ta death, Run the engine in an open area or with an exhaust evecuativn system in en enclusad area. I Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolungerl perivds. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable ta thoraughly wash your hands with soap and water as scan as possible after handling used oil. KEEP OUT OF REACH OF CHILDREN I The oil pump can be serviced with the engine installed in the frame. I The service procedures in this section must be performed with the engine oil drained. I When removing and installing the uil pump, use care not to allow dust or dirtlo enter the engine. I if any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly. I After the oil pump has been installed, check that there are no oil leaks and that oil pressure is correct. I Refer to section 19 for oil pressure indicator inspection. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Engine oil capacity At draining 3.5 I (3.7 US qt, 3.1 Imp qt) At disassembly 4.2 D (4.4 US qt, 3.7 Imp qt) ___> At oil filter change 3.8 ll (40 US qt , 3.3 Imp qt) Recommended engine oil HONDA 4-stroke oil or equvalent motor oil API service classification SE, SF or SG Viscosity: SAE 10W 7 40 Oil pressure at oil pressure switch 490 kPa (5.0 lrgf/crn2 , 71 psi) at ‘ ‘Wi ’ 6,000 min" (rpmi/lBO “C/‘l76 “F) l on pump rotor ‘ Tip clearance 0.15 (0.006) max ._ . 0.2010008) ‘ Body clearance 0.15-0.22 l0.006~0,009) 0.35 (0.014) w l Side clearance . 00270.07 10.001 70.003) 0.1D(0.004) Oil pump drive sprocket collarQD. 34.050m34.075(1.3405 1.3415) 34.03 [1.340) Oil pump drive sprocketlfl. 35.025m35.075(1.3789’13809) 35.10 (1.382) 4—1 LUBRICATION SYSTEM TORQUE VALUES Oil drain bolt 29 N-m (3.0 kgf-rn , 22 lbfrftl Oil pump cover bolt 8 N-m (0.8 kgfrm , 5.8 lbi-ftl CT bolt Oil pump driven sprocket bolt 15 N-m (1‘5 kgf-m , 11 Ibfrftl Apply a locking agent to the threads Oil filter cartridge 10 N-m (1.0 kgf-m , 7 lbf-f‘ll Apply clean engine oil to the D-ring TOOLS Oil pressure gauge 07506-3000000 Oil pressure gauge attachment 07406-0030000 Oil filter wrench 07HAA-PJ70100 TROUBLESHOOTING Engine oil level too low 0 Oil consumption I Clogged oil strainer screen 0 External oil leak I Oil pump worn or damaged I Worn piston ring or incorrect piston ring installation I Internal oil leak 0 Worn valve guide or seal I Incorrect all being used I Low oil level Low oil pressure Low or no oil pressure - Clogged oil orifice High oil pressure I Incorrect all being used I Plugged oil filter, gallery, or metering orifice I Incorrect oil being used No oil pressure IOil level too low I Oil pump drive sprocket broken - Oil pump damaged (pump shaft) - Internal oil leak 4—2 LUBRICATION SYSTEM OIL PRESSURE INSPECTION NOTE: If the oil pressure indicator light remains on a few seconds, check the indicator system before checking the oil pressure. Remove the two bolts and clutch cable guide. Remove the oil pressure switch terminal screw and terminal eyelet. Remove the oil pressure switch. install the oil pressure gauge attachment and oil pressure gauge to the oil pressure switch hole. TOOLS: Oil pressure gauge 07506-3000000 (Equivalent commercially available) Oil pressure gauge attachment 075104220100 (Equivalent commercially available) Check the oil level (page 3-12) Warm up the engine to normal operating tempera- ture (approximately 80 "(2/176 “Fl and increase the rpm to 6,000 min" (rpml and read the oil pressure. OIL PRESSURE: 490 We (50 kgt/cmz , 71 psi) at 6,000 min" (rpm) (30 °C/176 °F) Apply sealant to the pressure switch threads as shown. Install and tighten the oil pressure switch to the specified torque. TORQUE: 12 N-m (1.2 kgf-m , 9 ib‘f-ftl Connect the oil pressure cord terminal eyelet and tighten the screw to the specified torque. DO "m apply to the thread head ‘ 3 7 4 mm (0.1 - 0.2 in). TORQUE: 2 N-m (0.2 kgfrm , 1.4 (bf-(t) install the rubber cover. Install the clutch cable guide and tighten the bolts. Start the engine. Check that the oil pressure indicator goes out after one or two seconds. If the oil pressure indicator 4_3 stays on, stop the engine immediately and determine the cause (page 19-12]. LUBRICATION SYSTEM OIL STRAINER/PRESSURE RELIEF VALVE REMOVAL Drain the engine oil (page 3‘12). Remove the exhaust pipe (page 2-5). Remove the oil pan flange bolts and oil pan. Remove the pressure relief valve and O-ring. Remove the oil strainer and gasket. Check the oil strainer for damage or clogging. Clean the oil strainer screen. INSPECTION Check the operation of the pressure relief valve by pushing on the piston. Disassemble the relief valve by removing the snap ring. Inspect the piston for wear, sticking or damage. Inspect the spring for weakness or damage. Assemble the relief valve in the reverse order of. disassembly. LUBRICATION SYSTEM INSTALLATIO N Apply oil to the new O-ring and install it onto the relief valve. Install the relief valve into the crankcase. Apply oil to the new gasket and install it onto the oil strainer. Install the oil strainer into the crankcase while aligning its tab with the slot on the crankcase. Clean the oil pan mating surface thoroughly. Apply Three Bond 12073 or an equivalent to the mating surface. CAUTION: Do not apply sealant more than necessary. Carefully install the oil pan and tighten the flange bolts in a crisscross pattern in 2'3 steps. Install the exhaust pipe (page 2~5). Fill the crankcase with recommended oil (page 3-12). NOTE: After installation, check that there are no oil leaks. 4-5 LUBRICATION SYSTEM OIL PUMP REMOVAL Remove the following: ~C|utch assembly (page 9-4] * Oil strainer and pressure relief valve (page 4-4) Remove the bolt/washer, then remove the oil pump drive/driven sprocket and drive chain as an assembly. Remove the three flange bolts and oil pump assembly. DISASSEMBLY NOTE: If any portion of the oil pump is worn beyond the specified service limit, replace the oil pump as an assembly, Remove the oil pump cover bolt and cover. Remove the dowel pin. Disassemble the oil pump and clean the removed parts. INSPECTION Temporarily install the oil pump shaft. Install the outer and inner rotors into the oil pump body, Measure the tip clearance. SERVICE LIMIT: 0.20 mm (0.008 in] Measure the pump body clearance. SERVICE LIMIT: 0.35 mm (0.014 inl LUBRICATION SYSTEM Measure the side clearance using a straIght edge and feeler gauge‘ SERVICE LIMIT: 0.10 mm (0.004 In) Measure the oil pump drivan sprocket CoHar O.D, SERVICE LIMIT: 3403 mm (1.340 in} Measure the Oil pump drive sprocket I,D. SERVICE LIMIT: 35.10 mm (1.382 W SPBQCKETCOLLAR , ‘DRIvENSPROCKETj ASSEMBLY INNER ROTOR DRIVE PIN OIL PUMP SHAFT PUNCH MARK DOWEL PIN \/ OIL PUMP COVER OIL PUMP BODY OUTER ROTOR INNER ROTOR DRIVE PIN s Nm (0.3 kgflm , 5.3 Ibm) 4-7 THRUST WASHER LU BRICATION SYSTEM Before assembly, clean all disassembled parts ' 3- , ‘ ' F , -- ‘lNNEFl RC‘I’OFI thoroughly in solvent, wipe and dryt ~ - , , _ . ‘ Apply clean engine oil to the all slvding area, Install the outer and Inner rotors into the oil pump body with the outer rotor punch mark facing the pump cover. Install the oil pump shaft. Install the drive pin into the hole In the pump shaft and allgn the pin with the grooves in the inner rotor as shown. Install the thrust washer into the inner rotor groove. ‘PL’IMLP SHAFT; Install the dowel pin to the oil pump body. Install the oil pump cover. Install and tighten the oil pump cover bolt to the specified torque. TORQUE: 8 N-m (0.8 kgf‘m . 5t8 Ibf‘ftl Align the flat surfaces at the driven sprocket with the all pump drive shaft end. INSTALLATION Install the oil pump into the crankcase whlle aligning the pump shah lug with the water pump shaft groove. Install and tighten the three flange bolts securely, Applv oil to the oil pump drive sprocket collar, drive sprocket and drive chaint Install the drive sprocket collar onto the mainshafl, an assembly with the "OUT" mark on the driven sprocket facing out, 4-9 LUBRICATION SYSTEM OQKET LUBRICATION SYSTEM Apply a locking agent to the oil pump driven sprocket bolt ihreads. Install and lighten the driven sprocket bolt/washer to the specified torque. TORQUE: 15 N-m (1.5 kgf‘m , 11 lbf-ft) install the clutch (page 9-8), Fill the crankcase with recommended engine oil (page 3-12). and check for oil leaks. Check the oil pressure (page 4-3), OIL COOLER REMOVAL Drain the engine oil (page 3-12l‘ Remove ihs follawing: *Exhausi pipe (page 2-5) ~PAIR control valve assembly (page 527) —Oil filter cartridge (page 343) Remove the water hose. Remove the oil cocler assembly mountlng bolts Remove the oil cooler assembly and 0»ring. Remove rhe joint collars/O-rings from the crank- C858. LUBRICATION SYSTEM DISASSEMBLY Remove the oil cooler cover bol‘s and sealing washer. Remove the DH cooler cover and O-ring. Remove the bolt's, washers. a‘nd oi! comer. ‘ BOLTS/WASHERS Remove me O»nngs and Jomt collars from the all j cooler base, OILCOOLER ASSEMBLY OIL COOLER BASE OIL COOLER OIL COOLER COVER JOINT COLLAR 232' '75 O’RING 4-11 LU BRICATION SYSTEM Install the joint collars into the oil cooler base holes. O~HlNGSlJOlNT COLLARS Apply clean engine oil to the new O-rings and 3W I . . . if install them Into the oil cooler base. install the oil cooler with its arrow mark facing down. ARROW MARKS OIL COOLER Install the washers and bolts, tighten the bolts securely. Apply oil to the new O-ring and install it intu the groove of the oil cooler case. Assembler the oil cooler case and oil cooler base, then install the sealing washer and bolts. Tighten the bolts securely, 4-12 LUBRICATION SYSTEM INSTALLATION Apply clean engine oil to the new Orrings, and install them onto the joint collars. Install the joint collars to the crankcase with its large O.D. side facing the crankcase. Apply oil to the new O-ring and install it into the groove of the oil cooler base, Install the oil cooler assembly onto the crankcase. Install and tighten the oil cooler assembly mounting bolts. Connect the water hose to the oil cooler and tighten the clamp screw securely, Install the following: ' PAIR control valve assembly (page 5-27) *Exhaust pipe (page 2-5) ‘Oil filter cartridge (page 3-13l Fill the crankcase with recommended engine oil (page 342), and check for oil leaks. Fill the cooling system and bleed the air (page 641). 4-13 FUEL SYSTEM 12 N-m (1.2 kgf-m , 9 lbf-fi] 5. FUEL SYSTEM SERVICE INFORMATION 5-1 CARBURETOR ASSEMBLY 5-15 TROUBLESHOOTING 5-3 CARBURETOR COMBINATION 5‘20 AIR CLEANER HOUSING 5-4 CARBURETOR INSTALLATION 5-24 CARBURETOR REMOVAL 5-8 PILOT SCREW ADJUSTMENT 5-25 CARBURETOR SEPARATION 5-9 SECONDARY AIR SUPPLY SYSTEM 5-26 CARBURFI'OR DISASSEMBLY 5-11 FUEL VALVE 5-28 SERVICE INFORMATION GENERAL AWARNING ' Gasoline is extremely flammable and is explosive under certain oanditlons. KEEP 0U T OF REACH OF CHILDREN. ' Banding or twisting the control cables will impair smooth operation and could cause the cable to stick or bind, resulting in loss of vehicle control. ' Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion. CAUTION: Be sure to remove the diaphragms before cleaning air and fuel passages with compressed air. The diaphragms might be damaged. ' Refer to section 2 foriuel tank removal and installation. - When disassembling fuel system parts, note the location ofthe O-rings. Replace them with new ones on reassembly. 0 Before disassembling the carburetor, place the suitable container under the carburetor dram tubet loosen the bolt and drain the carburetor. ' After removing the carburetor, wrap the intake ports of the engine with a shop towel or cover it with piece of tape to prevent any foreign material from dropping into the engine. 3 The vacuum chamber and float chamber can be serviced with the carburetors assembled. 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 lets, resulting in hard starting or poor driveability. 5-1 FUEL SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Carburetor identification Except SW type VF49A number SW type 1 VP49I3 Main jet No‘1/4: # 100, No.2/3; #102 Slow jet # 40 Jet needle J7SL Pilot screw initial opening Except SW type 1 3/4 turns out SW type 2 1/8 turns out Float level 13.7 mm (054 in) Idle speed 1,300 i 100 min" (rpm) Carburetor vacuum difference Within 30 mm Hg (1.2 in H9) Base carburetor for synchronization l N03 carburetor TORQUE VALUES Boost joint for synchronization Insulator band screw Carburetor assembly bolt/nut, 5 mm 6 mm Fuel valve nut Fuel tank stay bolt/nut TOOLS Carburetor float level gauge Pilot screw wrench Except SW type SW type 2 Nut (0.25 kgf-m , 1.8 Ibf-fl) See page 1-14 5 N‘m (0.5 kgf-m , 3.6 Ibf‘ft) 1O N>m(1.0 kgf-m,7 lbI-ft) 34 N-m (3,5 kgf-m , 25 lbf-ft) 12 N-m 11.2 kgf-m , 9 lbf-I‘t) 07401-0010000 079084730002 07KMA-M560101 with 07PMA-MZZO1 10 5-2 TROUBLESHOOTING Engine won't to start I Too much fuel getting to the engine sAir cleaner clogged ~Flooded carburetors I Intake air leak I Fual contaminated/deteriorated I No fuel to carburetor » Fuel strainer clogged — Fuel tube clogged a Fuel valve vacuum tube clogged — Disconnected fuel valve vacuum tube — Float level misadjusted , Fuel tank breather tube clogged Lean mixture I Fuel jets clogged I Float valve faulty I Float level too low I Fuel line restricted I Carburetor air vent tuba clogged I Intake air leak I Throttle valve faulty I Vacuum piston faulty Rich mixture I Starting enrichment valve in ON position I Float valve faulty I Float level too high I Airjets clogged I Air cleaner element contaminated I Flooded carburetor FUEL SYSTEM Engine stall, hard to start, rough idling I Fuel line restricted I Ignition malfunction I Fuel mixture too lean/rich I Fuel contaminated/deteriorated I Intake air leak I Idle speed misadjustad I Float level misadjusted - Fuel tank breather tube clogged I Pilot screw misadiusted I Slow circuit or starting enrichment circuit clogged I Emission control system malfunction Afterburn when engine braking is used I Lean mixture in slow circuit I Air cutoff valve malfunction I Emission control system is malfunction *Secondary air supply system faulty , Loose, disconnected or deteriorated hoses of the emission control system Backfiring or misfiring during Moderation I Ignition system malfunction I Fuel mixture too lean Poor performance (drlveability) and poor fuel economy I Fuel system clogged I Ignition system malfunction I Emission control system malfunction -Secondary air supply system faulty -Loose, disconnected or deteriorated hoses of the emission control system 5-3 FUEL SYSTEM AIR CLEANER HOUSING REMOVAL NOTE: Refer to page 3-5 for air cleaner element replace» merit. Remove the following: — Fuel tank (page 2A4l *Air cleaner element (page 3-5) , Banery (page 16-5) Remove the sub-air cleaner housing clamp mount- ing screw. Disconnecl Ihe crankcase brealher tube from the air cleaner housing. Disconnem the PAIR (Pulse secondary air injection) air suction tube from the air cleaner housingl Loosen the carburetor connecring rube band screws, FUEL SYSTEM Remove khe air cleaner housing mounting bolt. Remove the air cleaner housing out of the frame to the left side. INSTALLATION AIR CLEANER HOUSING ELEMENT 5'5 AIR CLEANER HOUSING COVER FUEL SYSTEM Install the air cleaner housing into the frame from the left side, Adjust the connecting tube band angle. CONNECTlNG TUBE BAND %©@‘ Tighten the connecting tube band screws so that the band ends clearance is 10 i 1 mm (0.4 I 004 inl. 10 : 1 mm (D4i 0.04m) #6 Install and tighten the air cleaner housing mounting bolt. 5-6 Connect the PAIR air suction tube to the air cleaner housing. Connect the crankcase breather tube to the air cleaner housing. Clean the sub-air cleaner element. Install the sub-air cleaner housing clamp, tighten the screw securely. Install the following: ~ Battery lpage 1675) *Air cleaner element (page 3-5) -Fuel tank (page 2-4) 5-7 FUEL SYSTEM ; sue-AIR" . if FUEL SYSTEM CARBURETOR REMOVAL m__ Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN, Remove the air cleaner housing [page 5-4). Loosen the carburetor drain screws and catch the fuel with approved gasoline container. Remove the throttle sensor connector cover. Disconnect the throttle sensor 3P (Black) connector. Loosen the carburetor side insulator band screws. NOTE - After removing the carburetor assembly, do not place it up side down or the air intake might be deformed. '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. Remove the carburetor assembly. THROTTLE CABLES CHOKE CABLE Disconnect the choke cable lrorn the carburetor. Remove the throttle cables from the cable holder and disconnect the throttle cables from the throttle drum. FUEL SYSTEM CARBURETOR SEPARATION NOTE: The vacuum chamber and float chamber can be serviced without separating the carburetors. Disconnect the fuel tube from the fuel joint Disconnect the air vent tubes and sub-air cleaner tube. NOTE: At carburetor separation, it is not necessary to remove the throttle sensor from the carburetor body. If necessary, remove the screws and throttle sensor bracket assembly from the carburetor body. Remove the starting enrichment (SE) valve arm screws and washers. Remove the SE valve arm and plastic collars. Loosen and remove the carburetor connecting 6 mm not and 5 mm nut. NOTE. Loosen the nuts gradually and alternately. AIR VENT TUBES 5U B—AIR CLEANER TU BE FUEL TU BES THROTTLE SENSOR BRACKET SCREWS FUEL SYSTEM Separate the No. 3/4 carburetors from the No. 1/2 carburetors No. 3/4 No. 1/2 Remove the following: DOWEL PIN *Nol carburetor synchronization spring 73-way air joint pipe/O-rings Dowel pin (5 mm bolt side! *Distance collared dowel pin (6 mm bolt sidel DISTANCE COLLAHED DOWEL PIN Separate the No.1 carburetor from the No.2 No.2 No.1 carburetor. AIR VENTJOINT Remove the following: 7 No.1 carburetor synchronization spring -Thrust spring —Air joint rubber pipe *3vway air vent joint pipe/Orings >3»way fuel joint pipe/O-rings *Dowel pin (5 mm bolt side) *Dowel pin (6 mm bolt side) SPRING THRUST SPRING Separate the No.3 carburetor from the No.4 carburetor. ' AIR VENTJOINT AIR JOINT Remove the following: *Choke cable holder 7 No.4 carburetor synchronization spring —Thrust spring -Air joint rubber pipe iii-way air ventjoint pipe/O—rings —3-way fuel joint pipe/O-rings 'Dowel pin (5 mm bolt side) *Dowel pin [6 mm bolt sidel Remove the screws and throttle cable holder from the No.3 carburetor. 5-10 FUEL SYSTEM CARBURETOR DISASSEMBLY NOTE: Now the location of each carburetor part so they can be replaced in their uriginal locations. AIR FUNNEL Remove the screws and air funnel holder. Remove the air funnel from the holder. Remove (he Orring from the carburetor body. STARTING ENRICHMENT VALVE Remove the SE valve nut. Remove me SE valve and spring. SE VALVE SPRING 5-] l FUEL SYSTEM DIAPHRAGM/VACUUM PISTON VACUU M CHAMBER COVER Remove the screws and vacuum chamber cover. Remove the diaphragm spring and diaphragm/ DIAPHRAGM/VACUUM PISTON vacuum piston from the carburetor body. SPRING Temporarily install a 4 mm screw (example; JET NEEDLE HOLDER vacuum chamber screw) into the jet needle holder. ; Pull the screw and remove the je! needle holder. CAUTION: U Be careful rm! to damage the diaphragm. ' Do not remove the jet needle holder by pushing the iet needle Remove the spring and jet needle from the vacuum plsxon. 5—12 FUEL SYSTEM FLOAT AND JETS Remove the screws and float chambevt Remove the float pin, float andfloat valve. FLOAT VALVE FLOAT PIN 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 contaminat- ed. Check the operation ofthe float valve, Remove the following: #Main jet *Needle jet holder *Slowjet Turn the pilot screw in and record the number of turns it takes before it seats lightly. Remove the pilot screw, spring, washer and O-ring. CAUTION: Dar-rings to the pilot screw seat will occur if the pilot screw is tightened lgainst the seat. Inspect each jet for wear or damage and replace if necessary 5-13 MAIN JET FUEL SYSTEM AIR CUT-OFF VALVE Disconnect the air cut-off valve tube. Remove lhe alr cutvuff valve mounting screw, Remove khe air cm-off valve, air je‘ and O—rings. Clean the fuel sxrainer in the float valve seat using ‘ ' - - ‘F‘LOAT VALVE’SJEAT compressed air from the float valve seat side. ' ' Blow open each air and fuel passages in the carburetor body with compressed air. FUEL SYSTEM CARBURETORASSEMBLY JET NEEDLE HOLDER VACUUM CHAMBER COVER JET NEEDLE SPRING C\ )Q SE VALVE ._ A THROTTLE VALVE! VACUUM PISTON SLOW JET PILOT SCREW AIR CUTVOFF VALVE FLOAT VALVE FLOAT AIR FUNNEL AIR FUNNEL HOLDER FLOAT CHAMBER 5-15 FUEL SYSTEM AIR CUT-OFF VALVE Install the O-ring onto the air jet and air cut-off valve as shown. NOTE' install the air jet with its small and facing the air cut—off valve. Install the air jet and air cut-eff velve unto the carburetor. Install and tighten the mounting screw. Connect the air cutroff valve tube. FLOAT AND JETS Install the following: 7 Slowjet - Needle iet holder —Main jet CAUTION: Handle alliets with care; They can easily be scored or scratched install the pilot screw and return It to its original , _ MAIN JET‘ position as noted during removal. V Perform the pilot screw adjustment procedure if a new pilot screw is installed (page 525). 5-16 FUEL SYSTEM Install the float and float valve in the carburetor body, then install the float pin through the body FLOAT VALVE FLOAT PIN 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: 137 mm (0.54 in) TOOL: Carburetor float level gangs 0740141010000 The float cannot be adjustad. Replace the float assembly if the float level is out of specification. Install a new O-ring in the float chamber. Install the float chamber. FLLOA CHAMaER Install andtightan thathraa float chamber screws. ; i, ‘ : , _ FL’OAT’CHAMBER 5-17 I, ‘ :1 ‘ V Sciaigwsi FUEL SYSTEM DIAPHRAGM/VACUUM PISTON Check the condition of the O~ring on the jet needle holder, replace if necessary. Applvoil to the O~ring. Install the jet needle and spring into the vacuum piston. Press the let 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 carburetor body, aligning the diaphragm tab 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 spring. Install and tighten the vacuum chamber cover screws. CAUTION: Do not pinch the diaphragm under the chamber DOVOI‘. STARTING ENRICHMENT VALVE install the spring and SE valve. SE VALVE SPRING 5-18 Install the SE valve nut and tighten it securely. AIR FUNNEL Install the airfunnel into the holder as shown. Check that the O-ring is in good condition, replace if necessary. Install the Orring into the groove of the carburetor body. Align the cut-out on the air funnel with the groove in Ihe carburetor body, then install the air funnel/ holder. install and tighten the holder screws. 5-19 FUEL SYSTEM FUEL SYSTEM CARBURETOR COMBINATION 5 NM (0.5 kgf-m , 3.6 Ibf-fl) AIR VENTTUBES 10 N-m (1.0 kgf-rn,7 Inf-h) CONNECTION BOLT, 5 mm CONNECTION BOLT, 6 mm SUE-AIR CLEANER TUBE SE VALVE ARM DISTANCE COLLARED DOWEL PIN AIR JOINT DOWEL PIN DOWEL PIN THRUST SPRING SYNCHRONIZATION SPRING FUEL JOINT FUEL TU BES THROTTLE SENSOR 5-20 NOTE: Always replace the 0 ing with new ones. Install the throttle cable holder to the No.3 carburet- or and tighten the screws securely: Install the following: —Dowel pin (5 mm bolt side) —Dowel pin (6 mm bolt side) iii-way fuel joint pipe/new O-rings iii-way air vent joint pipe/new O-rings *Airjoint rubber pipe *Thrust spring — No.4 carburetor synchronization spring *Choke cable holder Assemble the No.3 and the N044 carburetors. Install the following: 'Dowel pin I5 mm bolt side] —Dowel pin IG mm bolt side] *3—wav fuel joint pipe/new O-rings 753‘an air vent joint pipe/new O-rings AAir joint rubber pipe —Thrust spring vNo.‘l carburetor synchronization spring Assemble the No.1 and the No.2 carburetors, Install the following: *Dowel pin (5 mm bolt side) ~Distance collared dowel pin [6 mm bolt side) isrwav air joint pipe/Orrings 7 No.2 carburetor synchronization spring Assemble the No,3/A and the No.1/2 carburetors, 5-21 FUEL SYSTEM TT -E CABLE HOLDER SCREWS \s No,4 AIR VENTJOINT No, 3 a W FUEL JOINT K THRUSTSFRING Bx DOWEL PIN r SPRING ‘ AIR VENTJOINT No. 2 No. 1 DOWEL PINS SPFIING —>‘3 THFIUST SPRING No. 3/4 DOWEL FIN he mm —, "\ SPRING AIR JOINT V, . .WMV m-.,.-, .- DISTANCE COLLAFIED DOWEL PIN FUEL SYSTEM install the 5 mm and 6 mm carburetor connecting _ bolts through the carburetors. 0“3 mm(0*0-1In) 4%9 NOTE 7‘ Before tigntenlng the carburetor connecting nuts, check there is no clearance between each of the carburetor joints. Tighten each connecting nuts gradually and alternately, be sure the bolt thread projections are equal height. Hold the nut and tighten the nut on other side to the specified torque. TORQUE: 5 mm nut: 5 N!“ (0.5 kgf-rn , 3.6 lbf'm 6mm nut: 10 N-mt‘l.0 kgfrm,7 lbf-ft) Smrr‘tNUT-y Install the plastic collars onto the No.2 and No.4 PLASTIC COLLARS carburetor bodies. Install the SE valve arm aligning its ends with the SE valve heads. 5-22 Install the plastic washers and tighten the.I SE valve arm screw securely, If the throttle sensor is removed, install the throttle sensor aligning its boss with the groove on the throttle shaft plate. Install and tighten the throttle sensor bracket mounting screws. Install the air vent tubes, sub \ idle speed with the throttle slop screw. ' WW FUEL SYSTEM REMOVAL Remove the exhaust pipe (page 2-5l4 Disconnect the following: 7 PAIR control valve vacuum tube 7 Secondary air tubes Remove the three bolts and FAIR control valve assembly. Disconnect the air suction tube from the PAIR control valves Remove the nuts and secondary air tubes From the cylinder head. Remove the gaskets. INSTALLATION Install the new gasket onto the secondary air ports‘ Install the secondary air supply tubes to the cylinder head. tighten the four nuts securelyv 5-27 FUEL SYSTEM Colnnsct the air suction tube to the PAIR control , v , ' ' , PM @NTROWEL va ve. ’ . . : Install the FAIR control Valve and tighten the three mounting bolts securely. Connect the following: *Sacondary air tubes 7 PAIR control valve vacuum tube install the removed parts in the reverse urder of removal FU EL VALVE INSPECTION Remove the fuel tank (page 2-4). Connect the fuel tube to the fuel valve and place the suitable gasoline container under the fuel tube. Turn the fuel valve on. If the fuel comes out of the fuel tube, replace the diaphragm. Connect a commercially available vacuum pump to the diaphragm vacuum outlet‘ Fuel should flow out from the fuel tube when vacuum is applied. if fuel flow is restricted, replace the diaphragm. DISASSEMBLY Drain the fuel from the fuel tank. Remove the four screws and diaphragm cover. Remove the spring, diaphragm and spacer. 5-28 FUEL SYSTEM Check the diaphragm for tears or other damage. 'y , L, DIAPHRAGM NOTE‘ Replace the diaphragm cover, spring, diaphragm and spacer as a set. Loosen the lock nut and remove the fuel valve assembly from the fuel tank. , FU,E,L VALVE’ Remove the fuel strainer and OAring from the fuel valve. Clean the fuel strainer with comprassed air. STRAlNERr , FUEL VALVE; I ASSEMBLY ‘LSTBAVINER; Install a new O-ring and fuel strainer onto the fuel valve. 5-29 FUEL SYSTEM Install the fuel Valve into the fuel tank. Tighten the fuel valve luck nut to the specified torque. TORQUE: 34 Nm (3.5 kgf‘m , 25 Ruth) Install the diaphragm assembly, spring and diaphragm cover so that the air vent hole of the spacer and vacuum pipe of the cover facing to the same direction as the fuel pipe of the fuel valve body. Install and tighten the screws. Install the fuel tank (page 2-4) Fill the fuel tank and make sure there are no fuel leaks. 5-30 COOLING SYSTEM SYSTEM FLOW PATTERN 6. COOLING SYSTEM SYSTEM FLOW PATTERN 6-0 SERVICE INFORMATION 6-1 TROUBLESHOOTING 6-2 SYSTEM TESTING 6-3 COOLANT REPLACEMENT 6-4 THERMOSTAT RADIATOR RADIATOR RESERVE TANK WATER PUMP 6-6 6-9 6- 1 4 6-1 4 SERVICE INFORMATION GENERAL AWARNINC I Wait until the engine is cool before slowly removing the radiator cap. Removing the can while the engine is hot and the coolant is under pressure may cause serious scalding. 0 Radiator coolant is toxic. Keep it away from eyes, mouth, skin and clothes. 7 If 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. U KEEP OUT OF REACH OF CHILDREN. I Use only distilled water and ethylene glycol in the cooling system. A 50—50 mixture is recommended for maximum corrosion protection. Do not use an alcoholrbased antifreeze. 0 Add coolant to the cooling system at the reserve tank. Do not remove the radiator cap except to refill or drain the system I All cooling system serwces can be done with the engine in the frame. 0 Avoid spilling coolant on painted surfaces. I After servicing the system, check for leaks with a cooling system tester. 0 Refer to section 19 for fan motor switch and coolant temperature sensor inspection. SPECIFICATIONS ITEM SPECIFICATIONS Coolant capacity Radiator and engine 2.079 (2.1 us qt, 1.3 Imp qt) Reserve tang_> 0.20 ll(0.21US qt 0.1a Imp qt) iRaidiator be p relief pressure 108—137 We (1.1—1.4kgf/cm’, 16~20 psi) Thermostat Begin to open 80—84% (176*183 “Fl Fully open {"Valve lift 95 ”C (203 “Fl 8 mm (0.3 inl minimum TORQUE VALUES Water pump cover bolt Thermo sensor unit Fan motor switch Fan motor nut Fan motor mounting nut 13 N-rn(1.3 kgf‘mfllbf-ft) CT bolt 10 N-m (1.0 kgf-m , 7 Ibftft) Apply sealantto the threads 18 N-m (1‘8 kgf-m,13|bf-ftl Apply sealantto the threads 5 Nvm (0.5 kgf-m , 3.6 lbI-th 3 N-m (0.28 kgf-m , 2.0 lbf-fi) 6-1 Apply a locking agent to the threads COOLING SYSTEM TROUBLESHOOTING Engine temperature too high 0 Faulty radiator cap - Insufficient coolant - Passages blocked in radiator, hoses or water jacket a Air in system - Faulty water pump - Thermostat stuck closed I Faulty temperature gauge or coolant temperature sensor I Faulty cooling fan motor a Faulty fan motor switch Engine temperature too low ~ Faulty temperature gauge or coolant temperature sensor - Thermostat stuck open I Faulty cooling fan motor switch Coolant leak u Faulty water pump mechanical seal ' Deteriorated O-rings - Damaged or deteriorated gasket - Loose hose connection or clamp c Damaged or deteriorated hose 0 Faulty radiator cap COOLING SYSTEM SYSTEM TESTING % The engine must be cuol bafwe removing the radiltcr cap, or sevare scalding may result. COOLANT (HYDROMETER TEST) Remove the fuel Iank (page 2—4). Remove the screw and rad1atur cap. TesI the coolam gravity using a hydromexer. STANDARD COOLANT CONCENTRATION: 50% Look for contamination and replace the coolant 1f necessary. COOLANT SPECIFIC GRAVITY \\Coolant temperature 3C (“F1 _+_ 015101520253035404550 Eolam r8110 % (32) 1 (41) 150) (59) 1681 (771 186) (95) 11041 1113) (122) 5 1.009 1.009 1.008 1.008 1.007 1.006 1.005 1.003 1.001 0.999 0.997 10 101311.0171.01710161101510141.0131.011 100910071005 15 1.028 1.027 1.026 1.025 1.024 1.021 1.020 1.016 1.016 1.014 1.012 20 1,035 1.035 1.0341033 1.031fl.029 1.027 1.0251023 1.021 1.019 25 1.045 1.044 1.043 104211.040 1.036 1.036 1.034 1.031 1.028 1.025 30 1.053 1.052 1.051 104711.045 104511.043 104111033 1035 1.032 35 1.053 1.062 1.060 1056,1056 10541052 1049 1.046 1.0431040 .40 1.072 12070 1.068 106051.064 106211.059 1.055 1.053 1.050 1.047 45 1.080 1.078 1.076 107411.072 1.069 1.065 1.063 1.060 1.057 1.054 50 ‘ , 1086 1064110132 1.080 1.077 107411.071 1.068 1.065 1.062 1.059 55 1.095 1.093 1.091 1.088 1.095 1.032 1.079 1.076 1.073 1.070 1.067 60 11.100 109511.095 1.052 1.089 1.086 1.083 1.050 1.077 1.074 1.071 6-3 COOLING SYSTEM Before installing the cap in me lesler. We! (he sealing surfaces. RADIATOR CAP/SYSTEM PRESSURE INSPECTION Pressure test the radiator cap using the radiator cap tester. Replace the radiator cap if it does not hold pressure, or if relief pressure is too high or too low. It must hold specified pressure for at least 6 seconds. RADIATOR CAP RELIEF PRESSURE: 108*137 kPa (1.1—1.4 kgflcm2 ,16>20 psi) Pressure the radiator, engine and hoses, and check for leaks. CAUTION: Excessive pressure can damage the cooling system components. Do not exceed 137 “’5 (1.4 kgI/cm‘, 20 psi}. Repair or replace components if the system will not hold specified pressure for at least 6 seconds. COOLANT REPLACEMENT PREPARATION _WARNING 0 Radiator coolant is toxic. Keep it away from eyes, mouth, skin and clothes. -If any coolant gets in your eyes, rinse them with water and consult a doctor immediately. *If any coolant is swallowed, induce vomiting, ghrgle and consult a physician immediately. *If any coolant gets on your skin or clothes, rinse thoroughly with plenty of water. I KEEP OUT OF REACH OF CHILDREN. NOTE. IThe 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. IMix only distilled, low mineral water with the antifreeze. RECOMMENDED MIXTURE: 50* 50 (Distilled water and antifreeze) 6-4 ANTIFREEZE SOLUTION IETHVLENE GLYCOL BASE SOLUTION) LOW MINERAL 0R DISTILLED WATER COOLANT COOLING SYSTEM REPLACEMENT/AIR BLEEDING WEE—— 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 levell, place the motorcycle in a vertical position on a flat, level surface. Remove the screw and radiator cap. Remove the dram bolt on the water pump cover and drain the system coolant. Remove the rear fender (page 2-4), Remove the fuse box. Disconnect the radiator reserve tank siphon tube and drain the reserve tank coolant. Empty the coolant and rinse the inside of the reserve tank with water. Connect the siphon tube to the radiator reserve tank. Install the water pump cover drain bolt with a new sealing washer, tighten the bolt securely. l , 6'5 WWW COOLING SYSTEM Fill the system with the recommended coolant through the filler opening up to tiller neck. Remove the radiator reserve tank cap and fill the reserve tank to the upper level line. Bleed air from 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 3—4 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. TH ERMOSTAT HOUSlNG PROTECTOR BOLTS REMOVAL Drain the coolant (page 6-5). Remove the bolts and thermostat housing protec- tor. 6-6 COOLING SYSTEM Remove the three bolts, protector bracket and thermostat housing cover. Remove the O-ring from the thermostat housing COVel. Remove the thermostat from the housing. INSPECTION um— -Wur insulated gloves and adequate eye pratutian. IKeep flammable materials away from the electric heating element. Visually inspect the thermostat for damage. 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 false reading, Replace the thermostat if the valve stays open at room temperature, or if it responds at temperatures other than those specified. THERMOSTAT BEGIN TO OPEN: 80*84°C(176*183"F) 6-7 VALVE LIFT: H mm (03 in) minimum at 85 °C (230 °F) BRACKET HOUSING COVER BO LTS THERMOSTAT O-RING HOUSING COVER THERMOSTAT THERMOMETER COOLING SYSTEM INSTALLATION THERMOSTAT THERMOSTAT HOUSING COVER PROTECTOR Install the thermostat into the housing with its air AIR BLEED HOLE bleed hole facing up, NOTE: Align the thermostat body with the groove of the housing. THERMOSTAT Apply grease to the new O-ring and install it into the thermostat housing cover groove, Install the thermostat housing cover onto the housing. HOUSING COVER COOLING SYSTEM Install the thermostat housing protector bracket BRACKET BOLTS and bolts, tighten the housing cover bolts, HOUSING COVER install the thermostat housing protector and tighten HOUSING PROTECTOR BOLTS the two bolts‘ Fill the system with recommended coolant and bleedtheairipages-E). RADIATOR CAUTION: Be careful not to damage the radiator fins while servicing the radiator. REMOVAL Drain the coolant (page 6-4). Remove the fuel tank (page 274), Disconnect the radiator sub-harness 3? (Blue) connector. Disconnect the siphon tube and upper radiator SIPHON TUBE hose from the right side of the radiator. UPPER RADIATOR HOSE COOLING SYSTEM Disconnect the lower radiator hose from the left side of the radiator. Remove the radiator mounting bolts. Remove the radiator from the right side. tacfi ‘ -‘.\___.. 1 COOLING FAN DISASSEMBLY Release the hooks and remove the radiator grill, RADIATOR GRILL Disconnect the fan motor switch connector and FAN MO‘l’OR/SHROUD‘ , releasethesubrharnesslromtheclamp‘ Remove the three bolts, ground eyelet and fan motor/shroud assembly. 6'10 ' GROUND EVELET COOLING SYSTEM Remove the nut and cooling fan. NUT COOL} NG FfAN Remove the flange nuts and fan motor. For fan mmor switch information, refer to page 13-11, COOLING FAN ASSEMBLY JI-l RADIATOR GRILL FAN MOTOR SWITCH 18 N~m (1,3 kgf‘m ,13Ibf-ft) M-go film 3 N-m (0.25 kgf‘m , 2.0 Ibf‘fl) COOLING FAN FAN MOTOR 5 N-m (0.5 kgf-m , 3.6 lbf-ft) FAN SHROUD 6-11 COOLING SYSTEM Install the fan motor onto the shroud and tighten the three flange nuts. Install the cooling fan onto the fan motor shaft by aligning the flat surfaces. COOLING FAN Apply a locking agent to the cooling fan nut threads. Install and tighten the nut to the specified torque. % NUT TORQUE: 3 N-rn (0.28 kgf‘m , 2.0 IbfAfl) COOLlNG E'AN install the fan motor/shroud assembly onto the FAN MOTOR/SHROUD radiator. _ ~\. . Route the fan motor switch cord and ground eyelet * ,‘ \\ properly. \ Install and tighten the three mounting bolts. Route the sub-harness, and connect the fan motor switch cord to the switch as shown. Clamp the sub-harness to the wire clamp. 6-12 . GROUND EVELET COOLING SYSTEM Install the radiator grill while aligning the tabs to the hooks on the radiator. RADIATOR GRILL INSTALLATION RADIATOR CAUTION: Be careful not to damage the radiator core. Install the radiator from the right side and align the boss on the engine hanger with the grommet of the radiator. Install and tighten the two mounting bolts. BOLT BOLT Connect the lower radiator hose and tighten the hose clamp screw securely. LOWER RADIATOR HOSE Connect the upper radiator hose and siphon tuba, SIPHON TUBE tighten the hose clamp screws securely. 6-13 UPPER RADIATOR HOSE COOLING SYSTEM Connect the radiator sub-harness 3P (Blue) connectur. Fill the system with recommended coolant lpage 6-5), install the fuel tank (page 2-4), RADIATOR RESERVE TANK REMOVAL/ INSTALLATION Remove the rear fender (page 24). Remove the fuse box. Disconnect the siphon tubes Remove the bolt and radiator reserve tank. Installation is in the reverse order of removal. Fill the system with recommended coolant and bleed the air (page 65). WATER PUMP MECHANICAL SEAL INSPECTION Inspect the inspection hole for signs of coolant leakage. If there is leakage, the mechanical seal is detective and replace the water pump as an assembly. 6-14 3PlELUEl CONNECTOR COOLING SYSTEM REMOVAL Drain the coolant (page 6-5]. Disconnect the lower radiator hose and bypass tube from the water pump cover. Remove the Iwa flange bolts, two SH bolts and water pump cover‘ Remove the O-ring Irom ma water pump body. Remove the water hose from the water pump body. Remove The water pump body from the crankcase. INSTALLATION .rfiu 1 WATER PUMP BODY WATER PUMP COVER 13 N-mI‘l‘3 kgf-m,9|bf-fi) 6_15 COOLING SYSTEM Apply engine oil to a new O-ring and install it onto the stepped portion at the water pump body. Install the water pump into the crankcase while aligning the water pump shaft groove with the oil pump shaft end. Connect the water hose to the water pump body I and tighten the clamp screw. Align the mounting bolt holes in the water pump and crankcase and make sure the water pump is securely installedt Apply grease to a new O»ring and install it into the groove in the water pump body. Instali the water pump cover. Tighten the two SH bolts first, then two flange bolts to the specified torque. TORQUE: 13 N-m (1.3 kgfrm , a lbfrfi) Connect the lower radiator hose and bypass tube, then tighten the clamp screws. Fill the system with recommended coolant (pageG-Sl. 6-16 ENGINE REMOVAL/INSTALLATION 20 Nrm [2.0 kgf-m ,14lbf-ft) 54 Nm (5.5 kgf-m , 4D Ibf‘fll 22 N-m (2‘2 kgf-rn,16lbf~fl) 7'0 7. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION 7-1 ENGINE INSTALLATION 7—6 ENGINE REMOVAL 7.2 SERVICE INFORMATION GENERAL - During engine removal and installation, supportthe motorcycle using a hoist or an equivalent. - Support the engine using a lack or other adjustable support to ease of engine hangar bolts removal. CAUTION: Do not use the oil filter as a jacking point. t The following components can be serviced with the engine installed in the frame. *Alternator/starter clutch (Section 10) *Clutch (Section 9] *Cylinder head/valves (Section 8) *Gearshift linkage (Section 8i -Oi| cooler (Section 4i iOil pump (Section 4) -Water pump (Section 6) - The following components require engine removal for service. icrankshaft/transmission (Section 12l *Piston/cvlinder (Section 11) SERVICE DATA ITEM SPECIFICATIONS Engine dryweight W 61.9kg(1§6.5|bsl Wm, Coo(ant capacity Radiator and engine 2.0 l (2.1 US qt , 1.8 Imp qt) Engine Oil capacity Atdisassembly 4.2 a (4.4 US at , 3.7 Imp qt) TORQU E VALU ES Drive sprocket special bolt 54 N-m (5.5 kgt-m , 40 Ibfvftl Front engine hangar bolt/nut 54 N-m [5.5 kgfrm , 40 lbfvft) Engine hanger bracket bolt 22 N-m (2.2 kgf-m,16lbf-fti Rear engine hanger bolt/nut (upperl 54 N-m (5.5 kgf-rn , 40 lbfvfti Rear engine hanger bolt/nut (lower) 54 N-m (5.5 kgi~rn , 40 Ibf-h) Gearshift pedal link bolt (gearshift spindle side) 20 N-m (2.0 kgI-m , 14 lbfvft) 7 ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Fer: Support the motorcycle securely using a hoist or equivalent, EEIE®MEETR \\ Remove the following: VSide cover (page 2-2] *Fuel (ank (page 274) 7 Carburetor (page 543) — Exhaust pipe (page 2-5) —FA|R control valve (page 5-27) Remove (he screw and speedometer cable. Remove the two heirs and drive sprocker cover. Remove the drive chain guide plate and dowel pins. Loosen the drive chain (page 348), Remove the drive sprocket special bolt, washerand drive sprocket. 7-2 Disconnec‘ the lower radiamr hose from the water pump cover, Disconnect khe upper radiator hose from the thermostat housing. Remove the bolts and clutch cable guide. Remove the spark plug caps, Remove the wire band. ENGINE REMOVAL/INSTALLATION UPPER RADIATOR HOSE ENGINE REMOVAL/INSTALLATION Remove the ierminal nut and stanev moior cable TERMI from the starter motor. Remove rhe starter motor mounting bolt and ground terminal. Disconnect the following oonneclors: AErIgine sub—harness 3P lBrownl connector *Igniiion pulse generator 2P (Blue) connector eAltarnator 3P (White) connector Remove the bolt and gearshift pedal link. Suppon the engine using a jack or other adjustable 7 support to ease of engine hanger bole removal. Remove the front right engine hanger bolt/nut and distance collar. Remove the bolts and engine hanger bracket. ENGINE REMOVAL/INSTALLATION Remove the front left engine hanger bolflnul and dislance cellar. Remove the swingarm pivm nut Remove the left pivot bracket mounting bolts. Slightly pull the pivot bracket outward and tilt it so that the lower engine hanger boll can be removed. Remove the rear lower engine hanger boll/nut and distance collar. ENGINE REMOVAL/INSTALLATION Remove the rear upper engine hanger bolt/nut and distance collart Carefully lower the adjustable support, then re- move the engine from the frame. ENGINE INSTALLATION NOTE' - Note the direction of the hanger bolts. I Use a floor jack or other adjustable support to carefully maneuver the engine into place. Install the engine into the frame. Install the rear upper engine hanger bolt/nut and distance collar. Install the rear lower angine hanger bolt/nut and distance collar. 7-6 ENGINE REMOVAL/INSTALLATION Install the left pivot bracket, then tighten the .. « VPlV’aTmEKE bracketbolts. ,‘ , z - ‘ Install and tighten the swingarm pivot bolt to the specified torque TORQUE: 88 Nm (9‘0 kgf-m , 65 lbf-ft) Install the front left engine hanger bolt/nut and distance collar. Install the front right engine hanger bracket and tighten the bolts to the specified torque. TORQUE: 22 N-m (2‘2 kgfrm,16|bf-ftl install the from right engine hanger boltjnut and distance collar. ENGINE REMOVAL/INSTALLATION Tighten the front engine hanger nuts to the specified torque. TORQUE: 54 N-m (5.5 kgf-m , 40 lbf-ftl Tighten rear lower engine hanger nut to the specifiedtorque. TORQUE: 54 N‘m (5.5 kgf-m , 40 lbf~ft| Tighten rear upper engine hanger nut to the specified torque. TORQUE: 54 N-m (5.5 kgf-m , 40 Ibf-ft) Install the gearshift pedal link aligning its slit with m the punch mark an the gearshift spindle. Install and tighten the pinch bolt to the specified torque. TORQUE: 20 N-m (2.0 kgf-m,14lbf-ft) 7-8 ENGINE REMOVAL/INSTALLATION Connect the following connectors: —Engine sub-harness 3P (Brown) connector - lgnltion pulse generator 2P (Blue) connector *AIternatol 3P (White! connector Install the starter ground cable and tighten the bolt, Connect the starter motor cable to the starter motor terminal, tighten the nut securelyt TER lnstall the wire bandt Install the spark plug caps. SPARK PLUG CAPS ENGINE REMOVAL/INSTALLATION Ccnnect the clutch cable to the clutch lifter arm. Install the clutch cable guide onto the right crankcase cover and tighten the bolts securely. Cunnect the lower radiator hose to the water pump cover and tighten the clamp screw securely. Connect the upper radiator hose to the thermostat housing and tighten the clamp screw securely. Install the drive sprocket with its "153T” mark facing outward. Install the washer and tighten the special bolt to the specified torque. TORQUE: 54 N-m (5.5 kgf—m , 40 lbf-ft) Install dowel pins and drive chain guide plate. 7-10 ENGINE REMOVAL/INSTALLATION install the drive sprocket cover. NOTE Align the hexagonal portion of the speedometer gearbox with the drive sprocket bolt head. Tighten the drive sprocket cover bolts. Install the speedometer cable and tighten the screw securely. Install the following: *PAIR control valve (page 5~27) ~Exhaust pipe (page 2-5) —Carburetor (page 5-24) —— Fuel tank (pa. 541) — Side cover (page 2-2) Pour recommended engine oil up to the proper level (page 3-12), Fill the cooling system with recommended coolant and bleed the air (page 65), 7-11 CYLINDER HEAD/VALVES 1O N~rn (1.0 kgfrm , 7 Inf-h) 12 N-m (1.2 kgf‘m , 9 {bf-ft) 20 N-rn (2,0 kgf-rn,14|bf-flb 8. CYLINDER HEAD/VALVES SERVICE INFORMATION 8-1 VALVE SEAT INSPECTION/ REFACING 8-15 TROUBLESHOOTING 8-3 CYLINDER HEAD ASSEMBLY 8—17 CYLINDER COMPRESSION TEST 8-4 CYLINDER HEAD INSTALLATION 8-19 CYLINDER HEAD COVER REMOVAL 8-4 CAMSHAFT INSTALLATION 8-20 CAMSHAFI' REMOVAL 8-5 CYLINDER HEAD COVER CYLINDER HEAD REMOVAL 8-8 INSTALLATION 8—23 CYLINDER HEAD DISASSEMBLY 8-10 CAM CHAIN TENSIONER LIFTER 8-25 CYLINDER HEAD INSPECTION 8-11 VALVE GUIDE REPLACEMENT 8-14 SERVICE INFORMATION GENERAL I This section covers service of the cylinder head, valves and camshaft. ' The camshah services can be done with the engine installed in the frame. ' The Cylinder head service can be done with the engine installed in the frame. ' When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations. ' Clean all disassembled pans with cleaning solvent and dry them by blowing them off with compressed air before inspec- tion. - Camshaft lubricating owl is fed through oil passages in the cylinder head. Clean the oil passages before assembling cylin- der head. - Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head. 8-1 CYLINDER HEAD/VALVES SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cylinder compression 1,275-11314 kPa (130‘1311 kgf/cmz, 185—191 psi) at 300 min" (rpm) Cylinder head warpage 0.10 (0.004) Valve, Valve clearance IN 0.16 i: 0.03 (0.006 t 0.001) 7 valve guide EX 0.22 i 0.03 (0.009 i 0.001) 7 Valve stem OD, IN 3975—3390 (01565701571) 3.965 (0.1561) 7 , EX 3365—3380 (111561701567) 3.955 (0.1557) Valve gulda I.D. IN z100074.012 (01575401580) 4.04(0.159) l EX z1.000—-£‘I.012 (0.1575‘04580) 4.04(0.159) StemrtoAguida clearance IN [1010—0037 (00004—00015) 0075 (0.0030) EX (102070.047(00008700019) 0.085 (0.0033) Valve guide projection above I IN 13.10—13.30 (11516—0524) 7 7 cylinder head > EX 1 LSD—11.50 (0445-41453) 7 Valve seatwidth INlEX 0.9041100103570043) , #151006) Valve spring free length IN/EX 35.36 (1.392) .35 (1.333) Valve lifter ) Valve lifter 0D. 7, ) IN/EX 25378—25393 (1.0223‘10233) 25.97 (1.022) Velvelifter bore |.D. ‘ IN/EX 2Gt010*26.026(10240710246) 26.04(1.025) Camshaft ) Cam lobe height IN 36.140—36.380 (1t4228—1.4323) 36.11 (1.422) ‘ EX _ , 3&00735540 (13898—13992) 3527 (1.389) ‘ Journal CLD. 23359723930 (0.9433‘03441) ‘ 24355103825) ‘ fignout ‘ 0.05 (0.002) ) Oil clearance l 0.020~0.062 (00003700024) 0.10 (0,004) TORQUE VALUES Cylinder head sealing bolt 32 N-m (3.3 kgf-m , 24 (bf-(t) Apply a locking agent to the threads Cylinder head socket bolt 47 N-m (4.8 kgf-m , 35 Ibr-ft) Apply oil to the threads No‘1 intake vacuum port plug 3 N-m (03 kgf-m , 2.2 Ibf‘l‘t) Cylinder head cover bolt 10 N-m (1.0 kgf-m , 7 Ibfrft) Camshaft holder flange bolt 12 N-m (1.2 kgf-m , 9 Ibfrft) Apply oil to the threads Breather plats flange bolt 12 N‘m (1.2 kgf—m , 9 lbfrft) Apply a lacking agent to the threads Cam sprocket bolt 20 N-rrl (2.0 kgf—m , 14 Ibfvft) Apply a locking agent to the threads Cylinder head stud bolt See page 1-14 Cam chain tensioner cap nut 12 N-m (1.2 kgf-m , 9 Ibf—ft) Cam chain tensioner lifter sealing bolt 10 N-m (1.0 kgf‘m , 7 lbf—ft) Timing hole cap 13 N-rn (1.8 kgfvm,13|bfvft) Apply grease to the threads 8-2 TOOLS Compression gauge attachment Valve spring compressor Valve spring compressor attachment Tappet hole protector Valve guide driver Valve guide reamar, 4.005 mm Valve seat cutters Seat cutter, 27.5 mm [45" IN) Seat cutter, 24.5 mm (45” EX) Fiat cutter, 27 mm (32“ IN) Fiat cutter, 24 mm (32" EX) Interior cutter, 26 mm (60“ IN) Interior cutter, 22 mm 150“ EX) Cutter holder, 40 mm TROUBLESHOOTING CYLINDER HEAD/VALVES 07RMJ-MV50100 07757-0010000 07959-KM30101 07HMGVMR70002 07743-0020000 07MMH-MV30100 Equivalent commerciallyavailabie ~these are commercially available 07780-0010200 0778070010100 07780-0013300 0778043012500 0778047014500 07780-0014202 07781-0010500 - Engine top-end problems usually affect engine performance. These problem can be diagnosed by a compression test or by tracing engine noises to the top-end with a sounding rod or stethoscope. I If the performance is poor at low speeds, check for white smoke in the crankcase breather tuber if the tube is smoky, check for a seized piston ring (Section 11). Compression too low, hard starting or poor performance at low speed 0 Valves: - Incorrect valve adjustment — Burned or bent valve ~ Incorrect valve timing Broken valve spring - Uneven valve seating I Cylinder head: 7 Leaking or damaged head gasket —Warped or cracked cylinder head I Worn cylinder, piston or piston rings (section 11) Compression too high, overheating or knocking I Excessive carbon buildrup on pistnn crown or combustion chamber Excessive smoke . Cylinder head: -Worn valve stem or valve guide -Damaged stern seal - Worn cylinder, piston or piston rings (section 11) Excessive noise I Cylinder head: — Incorrect valve adjustment ~Sticking valve or broken valve spring *Damaged orworn camshaft ~Wom or damaged cam chain —Worn cam sprocket teeth I Worn cylinder, piston or piston rings (section 11) Rough idle ' Low cylinder compression on CYLINDER HEAD/VALVES CYLINDER COMPRESSION TEST M If 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 exhaust contains poisonous carbon monoxide gas that ma y cause loss of consciousness and may lead to death. ’o‘impelass'lom G/xu Warm up the engine to normal operating temperature, Stop the engine and remove the all spark plug caps and spark plugs (page S-EI, Install a compression gauge into the spark plug hole. TOOL: Compression gauge 07RMJ7MY50100 attachment (Equivalent commercially available) 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 477 seconds, NOTE To avoid discharging the battery, do not operate the starter motor for more than seven seconds, Compression pressure: 1,275— 1,314 kPa (130*1311 kgf/cm2 , 185—191 psilat 300 min’IIrme 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 BOTS’MOUNT’NG RUEBERS Remove the following: *Ignition coiIIpage17-5) *Spark plug caps (page 3-5] Disconnect the crankcase breather tuba, Remove the bolts, mounting rubbers and cylinder head cover. 8-4 CYLINDER HEAD COVER CYLINDER HEAD/VALVES CAMSHAFT REMOVAL STOPPER TOOL WASHER TENSiONEH LIFTER Remove the cylinder head cover (page 3-4). Remove the cam chain tensioner lifter sealing bolt and sealing washer. Turn the tensioner lifter shaft fully in (clockwise) and secure it using the stopper tool. This tool can easily be made from a thin (1 mm thickness) piece of Steel‘ 15mm 19mm 3mm ‘ i 15mm‘ L 415mm METAL THICKNESS: 1,0 mm 4'5 m'“ Remove the timing hole cap and O-ring. Turn the crankshaft clockwise, align the "T" mark on the ignition pulse generator rotor with the index mark on the ignition pulse generator rotor cover. The timing marks ("IN” and “EX"l on the cam sprockets must be flush with the cylinder head surface and facing outward as shown. TIMING MARKS if the timing marks on the cam sprocket facing inwardv turn the crankshaft clockwise one full turn (360°) and realign the timing marks with the cylinder head surface so they are facing outward. 8-5 CYLINDER HEAD/VALVES If you plan to replace the camshaft and/or cam sprocket. loosen the cam sprocket bolts as follow: a ‘ , . ‘ x I": "will It is not necessary to remove the cam sprocket from the camshaft except when replacing the camshaft and/or cam sprocket. *Remove the cam sprocket bolt from intake and exhaust camshafts. NOTE. Be careful not to drop the cam sprocket bolts into the crankcase. *Turn the crankshaft one full turn (360”)! remove the other cam sprocket bolt from the Camshafts. -Remove the cam sprocket from the camshaft. Remove the bolts and cam chain guide B. Loosen and removethe camshaft holder bolts, then remove the camshaft holders and Camshafts. CAUTION: Fmrn outside to inside, laosen the bolts in a crisscross pattern in several steps or the camshaft holder might break. NOTE: 0 Suspend the cam chain with a piece of wire to prevent the chain from faliing into the crankcase. 0 It is not necessary to remove the dowel pins from the camshaft holders Remove the valve litters and shims. NOTE: I Be careful not to damagethe valve litter bore. U Shim may stick to the Inside of the valve lifter. Do not allow the shims to fail into the crankcase. - Mark all valve litters and shims to ensure correct reassembly in their original locations. I The valve lifter can be easily removed with a valve lapping too or magnet. I The shims can be easily removed with a tweezers or magnet. 8-6 CYLINDER HEAD/VALVES INSPECTION CAMSHAFT HOLDER Inspect the bearing surface of the camshaft holder for scoring, scratches, or evidence of insufficient lubrication, Inspect the oil orifices of the holders for clogging. BEARING SURFICES CAMSHAFI' HUNOUT Support both ends of the camshaft with valocks and check the camshaft runout with a dial gauge SERVICE LIMIT: 0.05 mm (0,002 in! CAM LOEE HEIGHT Using a micrometer, measure each cam lobe height SERVICE LIMITS: IN: 36.11rnm(1.422irl) EX: 35.27 mm (1,389 in) CAMSHAFr p". CLEARANCE PLASTIGAUGE Wipe any all from the Journals of the camshaft, cyiinder head and camshaft hoiders. Lay a strip of plastigauge lengthwise on top of each camshafljournal. CYLINDER HEAD/VALVES Install the camshaft holders and tighten the belts in a crisscross pattern in 2*3 steps. NOTE: Do nm rotate the camshaft when using plastigauge. TORQUE: 12 Nrm l’l.2 kgf-rn , 9 let) 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 inl 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 sen/ice limit. CAM CHAIN GUIDE 8 Inspect the cam chain slipper surface of the cam chain guide B for wear or damage. CYLINDER H EAD REMOVAL ‘ CAP NUT/SEALING WASHER Remove the following: —Exhaust system (page 2-5) *Carburetor (page 578) ifladiatur (page 59) —PAIR control valve (page 5-7) —Thermostat (page 96) *Camshaft (page 8—6) Remove the cam chain tensioner slider mounting cap nut and sealing washer. CYLINDER HEAD/VALVES Hemove Ihe cam chain tensions! sliden Remove the following: 7 Bypass tube ~Therma sensor connector (page 19-10) — PAIR control valve tubes (page 527) Remove the cvlinder head 6 mm bolts. Remove me ten 9 mm special boks. NOTE: Loosen the 9 mm spacial bolts in a crisscross pattern in 2-3 s‘eps‘ Remove the cvlinder head. CYLINDER HEAD/VALVES Remove the dowel pins and cylinder head gasket, CYLINDER HEAD DISASSEMBLY NOTE: Mark all parts during disassembly so they can be placed back in their original locations. Remove the carburetor insulators from the cylinder head. Remove the spark plugs from the cylinder head Flemova the valve lifters and shims. Install the tappet hole protector into the valve lifter bore, TOOL: Tappat hole protector 07HMG-MR70002 An aqulvalent tool can easily be made from a plastic 35 mm film container as shown. 8-10 5 k—s mmfi fl ‘ mm TOP EW _ / 1 L_ 31mm 15mm 25 mm 0.D. (When compressed) CYLINDER HEAD/VALVES Remove the valve spring cutters using the special tools as shown. TOOLS: Valva spvlng compressor 0775770010000 Valve spring comprassor attachment 07959-KM30'IO‘I CAUTION: To pravan! lass a! tension, do not compress the valve springs mars than necessary to ramava the cutters Remove the following: - Spring retainer *— Valve spring ~Vaive iStem seal *Spring seat NOTE: Mark all pans during disassembly so they can be placed back in their original locations. CYLINDER HEAD INSPECTION CYLINDER HEAD Remove carbon depnsits from the combustion chambers. Check the spark plug hole and valve areas for cracks. CAUTION: Avnid damaging the gasket surface. Check the cylinder head forwarpage with a straight edge and feeler gauge. SERVICE LIMIT: 0.10 mm (0.004 in) EXHAUST VALVE/Q Kg Q» ALVE SPRING COMPRESSOR VALVE SPRING RETAINER SPRING SEAT STEM SEAL V COMBUSTION CHAMBER fi/w \J OQ‘QO V 80 O (I II 09 CYLINDER HEAD/VALVES CAM CHAIN TENSIONER/CAM CHAIN GUIDE Inspect the cam chain lensioner and guide for excessive wear or damage. replace if necessary. VALVE SPRING Measure the free length of the valve spring. SERVICE LIMIT: 33.86 mm (1.333 in) Replace the spring if it is shorter than the service limit. VALVE LIFTER Inspect each valve lifter for scratches or abnormal wear. Measure the each valve lifter O.D. SERVICE LIMIT: 25.97 mm (1.022 in) VALVE LIFTER BORE Inspect each valve lifter bore for scratches or abnormal wear. Measure the each valve lifter bore |.D. SERVICE LIMIT: 26.04 mm (1.025 in) 8-12 CYLINDER HEAD/VALVES VALVE/VALVE GUIDE Inspect each valve for bending, burning or abnormal stem wear. Check valve movement in the guide, measure and record each valve stem OD. SERVICE LIMITS: IN: 3.965 mm (0.1561 in) EX: 3.955 mm (0.1557 in) Ream the guides to remove any carbon deposits before checking clearances. Insert the reamer from the combustion chamber side of the head and always rotate the reamer clockwise. TOOL: anva guide reamer, 4.008 mm 07MMH-MV90100 Measure and record each valve guide LD. SERVICE LIMIT: IN/EX: 4.04 mm (0.159 in) Subtract each valve stem 0.0. from the corresponding guide [.D. to obtain the stem-to- guida clearance SERVICE LIMITS: IN: 0.075 mm (0.0030in) EX: 0.085 mm (0.0033 in) If the stem-to-guide clearance is out of service limit, 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 845). 8 13 CYLINDER HEAD/VALVES VALVE GUIDE REPLACEMENT Chill the replacement valve guides in the freezer section of a refrigerator for about an hour. Heat the cylinder head to100—150 °C (212—300 “Fl with a hot plate or oven. MW— Ta avoid burns, 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 cylinder head. TOOL: Adiustable valve guide driver 07743-0020000 Adjust the tool setting depth with a pair of Vernier calipers as shown. DEPTH: IN: 13.10—13.30 mm (0516—0524 in) EX: 1130—1150 mm (0445—0453 in) TOOL: LVE GUIDE DRIVER Adiustabla valve guide driver 0774341020000 Drive in the guide from the top of the head. Let the cylinder head cool to room temperature. Ream the new valve guide after installation. Insert the reamer from the combustion chamber side of the head and also always rotate the reamer VALVE GUIDE REAMER clockwise. TOOL: Valve guide reamer, 4.008 mm 07MMH-MV90100 NOTE: Use cutting oil on the reamer during this operation Clean the cylinder head thoroughly to remave any metal particles. Reface the valve seat (see next page). 8—14 CYLINDER HEAD/VALVES VALVE SEAT INSPECTION/REFACING HANDVLAPPING T 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 handllapping tool. Remove and inspect the valves. CAUTION: The valves cannot be ground. If a valve lace is burned or badly worn or if It contacts the seat unevenly, replace the valve. inspect the width of each valve seat. STANDARD: O.SD*1.10 mm(0.03570.043in) SERVICE LIMIT: 1.5 mm [0‘06 in) If the seat is too wide, too narrow or has low spots, the seat must be ground. VALVE SEAT REFACING Follow the Valve seat cutters/grinders or equivalent valve seat relac/ng refecing equipment are recommended to correct /\ 45° manufacturer’s worn valve seats. operaling instructions. R‘s/ace the 595! Use a 45-degree cutter to remove any roughness or ROUGHNESS wilha 45-dsgrea irregularities from the seat. cutter whenever a valve guide is replaced. 8-15 CYLINDER HEAD/VALVES The location of the valve seat in relatlan to the valve lace Is very important Im good sealing. Use a 32-degree cutter to remove the top 1/4 of the existing valve seat material. Use a 60-degree cutter to remove the bottom 1/4 of the old seat. Remove the cutter and inspect the area you have refaced. Install a 45-degvee finish cutter and out the seat to the proper width. Make sure that all pitting and irregularities are removed. Refinish if necessary. Apply a thin coating of Prussian Blue to the valve seat. Press the valve through the valve guide and onto the seat to make a clear pattern. If the contact area is too high on the valve, the seat must be lowered using a 32-degrees flat cutter. 8-16 OLD SEAT WIDTH OLD SEAT WIDTH CYLINDER HEAD/VALVES If ‘he coniact area is too low on the valve, the seal must be raised uslng a (SO-degree innercutter. OLD SEAT WIDTH \ soy \- Refinish the: seat to specifications, using a HAND-LAPPINGTOOL 45'degree finish when I Afier cutting the sea, apply lapping compound to the valve face, and lap the valve using light pressure. Do not allow Afler lapping, wash all residual compound off the lapping compound cylinder head and valve. to enter the guides. CYLINDER HEAD ASSEMBLY VALVE LIFI'ER SHIM ? COTTER VALVE SPRING 5%.? a? STEM SEAL SPRING SEAT \ VALVE GUIDE l // EXHAUST VALVEE 8-17 INTAKE VALVE CYLINDER HEAD/VALVES Clean the cylinder head assembly with solvent and blow through all oil passages with compressed air. VALVE SPRING Install the valve spring seat. Install the new stem seal. RETAINER Lubricate the valve stem with molybdenum disulfide oil and insert the valve into the valve guide. & To avoid damage to the stem seal, turn the valve A a slowly when inserting. EXHAUST VALVE > SPRING SEAT STEM SEAL install the tappet hole protector into the valve liker bore. TOOL: Tappet hale protector 07HMG-MR70002 Install the valve spring with the tightly wound coils facing the combustion chamber. Install the valve spring retainer. 1 Install the valve cutters using the special tool as ‘L ESPRING COMPRESSOR shown. To prevent loss of tension, do not compress the valve spring more than necessary. TOOL: Valve spring compressor 07757-0010000 Valve spring compressor attachment 07959-KM30101 8—18 CYLINDER HEAD/VALVES Tap the valve stems gently with two plastic hammers as shown to seat the cutters firmly. CAUTION: Support the cylinder head above the mark bench surface to pravant possible valve damage. Install the insulators aligning their grooves with the ’ 'INLSULATORS basses on the cylinder head, _ ’ CYLINDER HEAD INSTALLATION Install the dowel pins and a new cylinder head gasket as shown. Install the cylinder head. Apply oil to the threads and seating surface oi the 9 mm special bolts/washers and install them. Tighten the 9 mm socket bolts in a crisscross pattern in 273 steps to the specified torques TORQUE: 47 Nm (4.8 kgf-m , 35 lbf-ft) CYLINDER HEAD/VALVES Install and tighten the 6 mm flange bolts. Install the cam chain tensiuner slider into the cylinderhead. Install the new sealing washer and tighten the cap nut. Connect the bypass tube. Install the following: *leant temperature sensor (page 19-10) *Camshaft (see below) —PA|R control valve (page 5-27) —Thermostat (page 6-8) *Radiator (page 6—13) —Carburetor (page 5-24) -Exhaust system (page 2-5) CAMSHAFT INSTALLATION Apply molybdenum disulfide oil to the outer surface of the each valve lifter, lnstall the shims and valve lifters into the valve lifter bares. 8-20 CYLINDER HEADNALVES Turn the crankshaft and align the "T" mark on the "T" MARK INDEX MARK ignition pulse generator rotor with the index mark on the ignition pulse generator rotor cover. Apply molybdenum disuifide oil to the camshaft journals of the cylinder head and camshaft holder. Install the Camshafts onto the cylinder head with INTAKE CAMSHAFT IDENTIFICATION the cam lobes for the No.1 cylinder facing up as MARKS shown, NOTE: Install the each camshaft to the correct locations with the identification marks. “IN": Intake camshaft ”EX”. xhaust camshaft Apply molybdenum disulfide oil to the cam lobes EXHAUST CAMSHAFT andjournals. Install the camshaft holders onto the Camshafts. CAMSHAFT HOLDERS HOLDER BOLTS NOTE: Install the each camshaft holder to the correct locations with the identification marks. “IN”: Intake camshaft holder xhaust camshaft holder 8-21 CYLINDER HEAD/VALVES Temporarily install the ten holder bolts until the cam holders lightly contact the cylinder head surface. CAUTION' Tightening thy camshaft holder bolts on only oneside might cause a camshaft holder to break. Tighten all camshaft holder bolts in the numerical order casted on the camshaft holder. TORQUE: 12 N-m (1.2 kgf‘m , S lbl-ftl Make sure that the ”T” mark on. the ignition pulse HT” MARK INDEX MARK generator rotor aligns with the Index mark on the ignition pulse generator rotor cover. Install the cam chain over the cam sprockets. TIMING MARKS Install the cam sprockets onto the camshaft flange with their timing marks on the cam sprockets are flush with the cylinder head surface and facing out- ward. NOTE: Install the each cam sprocket to the correct locations with the identification marks, "IN": Intake cam sprocket "EX”: Exhaust cam sprocket Clean and apply a locking agent to the threads of the cam sprocket bolt. Install the cam sprocket boltst Turn the crankshaft clockwise one full turn (360°l and tighten the other cam sprocket bolts. TORQUE: 20 Min (2.0 kgf-m,14lbf-fll 8'22 SPROCKET BOLTS CYLINDER HEAD/VALVES Remove the two camshaft hoIder bolts (casted No.10). InstaH the cam chain guide B, reinstall and tighten the bolts to the specified torque. TORQUE: 12 N-m (1.2 kgf-m , 9 lbf-h) Remove the stopper tool from the cam chain tensioner lifter. lnstaH a new sealing washer and tighten the sealing balt, Rechsck the valve timing. CAM CHAIN GUIDE B STOPPER TOOL CYLINDER HEAD COVER INSTALLATION Install the new gasket and crankcase breather separator to the cylinder head cover. 8-23 CYLINDER HEAD/VALVES Apply a locking agent to the crankcase breather separatur mounting bolt threads. Tighten the bolts to the specified torque. TORQUE: 12 N-rn (1.2 kgfvm , 9 |bf~ft) Install the cylinder head packing into the groove of the cylinder head cover. Apply sealant to the cylinder head semi-circular cut-outs as shown. 5*10 rnrn (0.2‘0.4 in) ‘ 5*10 mm (0.2 0.4in) Install the cylinder head cover onto the cylinder 6: head. Install the washers with their “UP" mark facing up. 8-24 CYLINDER HEAD/VALVES Install and tighten the cylinder head cover special BOLTS bolts to the specified torque. NOTE Tighten the ”A” marked side bolts first. TORQUE: 1D N-m (1.0 kgf-m , 7 lbf-ftl Connect the crankcase breather tube. Install the ignition coil and spark plug naps. Install the following: *Carburemr (page 5-24) CYLINDER HEAD COVER *Air cleaner housing (page 5-5) CAM CHAIN TENSIONER LIFTER 30m smppga TOOL WASHER : REMOVAL TENSIONER LIFTER Remove the cam chain tensioner sealing bolt and sealing washer. Turn the tensioner shaft fully in (clockwise) and secure it using the stopper tool to prevent damaging the cam chain. See page 8-5 for detail of the tool. Remove the bolts, sealing washers and cam chain tensioner lifter. Remove the gasket. A TENSIONER LIFTER INSTALLATION @ GASKET TENSIONER LIFTER Install the new gasket onto the cam chain tensioner lifter. NOTE Note the direction of the gasket. 8-25 CYLINDER HEAD/VALVES Install the cam chain tensioner lifter into the BOLTS cylinder block, @ SEALING WASHER Install the new sealing washers and bolts, lhen tighten the belts to the specified torque. TORQUE: 10 Mm 110 kgf-m , 7 Ibf-ft) TENSIONER LIFTER Remove the stopper tool. Install a new sealing washer and tighten the sealing g SEALING WASHER bolt securelv‘ BOLT TENSIONER LIFTER 8-26 CLUTCH/GEARSHIFI' LINKAGE ZD N-m (2.0 kgf-m , 14 Ibf-fi) 108 Mm [11.0 kgf-m , BO Ibf-ft) 12 N-m (1.2 kgf-m , 9 lbf-fl) 0 Wk @ 12 N-m (1.2 kgf-m , 9 lbf-fi) 9-0 23 N-m (2.3 kgf-m,17lbf~ffl 9. CLUTCH/GEARSHIFT LINKAGE SERVICE INFORMATION 9-1 CLUTCH 9-4 TROUBLESHOOTING 9-2 GEARSHIFT LINKAGE 9-11 RIGHT CRANKCASE COVER RIGHT CRANKCASE COVER REMOVAL 9-3 INSTALLATION 9-14 SERVICE INFORMATION GENERAL - This section covers service of the clutch and gearshift linkage. All service can be done with the engine installed in the frame. I Transmission DlI viscosity and level have an effect on clutch disengagement. When the clutch does not disengage or the motorcvcle creeps with clutch disengaged, inspect the transmission oil level before servicing the clutch system 0 See section 12 for shift forks, shift fork shaft, shift drum and transmission service. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT E “Clutchleverfree play 10—20 (3/8—13/16) Clutch spring free lengi 49.7 (1.96] fl. 45.3 (1.90) Clutch discthickness n 2.9273.03(o.115~o.121l 250 (0.1g) Clutch plate warpage ,, 0.30 (0.012) Clutch Outer guide LD. 21.994‘22007 (0.8659T03564l 22.017 (0.8668) O.D. 34375—34391 (1.3770T13776l 34.965 (1.3766) Mainshaft on at clutch outerguide 21980—21393 (036547036591 ‘ 21.95 (0.664) TOROU E VALU ES Clutch center lock nut Clutch spring bolt Shift drurn Canter socket bolt Shift drum stopper pivot bolt Gearshift return spring pin Gearshift pedal link bolt (gearshift spindle sidel TOOLS Clutch center holder Driver Attachment, 37 X 40 mm Attachment, 42 X 47 mm Film, 35 mm 108 Nvm (11.0 kgf‘m , BO lbf-ftl Apply Oil to the threads and flange surface Stake the nut 12 N-rn (1.2 kgf-m , 9 Ibf‘ftl 23 NM (2.3 kgf-m ,17lbf‘ftl 12 N-m (1.2 kgf-m , 9 lbI-ftl 23 N-n'l (2.3 kgf-m , ‘l7 Ibf'fi) 20 Nvm (2.0 kgf-m ,14lbf-ft) D7JMBAMN50301 07749-0010000 07746-0010200 0774670010300 0774643040300 9-1 CLUTCH/GEARSHIFT LINKAGE TROUBLESHOOTING Hard to shift - Incorrect clutch adjustment I improper oil viscosity I Bent shift fork I Bent shift fork shaft I Bent fork claw I Damaged shift drum cam groove I Loose stopper plate bolt I Damaged stopper plate and pin I Damaged gearshift spindle Transmission jumps out of gear I Worn shift drum stopper arm I Weak or broken shift arm return spring I Loose stopper plate bolt I Bent shift fork shaft I Damaged shift drum earn groove I Damaged or bent shift forks I Worn gear engagement dogs or slots Gearshift pedal will not return I Weak or broken gearshift spindle return spring I Bent gearshift spindle Clutch lever too hard to pull in I Damaged, kinked ordiny clutch cable I Damaged clutch lifter mechanism I Faulty clutch lifter bearing I Clutch lifter piece installed improperly Clutch slips when accelerating I Incorrect clutch adjustment I Worn clutch disc I Weak clutch springs ITransmission oil mixed with molybdenum or graphite additive Motorcycle creeps with the engine idling I Incorrect clutch adiustment I Clutch plate warped I Loose clutch lock nut I Oil level too high I Improper oil viscosity I Damaged clutch lifter mechanism I Clutch lifter piece installed improperly 9-2 CLUTCH/GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL Drain the engine oil (page 342D. Remove the clutch cable holder SH bolts and clutch cable holder, then disconnect the clutch cable from the dutch arm. Remove the oil filler cap/dipstick. Remove the right crankcase cover SH bolts and right crankcase cover. Remove the gasket and dowel pins. CLUTCH LIFTER INSPECTION Remove the clutch lifter piece, Remove the clutch lifter arm. return spring and washer. Check the return spring for fatigue or damage. Check the clutch lifter arm shaft for wear or bending. Check the needle bearings for wear, damage or loose fit. Check the 0” seal for fatigue or damage. CLUTCH/GEARSHIFT LINKAGE CLUTCH REMOVAL Remove the right crankcase cover (page 93). Remove the clutch lifter rod and bearing. Remove the clutch flange bolts, lifter plate and springs. Unstake the clutch center lock nut. CAUTION: Be careful not ta damage the mainshafr threads Hold the pressure plate with the clutch center 7 holder, then remove the lock nut. TOOL: Clutch center holder 07724—0050002 Discard the lock nut. Remove the lock washer and thrust washer. Remove the following: CLUTCH DISC B 7 Clutch center 7Judder spring 7 Spring seat 7 Clutch disc A 7 Clutch plates 7 Clutch disc B CLUTCH DISC A SPRING SEAT CLUTCH PLATES 9 4 JUDDER SPRING ' CLUTCH CENTER CLUTCH/GEARSHIFT LINKAGE Remove the pressure plate and thrust washerv insert a 5 mm pin (or suitable tool) into the holes in the primary driven gears to align the gear teeth‘ Pull the clutch outer guide out by pinching the ribs on the clutch outer guide and sliding the guide forward. positioning the projections of the crankcase between the teeth of the primary driven gears. IMAr—w DRIVEm‘qEfiRfl INSPECTION Clutch lifter bearing Turn the inner race of the lifter bearing with your finger. The bearing should turn smoothly and freely without excessive play. If necessary replace the bearing. 9-5 CLUTCH/GEARSHIFI' LINKAGE clutch spring Measure the clutch spring free length. SERVICE LIMIT: 483 mm [130 inl Clutch disc Replace the clutch discs if they show signs of scor- ing or discoloration, Measure the disc thickness of each dlsc. SERVICE LIMIT: 260 mm (0102 in] Clinch plate Check each disc plate for warpage on a surface plate using a feeler gauge, SERVICE LIMIT: 0.30 mm (0.012 inl Clutch center Check the grooves of the clutch center for damage or wear caused by the clutch plates. Replace if necessary. CLUTCH/GEARSHIFI' LINKAGE Clutch outer Check the slots of the clutch outer for damage or wear caused by the clutch discs. Replace if necessary. NEEDLE BEARING; ' I Check the serrated teeth of the primary driven gear for wear or damage. Check the needie bearing for wear or damage, PRIMARY DRIVEN GEA'H Judder spring/spring seat Check the judder spring and seat for damage or warpage. SPRINGSEAT, ‘ JUDDER’SPRING’ Clutch outer guide Measure the O.D. and LD. of the clutch outer guide. SERVICE LIMITS: O.D.: 34.965 mm (1.3766 ini I.D.: 22.017 mm (0.8668 in! Mainshaft Measure the mainshaft 0.0, at ciutch outer guide sliding surface. SERVICE LIMIT: 21.95 mm [0.564 in) CLUTCH/GEARSHIFT LINKAGE clutch lifter rod Check the clutch lifter rod Iorwear or damage. CLUTCH OUTER NEEDLE BEARING REPLACEMENT Press the needle bearing out at the clutch outer using the special tools. TOOLS: Driver 077490010000 Attachment, 37 x 40 mm 07746-0010200 Film, 35 mm 07746-004030!) Press a new needle bearing into the clutch outer so that the casing of the needle bearing is flush with the inner edge of the clutch outer as shown. NOTE: Press the needle bearing into the clutch outer with the marked side facing up TOOLSV Driver 0774970010000 Attachment, 42 x 47 mm 077400010300 Pilot, 35 mm 07746-0040800 INSTALLATION Apply molybdenum disulfide oil to the clutch outer needle bearing. Install the clutch outer onto the mainshaft by posi— tioning the projections of the crankcase between the teeth of the primary driven gears. CLUTCH/GEARSHIFT LINKAGE Line up the gear teeth of the primary driven gears with a 5 mm pin (or suitable tooll. Apply molybdenum disulfide oil to the clutch outer guide. Install the clutch outer guide with the ribbed side facing out, Install the clutch outer, aligning the clutch outer holes with the oil pump driven sprocket pushing in on the clutch outer lightly. After installing the clutch outer guide, remove the 5 mm pin (or suitable tool) from the primary driven gear. Install the washer onto the mainshalt. Coat the clutch discs. plates with clean engine oil. Install the spring seat and judder spring onto the clutch center as shown. Install the clutch disc A (larger l.D. disc) into the clutch outer. Stack the clutch discs and plates alternately. NOTE: Note the direction of the judder spring. JUDDER SPRING SPRING SEAT CLUTCH DISC A CLUTCH PLATE CLUTCH DISC B Install the pressure plate to the clutch center aligning the punch marks between the clutch center _ ‘ _, _ and pressure plate. 9 9 PUNCH MARKS'. . 4 CLUTCH/GEARSHIFT LINKAGE install the clutch center assembly into the clutch OLI‘BI'. NOTE: Install the outer clutch disc A in the shallow slot on the clutch outer. Install the thrust washer unto the mainshaft. Install the cone washer onto the malnshatt with its "OUTSlDE" mark facing out, Apply oil to the new clutch center lock nut threads, then install it onto the mainshal‘t. Hold the pressure plate with the clutch center holder and tighten the lock nut to the specified torque. TORQUE: 108 Nam [11.0 kgf-m , 80 Ibf-ftl Stake the lock nut into the mainshaft grooves Install the clutch springs onto the pressure plate V bosses. :LIETER Mfie Install the clutch lifter bearing and lifter rod into the clutch lifter plate Install the clutch lifter plate assembly. 9-10 CLUTCH/GEARSHIFT LINKAGE Tighten the bolts in a crisscross pattern in several steps, then tighten them to the specified torque. TORQUE: 12 N-m (1.2 kgf-m , 9 lbf‘ftl NOTE: If the clutch lifter rod comes out while tightening the clutch lifter plate bolts, push the rod all the way in to prevent the rod from being bent or damaged. Install the right crankcase cover (page 9-14). GEARSHWTUNKAGE REMOVAL Remove the following: — Right crankcase cover (page 9-3] iclutch assembly (page 9-4) Remove the bolt and gearshift pedal link. Pull the gearshift spindle assembly and thrust washer out of the crankcase. Remove the shift drum center bolt, shift drum center and dowel pin. 9-11 CLUTCH/GEARSHIFI' LINKAGE Remove the stopper arm bolt, stoppar arm, washer and return spring. INSPECTION Check the gearshift spindle for wear, damage or bending‘ Check the return spring for fatigue or damage. Check the needle bearing for wear or damage‘ Check the oil seal for fatigua or damage. INSTALLATION Install the following: *Washer —Return spring *Stapper arm Tighten the stopper arm bolt, 9-12 CLUTCH/GEARSHIFT LINKAGE Install the dowel pin onto the shift drum. Install the gearshift cam while holding the stopper arm using a screwdriver as shown NOTE: Align the large cut out of the shift drum center with the dowel pin on the shift drum. Apply a locking agent to the shift drum center socket bolt threads. Install and tighten the center bolt to the specified torque. TORQUE: 23 N-m (2.3 kgf‘m , ‘l7 lbf~ftl install the thrust washer and gearshift spindle assembly into the crankcase while aligning the spring ends with the crankcase stopper pin. Install the gearshift pedal link aligning its slit with rm‘éfi M the punch mark on the gearshift spindle. Install and tighten the pinch bolt to the specified torque. TORQUE: 20 Mm (240 kgf-rn,14lbf-ftl Install the following: —C|utch assembly (page 9-8) *Right crankcase cover (page 9-14l CLUTCH/GEARSHIFT LINKAGE ¥||8HT CRANKCASE COVER INSTALLA- lnstall the fallowing: 7 Dust seal 7Washsr — Return spring 7 Clutch lifter arm NOTE: Hook the return spring and onto the right crankcase cover, Apply a sealant to the mating surfaces of the crankcase as shown, 10415 mm (0.440.6inl 10—15 mm (0440.6 in) Install the dowel plns and new gasket. Install the right crankcase cover. Connect the clutch cable to the clutch lifter arm and set the bracket, then lnstall and tighten the right crankcase cover boltst Pour the recommended engine oil (page 3-12]. 9-14 ALTERNATOR/STARTER CLUTCH 103 N‘m110.5 kgf-m , 76 mm) 10. ALTERNATOR/ STARTER CLUTCH SERVICE INFORMATION 10-1 FLYWHEEL REMOVAL 10-4 TROUBLESHOOflNG 104 STARTERCLUTCH 105 ALTERNATOR COVER REMOVAL 10-2 FLYWHEEL INSTALLATION 10-8 STATOR 10-3 ALTERNATOR COVER INSTALLATION 10-9 SERVICE INFORMATION GENERAL 0 This section covers service of the alternator, flywheel and starter clutch. All service can be done with the engine installed in the frame‘ ' Refer to section 16 for alternator stator inspection. SPECIFICATIONS Unit mm (inl ITEM STANDARD ‘ SERVICE LIMIT Starterdriven gear 0.0. 51.599i51718[2.0354T200361) l 51.634l2.0348) m TORQUE VALUES Flywheel flange belt 103 N>m (10,5 kgf-m , 76 IthI Apply oil to the threads Stator mounting socket bolt 12 Nvm (1.2 kgf-m , S lbf-ft) Alternator wire clamp socket bolt 10 N-m (1.0 kgf-m , 7 [bf‘ftl Starter clutch outer socket bolt 16 N-m11.6 kgfvm,12|bfrftl Apply a locking agent to the threads TOOLS Flywheel holder 07725-0040000 Rotor puller 07733-0020001 Engine does not turn ' Faulty starter clutch 0 Damaged idle gear/shaft 10-1 ALTERNATOR/STARTER CLUTCH ALTERNATOR COVER REMOVAL Remove the air cleaner housing (page 5-4). Disconnect the alternator 3P (White) connector. Release the alternator wire from the wire clamp. Remove the alternator cover SH bolts and alternatnrcover. CAUTION: The alternator cover (stator) is magnetically attached to the flywheel, be careful during removal. NOTE‘ The engine oil will run out when the alternator cover is removed. Set 3 clean oil pan under the engine and add the recommended oil to the specified level after installation. Remove the gasket and dowel pin. 10-2 ALTERNATOR/STARTER CLUTCH STATOR ’ SOCKéT Bo REMOVAL ' ’ Remove the alternator wire grommet from the alter- nator cover. Remove the socket bolt and stator wire holdert Remove the socket bolts and stator. « STATOR -_ t. INSTALLATION 12 N-m (1V2 kgf-m,9 mm; 10 N-m (1.0 kgfvm , 7 Ibf-ft) WIRE HOLDER E EK . ‘K j , ‘ ‘ STATUE JI SEAL ALTERNATOR COVER Install the stator into the altarnatur cover. Apply sealant to the wire grommet, then install the wtre grommet Into the alternator cover groove securely‘ 10-3 ALTERNATOR/STARTER CLUTCH install and tighten the socket bolts to the specified SOCKET BOLTS SOCKETBOLT ’ tarque. _ I ', ' ' ‘ TORQUE: 12 NM (1.2 kgt-rn , 9 lbi-ft) Install the wire holder and tighten the socket bolt to the specified torque. TORQUE: 10 N-m (1,0 kgf-m , 7 lbf-ft) FLYWHEEL REMOVAL Remove the alternator cover (page 102). Hold the flywheel using the flywheel holder, then remove the flywheel bolt. TOOL: Flywheel hnldsr 07725—0040000 Remove the washer. Remove the flywheel using the special tool. TOOL: Rotor puller 07733-0020001 Remove the woodruff key. Remove the starter idle gear shaft and idle gear. 10-4 ALTERNATOR/STARTER CLUTCH STARTER CLUTCH INSPECTION Check the operation of the one-way clutch by turning the driven gear. You should be able to turn the driven gear counter- clockwise smoothly, but the gear should not turn clockwise. DISASSEMBLY SOCKET BOLTS Remove the starter driven gear by turning it counterclockwise. Hold the flywheel with a flywheel holder, and remove the starter clutch mounting socket bolts. TOOL: Flywheel holder 07725-004000!) FLYWHEEL HOLDE Remove the starter one~way clutch assembly. FLYWHEEL ONE-W V LUTCH ASSEMBLY INSPECTION Check the starter driven gear for abnormal wear or damage. Measure the starter driven gear boss OD. SERVICE LIMIT: 51584 mm (20348 in) 10-5 ALTERNATOR/STARTER CLUTCH Check the one‘way clutch sprag for abnormal wear, CLUTCH OUTER ONE-WAY CLUTCH damage or irregular movemant. Check the one-way clutch roller contact surface of the clurch outer for abnormal wear or damage, replace if necessary. Check the starter idle gear shaft, gear and shaft jour- nal for wear or damage, replace if necessary. ASSEMBLY STARTER CLUTCH OUTER FLYWHEEL STARTER DRIVEN GEAR 0NE»WAY CLUTCH 10-6 QM 16 N-m (1,6 kgfrm, 12 mm) ALTERNATOR/STARTER CLUTCH Apply oil to the starter one-way clutch. Install the one-way clutch into the clutch outer with the flange side facing the flywheel, ONE-WAY 'LU'TCH' ’ install the starter one-way clutch assembly onto the FLYWHEEL flywheel. Clean and apply a locking agent to the starter clutch SOCKET BOLTS outer mounting bolt threads. Hold the flywheel with a flywheel holder, and tighten the starter clutch mounting socket bolts. TOOL: Flywheel hold-r 077250040000 YOROUE: 16 Nm (1.6 kgf-m. 12 lbf‘ftl FLYWHEEL [49>me ' Install the starter driven gear into the one-way clutch. Recheck the one~way clutch operation, You should be able to turn the driven gear counter- clockwise smoothly, but the gear should not turn clockwise. 10-7 ALTERNATOR/STARTER CLUTCH FLYWHEEL INSTALLATION Apply oil to the starter idie gear and gear shaft, and install them. Clean any oil from the crankshaft taper. install the woodruff key on the crankshaft. Install the flywheel aligning the key way in the fly- wheel With the woodrufl key on the crankshaft. Apply oil to the flywheel bolt threads and seating surface, Install the washer and flywheel bolt. Hold the flywheel using the flywheel holder, than tighten the bolt to the specified torque. TOOL: Flywheel holder 07725-0040000 TORQUE: 103 N-m (10.5 kgl-m , 76 IbH‘tl ALTERNATOR/STARTER CLUTCH ALTERNATOR COVER INSTALLATION Apply sealant to the mating surface of the crankcase as shown. 10415 mm 10—15 mm Install the dowel pin and new gasket. Install the alternator covert CAUTION: The alternator cave: {stator} is magnetically attached to the flywheel, be careful during installatinn. Install and tighten the SH bolts. Route the alternator wire properly (page 1-22l. Clamp the alternator wire with a wire clamp. 10-9 WIRE CLAM ALTERNATOR/STARTER CLUTCH Connect the alterna‘or 3P (White) connector. InskaH me air cleaner housing (page 5~5L Add the recommended oil up to proper )evel (page 3-12). 10—10 CHANKCASE/PISTON/CYLINDER 39 N-m14.0 kgf-m ,29 lbf-m 25 N-m(2.6kgf-m. 191bf-ft) 24 N-m (2.4 kgf‘m , 17 Ibf-f!) 11 11. CRANKCASE/PISTON/CYLINDER SERVICE INFORMATION 11-1 PISTON/CONNECTING ROD 11-4 TROUBLESHOOTING 11-2 CRANKCASE COMBINATION 11-11 CRANKCASE SEPARATION 11-3 SERVICE INFORMATION GENERAL 0 The crankcase must be separated to sen/ice the crankshaft, piston, cylinder and transmission. ' The following parts must be removed before separating the crankcase. *Alternator/flywheel (Section iUl *Ciutch (Section 9) *Cylinder head lSection 8i *Engine lSection 7) *Gearshift linkage (Section lol *0“ pump (Section 4) ' Mark and store the disassembled pans to ensure that they are installed in their original locations. I Mark and store the bearing inserts to be sure of their correct locations for reassembly. If the inserts are improperly installed, they will block the oil hole, causing insufficient lubrication and eventual engine seizure. ' The connecting rod bearing inserts are select fit and are identified by color codes. Select replacement bearings from the code tables. After installing new bearings, recheck them with plastigauge to verify clearance, Apply molybdenum disul- fide oil to the crank pin during assembly, m ll-l CRANKCASE/ PISTON/ CYLINDER SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cylinder |.D, 65.000765.015(2.559172.5596) 65.10 (2.563) Out of round 7 0.10 (0.004) Taper — 0.10 (0.004) Warpege , 0.10 (0.004) Piston) piston Piston mark direction “1N" mark facing toward the intake side rings Piston O.D. 64970764390 (2.55797 2.5587) 64.90 (2.555) Piston D.D. measurementpoint 11 mm (0.4 in) from bottom of skirt — Piston pin bore |.D. 17.0027 17.008 (115654700696) 17.02 (0.670) Piston pin (1D. 16394717000 (06691706693) 15.98 (0.669) Pistonvto-piston pin clearance , 0002—0014(00001700006) 0.04 (0.002) Piston ring-to-ring Top 002570.060 (00010—00024) 0.08 (0.003) groove clearance ( Second 001570.050 (00006700020) 0.08 (0.003) Piston ring end gap j Top 02070.35 (0.00870.014) 05 (0.02) Second 03570.50 (0014—0020) 0.7 (0.03) ‘ Oil (side rai)) 0.20’010 (000870023) 77 1.0 (0.04) Cylinder-to»piston Clearance 001070.045 (00004700018) 0.10 (0.004) Connecting rod small and LD. 17016717034(06699-06706) 17.04(0.671) Connecting rod-to-pistcn pin clearance 0.07 6 — 0.040 (0,0006— 0.0015) Crank pin oil clearance 0.028—0052 (00011700020) 0.0610002) TORQUE VALUES Main journal bolt Crankcase bolt, 10 mm 8 mm Lower crankcase sealing bolt, 20 mm Lower crankcase sealing bolt, 14 mm Connecting rod nut Oil pressure switch terminal screw TROUBLESHOOTING Cylinder compression is too low, or engine is hard to start - Blown cylinder head gasket I Worn, stuck or broken piston ring ' Worn or damaged cylinder or piston 0 Sent valve, or bent and deteriorated valve seat Cylinder compression is too high, or engine overheats or knocks I Carbon deposites on the cylinder head and/or piston crown Piston sounds 0 Worn cylinder, piston and/or piston ring ' Worn piston pin hole and piston pin 0 Worn connecting rod small and 11-2 25 N-m (2.6 kgfrm,19lbf~fl) 39 Nrm (4.0 kgf—m ,291bf-ft) 24 N-m (2.4 kgi-m , 17lbf-ft) 29 N-m (3.0 kgf~m ,221bf-ft) 25 N-m (2.5 kgf—m , 18 Ibf-ft) 25 N-rn (2.6 kgf—m , 1910”!) 2 N-m (0.2 kgf‘m,1.4|bf‘fl) Apply oil to the threads Apply a locking agent to the threads Apply a locking agent to the threads Apply oil to the threads Excessive smoke 0 Worn, stuck or broken piston ring I Worn valve stem seal Excessive noise - Worn connecting rod big end bearing 0 Bent connecting rod I Worn crankshaft rnain journal bearing - Worn transmission bearing Engine vibration - Excessive crankshaft runout CRANKCASE/ PISTON/ CYLINDER CRANKCASE SEPARATION NOTE: ' fl ‘ Refer to Service Information (page 11-1) for ‘Lw’\ removal of necessary pans before separating the ’ ' crankcase. Remove the bolt, collar and cam chain guide. Remove the cam chain and cam chain drive sprocket, Disconnect the neutral switch connector from the switch. Remove the oil pressure switch terminal screw, then remove the engine sub—harness lrom the engine. Remove the upper crankcase 6 mm bolls, sealing washer and 5 mm bolt, Remove the lower crankcase 6 mm and 10 mm bolls. Loosen the main journal 8 mm bolts in a crisscross pattern in 2 ~3 steps, then remove the 8 mm bolts. 11-3 CHANKCASE/PlSTON/CYLINDER Separate the lower crankcase from the upper crank- case. Remove the dowel pins and oil orifices. PISTON/CONNECTING ROD PISTON/CONNECTING ROD REMOVAL CAUTION: - Before piston removal, place a clean shop towel around the connuting rod to prevent damaging the cylinder sleeve. . Do not try to remove the piston/connecting rad assembly from bottom of the cylinder; the assembly will be sticked so that the ail ring expands In the gap between the cylinder liner and the upper cranks-ea, - Do not interchange the bearing inserts, They must be installed In their original locations or the correct bearing ail clearance may not be abtnlned, resulting in engine damage, NOTE‘ Mark all parts during removal so they can be replaced intheiroriginal locations. Remove the nuts and connecting rod bearing cap. Remove the piston/connecting rod assembly from PISTON/CONNECTING ROD ASSEMBLY the top of the cylinder. PISTON REMOVAL PISTON PIN CLIP Remove the piston pin clip with pliers Press the piston pin out of the piston and remove the piston from the connecting rod‘ 1 1-4 PISTON PIN CRANKCASE/PISTON/CYLINDER PISTON DISASSEMBLY Remove the piston rings. NOTE: Do not damage the piston rings during removal. Remove any carbon deposits from the piston ring grooves, using an old piston ring as shown. PISTON INSPECTION Temporarily install the piston rings to their proper position with the mark facing up. Measure the piston ring-to-ring groove clearance with the rings pushed into the grooves. SERVICE LIMITS: Tap: 0.08 mm (0.003 in) Second: 0.08 mm (0.003 in) Inspect the piston for wear or damage. Insert the piston ring squarely into the bottom of the cylinder and measure the ring and gap. NOTE: Push the rings into the cylinder with the top of the piston to be sure they are squarely in the cylinder. SERVICE LIMITS: Top: 0.5 mm (0.02 in) Second: 0.7 mm (003 in) Oil [side ra in mm (0.04 in) 1 1-5 CRANKCASE/PISTON/CYLINDER Measure the diameter ofthe piston at 11 mm (0.4 in) from the bottom and 90 degrees to the piston pin hole. SERVICE LIMIT: 64.90 mm (2.555 in) Measure the piston pin bore. SERVICE LIMIT: 17.02 mm (0.670 in) Measure the DD. 01 the piston pin. SERVICE LIMIT: 16.93 mm (0.669 W Calculate the piston-to-piston pin clearance. SERVICE LIMIT: 0.04 mm [0.002 in) CYLINDER INSPECTION Inspect the top of the cylinder for warpage. SERVICE LIMIT: 0.10 mm (0.004 in) 11-6 CRANKCASE/PISTON/CYLINDER Inspect the cylinder bore for wear or damage. Measure the cylinder [.D. in X and Y axis at three levels. Take the maximum reading to determine the cylinderweer. SERVICE LIMIT: 65.10 mm (2.563 in) Calculate the piston-tavcylinder clearance. Take a maximum reading to determine the clearance. Refer to page 11-6 for measurement of the piston 0.D. SERVICE LIMIT: 0.10 mm (0.004 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 (0.004 in) Out of round: 0.10 mm (0.004 ini MIDDLE The cylinder must be rabored and an oversize piston fitted if the service limits are exceeded. BOTTOM The follawing oversize pistons are available: 0.75 mm (0.030 in) 1.00 mm (0.03901) The piston to cylinder clearance for the oversize pis» ton must be: 0.015 7 0.050 mm (0.0006 ~ 0.0020 in). CONNECTING ROD INSPECTION Measure the connecting rod small end I.D. SERVICE LIMIT: 17.04 mm (0.671 in) Temporarily install the connecting rod to the crank shaft. Install the bearing inserts and bearing cap, and tighten the bolts. Measure the connecting rod side clearance. SERVICE LIMIT: 0.30 mm (0.012 in) 11-7 CRANKCASE/PlSTON/CYLINDER CRANK PIN BEARING INSPECTION Wipe all oil from the bearing inserts and carnk pins. Put a piece of plastigauge on each crank pin. NOTE; ' Do not put the plastigauge over the oil hole in the crank pin. 0 Do not rotate the crankshaft during inspection. Install the bearing caps and connecting rods on a correct crank pins, and tighten the cap nuts to the specified torque. TORQUE: 25 N-m (2.6 kgf-m , 191bf‘fl) Remove the connecting rod caps and measure the compressed plastigauge on each crank pin. SERVICE LIMIT: 0.06 mm (0.002 in) if the connecting rod bearing clearance is beyond tolerance, selects replacement bearing. CRANK PIN BEARING SELECTION Record the connecting rod |.D. code number (‘1 or 2) or measure the ID. with the bearing cap installed without hearing inserts. 11-8 -|.D.COD,E: NUMBER f CRANKCASE/PlSTON/CYLINDER If you are replacing the crankshaft, record the corresponding crank pin O.D. code number (A or 8), NOTE Numbers (A nr B) on the crank weight are the codes {or the crank pin 0.0,5 starting from the left. If you are reusing the crankshaft, measure the crank pin CD. with the micrometert Cross-reference the crank pin Hand rod codes to COLOR CODE determine the replacement bearing color. BEARING THICKNESS: A (Brown) : Thick 5 (Green) : I C (Vellow) 1 Thin CRANK PIN BEARING SELECTION TABLE Unit: mm (in CONNECTING R001.Q.7cgo£ia# 1 2 34000—34008 34008—34316 ‘ (13336—13389) (13389—43392) l 31.492>31.500 C B CRANK PIN 0.0. (12395712402) (Yellow) (Green) CODE LETTER 31.454—31 .492 B A B “239571.2353) | (Green) (Brown) Install the bearing inserts into the connecting rod and bearing cap. NOTE: Align the oil hole between the connecting rod and bearing, and also align the bearing tabs with the grooves in the connecting rod and bearing cap, 11-9 BEARING INSERTS CRANKCASE/PlSTON/CYLINDER Do not a/igh ms pisinn pin clip and gap with the piston cut-out. Install the pistan/connecting rod assembly with the piston ”IN” mark facing to the intake side. PISTON ASSEMBLY Clean the piston ring grooves thoroughly and install the piston rings. NOTE‘ I Apply oil to the piston rings. I Avoid piston and piston ring damage during installation. I Install the piston rings with the marking (R) facing up. I Do not mix the top and second rings; the top ring is narrower than the second ring in width. Space the piston ring and gaps 120 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. NOTE: Install the connecting rod with its oil hole side facing the "IN” mark on the piston crown. Apply oil to the piston pin outer surface. install the piston pin, and secure it using a new piston pin clip. Apply oil to the cylinder sleeve and piston rings. Install the piston/connecting rod assembly into the cylinder using a commercially available piston ring cumpressortool. CAUTION: I While installing the piston, being careful not to damage the top surface a! the cylindcr, especially around the cylinder here. I Be careful not to damage the cylinder sleeve and punk pin with the connecting rod bait threads. 11-10 TOP RING SECOND RING SPACER w PISTON PIN CLIP OIL HOLE it PISTON/CONNECTING ROD ASSEMBLY CHANKCASE/PlSTON/CYLINDER Makesura ring Use the handle of a plastic hammer to tap the compressar tool piston into the cylinder. sits flush with top surface of the cylinder. PISTON RlNG COM RESSOR Apply molybdenum disulfide oil to the crankpin "3? bearing su rfaces. Install the bearing cap. Apply oil to the connecting rod nutthreads and seat ing surfaces. Install the nuts and tighten them gradually and alter- nately‘ TORQUE: 25 N-m (2.6 kgf-m ,19lbf-ftl CRANKCASE COMBINATION Apply a light, but through, coating of liquid sealant to the crankcase mating surface except to the main bearing journal bolt (lower crankcase belt, 8 mm) area and the oil passage area as shown. 11-11 CRANKCASE/PlSTON/CYLINDER Install the or! Install rhe oil orifices to the upper crankcase. orifices with their cut-m1! With the upper crankcase grcaves Install dowel pins in the upper crankcase. Assemble the crankcase halves, aligning the shift fork claws with the shifter gear grooves. Check for smoorh transmission operation. 11-12 CENTER SHIFT FORK LEFTSHIFI' FORK RIGHT SHIFTFORK Mam GEAR C6 GEAR ”3—? o 0 C5 GEAR CRANKCASE/PISTON/CYLINDER Apply oil to the main journal bolt threads and seating surfaces. Install the main journal 8 mm bolts. Loosely install all the lower crankcase bolts. Make sure the upper and lower crankcase are seated securely. Tighten the main journal 8 mm bolts in numerical order casted on the lower crankcase in several steps, then tighten them to the specified torque. TORQUE: 25 NJ" (2.6 kgf-m ,19 lbf-f‘t) Tighten the lower crankcase 10 mm bolt. TORQUE: 39 N-m (4.0 kgf-m , 29 lbf-ft) Tighten the 6 mm bolts. install a new sealing washer and upper crankcase 8 mm bolt. Install a new sealing washer and 5 mm bolts. NOTE: The sealing washer location is indicated on the uppercrankcase using the “A" mark. Tighten the 6 mm bolts in a crisscross pattern in 2 or 3 steps. Tighten the 8 mm bolt to the specified torque. TORQUE: 24 N-m (2.4 kgf-m,17lbf-ft) 11-13 6 mm BOLTS 8 mm BOLTS 10 mm BOLT 8 mm BOLT 6 mm BOLTS CRANKCASE/PlSTON/CYLINDER Route the engine sub-harness. install the oil TERMINA CREW pressure switch terminal to the switch, L 5/ Tighten the oil pressure switch terminal screw to the specified torque. .. TORQUE: 2 N-m (0.2 kgf~m,1.4|bf-ft] Install the neutral switch connector. Install the cam chain drive sprocket aligning its wide groove with the wide teeth oi the crankshaft. Install the Cam Chain through the crankcase. Install the cam chain guide, collar and bolt. Install the removed parts in the reverse order of removal. 11-14 CRANKSHAFT/TRANSMISSION 12 12. CRANKSHAFT/TRANSMISSION SERVICE INFORMATION 12-1 CRANKSHAFT 12-3 TROUBLESHOOTING 12-2 TRANSMISSION 12-7 SERVICE INFORMATION GENERAL - The crankcase must be separated to service the crankshaft and transmission. Refer to section 11 for crankcase separa- tron/assembly. ' Be careful not to damage the crankshaft main journal and iournal bearing while removing or installing the crankshaft. ' Mark and store the disassembled parts to ensure that they are installed in their original locations. 0 Mark and store the bearing inserts to ensure that the parts are in their correct locations during reassembly. If the inserts are improperly installed, they will block the oil hole, causing insufficient lubrication and eventual engine seizure. I The main journal bearing inserts are a select fit and are identified by color codes. Select replacement bearings from the code tables. After installing new bearings, recheck them with a plestigauge to verify clearance. Apply molybdenum disul- fida oil to the mainjournal during assembly. SPECIFICATIONS Unit. mm (in) ITEM STANDARD SERVICE LIMIT Crankshaft Side clearance 0.107015 (0.0047: 0.010I 0.3010012) Runnut . — 0.06 (0.00217 i Mainjournel oil clearance 0020-0045 (00008—00018) 0.05 (0.002) Transmission Gear |.D. M5, M8 28.000"28.021 (1,1024m1.1032) 23.04I1.104) C2, C3, C4 31000—31025 (1,2205m12215) 31.04 (1.222) Bushing O.D. M5, M5 27353—27330(1.1007—1.1016) 27.94(1.100) C2 30359-30380 (1.2189*1.2197) 303411.218) C3, C4 . 30350—30375I1.2185*1.2195) 30.93I1.218I Bushing |.D. M5 24385—25006 (0.9337>0.9345I 25016103849) 7 I C2 Z7.985*28.006(1.1018?1.1DZSI ZE.021I1.1032I Gear-to»bushing M5, M6 0020—0062 (0.0008*0.0024I ‘ — clearance l C2, C3, CA 0020-0070 (0.0008i0.0028l _ — Mainshaft O.D. M5 W 24.967* 24.98010.9830~0.9835) 24360108527) 7‘ ‘ Clutch outer guide 21.980'21353 (0.8654*0.3659) 213510364) CountershaftOD. I C2 27.967‘27880I1.1011*1.10161 273611.101) Eushing-to-shaft F M5 0005—0039 (0.0002*0.001SI l ‘ clearance . CZ 0005—0038 l0.0002*0.0015l * Shift fork, fork Shirt fork i Fork ID. ”000712021 IO.4724*0.4733I 11030104736) shaft _ 1 Claw thickness 5.93—6.00 (023370.236) 5.9010232) Fork shaft O.D. 11857—11868 10.4707*0,4712) 113510470) 12-1 CRANKSHAFT/TRANSMISSION TORQUE VALUES Connecting rod nut 25 N-m (2.6 kgf-m , ‘lBlbf-ft) Apply oil to the threads and seating surface TOOLS Driver, 40 mm LDr 07746-0030100 Attachment, 25 mm [lNl 07746-0030200 Attachment, 30 mm (W) 07746-0030300 TROUBLESHOOTING Excessive noise Transmission iumps out of gear I Worn connecting rod big end bearing 0 Worn gear dogs and slots 0 Bent connecting rod 0 Bent fork shaft ' Worn crankshaft main journal bearing 0 Broken shift drum stopper ' Worn transmission bearing ~ Worn or bent shift forks ' Broken shift linkage return spring Hard to shift I Improper clutch operation Engine vibration O Incorrect transmission oil weight I Incorrect clutch adjustment 0 Bent shift fork - Bent fork shaft I Bent fork claw U Damaged shift drum cam groove - Bent shift spindle - Excessive crankshaft runout 12-2 CRANKSHAFI'ITRANSMISSION CRAN KS HAFT " , f IEIINGZQA WN Uflfsmmw REMOVAL Separate the crankcase halves (page 11-3). Remove the connecting rod bearing cap nuts and bearing caps. CAUTION: Before remnval, pasitian all the pistons at TDC {Tap Dead Center] to prevent damaging the crank pin with the connecting rod bolt threads. Remove the crankshaft Remove the main journal bearings from both the crankcase halves. INSPECTION CRANKSHAFI' HUNOUT Hold the crankshaft both end. Set a dial indicator on the center rnain journal of the crankshaft Rotate the crankshaft two revolutions and read runout at the center journal. SERVICE LIMIT: 0.05 mm (0.002 in) 12-3 CRANKSHAFI'ITRANSMISSION MAIN JOURNAL BEARING Inspect the main journal bearing inserts for damageorseperstion, Wipe the oil from the bearing inserts and journals. .. PLASTIGAUGE Reinstall the upper crankcase's main journal . $37 bearing inserts, then carefully lower the crankshaft in place. Put a piece of plastigauge on each journals. NOTE: I Do not putthe plastigauge over the oil hole in the main bearing journal of the crankshaftr I Do not rotate the crankshaft during inspection. Assemblethe crankcase halves. Tighten the main journal bolts in numerical order casted on the lower crankcase in several steps, then tighten them to the specified torque. TORQUE: 25 N-rn (2.6 kgf-m,19|bf-ft) Remove the main journal bolts and luwer crankcase. Measure the compressed plastigauge on each jour- nal. SERVICE LIMIT: 0.05 mm (0.002 in) If the main bearing clearance is beyond tolerance, select a replacement bearing. 12-4 CRANKSHAFT/TRANSMISSION MAIN JOURNAL BEARING SELECTION Record the crankcase I‘D. leners from rhe pad on the left side of the upper crankcase as shown. NOTE, The Ieners (A, B or C) on the upper crankcase are the codes for the main journal 1.0.5 from lefl to right. Record the corresponding main journal 0D. code numbers frnm the crank waighr NOTE: The numbers (1 or 2] on the crank weight are Ihe codes for the main journal O‘D.s from left to right. Cross reierance the case and journal codes to deter» mine the replacemenl bearing color codes, BEARING THICKNESS: AlBruwnl Thick COLOR CODE BIGree ClVellnw DlPinkl: Thin CAUTION: After selecting new burings, recheck the clearance with a plastigauge. Incarrec't clearance can cause savm angina damage, MAIN JOURNAL BEARING SELECTION TABLE Unit: mm (in) CRANKCASE m CODE A l3 c saloon—36.007 36007—36014 36014—36021 (1.4173—1A176) (1.4176—1.4179) (14179»14181) 32393— 513.000 D C B CRANKSHAFT I (11989—12992) (Pink) lYallowl (Green) O.D. CODE 2 32‘986*32.993 C I B A (11986—11359) (Vellow) lGreenl (Brown) 12-5 CRANKSHAFT/TRANSMISSION STARTER CLUTCH NEEDLE BEARING REPLACEMENT Remove the needle bearing with a commercially available universal bearing puller. CAUTION: To protect the crankshalt main jaurnal from the bearing puller claws, cover the main jaumal properly; warn main journal burings are usable as pmtemors. Drive a new needle bearing onto the crankshaft. TOOLS: Driver. 40 mm ID. 07746-0030100 Attachment. 30 mm ID. 0774670030300 INSTALLATION Install the main Journal bearings into the upper and lower crankcase. NOTE: The bearing tabs should be aligned with the grooves in the case. Apply molybdenum disulfide oil to the upper and lower main journal bearings. Install the crankshaft. CAUTION: Before installation, position all the pistons at TDC (Tap Dead Center} to pravent damaging the crank pin with the connecting rod bait threads. 12-6 WORN MAIN JOURNAL BEARINGS DRIVER/ ATTACHMENT NEEDLE BEARING CRANKSHAFT/TRANSMISSION Install the connecting rod bearing caps. Apply oil to the connecting rod nut threads and seat. ing surfaces. Install and tighten the nuts gradually and alternately. TORQUE: 25 NM (2,6 kgf-m, 19 IN“) Assemble the upper and lower crankcase lpaga 11-11). TRANSMISSION REMOVAL/DISASSEMBLY Separate the crankcase (page 11~3l, Remove the countershafl assembly from the upper crankcase. Remove the bearing set ring and dowel pin. Remove the bolts and mainshafl bearing set plate. Remuve the mainshafl assembly. 12-7 CRANKSHAFr/TRANSMISSION Remove the bolts and shift drum bearing set plate‘ Remove the shift fork shaft and shift forks. Remove (ha shift drum bearing and shift drum. DISASSEMBLY Disassemble (he mainshaft and countershaft. 12-8 MAINSHAFT COUNTERSHAFT CRANKSHAFT/TRANSMISSION INSPECTION NEEDLE BEARING Check the mainshafl and countershah needle bear» ings for damage or excessive wear. in; Check the gear dogs, dog holes and teeth for abnor- mal wear or lack 0f lubrication. Measure the ID. of each gear. SERVICE LIMITS: M5,M6: 28.04 mm(1,104in) C2, (33, C4: 31.04 mm (1.222 in) Check the shift fork groove of the shifter gear for excessive wear or damage. Measure the LB. and CD. of each gear bushing. SERVICE LIMITS: 0.0.: M5, M6: 27.94 mm (1,100 in) 02: 30.94 mm(1.21Ein) (23,04: 30.93 mm(1.218in) I.D.: M5: 25.016 mm (0.9849 in) (22: 28.021 mm (1.1032 in) Measure the D.D. of the mainshaft and countershaft. M5 SERVICE LIMITS: M5: 24.960 mm (0.9827 in) CZ: 27.96 mm (1.101 in) 12-9 02 CRANKSHAFT/TRANSMISSION MAINSHAFI' BEARING REPLACEMENT NOTE, Do not try to remove the countershaft bearing from the shaft. If the bearing is worn or damaged, replace the countershaft as an assembly. Turn the outer race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing inner race fits tightly on the shaft, Remove and discard the malnshaft bearing, if the race does not turn smoothly, quietly, or fits loosely on the mainshaft. Replace the countershaft, collar, and bearing as an assembly, if the race does not turn smoothly, MAINSHAFT quietly, or fits loosely on the countershaft. MAINSHAFI' BEARING Press out the mainshaft from the bearing using a hydraulic press. Install a new mainshaft bearing onto the mainshaft by pressing the mainshaft bearing inner race using DRIVER, 40 mm LD. ATTACHMENT, the special tools. 25 mm (IN) TOOLS: Drlver, 40 mm |.D. 07746-0030100 MAINSHAFT Attachment, 25 mm (IN) 07746-0030200 BEARING MAINSHAFI' NOTE: Install the bearing with its marking facing out Check the shift fork and fork shaft for wear or damage, Measure the LD. of the shift fork. SERVICE LIMIT: 12.030 mm (0.4736 in) Measure the shift fork claw thickness. SERVICE LIMIT: 590 mm (0.232 in] 12-10 CRANKSHAFr/TRANSMISSION Measure the OD. of me shift fork shaft. SERVICE LIMIT: 1195 mm 10.470 in) Inspect the shift drum grooves for wear or damage. SHIFT DRUM BEARING Turn the outer race of the shift drum bearing with yourfingar. The bearing should turn smoothly and freely without excessive play If necessary, replace the baaring, ASSEMBLY Mninshah: M6 SPLINE BUSHING SPLINE WASHER M6 GEAR (23T) SNAP RING SPLINE WASHER LOCK WASHER M2 GEAR (16TF / / 5... “ ‘\\ @ \ SPLINE WASHER SNAP RING M5 BUSHING MAINSHAFT/M‘l GEAR(14T) THRUSTWASHER NEEDLE BEARING BEARING CASE CRANKSHAFT/THANSMISSION Cnuntershaft: SPLINE WASHER C3 GEAR I28T) SNAP RING C4 GEAR BUSHING cs GEAR (251-) F“ j.» ,' SNAP RING BEARING CASE SPLINE WASHER I \ {9 c2 GEAR BUSHING “\ TWHIESUHSEIES c2 GEAR (3er \ > r, COUNTERSHAFI' @7 \\ SNAP RING 0- x s \ V \ ‘1“ AA \ SFLINE \\ e,‘ I \\WASHER \ _, @ \\ NEEDLE BEARING \\ E \ LOCKWASHER "7'5 c5 GEAR (24T) A “" \ - ~ ~ SPLINE WASHER C3 GEAR SPLINE BUSHING C4 GEAR (26T) Assemble the transmission gear and shafts, Coat each gear with clean engine oil and check for :3 smooth movement. é Apply molybdenum disulfide OH to the shIfl fork _ grooves in (he M3/4, C5 and C6 gear. INSTALLATION BEARING Install the shift drum and bearing into the lower crankcase. 12-12 CRANKSHAFT/TRANSMISSION NOTE: The shift forks have loca‘lon marks. “H” for right "C" for center ”L” for left Face Ms shin lurk Install the shift forks and shift fork shaft. identification marks In H15 clutch side. Apply a locking agent to the shifl dmm bearing set plate boll threads. Install the shift drum bearing set plate with their "OUT" mark facing out. Install and tighten the set plate bolis securely, Install the mainshafl assembly onm the upper crankcase. 12-13 CRANKSHAFT/TRANSMISSION Install the mainshaft set plate with its “OUT SIDE” mark facing cut. Apply a locking agent to the set plate bolt threads. Install and tighten the set plate bolts. Install the dowel pin and bearing set ring on the upper crankcase. Install the countershaft by aligning the ceuntershaft bearing set ring with the groove on the cauntershaft bearing, and aligning the bearing cap hole with the dowel pin. After installation, check for smooth transmission operation. Assemble the crankcase halves (page 11-11). 12-14 FRONT WHEEL/SUSPENSION/STEERING 26 N-m (2,7 kgfrm , 20 Ibf-ft) 23 N-m (2.3 kgf-m,17|bf‘ft) 39 N-m (4.0 kgf‘m , 29 ”3“!) 12 N~m (1.2 kgf-m ,_9 lbf-ft) 22 N'm (2,2 kgf-m,16|bf-fl) 30 Nrm (3.1 kgf-rn , 22 Ibf-ft) 22 N>m (2.2 kgf>m,16|bf‘ft) 13 13. FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION 13-1 FRONT WHEEL 13-9 TROUBLESHOOTING 13-2 FORK 13-16 HANDLEBAH 13-3 STEERING STEM 13-25 SERVICE INFORMATION GENERAL AWARNII‘IG A contaminated brake disc a! pad reduces flapping power. Discard cantaminated pads and clean a contaminated dlsc with a high quality brake degreasing agent. I When servicing the front wheel, Iork or steering stern, support the motorcycle using a safety stand or hoist. I Refer to section 15 for brake system information. - 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 dgpth 7 1.5 [0.06) Coidlire pressure Driver only gorkfa 12.50 kgf/gnjli, 35 psi] 7 _ Driver and passenger 250 kPa (2.50 kgi/crrl1 , 36 psi] — Axle runout * fl K 020 (0.008) Wheel rim runout Radial 2.0 (0.08) g Axial — 2.0 (0.08] Fork Sgrlng frgerlength 309.2 (12.17) 303.0(1133i Spring direction With the [gamed and facing down Tube runour 0.20 (0.008) Recommended fork fluid Eorfifluiiqii _ a , _ , 7 Fluid level 102 (4.0) — Fiuid capacity 436 i 2.5 cm’ (16.4 i 0.03 US oz, 17.1 —~ 1* 0.09 Imp oz) Steering head bearing Dre-load 03841.47 N (0.10—0.15 kgf , 0.22—0.33 Ibfi 13-1 FRONT WHEEL/SUSPENSION/STEERING TORQUE VALUES Handlebar holder bolt Steering stern nut Top thread A Top thread E Fork top bridge pinch bolt Fork bottom bridge pinch bolt Front axle bolt Front axle holder bolt Front brake disc mounting bolt Fork cap Fork socket bolt 26 Nm (2,7 kgfrrn , 20 Ibf-ftl 103 Mm (105 kgf-rn , 76 Ibf-ftl 23 N-rn (2,3 kgf-rn ,17lbf-I‘ti 39 Mn! (40 kgf-m , 29 lbf-ftl 59 N-m (6,0 kgf‘m , 43 lbf-ftl 22 N-rn (2,2 kgf-m ,16Ibf-ftl 20 N-m (2.0 kgf-m,14lbf-ftl 23 N-rn (2.3 kgf-m , l7 Ibf-ftl 20 Nm (2.0 kgf-m,14|bf-ftl 3* See page 13-30 ALOC bolt Apply a locking agent to the TOOLS Bearing remover shaft Bearing remover head, 20 mm threads 07746-0050100 07746-0050600 Driver 077490010000 Attachment, 42 X 47 mm Attachment, 52 X 55 mm Pilot, 20 mm Slider weight Oil seal driver attachment Steering stem socket Ball race remover 07746-0010300 07746-0010400 07746-0040500 07947-KA50100 07947-KF00100 0791673710101 0794641710500 Steering stem driver 07946—M300000 TROUBLESHOOTING Hard steering Wheel turns hard I Faulty or damaged steering head bearings I Insufficient tire pressure I Steering head bearing adjustment nut too tight Steers to one side or does not truck straight - Unevenly adjusted right and left fork legs I Bent fork I Bent axle I Wheel installed incorrectly I Faulty steering head bearings I Bent frame 0 Worn wheel bearing I Worn swingarm pivot components Front wheel wobhling I Bent rim I Worn front wheel bearings - Faulty tire I Unbalanced tire and wheel 13-2 I Faulty wheel bearing I Eent front axle I Brake drag Soft suspension I Insufficient fluid in fork I Weak fork springs I Tire pressure too low Hard suspension - Incorrect fluid weight I Bent fork tubes I Clogged fork fluid passage Front suspension noisy I Insufficient fluid in fork I Loose fork fasteners FRONT WH EEL/SUSPENSION/STEERING HANDLEBAR REARVIEW MIRRORS REMOVAL Remove the reerview mirrors Disconnect the front brake switch wire connectors from the switch. Remove the master cylinder holder bolts, holder and master cylinder assemblyl Remove the right handlebar switch/throttle housing SWlTCH/THROTTLE HOUSING screws. Remove the fuel tank (page 2-4). Loosen the throttle cable lock nuts at the carburetor and loosen the adjusting nuts. 13-3 FRONT WHEEL/SUSPENSION/STEEHING Disconnect the throttle cable ends from the throttle pipe and remove the right handlebar switch/throttle housing. SWITCH/THROTTLE HO Remove the screw and the handlebar weight. DlSOOl’l'neC‘ the clutch switch wire connectors from LEVER BRACKET CONNECTORS the swrtch. - ' Remove the clutch lever bracket holder bolts, holder and clutch lever bracket assembly. Remove the left handlebar switch screws. 13-4 FRONT WHEEL/SUSPENSION/STEERING Disconnect the choke cable from the choke lever and remove the left handlebar switch. Remove the left handlebar weight, handlebar grip rubber and choke lever. Remove the upper holder bolts, holder and handlebar. INSTALLATION Place the handlebar on the lower holders aligning the punch marks on the handlebar with the top surface of the lower holders. install the upper holder with its punch mark facing forward. Install the upper holder bolts. Tighten the front bolts first, then tighten the rear bolts. TORQUE: 26 N-m (2.7 kgf-m , 20 lbf-ftl 13-5 CHOKE CABLE END CHOKE LEVER GRIP RUBBER HANDLEBAR WEIGHT CHOKE LEVER HOLDER BOLTS HANDLEBAR HOLDER PUNCH MARKS HOLDER BOLTS HANDLEBAR HOLDER FRONT WHEELISUSPENSION/STEERING F or ease-y Installation, apply soapy water to the rubber Gushinns. HANDLEBAR WEIGHT REPLACEMENT Remove the grip from the handlebar. Straighten the weight retainer tab by the screwdriver or punch. Temporarily install the handlebar weight and screwl then remove the inner weight by turning the handlebar weight. NOTE: Apply lubricant splay (CRC 5756 or an equivalent) through the tab retainer hole to the rubber for easy removal. Remove the handlebar weight front the inner weight. Discard the retainer. Install the new retainer onto the handlebar inner weight. Install the handlebar weight onto the inner weight aligning its boss with the slut in the inner weight. Install a new mounting screw. Insert the handlebar weight assembly into the handlebar. Turn the handlebar weight and hook the retainer tab with the bake in the handlebar. Install the choke lever onto the left side of the handlebar. 13-6 RETAINER RING RETAINER TAB 2} RUBBER CUSHION INNER WEIGHT RETAINER HOLE INNER WEIGHT 5% HANDLEBAR WEIGHT ‘te '@ @RETAINER RING RETAINER RING RETAINER TAB —-— RETAINER RING INNER WEIGHT HANDLEBAR WEIGHT CHOKE LEVER FRONT WHEEL/SUSPENSION/STEERING If the handlebar grips were removed, apply Honda Bond A or equivalent to the inside ofthe grip and to the clean surfaces of the right and left handlebar. Wait 3—5 minutes and install the grip. Rotate the grip for even application of the adhesive. NOTE. Allow the adhesive to dry for an hour before using. Connect the choke cable to the choke lever. Install the left handlebar switch aligning its locating pin with the hole in the handlebar. Tighten the forward screw first, then the rear screw. install the clutch lever bracket assembly aligning the end of the bracket with the punch mark on the handlebar. Install the clutch lever bracket holder with the “UP" mark facing up. Tighten the upper bolf first, then the lower bolt. TORQUE: 12 N-m (1.2 kgfvrn , 9 lbf-ftl Connect the clutch switch wire connectors. 13-7 GRlP GRIP CHOKE CABLE END CHOKE LEVER FRONT WHEEL/SUSPENSION/STEERING Install the handlebar weight and tighten the screw ’ _ ’ ‘ ’ H NDLEBAR wast-{f securely. ’ ‘ ‘ ’ ‘ _ ‘ , ‘ SCREW , . Apply grease to the throttle pipe sliding surface, THROTTLE PlpE then install the throttle pipe onto the handlebar. ,fil Connect the throttle cables to the throttle grip flange. Install the right handlebar switch/throttle housing aligning its locating pin with the hole in the handlebar. SWITCH/THROTTLE H6 L Tighten the forward screw first, then the rear screw, SWITCH/THROTTLE HOUSING 13-8 FRONT WHEEL/SUSPENSION/STEERING FRONT WHEEL 13-9 Connect the throttle cables to the carburetor ADJUSTING NUTS bracket, adjust thethrottle gripfree play (page 3-4), Install the master cylinder aligning the end of the BRAKE MASTER CYLlNDER' master cylinder with the punch mark on the ' _ , « - » handlebar. Install the master cylinder holder with the "UP" mark facing up. Tighten the upper bolt first, then the lower bolt, TORQUE: 12 N-n'l (1.2 kgl-m , 9 Ibf-ftl Connect the brake switch wire connectors. Install the rearview mirrors and tighten the nuts to the specified torque TORQUE: 34 Nm (3.5 kgf-rn ,25 lbf‘ft) REARVIEW MIRRORS REMOVAL m—_ A contaminated brake disc ar pad reduces stopping power. Discard cantamirmted pads and clean a contaminated disc with a high quality brake degassing agent. Support the motorcycle securely using a safety stand or a hoist. Remove the mounting bolts and left brake caliper. CAUTION: Support the brake caliper with a piece of wire so that it does not hang from the brake hose. Da nnt twist the brake hose NOTE. Do not operate the brake lever after the brake caliper is removed. FRONT WHEEL/SUSPENSION/STEERING Loosen the right axle pinch bolt. Remave the axle bulb Loosen lhe left axle pinch bolt. Remove the axle and the front wheel. Remove the left side collar. Remove the right side collar. 13-10 \9 AXLE BOLT FRONT WHEEL/SUSPENSION/STEERING Except Michelin lire: INSPECTION Axle Set the axle in V-block and measure the runout. Actual runout is 1/2 the total indicator reading. SERVICE LIMIT: 0.20 mm "3.008 inl Wheel hearing Turn the inner race of each bearing with yourfinger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. Remove and discard the bearings if they do not turn smoothly, quietly, or if they fit loosely in the hub. NOTE: Replace the hearings in pairs. Install the new bearings into the hub using the special tools (page 1342i. 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 aver all safety of the motorcycle. Always check balance when the tire has been remand from the rim. NOTE: For optimum balance, the tire balance mark (a paint dot on the side wall) must be located next to the valve stern. Remount the tire if necessary. 13-11 WHEEL BEARING FRONT WH EEL/SUSPENSlON/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 lowest (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 bolts and brake discs. Remove the dust seals. Install the hearing remover head into the bearing. From the opposite side, install the bearing remover shaft and drive the bearing out of the wheel hub. Remove the distance collar and drive out the other bearing. TOOLS: Bearing remover head, 20 mm 0774643050600 Bearing remover shaft 07746-0050100 13—12 FRONT WHEEL/SUSPENSION/STEERING ASSEMBLY rfil DUSTSEAL $9 20 N," (2.0 kgm , 14 MM DISTANCE COLLAR RIGHT BRAKE DISC RIGHT WHEEL BEARING (6004 UU) LEFT BRAKE DISC LEFTWHEEL BEARING (6004 UU) CAUTION: ” DRIVER Never install the old bearings. Once the bearings has been remaved, the bearing must be replaced with new unes. Drive in a new right bearlng squarely, Ins‘all the dislance collar, then drive in the left bearing using the special tools, TOOLS: Driver 07749-0010000 Attachment, 42 X 47 mm 077460010300 Pilnt, 20 mm 07746-0040500 m— Da not get grease on the brake discs or stopping power will be reduced. lnslall the brake discs on the wheel hub‘ Install and tighten xhe new mounting bolts to the specified torque‘ TORQUE: 20 Nm (2.0 kgf-m , 14 lbf ft) Apply grease to the dust seal lips, then install Them imo the wheel hub. 13-13 FRONT WHEEL/SUSPENSION/STEERING INSTALLATION install the left side collar, Install the right side collan Install the front wheel between the fork legs while aligning the left brake disc between the left brake caliper pads. Apply thin layer of grease to the front axle surface. Install the front axle from the left side. Hold the axle and tighten the axle bolt to the specified torque. TORQUE: 59 NW! (60 kgf-m , 43 Ibf-ft) Tighten the right axle pinch bolt to the specified torque‘ TORQUE: 22 N-m (2.2 kgf‘m ,16lbf‘fl) 13-14 AXLE BOLT PINCH BOLT FRONT WHEEL/SUSPENSION/STEERING lnstall the left brake caliper and tighten the new mounting bolts to the specified torque. TORQUE: 30 Ni“ (3.1 kgf-m,22 Ibf-ft) With the front brake applied, pump the fork up and down several times to seat the axle and shack brake operation. Tighten the left axle pinch bolt to the specified torque. TORQUE: 22 Nrm (2.2 kgf-m,16|bf-ft) PINCH BOLT Check the clearance between the brake disc and FEELEH GAUGE caliper bracket on each side after installation. The clearance should be at leasl 0.7 mm (0.03 inl. 13-15 FRONT WHEEL/SUSPENSION/STEERING FORK REMOVAL Remove the from wheel (page 13-9). Remove the bolts and left brake caliper (page 15-18’. CAUTION: Do not hang the brake caliper from the brake hose. Remove the bolx and brake hosa joim on each side‘ Remove the bolts and front fender. Loosen the fork (op pinch bolt. When the fork is to be disassembled, loosen the furk cap, but do not remove it yet. 13-16 FRONT WHEEL/SUSPENSION/STEERING Loosen the fork bottom pinch bolt and remove the fork who from rho fork top bridge and steering sfem. BOTTOM PINCH BOLT DISASSEMBLY Hold the fork slider in a vice with sof! jaws or a shop towel Remove the fork sockef bolt with a hex wrench. F®RK SOCKET BOLT Remove the fork cap. FORK CAP The folk spring is under spring pressure. Use care when removing it 2:339 the distance collar, spring seat and fork DISTANCE COLLAR Four out the fork fluid by pumping the fork tube up and down several times. FRONT WHEEL/SUSPENSION/STEERING Remove the fork socket ban and sealing washer. Remove the fork piston and rebound spring from the fork tubs. Remove the dust seal, Remove the oil seal stopper ringt 13-18 FRONT WHEEL/SUSPENSION/STEERING Pull the fork tube out until resistance from the slider bushing is felt 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 bushing. Remove the oil lock piece from the fork slider. Remove the oil seal, backup ring and slider bushing from the [ark tuber NOTE‘ Do not remove the fork tube bushing unless it is necessary to replace it with a new one. INSPECTION Fork spring Measure the fork spring free length SERVICE LIMIT: 303.0 mm (11.93 in) 13-19 FRONT WHEEL/SUSPENSION/STEERING Fork tuba/slider/pistun Check the fork tube, fork slider, oil lock piece and fork piston for score marks, and excessive or abnormal wear. Check the fork piston ring for wear or damage. Check the rebound spring for fatigue or damage. Place the fork tube in V-block and measure the runout. Actual runout is 1/2 the total indicator reading. SERVICE LIMIT: 0.20 mm (DVOOE in) Fork tuba bushlng Visually inspect the slider and for tube bushings. Replace the bushings if there is excessive scoring or scratching, or if the teflon is worn so that the copper surface appears on more than 3/4 of the entire surface. Check the back—up ring; replace it if there is any distortion at the points shown. 13-20 FORK SLIDER I REBOUND SPRING FORK’TUBE FORK PISTON DIAL INDICATOR FORK TUBE BUSHING COPPER SURFACES BACKUP RING CHECK POINTS FRONT WHEEL/SUSPENSION/STEERING ASSEMBLY FORK PISTON RING FORKTUBE DISTANCE COLLAR DUST SEAL STOPPER RING FORKCAP , 23 N-m (2.3 kgf-m, OIL SEAL /" 17 mm) BACK‘UP RING " SLIDER BUSHING FORK TUBE BUSHING SPRING SEAT FORK SLIDEFI FORK PISTON \fl FORK SPRING OIL LOCK PIECE 20 N-m (2.0 kgf-m,14|bf-fl) REBOUND SPRING Before assembly, wash all parts with a high flash or non—flammable solvent and wipe them dry. FOFIK TUBE BUSHIN'G Install a new fork tube bushing if the bushing has been removed. Install the rebound spring to the fork piston. Install the rebound spring and fork piston into the forktube. Install the oil lock piece onto the fork piston end, FORK TUBE FORK PISTON REBOUND SPRING Apply recommended fork fluid to the fork tube V bushing, then install the fork tube into the fork slider. 13-21 OIL LOCK PIECE F’onk SLI n t FRONT WHEEL/SUSPENSION/STEERING Insla/I the oil seal with Its marked Side facing up. Hold the fork slider in a vise with soft jaws or a shop towel. Apply a locking agent to the for socket bolt threads and install and tighten the socket bolt with a new sealing washer into the fork pistont NOTE: If the fork piston turns with the socket b0”! temporarily install the fork spring and fork cap. TORQUE: 20 N‘m (2,0 kgf—m, 14 lbl‘ft) Applv recommended fork fluid to the guide bushing, and new fork oil seal lips. Install the fork oil seal, back-up ring and guide bushing onto the fork tube. Drive the oil seal in using the special tools, TOOLS: Slider weight 07947-KA50100 Oil seal driver amchmem 07947-KF00100 Install the stopper ring into the fork slider groove securely. install the dust seaL 13-22 OIL SEAL FRONT WHEEL/SUSPENSION/STEERING Pour the specified amount of recommended fork fluid into the fork tube. RECOMMENDED FORK FLUID: Fork fluid FORK FLUID CAPACITY: 486 i 2.5 cm” (16.4 i 0.08 US 02, 17.1 i 0.09 Imp 02) Pump the fork tube several times to remove trapped air from the lower portion of the fork tube‘ Compress the fork leg fully and measure the oil level from the top of the fork tuba. FORK OIL LEVEL: 102 mm 14.0 in) 102 mm [4.0 in) Pull the fork tube up and install the fork spring with _ SPRING DISTANCE COLLAR the tightly wound coil and facing down, Install the fork spring seat and distance collar. e?) / SPRING SEAT Apply fork fluid to the new O-ring. FORK CAP Install a O-ring onto the fork cap, Install the fork cap onto the fork tube. 13-23 FRONT WHEEL/SUSPENSION/STEERING INSTALLATION Install the fork tube inta the steering stern and fork top bridge. f Align the top end of the fork tube with the upper surfacs of the top bridge as shown‘ Tighten the bottom bridge pinch bolt, TORQUE: 39 N-m 14,0 kgf-m ,29 Ibf-ft) Tighten the fork cap to the specified torque if it was removed. TORQUE: 23 N-m (2.3 kgf-m,17lbf‘ft) Tighten the fork top pinch bolt to the specified torque. TORQUE: 11 N-m (1.1 kgf-rn , B Ibf-ft) 13-24 , i, fiwhmgiamtf FRONT WHEEL/SUSPENSION/STEERING Install the front tender and tighten the bolts to the ‘ BOLTS FRONT FENDER specified torque. TORQUE: 12 N-m (1.2 kgf-rn , 9 Ibf‘ftl Install the both brake hose joint and tighten the bolts to the specified torque. TORQUE: 12 N-m (1.2 kgf-m , 9 Ibfvh) Install the front wheel (page 13-14). Install the brake calrpers(paga15A20) STEERING STEM REMOVAL Remove the following: ~Handlebar (page 1373I *Front wheel (page 13-9) *Headlight case (page 19*3I -Combinatlon meter (page 19-5) ~Front brake calipers (page 15-18I Remove the bolt and front brake hose clamp. Remove the bolt and horn unit. 13—25 FRONT WH EEL/SUSPENSION/STEERING Loosen and remove the steering stem nut. Remove the fork legs (page 13—16). Remove the washer and ‘he top bridge. Remove the headlight case bracker assembly from the steering stem. S‘raighten the fiabs of the lock washer. Remove the lock nm and lock washer. 13-26 TOP BRIDGE FRONT WHEEL/SUSPENSIONISTEERING Remove the steering stem bearing adjusting nut using the special tool. TOOL: Steering stern socket 0791673710101 Remove "19 following DUST SEAL INNER RACE 7 Dust seal , - Upper bearing inner race -Upper bearing -Steering stem LOWER BEARING , Lower bearing STEERING STEM BEARING REPLACEMENT AWACHMENT NOTE: Always replace the bearings and races as a set. Remove the upper bearing outer races using the Q special tools. TOOLS: / Driver attachment 07953-MJ10100 O / Driver handle O7953»MJ10200 13-27 DRIVER HANDLE FRONT WHEEL/SUSPENSION/STEERING Remove the lower bearing outer races using the special tool. TOOL; Bearing race remover 07946-3710500 BEARING RACE REMOVER Install the steering stem nut onto the stem to LOWERINNER RACE prevent Ihe 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 stern, Remove the dust seal. DUST SEAL INSTALLATION STEM NUT TOP BRIDGE M103 Nrm (10.5 kgf‘m , 76 Ibf-rt) LOCK NUT LOCK WASHER TOP THREAD UPPER DUST SEAL UPPER INNER RACE UPPER BEARING UPPER OUTER RACE LOWER OUTER RACE LOWER BEARING LOWER INNER RACE STEERING STEM LOWER DUST SEAL 13-28 FRONT WHEEL/SUSPENSION/STEERING Apply grease to new dust seal lips and install it ‘y : - ‘ ’_ fiERING STEM DRIVER over the steering stem. : - V ’ -, - ’ ’ _ Install a new lower bearing inner race using a special tool and a hydraulic press. TOOL: Steering stem driver 07946-Ml300000 Drive a new upper bearing outer race into the ‘ A'I'I'ACHMENT steering head pipe. TOOLS: Driver 07749-0010000 Attachment,42 X 47 mm 07746-0010300 Drive a new lower bearing outer race into the steering head pipe. TOOLS: Driver 07749-0010000 Attachment, 52 X 55 mm 07746-0010400 Apply grease to the lower bearing, then install it onto the steering stern. Insert the steering stem into the steering head pipe. STEERING STEM Apply grease to the upper bearing. upper inner INNER RACE race and dust seal lips. r—fil w—fifl Install upper bearing, inner race and dust seal. 13-29 FRONT WHEEL/SUSPENSION/STEERING Egan!“ stern bearing adjusting nut and hand STEERING STEM SOCKET Tighten the stern bearing adjusting nut to the initial torque. TOOL: Steering stem socket 07916-3710101 TONGUE: 25 N-m (2.5 kgf-rn,18|bf-t"t) Move the steering stem right and left, lock-to-Iock, five times to seat the bearings. Make sure that the steering stem moves smoothly, without play or binding. Retighten the bearing adjusting nut to the specified STEERING STEM SOCKET torque. TORQUE: 25 N-m (2.5 kgf-m,18|bf-ft) Recheck that the steering stem moves smoothiy without play or binding, Instail the new look washer onto the steering stem. LOCK NUT Align the tabs of the lock washer with the grooves in the adjustment nut and bend two opposite tabs (shorter) down into the adjustment nut groove. g LOCK WASHER 13_30 ADJUSTMENTNUT FRONT WHEEL/SUSPENSION/STEERING Install and finger tighten the lock nut, Hold the bearing adjusting nut and further tighten the lock nut within 1/4 turn (90") enough to align its grooves with the lock washer tabs. LOCKWASHER TAB _ Bend the lock washer tabs up into the lock nut groove. Install the headlight case bracket onto the steering stern, NOTE Route the wires, cables properly (page 1—22). Install the top bridge and washer. TOP BRIDGE WASHER lnslall the fork legs (page 12—24), Install the stem nut. Tighten the steering stem nut to the specified torque. TORQUE: 103 N-m [10.5 kgf-rn , 76 Ibfvl‘tl 13-31 FRONT WHEEL/SUSPENSION/STEERING Install the brake hose clamp and tighten the bolt securelyl install the horn unit bracket and tighten the bolt securely. f‘ Ho‘afigfuwn B'MKET LAMP BOLT ‘ v BRAKE H0553; Install the following: -Handlebarlpage13-5i - Front wheellpage13-14l - Headlight case (page 1973] -Combination meter (page 19—8) — Front brake Calipers (page 1520) STEERING HEAD BEARING FRELOAD Support the motorcycle using a work stand or box under the engine and raise the front wheel off the ground. Position the steering stem to the straight ahead position. Hook 3 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 preload should be within 0.98-1.47 N (0.10— 01 5 kgfv 0.22*O.33 lbf). If the reading do not fall within the limits, lower the front wheel on the ground and adjust the steering bearing adjusting nut 13-32 REAR WHEEL/SUSPENSION 37 N-m (3.8 kgf-rn , 27 Ibf-fth 37 N-m (3.3 kgf‘m , 27 Ibf-ft) 88 N-m (9.0 kgf-m , 65 lbf-ft) 14 14. REAR WHEEL/SUSPENSION SERVICE INFORMATION 14-1 SHOCK ABSORBER 14-10 TROUBLESHOOTING 14-2 SWINGARM 14-12 REAR WHEEL 14-3 SERVICE INFORMATION GENERAL A'AWAFINING I A contaminated brake disc or pad reduces stopping pawan Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. - The shock absorber contains nitrogen under high pressure. Do not allow fire or hast near the shock absorber. ' Before disposal of the shock absorber, release the nitrogen (page 14-11). . When servicing the swingarm or shock absorber, support the motorcycie using a safety stand or hoist. - Refer to section 15 (or brake system information. ' Use only tires marked “TU BELESS” and tubeless valves on rim marked “TUEELESS TIRE APPLICABLE”. I Use genuIne Honda replacement bolts and nuts Ior all suspension pivot and mounting point. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Minimum tire tread depth 2.0 (0.03) CoId tire pressure Jriver only 290 kPa (2,90 kgf/cmz , 43 psi) ¥ Driver and passenger 290 kF‘a (2.90 kgf/cm’ , 42 psi) 7, fole runout — 0.20 (0.008) Wheel rim runout Radial 7 2.0 (0.08) m Axial 7 7 A 2.0 (0.08) Drive chain Size/Iink DID 525VMZ‘1IOLE A 7 , ( RK 525ROi110LE — Slack 30*40('I.2—1,6I i 50(2.0) Shock absorber pre—Ioad adjuster standard position 2nd groove TORQUE VALUES Rear axle nut Rear brake disc mounting bolt Final driven sprocket nut Swingarm pivot nut Drive chain case bolt Drive chain slider bolt Drive chain adjuster lock nut Rear shock absorber upper mounting nut Rear shock absorber lower mounting nut 88 N-m (9.0 kgf-m,65 Ibf-it) U»nut ALOC bolt 108 Nm (11.0 kgfrm , 80 Ith) U-nut 88 N-m (9.0 kgf-rn,65 Ibfvft) U-nut 42 Nm (4.3 kgf-rn , 31 Ibhft) 12 N-m (1.2 kgf-m , 9 Ibf-fll S N-m (0.9 kgf-m , 6.5 lbf‘fll 21 N-m (2.1 kgf-m,15|bf-ft) 37 Nm (3.8 kgf-m , 27 IbH‘t) U-nut 37 N-rn (3.8 kngm , 27 Ibf-ft) U-rIut 14-1 REAR WHEEL/SUSPENSION TOOLS Bearing remover shaft Bearing remover head, 17 mm Driver Attachment, 32 X 35 mm Attachment, 42 X 47 mm Attachment, 52 X 55 mm Film, 15 mm Pilot, 17 mm Pilot, 22 mm Attachment, 28 X 30 mm Driver shah Needle bearing remover attachment Needle bearing remover TROUBLESHOOTING Soft suspension - Weak shock absorber spring 0 Incorrect suspension adiustment 0 Oil leakage from damper unit 0 Tire pressure too low Hard suspension - Damaged shock absorber mounting hearing I Bent damper rod - Damaged swingarm pivot bearings . Bent swingarm pivot I Incorrect suspension adjustment U Tire pressure (00 high 07746-0050100 077460050500 07749-0010000 07746-0010100 0774643010300 07746—0010400 0774670040300 07746-0040400 07746-0041000 079464870100 07946-MJ00100 07GMD»K‘|70200 07LMCvKV30100 Steers to one side or does not track straight - Bent rear axle . Axle alignment/chain adjusimeni not equal on both sides Rear wheel wobbling 0 Bent rim 0 Worn rear wheel bearings 0 Faulty tire 0 Unbalanced tire and wheel - Tire pressure too low I Faulty swingarm pivot bearings 14—2 REAR WHEEL/SUSPENSION REAR WHEEL REMOVAL Loosen the rear axle nut. Loosen the lock nut and drive chain adjusting nut and make a drive chain slack fully, Support the motorcycle securely using a hoist or equivalent. Remove the axle nut, washer and rear axle washer. Derail the drive chain from the driven sprocket. Do not aperale the Remove the axle and rear axle washer from the left brake pedal alter Slde and remove the rear wheel. ms rear wheel is removedt Remove the side collars‘ 14—3 REAR WHEEL/SUSPENSION INSPECTION Axle Place the axis in V»b|ocks and measure the ru nout. Actual runout is ‘l/2 the total indicator reading. SERVICE LIMIT: 0.20 mm “1008 in) Wheel bearing Turn the inner race of each bearing with your finger. Bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. Remove and discard the bearings if the races do not turn smoothly and quietly, or if they fit loosely in the hub. NOTE: Replace the wheel bee rings in pairs. WHEEL BEARING Whul rim runout Check the rim runout by placing the wheel in a turning stand. Spin the wheel slowly and read the runout using a dial indicator. Actual runout is 1/2 the total indlcator reading. SERVICE LIMITS: Radial: 2.0 mm (0.08 in) Axial: 2.0 mm 10.08 in) Driven sprocket Check the condition of the final driven sprocket teeth. Replace the sprocket if lt is worn or damaged. NOTE: I If the final driven sprocket requires replacement, inspect the drive chain and drive sprocket. ' Never install a new drive chain on a worn sprocket or a worn chain on new sprockets. Both chain and sprocket must be in good condition or the replacement chain or sprocket will wear rapidly. Wheel balance See Page 13-10 for wheel balance. 14-4 DISASSEMBLV Remove the bolts and brake disc. Remove the right dust seal. Remove the left dust seal. NOTE' If you will be disassemble the driven flange, loosen the driven sprocket nuts before remuvmg the driven flange from the wheel hub. Remove the driven flange assembly from the left wheel hub. Remove the wheel damper rubbers. Remove the OArihg. 14-5 REAR WHEEL/SUSPENSION REAR WHEEL/SUSPENSION D""°”""“9° ”WW '°'“°"" BEARING DRIVEN FLANGE COLLAR Remove the driven flange from the wheel hub, then , remove the driven sprocket nuts and sprocket. Remove the dust seal. Remove the driven flange collar. Drive outthe driven flange bearing. Wheel bearing removal H AFT Install the bearing remover head into the bearing. , Always ’SPISCB From the opposite side install the bearing remover the bearings in shaft and drive the bearing out of the wheel hub. [78/va Remove the distance collar and drive out the other bearing. TOOLS: Bearing remover head, 17 mm 07746-0050500 Bearing remover shaft 07746—0050100 ASSEMBLY HIGHT DUST SEAL @ 42 N-m (4.3 kgf-m,31lbl-ftl DRIVEN FLANGE COLLAR E , ,Efi, DRIVEN FLANGE ,6“ LEFT DUST SEAL DRIVEN FLANGE BEARING (6303Ul RIGHTWHEEL BEARING (6303Ul DISTANCE COLLAR 108 NW] (11.0 kgf‘m , 80 Ibf-ftl LEFT WHEEL BEARING (6303U) @— BGR'NG DAMPER RUBBERS 14—6 REAR WHEEL/SUSPENSION Wheelbearinginstallation , , .V , DRIVER install Me bearing Drive in a new righl bearing squarely, with the making Instail ihe distance collar, then drive in the ieft side facing our bearing. TOOLS: Drivar 077490010000 Attachment, 42 X 47 mm 07746-0010300 Film, 17 mm 077460040400 Driven flange bearing installation Place the bearing onto ihe suirable base with its marking facing dawn. Drive the collar to the driven flange bearing using the special toois. TOOLS: Driver 07749-0010000 Attlchment, 28 X 30 mm 079464870100 Pilot, 17 mm 0774643040200 Drive the new driven flange bearing into {he driven flange using the special toois. TOOLS: Driver 07749-0010000 Attachment, 52 X 55 mm 0774641010400 Pilot, 17 mm 0774670040200 Fieplacelhe Install the wheel damper rubbers imo the wheel damper rubbers as hub, use!» Apply grease to the new O-ring and install ii into khe groove of the wheel hub. 14-7 REAR WH EEL/SUSPENSION Apply grease to the driven flange and rear wheel DRIVEN FLANGE ASSEMBLY hub Contact area. Install the driven flange assembly into the left wheel hub. If the driven sprocket was removed. install the driven sprocket and tighten the nuts TORQUE: 108 N-rn (11.0 kgf-m , 80 ibf-hi Apply grease to the left dust seal lips, then install it into the driven flange. Install the brake disc with its "DRIVE” mark facing out. Install and tighten the new bolts to the specified torque. TORQUE: 42 N-m (4.3 kgf‘m , 31 lbf-ftl Applv grease to the dust seal lips. then install it into the right wheel hub. REAR WHEEL/SUSPENSION INSTALLATION Apply grease to the side collar inside and grooves. Install the side col Ia rs. If the drive chain adjusters has been removed. install the drive chain adjusters into the swingarm with their cutout side facing outward. Install the rear brake caliper bracket onto the guide of the swingarrn. Be careful not to Place the rear wheel into the swingarm carefully damage the brake aligning the brake disc between the brake pads. pads. lnstall the drive chain uverthe driven sprocket. 14-9 REAR WHEEL/SUSPENSION Install the axle washer with its “F" mark facing forward. Install the axle from the left side. Install the axle washer with its "F" mark facing forward install the plain washer and loosely install the axle nut. Adjust the drive chain slack (page 3»17l. Tighten the axle nut to the specified torque. TORQUE: 88 N-m (9.0 kgf-m , 65 lbf-hl SHOCK ABSORBER REMOVAL Support the motorcycle securely using a hoist or equivalent, Remove the following: 7 Rear wheel (page 14-3) —Side covers lpage 2-2) Remove the shock absorber lower mounting bolt/ nut. 14-10 AXLE WASHER "F" MARK AXLE REAR WHEEL/SUSPENSION Remove the shock absorber upper mounting bolt] nut and shock absorber INSPECTION Visually inspect the damper unit for damage, Check for the: * Damper rod for bend or damage * Damper unit for deformation or oil leaks 7 Bump rubber for wear or damage —Spring for damage Inspect all the other parts lorwear or damage If necessary, replace the shock absorber as an assembly. SHOCK ABSORBER DISPOSAL PROCEDURE Center punch the damper to mark the drilling point. Wrap the damper unit inside a plastic bag, Supportthe damper in a vise as shown, Through the open end of the bag, insert a drill motor with a sharp 2—3 mm (5/64—1/8 in) drill bit. M ' Do not use a dull drill bit which could cause a build-up of excessive heat and pressure inside the damper, leading to explosion and severe personal injury ' The shock absorber contains nitrogen gas and oil under high pressure, Do not drill any Iarther down the damper case than the measurement given above, or you may drill Into the oil chamber; ail escaping under high pressure may cause serious personal injury. ' Always wear eye protection to avoid getting metal shaving in your eyes when the gas pressure is released The plastic bag is only intended to shield you from the escaping gas. 35 mm H4 in) 1 Hold the bag around the drill motor and briefly run the drill motor inside the bag; this will inflate the bag with air Irom the motor and help keep the bag 14-11 from getting caught in the bit when you start. REAR WHEEL/SUSPENSION INSTALLATION Install the shock absorber into the frame. Install and tighten the upper maunting bolts/nuts to the specified torque. TORQUE: 37 N-m (3‘8 kgf‘m , 27 Ibf-ftl Install and tighten the lower mounting bolts/nuts to the specified torque. TORQUE: 37 N-rn [3‘8 kgf-m , 27 Ibf-ftl Install the removed parts in the reverse order of removal. SWINGARM REMOVAL Support the motorcycle securely using a hoist or equivalent. Remove the rear wheel (page14-3]. Remove the shock absorber lower mounting belt/ nul. Remove the two brake hose clamp bolts. 14-12 BRAKE HOSE CLAMPS REAR WHEEL/SUSPENSION Remove the gearshift peda! link pinch butt and gearshih pedal I‘mkfrom the spind‘e, Remove the bolts and lefl footpeg holder. Remove the ban; and drive chain case. Remove the swingarm pivo! nut. REAR WHEEL/SUSPENSION Remove the left pivot bracket mounting bolts. Remove the swingarm pivot bolt and swingarm. DISASSEMBLY/INSPECTION Remove the bolts and drive chain slider. Remove the pivot collar, side collars and dust seals from the swingerm pivot. Check the dust seals and collar for damage or fatigue. Remove the shock absorber pivot dust seals and collar. Check the dust seals and collar for damage or fatigue. Check the needle bearing for damage. Turn the inner race of right pivot bearings with yourfinger. Bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. Remove and discard the bearings if the races do not turn smoothly and quietly, or if they fit loosely in the pivot. 14-14 BEARING REAR WHEEL/SUSPENSION PIVOT BEARING REPLACEMENT Remove the snap ring. I _ SNAPHING Press the right pivot bearings (radial ball bearings) . . . . DRIVER SHAFT out tram the swmgarm pivot using the special tool. TOOL: Drivar shaft 07946-MJ00100 Press the left pivot bearing (needle bearing) out of BEARING the swingerm pivot using the special tools. ‘ HEMOVEH ATTACHMENT TOOLS: Bearing remover attachment 07GMDAKT70200 Driver shaft 07946-MJ00100 Press a new left pivot inner bearing lneedle bearingl into the swingarm pivot using the special tools: DHIVEH TOOLS: Driver 07749-001000!) Attachment. 25 x 30 mm 07746-1870100 28,29 mm Flint, 22 mm 07746-0041000 [1,107 1.14 in) NOTE‘ : ' Press the inner needle bearing into the swingarm with the marked side facing out. - Install the inner bearing so that the needle bearing surface is lower 28—29 mm (11071.14 inl from the end of the swingarm pivot surface. 14—15 \ ATTAGHMENT/PILQT REAR WHEEL/SUSPENSION Press a new left pivot outer bearing (needle DRIVER bearing) Into the swmgarm pivot using the special 4_5 mm “0'57 (0.164110 in) TOOLS: Drlvov 0774943010000 Attachment, 28 X 30 mm 077464870100 Pilot, 22 mm 07746-0041000 NOTE- ' Press the outer needle bearing into the swingarm with the marked side facing out 0 Install the outer bearing so that the needle bearing surface is lower 475 mm (0.167020 in) from the end of the swingerm pivot surface. DRlVER Press new right pivot bearings (radial ball bearing) into the swingarm pivot one at a time. TOOLS: Driver 077490010000 Attachment, 32 x 35 mm 07746-0010100 Film, 15 mm 0774670040300 g g i. ATTQIggM E NT/Pl L®T Install the snap ring into the swingarm pivot groove securely. SNAP RING SHOCK LINK PIVOT BEARING ‘ ' REPLACEMENT - NEEDLE BEARJNG REMOVER Remove the needle bearing out of the shock link using special tool. TOOL: Needle bearing remover O7LMC—KV30100 REAR WHEEL/SUSPENSION Pack a new needle bearing with multi-purpose grease. . Install a new needle bearing into the shock link so that the needle bearing surface is lower 5.0755 mm (0.20%).22 in) from the end of the shock link surface. NOTE: Press the needle bearing into the shock link with the marked SIdE facing out, 50*55 mm (0.20-0.22 in] TOOL: Needle hearing remover O7LMC-KV30100 ASSEMBLY PIVOT COLLAR .& DUST SEAL fl NEEDLE BEARING SWINGARM .& DUST SEAL SIDE COLLAR SNAP RING .fiu RADIAL BALL BEARINGS SIDE COLLAR fl. DUST SEAL ,fiq DUST SEAL DRIVE CHAIN SLIDEFI Apply grease to the dust seal lips, then install the dust seals and pivot collar into the shock absorber pivot. Apply grease to the dust seal lips, then install the dust seals, side collars and pivot collar into the swingarm pivot. 14-17 a—fiil eUSTSEAL , REAR WHEEL/SUSPENSION Install the drive chain slider onto the swingarm DRIVE CHAIN SLIDER aligning its bosses with the holes in the swingarm. Install the collars and bolts, then tighten the bolts to the specified torque. TORQUE: 9 N-m (0.9 kgf-rn , 6.5 Ibf-ft) INSTALLATION Apply thin cuat uf grease to the swingarm pivot bolt surface. Install the swingarm into the frame. Install the left pivot bracket and swingarm pivot bolt from the left side. Install the left DIVOI bracket mounting bolts, Install the drive chain case aligning its slit with the boss an the swingarm. 14—18 REAR WHEEL/SUSPENSION Install and tighten the drive chain case mounting bolts to the specified torque. ‘ ’Dfillv CHAIN CASE TORQUE: 12 N-m [1.2 kgf‘m , 9 lbf-ft) Install and tighten the swingarm pivot nut tn the specified torque. TORQUE: 88 N-m (9,0 kgf‘m , 65 lbf-fl) Tighten the left pivot bracket mounting bolts. Install the left footpeg holder and tighten the mounting bolts to the specified torque, TORQUE: 26 N-rn (2.7 kgfrm , 20 lbf-fii 14-19 REAR WHEEL/SUSPENSION Install iha gearshift pedal link to the spindle aligning its silk with the punch mark on the spindle Tighten the pinch bolt. Install the shock absorber Inwar mounting bolt/nut, tighten the nu to the specified xorque. TORQUE: 37 N-m (3.8 kgf‘m , 27 lbf~fli Route the brake hose properly, lighten the brake hose clamp bolts. Install the rear wheel (page 14-9). BRAKE HOSE CLAMPS 14-20 HYDRAULIC BRAKE 12 MM [12 kgfrm , 9 \bf-f!) 1 N-m (0.1 kgf-m , 0.7 Ibfvft) 34 N-rn (3.5 kgf-m , 25 Ibf-ft) 34 N-m (3.5 kgf~m , 25 let) 2 Nrm (0.25 kgf—m ,1.8lbf~ffl 13 N-m(1.3kgf~m,13|bf‘f1) 15 15. HYDRAULIC BRAKE SERVICE INFORMATION TROUBLESHOOTING BRAKE FLUID REFLACEMENT/ AIR BLEEDING BRAKE PAD/DISC FRONT MASTER CYLINDER 15-2 15-3 15.4 15—6 15-9 REAR MASTER CYLINDER FRONT BRAKE CALIPER REAR BRAKE CALIPER BRAKE PEDAL 15-13 1548 15-21 15-24 34 N-m (3.5 kgf‘m , 25 [MM 18 N-m(1.Bkgf«m,13lbI-fi) 15-1 26 N-m (2.7 kgf—m , 20 Ibf‘ft) 23 N«m (2.3 kgf-m,17|bf-ftl 2 N-m (0.25 kgf‘m,1.8|bf-ft) HYDRAULIC BRAKE SERVICE INFORMATION GENERAL AWARNING I A contaminated brake disc or pad reduces stopping pawer. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. I Check the brake system by applying the brake lever nr pedal. o 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 harizontal first. - Never allow contaminates (dirt. water. etc.) to get into an open reservoir. 0 Once the hydraulic system has been opened, or if the brake feels sponuv, the system must be bled. I Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid they may not be compatible. 0 Always check brake operation before riding the motorcycle. SPECIFICATIONS Unit: mm (in) ITEM 1 STANDARD SERVICE LIMIT Front Specified brake fluid ‘ 707ng 7 7 Brake disc thickness ‘ 4.5 (0.18) 3.5 (0.14] Brake disc rurlout i __ 0.30 (0.012) Master cylinder L D. 14.000i14.04%(05512—05529) 14.055 (0.5533) Master piston 0. D. 13.957i13.984 (05495—05506) 13.945 (0.5490) Caliper cyjinder |. D. Z7.000*27.050 (1.0630‘ 0650) 27.060 (1.0654) Caliper piston 0. D. l 26.935i26.968 (10604—10617) 26.910 (1.0594) Rear 7 Specified brake fluid ‘ DOTA A Brake pedal height 67.5 [2.65) Brake disc thickness 5.0 (0.20) 4.0 (0.16) Brake disc runout ‘ . 0.30 (0.012) Master cylinder I. D. , 14300714043 (05512—05529) 14.055 (0.5533) Master piston 0. D. 13.957- 13.934 (0.5495*0.5506) 13.945 (0.5490) Caliper cylinderl. D. 38.18—38.23 (1503*1505) 38.24(1.506) Caliper piston O. D. 38.098‘38148 (1.4999~1.5019) 38.09 (1.500) 15-2 TORQUE VALU ES Front brake master cylinder holder bolt From brake master cylinder cap screw Brake lever pivot belt Brake lever pivot nut Front brake switch screw Front brake caliper mounting bolt Front brake caliper slide pin (main) Front brake caliper slide pin (sub) Fad pin Pad pin plug Front brake hose clamp bolt Brake caliper bleeder Rear master cylinder mounting bolt Rear master cylinder hose joint screw Rear master cylinder push rod nut Rear brake caliper slide pin (main) Rear brake caliper slide pin (sub) Rear brake hose clamp bolt Brake hose oil bolt TOOLS Snap ring pliers TROUBLESHOOTING Brake lever/pedal soft or spongy I Air in hydraulic system I Leaking hydraulic system I Contaminated brake pad/disc I Worn caliper piston seal I Worn master cylinder piston cups I Worn brake pad/disc I Contaminated caliper I Caliper not sliding properly I Low brake fluid level I Clogged fluid passage I Warped/deformed brake disc I Sticking/worn caliper piston I Sticking/worn master cylinder piston I Contaminated master cylinder I Bent brake lever/pedal Brake lever/pedal hard I Clogged/restricted brake system I Sticking/worn caliper piston I Caliper not sliding properly I Clogged/restricted fluid passage I Worn caliper piston seal I Sticking/worn master cylinder piston I Bent brake lever/pedal 12 N-m (1.2 kgf-m , 5 lbfll‘!) 1N-m (0.15 kgf-m ,1.1lbf-ft) 1 N-m (0.1 kgf~m . 0.7 lbf‘fll 6 N-rn (0.6 kgf-m , 4.3 lbf-ftl 1N-m (0.12 kgr-m,o.srbrrt) 30 N-m (3.1 kgf-m , 22 lbfvftl 23 NM (2.3 kgf-rrl ,17Ibf-ftl 13 N‘rn (1.3 kgf-m , 9 lbfrft) 1B N-m (1.8 kgf-m ,13Ibf‘f‘t) 2 N'm (0.25 kgf-m ,1.8|bflft) 12 N‘m (1.2 kgf-m , 9 Ibfrft) 6 N-m (0.6 kgf-m , 4.3 Ibf‘ftl 12 N-m (1.2 kgf-m , 9 Ibf-ftl 1Nvm (0.15 kgf'm ,1.1lbf'ft) 18 N~m (1.8 kgi-m,13|bfvftl 27 N-m (2.8 kgf-m , 20 MFR) 23 N’lTi (2.3 kgf-m ,17lbf'fll 9 N-m (0.9 kgf-m , 6.5 lbf-ftl 34 N‘l’l’i (3.5 kgf-m , 25 lbf-ftl 07914-SA50001 HYDRAULIC BRAKE ALOC bolt Apply a locking agent to the threads Apply a locking agent to the threads Apply a locking agent to the threads Apply a locking agent to the threads ALOC bolt ALOC bolt or 07914-3230001 Brake grab or pull to one side I Contaminated brake pad/disc I Misaligned wheel I Clogged/restricted brake hose joint I Warped/deformed brake disc I Caliper not sliding properly Brake drag I Contaminated brake pad/disc I Misaligned wheel I Worn brake pad/disc I Warped/deformed brake disc I Caliper not sliding properly 15-3 HYDRAULIC BRAKE BRAKE| FLUID REPLACEMENT/AIR BLEED NG wnen uslrlg a brake bleeder. follow me manufacturer‘s operating instructions. m— A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degassing agent, CAUTION: I Do not allow foreign material to enter the system when filling the reservoir. I Avoid spilling fluid on painted. plastic, or rubber parts. Place a rag over these parts whenever the system is serviced. BRAKE FLUID DRAINING For the front brake, turn the handlebar to the left until the reservoir is parallel to the ground, before removing the reservoir cap. Remove the screws, reservoir cap, set plate and diaphragm. For the rear brake. remove the reservoir cap, set plate and diaphragm. Connect a bleed hose to the caliper bleed valve. Loosen the bleed valve and pump the brake lever or pedal. Stop pumping the lever when no more fluid flows out of the bleed valve, BRAKE FLUID FILLING Fill the reservoir with DOT 4 brake fluid from a sealed container. CAUTION: - Use only DOT 4 brake fluid from a sealed container. - Do not mix difierent types of fluid, There are not compatible. 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‘ Check the fluid level often while bleeding the brakes to prevent air from being pumped into the system. HYDRAULIC BRAKE ii sir ls entering the bleeder from around the bleed valve Ihrsflds, seal the threads Wltli let/on tape. Repeat the previous step procedures until air bubbles do not appear in the plastic hose. NOTE. If a brake bleeder is not available, fill the master cylinder and operate the brake [ever or pedal to fill the system Close the bleed valve. Next, perform the available BLEEDING procedure. BRAKE BLEEDING Connect a clear bleed hose to the bleed valve. Pump up the system pressure with the lever or pedal until there are no air bubbles in the fluid flowing out of the master cylinder and lever resistance is felt. 1t Squeeze the brake lever or push the brake pedal, open the bleed valve 1/2 turn and then close the valve. NOTE Do not release the brake lever or pedal until the bleed valve has been closed 2. Release the brake lever or pedal until the bleed valve has been closed. Repeat steps 1 and 2 until bubbles cease to appear in the lluid coming out of the bleed valve. Tighten the bleed valve. TORQUE: 6 N-m (0,6 kgf-rn , 4.3 lbf-ft) Fill the fluid reservoir to the upper level. Reinstall the diaphragm and diaphragm plate. On the tram brake, install the reservoir cap, and tighten the screws. On the rear brake, install the reservoir cap securely. 1 5-5 BRAKE B LEE DIAPHRAGM HYDRAULIC BRAKE BRAKE PAD/DISC FRONT BRAKE PAD REPLACEMENT Push the caliper pistons all the way in to allow insiallation of new brake pad. NOTE' Check the brake fluid level in the brake master cylinder reservoir as this operation causes the level to rise. Remove the pad pin plugs and loosen the pad pins. Remove the pad pins and brake pads. Clean the brake caliper inside especially around the pistons. Make sure that the pad Sprll’lg is in place. Always replace the Install the new brake pads. brake pads In Push the brake pads against the pad spring, then pans to assure install the pad pins. even dlsc pressure HYDRAULIC BRAKE Tighten the pad pins, TORQUE: 18 N-m (1.8 kgf-m,13|bf‘ft) Install and tighten the pad pins. TORQUE: 2 N-m (0.25 kgf-rn,1.8|bf-ftl REAR BRAKE PAD REPLACEMENT 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 m the brake master cylinder reservoir as this operation causes the level to rise. Remove the pad pin plug and loosen the pad pin. HYDRAULIC BRAKE Remove the pad pin and brake pads. ‘ WPADS \\ Clean the brake caliper inside especially around the pistons Always replace the Make sure the brake pad spring is in place. brake pads in install the new brake pads. pans to assure even disc pressure. Install the pad pin while pushing the pads against the pad spring so that the pad ends are positioned nntn the retainer on the caliper bracket, Install and tighten the pad pint TORQUE: 18 N-m (LB kgf~m ,13lbf-ft) Install and tighten the pad pin plug. TORQUE: 2 N-m (0.25 kgirm , 1.8 lbfrhl 15-8 HYDRAULIC BRAKE BRAKE DISC INSPECTION Visually inspect the brake disc for damage or cracks, Measure the brake disc thickness with a microme- ter. SERVICE UMITS: FRONT: 3.5 mm (0.14 in) REAR: 4.0mml0.16in) Replace the brake disc if the smallest measurement is less than the service limit. Measure the brake disc warpage with a dial indicator. SERVICE LIMIT: 0.30 mm (0.012 ml Check the wheel bearings for excessive play, ii the warpage exceeds the service limit. Replace the brake disc if the wheel bearings are normal. FRONT MASTER CYLINDER REMOVAL Drain the tram hydraulic system (page 15-3). Remove the rearvlew mirror from the master cylinr der. Disconnect the brake light switch wire connectors. Remove the pivot nut/bolt and brake lever. \ \\ ’ " \ . £3595 :3 A memun c‘rmRs Remove the brake hose oil bolt, sealing washers _ SEALlNG WASHERS , MASTER CYLINDER and brake hose eyelet. , , V CAUTION: Avoid spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is serviced. Remove the bolts from the master cylinder holder and remove the master cylinder assembly. 15_9 “ _ y ' HOLDER BOLTS HYDRAULIC BRAKE DISASSEMBLY Remove the screw and brake light swiich. Remove the boot. Remove the snap ring from the master cylinder " ' _ , , ' SNAP RING body using the special ioul as shown. , TOOL: Snap ring pliers 07914VSA50001 or 07914-3230001 Remove the master piston primary cup and spring. Clean the inside of the cylinder and reservoir with brake fluid. PRIMARY CUP 15-10 V SPRING MASIERPISTON HYDRAULIC BRAKE 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 i. D. SERVICE LIMIT: 14.055 mm (0.5533 in) Measure the master cylinder piston 0. D. SERVICE LIMIT: 13.945 mm (0.5490 in) ASSEMBLY 1N-m (0.15 kgfvm,1.1lbf-h) RESERVOIR COVER BOOT MASTER PISTON SET PLATE SPRING DIAPHRAGM SNAP RING MASTER CYLIN DER é BRAKE LIGHT SWITCH 15—11 HYDRAULIC BRAKE CAUTION: Keep the piston, cups, spring, snap ring and boat as a sat; da no! substitute individual parts Coat all parts with clean brake fluid before assembly. Dipthe piston in brake fluid, Install the primary cup to the spring. Install the sprlng and piston assembly into the master cylinder. CAUTION: ' L .SFRING’ IMASTERV FlSTUN When installing the cups, do not allow the lips to mminsiue aut. . __ . , ‘ 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 O7814»SAEDOD1 or 079148230001 lnstall the boot. Install the brake light switch and tighten the screw to the specified torque. TORQUE: 1 N-m (0.12 kgfrm , 0.9 lbf-fll 15-12 . ‘BRAKEL’IGHHW HYDRAULIC BRAKE Place the master cylinder assembly on the handlebar. Align the end of the master cylinder with the punch mark on the handlebar. W SEALING WASHERS, MASTER CYLINDER ~4 , _ Install the master cylinder holder with the “UP" mark facing up. Tighten the upper bolt first, then the lower bolt, Install the brake hose eyelet with the oil bolt and new sealing washers. Push the brake hose against the stopper, tighten the oil bolt to the specified torque. ' A - L BgLT‘ 'EYE—LETJOINW TORQUE: 34 Nrm13.5 kgl-m . 25 lbf-ftl ’ ' Connect the brake light switch wire connectors. Install the brake lever assembly, tighten the pivot bolt. TORQUE: 1 N-rn (0.1 kgf~m , 0,7 |bf~ft) Hold the pivot bolt and tighten the pivot nut. TORQUE: 6 NW (0.6 kglvm , 4.3 lbt-l‘t) Install the rearview mirror. -' Fill the reservoir to the upper level and bleed the L, brake system (page 15-3). REAR MASTER CYLINDER REMOVAL Drain the rear hydraulic system (page 15-3). Remove the brake hose oil bolt, sealing washers and brake hose eyeletjoint. CAUTION: Avoid spilling fluid nn painted, plastic, or rubber parts. Place a rag over these parts whenever the system Is serviced. Loosen the rear master cylinder mounting bolts. Remove the bolts and right footpeg holder. 15-13 HYDRAULIC BRAKE Remove the bolt and rear brake reservoir from the lrame, Remove and discard the brake pedal joint cotter pin. Remove the joint pin. Remove the mounting boits and rear master cylinder from the lootpeg holder. DISASSEMBLY Remove the screw and reservoir hose joint and O-ring from the master cylinder. Remove the boot. Remove the snap ring from the master cylinder body using the special tool as shown. TOOL: Snap ring pliers D7914-SA50001 or 07914-3230001 Remove the push rod, master piston and spring. Clean the inside of the cylinder with brake fluid. 15-14 HYDRAULIC BRAKE 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 l, D. SERVICE UMIT: 14.055 rrIm (0.5533 in) Measure the master cylinder piston 0. D. SERVICE LIMIT: i3.945 mm (0.5490 in) ASSEMBLY MASTER CYLINDER RESERVOIR CAP V a ,‘V RESERVOIR JOINT I SET PLATE I I b @/ l V 1N-m(0.15kgf~m.1.1|bI-fti ~ SPRING» MASTER PISTON Q M r a PRIMARY CAP Keep the piston, cups, spring, snap ring and boat as a set; do not substitute individu-l parts. DIAPHRAGM RESERVOlR LOWER JOINT CAUTION: Coat all parts with clean brake fluid before PRIMARY CAP assembly. Dip the piston in brake fluid. Install the primary cup to the spring. Install the spring and piston assembly into the master cylinder, Apply grease to the piston contact area of the push rod. CAUTION: Q Whan installing the cups, do not allow the lips to SPRING MASTER PISTON turn inside out. 15-15 PUSH ROD/LOWER JOINT HYDRAULIC BRAKE install the push rod into the master cylindert _ SNA’P‘RING install the snap ring using the special tool. ’ V CAUTION: E i Be certain the snap ling is firmly seated in the ‘ graove, TOOL: Snap ring pliers 079145160001 or 0791473230001 Install the boot. Ifthe push rod is disassembled, adjust the push rod length as shown. After adjustment, tighten the lock nut to the specified torque. TORQUE: 18 N‘m (1‘8 kgf-m , 13 Ibf‘ft) 67.5 mm (2.66 inl a OvRING Apply brake fluid to a new O-ring and install it onto the reservoir joint. Install the reservoir joint into the master cylinder. Apply a locking agent to the reservoir joint screw threads, Install and tighten the screw to the specified torquet TORQUE: 1N-m (0.15 kgf-m,1.1|bf-ftl 15-16 HYDRAULIC BRAKE INSTALLATION - V ) MASTER CVLlNDERt‘: Place the master cylinder onto the right footpeg X‘ 3 holder. Connect the brake pedal to the push rod lowerjoint. Install the joint pin and secure it With a new cotter pin. Install the right footpeg holder onto the frame and tighten the two mounting bolts to the specified torque. TORQUE: 26 N-m (2.7 kgf‘m , 20 [bf-ft) Install and tighten the rear master cylinder mount- ing bolts to the specified torque. TORQUE: 12 N-rn (1.2 kgf~m , 9 Ibf-ftl Install the brake hose eyelet joint with the oil bolt and new sealing washers. Push the eyelet joint against the stopper, then tighten the oil bolt to the specified torque. TORQUE: 34 N-m (3.5 kgf-m , 25 |bf~ftl Install and tighten the brake resen/oir mounting bolt. Fill the reservoir to the upper level and bleed the brake system (page 15-3). HYDRAULIC BRAKE FRONT BRAKE CALIPER REMOVAL Drain the brake system ipage15—3). Remove the brake pads (page 15-6)t Remove the oil bolt, sealing washers and brake hose eyelet joint, Remove the caliper mounting bolts and front brake caliper. CAUTION: Avoid spilling fluid on paintett plastic. or rubber parts. Place a rag aver than pm: whenever the ”mm" ”Mm" CALIFER PIN BOOT PAD RETAINER DISASSEMBLY Remove the caliper bracket from the caliper body. Remove the pad retainer and caliper pin boat from the bracket Remove the pad spring and bracket pin boot from the caliper bodyr BRACKET PIN BOOT r PAD SPRING Place a shop towel over the piston, Position the caliper body with the pistons down and apply small squins of air pressure to the fluid inlet to remove the pistons Do not use high pressure air or bring the nozzle too close to the inlet. Push the dust and piston seals in and lift them out. plsTON SEAL CAUTION: Be careful not to damage the piston sliding surface. Clean the seal grooves with clean brake fluid. 15-18 / DUST SEAL INSPECTION Check the caliper cylinder for scoring or other damage, Measure the caliper cylinder |. D. SERVICE LIMIT: 27.060 mm (1.0654 in) Check the caliper pistons for scratches, scoring or other damage Measure the caliper piston O, D‘ SERVICE LIMIT: 26.910 mm [1.0594 in) ASSEMBLY a CALIPER PISTON FAD RETAINER (-fii CALIPER PIN BOOT CALIPER BRACKET 23 N-m (2.3 kgf~m ,17lbI- ’6 BRACKET PIN BOOT ,fii DUST SEAL PISTON SEAL CALIPER BODY PAD SPRING 15-19 HYDRAULIC BRAKE @27 N-m (2‘s kgf-m , 20 lbi~ft) HYDRAULIC BRAKE Note the metal/align direction er the pad Spring. Coat the new piston seals with clean brake fluid. Coal the new dust seal with silicone grease. Install the piston and dust seal 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. Install the pad spring in the caliper body. Install the bracket pin boot into the caliper body. If a caliper and bracket pin boots are hard or deteriorated, replace them with new ones. Install the brake pad retainer and caliper pin boot into the caliper bracket. Apply silicone grease to the caliper and bracket pins and install the caliper bracket over the caliper body. INSTALLATION install the caliper and tighten the new mounting bolts to the specified torque. TORQUE: 30 N-m (3.1 kgfrm , 22 ibf-fti Install the brake hose eyelet joint to the caliper body with two new sealing washers and Oil bolt. Align the brake hose eyelet to the stopper on the caliper, than tighten the oil bolt to the specified torque. TORQUE: 34 N-m 13.5 kgf—m , 25 Ibf-ft) Fill and bleed the brake hydraulic system (page 15'3" 15-20 % PISTON SEAL a PISTON rfii ousr SEAL $/ BRACKET FIN BOOT L 3 @«fl ., Wt PAD SPRING ’61 CALIPER PIN eoo FAD RETAINER HYDRAULIC BRAKE REAR BRAKE CALIPER REMOVAL Drain the rear brake hydraulic system (page 15-3). Remove the rear brake pads (page 15-7). Remove the oil bolt, sealing washers and brake hose eyelet joint. CAUTION: Avald spilling fluid on painted, plastic, or rubber parts. Place a rag over these parts whenever the system is serviced. Remove the caliper mounting bolt. Pivot the caliper up and remove it. DISASSEMBLY Remove the pad spring, sleeve and boot from the caliper body. Remove the brake pad retainer and caliper pin boot from the caliper bracket. Place a shop towel over the piston. Position the caliper body with the piston down and apply small squirts of air pressure to the fluid inlet to remove the piston. M DD nut use high pressure air nr bring the nazzlo too close to the inlet. 15-21 HYDRAULIC BRAKE Push the dust seal and pismn seal in and lift them out, CAUTION: Be careful nut to damage tha piston sliding surface. Clean the seal grooves With clean brake fluid. INSPECTION Check the caliper cylinder for scoring or other damage. Measure Ihe caliper cylinder L Di SERVICE LIMIT: 35.24 mm (1.506 in) Check the caliper piston for scratches, scoring or o‘her damage. Measure the caliper pismn O, D. SERVICE LIMIT: 38.09 mm (1.500 inl ASSEMBLY ,fioUST SEAL 6N-m (0.6 kgt-m,4,a mm) & CALIPER PISTON A EFl B DV a PISTON SEAL C LIP O 27 N‘m (2.8 kgf‘m , 20 [bf-ft) SLEEVE v 23 N' 2.3 k f- ,17lbf-ft 15-22 ml 9 m l Coat the new piston seal with clean brake fluid. Coat the new dust seal with silicone grease, Install the piston seal and dust seal into the groove of the caliper body. Coat the caliper piston with clean brake fluid and install it into the caliper cylinder with its opening end toward the pad. If the caliper and bracket pin boots are hard or deteriorated, replace them with new ones. Install the pad retainer and caliper pin boot into the caliper bracket. Install the pad spring into the caliper body, Apply silicone grease to the inside of the bracket pin boot. Install the bracket pin boot and sleeve into the caliper. INSTALLATION Apply silicone grease to the caliper pin and install the caliper onto the bracket. Install and tighten the new rear brake caliper mounting bolt to the specified torque. TORQUE: 23 N-m (2,3 kgf-m,17|bf-ftl Install the brake hose eyelet to the caliper body with two 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: 34 Nrm13.5kgf-m,25lbf-ft) Install the brake pads (page 154). Fill and bleed the rear brake hydraulic system lpage15-3l. 15-23 PISTON SEAL HYDRAULIC BRAKE a PISTON HYDRAULIC BRAKE BRAKE PEDAL REMOVAL Remove the right footpeg holder mounting bolts. Remove and discard the braka pedal ioim cotter pinI Remove me joint pin, firm SPRING ~ :4 ‘ 1' Unhook the return spring and remove the brake Iigm swiIch from the step holder, Unhookxhe brake pedal return spring. Remove the snap ring, washer and brake pedal. INSTALLATION BRAKE LIGHT SWITCH SWITCH SFRI NG RETURN SPRING BRAKE PEDAL WASHER SNAP RING 15-24 HYDRAULIC BRAKE Apply grease to the sliding surface of the brake ml‘thHT FW pedal and footpeg holder. Install the brake pedal. Install the washer, then install the snap ring Into the firm“ SPglN groove securelv‘ ~' Hook the brake pedal return springt install the brake light switch and hook the switch spring. Connect the brake pedal to tha push rod Iowerjoint. Install the joint pin and secure it with a new cotter pin. Install the right iootpeg holder and tighten the mounting bolts to the specified torque. TORQUE: 26 Nm (2.7 kgfm , 20 lbf-ft) 15-25 BATTERY/CHARGING SYSTEM SYSTEM DIAGRAM IGNITION SWITCH REGULATOR/RECTIFIER \ I'! 1% ALTERNATOR EATI'EHY r—1 / REGULATOR] RECTIFIER ALTERNATOR 16 l ' e l MAIN FUSE 30A |——l Y Y IY (ISRIW BATTERY 16. BATTERY/CHARGING SYSTEM SYSTEM DIAGRAM 16-0 CHARGING SYSTEM INSPECTION 16-6 SERVICE INFORMATION 16-1 ALTERNATOR INSPECTION 16-8 TROUBLESHOOTING 16-3 REGULATOR/RECTIFIER 16-8 BA‘I'I’ERY 16-5 SERVICE INFORMATION GENERAL AWARNING - The battery gives of! explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. - The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield — ll electrolyte gets on your skin, flush with water. 7 ll electrolyte gets in your eyes, flush with water lar at least 15 minutes and call a physician immediately. I Electrolyte is poisonous. a If swallowed, drink large quantities of water or milk and follow with milk at magnesia or vegetable oil and call a physician. 0 KEEP OUT OF REACH OF CHILDREN. I Always turn off the ignition switch before disconnecting any electrical component, CAUTION: Some electrical components may be damaged ll terminals or connectors are connected or disconnected while the ignition switch is ON and current is present. - 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. n c 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, IThe battery can be damaged of overcharged or underchargad, or If 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. a 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. - 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 GM for long periods of time without riding the motorcycle. 16-1 BATTERY] CHARGING SYSTEM - The battery will self-discharge when the motorcycle is not in use. For this reason, charge the battery every two weeks to prevent sulfation Ircm occurring. - Filling 3 new battery with electrolyte will produce some voltag ut in orderto achieve its maximum performance, always charge the battery. Alsn, the battery life is lengthened when i si tially charged, 0 When checking the charging system, always follow the steps in the troubleshooting flow chart (page 16-3). Buttery charging This model comes with a maintenance »free (MFI battery. Remember the following about MF batteries. 7 Use only the electrolyte that comes with the battery - Use all of the electrolyte —- Seal the battery properly 7 Never open the seals again CAUTION' For battery charging, do nut exceed the charging current and time specified on the battery. Use of excessive current or charging time may damage the battery. SPECIFICATIONS ITEM SPECIFICATIONS Battery Capacity 12V~6Ah Current leakage 1.2 mA max. Voltage Fully charged 13.0m13.2V (20 “(3/68 °Fl Needs charging Below 12.3V Charging current Normal 0.3 A/S—IO h 7 Quick 4.0 A/‘l.0 h Alternator Capacity 0.34 kW/5,000 min“ (rpm) Charging coil resistance (20 “C/GB “Fl 0.1 *1.0 $2 Regulator/rectifier regulated voltage l l3.0* 15.5 V/5,000 min" (rpm) 16-2 BATTERY/CHARGING SYSTEM TROUBLESHOOTING 1. Battery undarcharging (Voltage not raised to regulated voltage)‘ Correct Measure the charging voltage with the battery Check the battery current leakage (Leak test; page fully charged and in good condition (page 1676i 16-7), Correct Incorrect - Faulty battery Standard regulated voltage is not reached when the Disconnect the regulator/rectifier connector and engine speed increases. recheck the battery current leakage. Correct Incorrect 0 Shoned wire harness ' Faulty ignition switch ' Faulty regulator/rectifier Inc rre t . Check the voltage between the battery line and ——>° c tShorted Wire harness ground line of the regulator/rectifier (page 168i. I Poorly connected connector Correct Check the resistance of the charging coil at tho Incorrect charging coil line of the regulator/rectifier Checkthealternatorchargingcoillpege16-8)‘ connector (page 16%). Incorrect Correct Correct 0 Poorly connected alterna- tor connector I Faulty charging coil I Faulty regulator/rectifier 16-3 BATTERY/CHARGING SYSTEM 2. Battery overcharging (regulated voltage too high). Measure the charging voltage with the battery fully charged and in good condition (page 16—6). Regulated voltage greatly exceeds the standard value, Check the continuity between the ground line and frame of the regulator/rectifier connector (page 16—8). Corr-ct C orrect - Faulty battery Incorrect . . . 0 Open circuit In Wl re harness - Poorly connected connector 0 Faulty regulator/rectifier I Poorly connected connector 16-4 BATTERY Always turn the lgnllioll swmm OFF before rsmaving the battery. REMOVAL/ INSTALLATION Remove the right side cover (page 2-2). Remove the holder band and pull the battery out. Disconnect the negative cable and then the positive cable. and remove the battery. Install the battery in the reverse order at 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 INSPECTION Measure the battery voltage using a digital multimeter. VOLTAGE: Fullycharged: 13.0i'l3.2V Undercharged: Below12.3V TOOL: Digital multimeter Commercially available BATTERY CHARGING % I The battery gives off explosive gases: keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. I Turn power ONIOFF at the charger, not at the battery terminal. Remove the battery (see above). Connect the charger positive (+l cable to the battery positive l+) terminalt Connect the charger negative l—l cable to the battery negative l-) terminal. CAUTION: ' Guickvcharging should only be bone in an amargenny; slaw charging is preferred. ' For battery charging, du nnt extend the charging current and time specified on thy battery. Using excessive current or extending the charging time may damage the battery, 16-5 BATTERY/CHARGING SYSTEM BATTERY POSITIVE TERMINAL NEGATIVE TERMINAL BATTERY BATTERY CHARGER BATTERY/CHARGING SYSTEM CHARGING SYSTEM INSPECTION Be sure the battery is in gaad candincn belare performing this test NOTE: I When inspecting the charging system, check the system components and lines step»byastep according to the troubleshooting on page16-3. I Measuring circuits with a large capacity that exceeds the capacity of the tester may cause damage to the tester. Befere starting each test, set the tester at the highest capacity range first, then gradually lower the capacity ranges until you have the correct range, - When measuring small capacity circuits, keep the ignition switch off. If the switch is suddenly turned on during a test, the tester fuse may blew. REGULATED VOLTAGE INSPECTION WEB—— If the engine must be running to da some wark, make sure the area is well-ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carban monaxide gas that may cause loss a! consciousness and lead to death. Run the engine in an apen area or with an exhaust evacuation system in an enclosed am. Warm up the engine to normal operating temperature. Stop the engine, and connect the multimeter as shown. CAUTION: ' To prevent a shart, make absolutely certain which are the pasitive and negative terminals or cable. - Do not disconnect the battery at any cable in the charging system without first switching of! the ignitian switch. Failure to follow 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 min" (rpml. STANDARD: 13.0 - i5.5 V at 5,000 min" (rpml 16-6 BATTERY/CHARGING SYSTEM The battery is normal it the specified regulated voltage is displayed on the multimeter, NOTE- The speed at which the voltage starts to rise cannot be checked as it varies with the temperature and loads of the generator. A frequently discharged battery is an indication that it is deteriorated even if it proves normal in the regulated voltage inspection. The charging circuit may he abnormal if any of the tollowing symptoms is encountered. (DVoltage not raised to regulated voltage (page 153): quen or short circuit in the charging system wire harness or poorly connected connector. . Open or short of the alternator. e Faulty regulator/rectifier. @Regulated voltage too high (page 164i: 0 Poorly grounded voltage regulator/rectifier. - Faulty battery. - Faulty regulator/rectifier. CURRENT LEAKAGE INSPECTION Turn the ignition switch off and disconnect the negative battery cable from the battery. Connect the ammeter (+l probe to the ground cable and the ammeter l—l probe to the battery (—l terminal. With the ignition switch off, check for current leakage. NOTE: - When measuring current using a tester. set it to a high range, and then bring the range down to an appropriate level. Current flow higher than the range selected may blow out the fuse in the tester. 0 While measuring current, do not turn the ignition switch on. A sudden surge of current may blow out the fuse in the tester. SPECIFIED CURRENT LEAKAGE: 1.2 mA max. If current leakage exceeds lhe specified value, a shorted circuit is likely. Locate the short by disconnecting connections one by one and measuring the current. 16-7 NORMAL CHARGING - VOLTAGE REGULATED ‘_ > VOLTAGE BA‘I'I'ERV VOLTAGE 1 I I VOLTAGE —> I ._.r_r_'_'_'_‘ ENGINESPEED —> min"lrpm) E ABNORMAL CHARGING VOLTAGE I S VOLTAGE —' l ENGINE SPEED _’ min"(|’pm) AMMETER GROUND CABLE BATTERY/CHARGING SYSTEM ALTERNATOR INSPECTION Ir Is not necessary ID remove the stator coil to make this test Remove the left side cover (page 2-2). Disconnect the alternator 3P (Natural) connector. Check the resistance between all three terminals. Yellow STANDARD: 0,171.0 S? (at 20 "0/68 “Fl 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. REGULATOR/RECTIFIER SYSTEM INSPECTION Remove the fuel tank (page 241). Disconnect the regulator/rectifier 3P (Natural) connector. and check it for loose contact or corroded terminals. If the regulated voltage reading (see page 15-6) is out of the specification, measure the voltage between connector terminals (wire harness side) as follows: Item Terminal Specification Battery Red/White lJ—l Battery voltage charging and should register line groundla) Charging coil Yellow and O.1*‘l.0 S2 line Yellow i (at 20 ’C/SB ”F I Ground line 1 Green and ‘ Continuity i 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 3F (NATURAL) CONNECTOR BATTERY/CHARGING SYSTEM REMOVAL/INSTALLATION REGULATOR/HEW.“ Disconnect the regulator/rectifier 3F (Natural) connector. Remove the regulamrlrectlfier unit mounting bolts, ground eyelet and regulator/rectiflen Install the regulator/rectifier unit in lhe reverse order of removal, 3F (NATURAL) CONNECTOR BOLTS 16-9 IGNITION SYSTEM SYSTEM DIAGRAM Na‘2/3 IGNITION COIL IGNITION SWITCH SPARK PLUGS THROTTLE SENSOR IGNITION PU LSE GENERATOR BATI'E RV SIDE STAND SWITCH IGNITION swncn FUSE 10A 9 Ema—u mm: FUSE W 'V" m SIDE aArrEnv FUSE IOA :- i ENGINE STOP swrrcn m] Tu hammer .— IGNITION COIL G THROTTLE SENSOR 17 m, Lg GIN sum: mmcnon L. NEUTRAL WW" SWITCH a 3 5m: sum: fiwfi cm-(o—m IGNITION PULSE NEUTRAL mnlcnon ““5 —©'”$'I SWITCH CLUTCH SWITCH ENEHATOI BLACK VELLDW CLUTCH SWITCH LIGHT GREEN 17. IGNITION SYSTEM SYSTEM DIAGRAM 17.0 IGNITION PULSE GENERATOR 17-8 SERVICE INFORMATION 17-1 THROTTLE SENSOR 17-10 TROUBLESHOOTING 17-3 IGNITION CONTROL MODULE 17-11 IGNITION SYSTEM INSPECTION 17-4 IGNITION TIMING 17-12 IGNITION COIL 17-6 SERVICE INFORMATION GENERAL AWARNING If the engine must be running to do some work, make sure the area is wall-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‘ Same electrical components may be damaged if terminals or connectors are connectad or disconnected while the ignition switch is ON and current is present. ' When servicing the ignition system, always follow the steps in the troubleshooting sequence on page 17-3. - The ignition timing does not normally need to be adjusted since the Ignition Control Module llCM) is factory preset. 0 The IBM may be damaged it dropped. Also if the connector is disconnected when current is flowing, the excessive volt- age may damage the module. Always turn off the ignition switch before servicing. ' Afaulty ignition system is often related to poor connections, Check those connections before proceeding. Make sure the battery is adequately charged. Using the starter motor with a weak battery results in a slower engine cranking speed as well as no spark at the spark plug. I Use spark plug of the correct heat range.Us1ng spark plug with an incorrect heat range can damage the engine, SPECIFICATIONS ITEM SPECIFICATIONS Spark plug CHSEHaNNGKl U27FER9 (DENSOI Spark plug gap 0.8—0.9 mm (0.03—0.04in) Ignition coil peak voltage 100Vminimum Ignition pulse generator peakvoltage W 7 #01 V minimum Ignition timingf'F” mark) 7‘J BTDC at idle 17-1 IGNITION SYSTEM TORQUE VALUES Spark plug Timing hole cap Ignition pulse generator rotor bolt TOOLS Imrie diagnostic tester (model 625) or Peak voltage adaptor 12 N-m (1,2 kgf-m , 9 lbf-ft) 18 N-m11.8 kgt-m,13leti Apply grease to the threads 59 Nvm (5.0 kgf-m , 43 lbf‘ftl Appiv oil to the threads 07HGJ-0020100 with Commercially available digital multimeter [impedance 10 MQIDCV minimum) 17—2 IGNITION SYSTEM TROUBLESHOOTING ' Inspect the following before diagnosing the system. >Faully spark plug 7 Loose spark plug cap or spark plug wire connection *Wator got into the spark plug cap (leaking the ignition coil secondary Voltage) 0 If there is no spark at either cylinder, temporarily exchange the ignition coil with the other good one and periorm the Spark test. It there is spark, the exchanged ignition coil is faulty. O “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 starter motor). No spark at all plugs Unusual condition Probable cause (check in numerical order) Ignition No initial voltage with ignition and 1. Faulty engine stop switch. coil engine stop switches 0N. (Other electri- 2. An open circuit in Black/White wire between the ignition coil primary cal components are normal) and engine stop switch. voltage 3. Loose primary terminal or an open circuit in primary coil. 4. Faulty ICM (in case when the initial voltage is normal while disconnecting ICM connector. Initial voltage is normal, but it drops 1. Incorrect peak voltage adaptor connections. down to 2 74 V while cranking the 2. Underchargad battery. engine. 3. No voltage between the Black/White H») and Body ground (-I 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 Yellow/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. - Side stand switch line: Green/White wire - Neutral switch line: Light Green and Light Green/Pied wire 9. Faulty ignition pulse generator (measure the peak voltage). 10. Faulty ICM (in case when above No. ‘l~9 are normal]. Initial voltage is normal, but no peak 1.Fau|ty peak voltage adaptor connections. voltage while cranking the engine. 2. Faulty peak voltage adaptor. 3. Faulty ICM (in case when above No. 1 2 are normal). Initial voltage is normal, but peak volt- 1.The multimeter impedance is too low: below IO M (2 (DEV. age is lower than standard value. 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 peakvoltage are normal, but 1. Faulty spark plug or leaking ignition coil secondary current does not spark. ampere. 2. Faulty ignition coil. Ignition Peak voltage is lower than standard ‘l.The multimeter impedance is too low; below 10 M SZ/DCV. pulse value. 2. Cranking speed is too low (battery under charged). generator atThe 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. Faultv ICM (in case when above No.1m3 are normal). No peak voltage. 1.Fau|ty peak voltage adaptor. 2. Faulty ignition pulse generator. ignition There is a continuity between Black and 1.Fau|ty ignition switch. switch Pink terminals in either of the directions. 2. Specified tester is not Used. There is no continuity between Black 1. Blown fuse (E) 10 A. and Pink terminals in either of the direc- 2. Faulty engine stop switch. 1 7 3 tions. 3. Feulty ignition switch. 4. Specified tester is not used. IGNITION SYSTEM IGNITION SYSTEM INSPECTION NOTE. 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 Dr commer- cially available digital multimeter with an imped- ance of 10 MSZ/DCV minimum. ' The display value differs depending upon the internal impedance of the multimeter. ' If using lmrie diagnostic tester (model 625), follow the manufacturer's instructions. Connect the peak voltage adaptor to the digital DIGITAL MULTIMETER multimeter, or use the lmrie diagnostic tester. ' " . TOOLS: Imrie diagnostic tester (model 625) or Peak voltage adaptor D7HGJ-0020100 with commercially available digital multimeter (impedance 1!) M QIDCV minimum) fé‘lEmON COIL PRIMARY PEAK VOLT- mm___ 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. GOOD KNOWN SPARK PLUG '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 cylinder as done in a spark test. 17-4 DU n0! disconnect the ignition coil primary wires With the ignition coil primary wire connected, connect the peak voltage adaptor or lmrie tester to the ignition coil CONNEC‘HON: No. 1/4 coiI:B|acl Q .\ \ \wwflw I \flv)” In I NEUTRAL SWITCH SIDE STAND SWITCH IGNITION SWITCH BATTERV STARTER RELAY M 6 $1 SWITCH HIBI n L 30A STARTER MOTOR FUSE FUSE 10A 10A I ' ILO/ o—vm NEUTRAL STARTER SWITCH CLUTCH SWITCH INDICATOR DIODE CLUTcH swrrcn M m—«:»: SIDE STAND NEUTRAL G/W INDICATOR swn'cH up L BI ......... aucx J: SIDE STAND VELLOW - swrrc» VIII 18 Lg ......... LIGHT GREEN 18. ELECTRIC STARTER SYSTEM DIAGRAM 18-0 STARTER MOTOR 184 SERVICE INFORMATION 18-1 STARTER RELAY SWITCH 18-10 TROUBLESHOOTING 18—2 DIODE 18-11 SERVICE INFORMATION GENERAL I The starter motor can be removed with the engine in the frame SPECIFICATION Unit: mm (in) ITEM STANDARD SERVICE LIMIT Starter motor brush length 12.0‘13.0(0.47*0.51I 4.5 (0.18] 18—1 ELECTRIC STARTER TROUBLESHOOTING Starter motor does not turn 0 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. ”CLICK" heard “CLlCK” not heard Disconnect the starter relay switch connector, and check the relay coil ground wire lines as below for continuity: 1.Green/Fled terminal-clutch switch diode- neutral switch line lwith the transmission in neutral and clutch lever released). 2.Green/Recl terminal/clutch switch-side stand switch line (in any gear except neutral. and with the clutch lever pulled in and the side stand up. Normal Connect the starter relay swltch connector. With the ignition switch ON and the starter switch pushed, measure the starter relay voltage at the starter switch connector (between Yellow/ Red 1+ ) and ground (—l. Battery voltage registered Check the starter relay switch operation. Abnormal Abnormal No voltage Normal 18-2 Apply battery voltage to the starter motor directly and check the operation. Normal l Abnormal - Poorly connected starter motor cable 0 Faulty starter relay SWltch (page 1840) - Faulty starter motor 0 Faulty neutral switch (page 19-15) 0 Faulty neutral diode o Faulty clutch switch . Faulty clutch/side stand diode - Faulty side stand switch 0 Loose or poor contact connector 0 Open circuit in wire harness - Faulty ignition switch - Faulty starter switch a Blown out main or sub-fuse - Loose or poor contact of connector - Open circuit in wire harness - Loose or poor contact staner relay switch connector I Faulty starter relay switch ELECTRIC STARTER The starter 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. with the ignition switch ON. Normal Check the clutch switch operation. Normal Check the side stand switch, Normal Abnormal Abnormal Check the side stand indicator operates properly M, I Faulty side stand switch I Burnt bulb 0 Open circuit in wire harness e Faulty clutch switch - Faulty side stand switch _'-—.———> I Open circuit in wire harness Starter motor turns engine slowly - Low battery voltage - Poorly connected battery terminal cable - Poorly connected starter motor cable 0 Faulty starter motor . Poor connected battery ground cable Starter motor turns, but engine does not turn 0 Starter motor is running backwards *Case assembled improperly —Terminals connected improperly o Faulty starter clutch I Damaged or faulty starter drive gear Starter relay switch " cks”, but engine does not turn over - Crankshaft does not turn due to engine problems 18-3 n Loose or poor contact connector E LECTRIC STARTER STARTER MOTOR REMOVAL WEE—— With the ignition switch OFF, remove the negative cable at the battery before servicing the starter motor. Remove the air cleaner housing (page 5-4) Remove the terminal nut and the starter motor cable from the starter motor. Remove the starter motor mounting bolts and ground cable. Pull the starter motor out of the crankcase. DISASSEMBLY NOTE: Record the location and number of shims. Remove the following: —Starter motor case bolts —Front and rear covers iArmeture FRONT COVER REAR COVER INSPECTION Check for continuity between the cable terminal and the brush wire (the indigo colored wire or the insulated brush holderl. There should be continuity. 18—4 ELECTRIC STARTER Check for continuity between the motor case and the cable terminal. There should be no continuity. Check for continuity between (H and (-) terminals of the brush holder. There should be no continuity. Inspect the brushes for damage and measure the brush length. SERVICE LIMIT: 4.5 mm (0‘18 in) Check the bushing of the rear cover for wear or damage. 18-5 ELECTRIC STARTER Check the front cover oil seal for fatigue or other OIL SEAL NEEDLE BEARING damage. Check the needle bearing for damage. Inspect the commutator bars for discoloration. Bars discolored in pairs indicate grounded armature coils, in which case the starter motor must be replaced. coMMUfATOH'BARs? NOTE: Do not use emery or sand paper on the commu- tator. Check for continuity between individual commu- tator bars; there should be continuity. Also' check for continuity between individual commutator bars and the armature shaft; there should be no continuity. 18-6 ELECTRIC STARTER Remove the fnlIowing: , Nut *Washer —Insula(ors *Orring *Brush holder assembly ~Brushltermina| ,O-RING INSULATORS WASHER NUT BRUSH HOLDER ASSEMBLY ARMATURE INSU LATED WASHER SHIMS LOCK WASHER @ SEAL RING @ a @ FRONT COVER \ ' REAR COVER BRUSH SPRINGS BRUSH HOLDER CABLE TERMINAL & BRUSH INSULATOR SEAL HING MOTOR CASE Set the brushes on the brush holder. Align the terminal InstaII (he brush holder emu the motor case. ()1th brush holder with the molar Case insulator. 18-7 ELECTRIC STARTER Insta/i the lnslllamrs properly as noted during removal. Install the shims properly as noted during removal install the shims properly as noted during removal. 18-8 Installtha following: -O-ring —lnsu|ators *Washer —Nut Push and hold the brush inside the brush holder, and install the armature through the brush holder, When installing the armature into the motor case, hold the armature tightly to keep the magnet from pulling the armature against the motor case. CAUTION: 0 The coil may be dlrnlgad if the magnet pulls the armature against the case. O Thu sliding surfaces of the brushes can be damayad if they are not installed properly. Set the brush springs. Install the seal ring on the motor cases Install the same number of rear shims in the same locations as when disassembled, Apply thin coat of grease to the armature shaft end. Install the shims on the armature shaft. Install the rear cover aligning its groove with the brush holder tab. Install the seal ring on the motor case. Install the same number of front shims in the same locations as when disassembled. Install the insulated washer, Apply grease to the front cover all seal and needle bearing. Install the lock washer on the front cover. Install the front cover to the motor case. CAUTION: Wllan installing the cover, take care to pun/ant damaging the all seal lip with the shaft. INSULATORS WASHER ELECTRIC STARTER Align the marks between the motor case and cover. , INDEX lZINEIS ' lnstall and tighten the motor case bolts securely. BOLTS Apply clean engine oil to the new O-ring‘ g ’ a O-RING Install a new Orring onto the starter motor boss. INSTALLATION Install the starter motor onto the crankcase. Route the starter motor cable and ground cable properly. Install the ground cable and tighten the starter y“ motor mounting bolts. “fl 18-9 ELECTRIC STARTER Install the starter motor cable to the terminal, then tighten the terminal nut securely. Install the removed parts in the reverse order of removal. STARTER RELAY SWITCH OPERATION INSPECTION Remove the rear cowl (page 2-3). Shift the transmission into neutral. Turn the ignition switch ON and depress the starter switch button. The coil is normal ifthe starter relay switch clicks. If the switch “CLICK" is not heard, inspect the relay switch using the procedure below. GROUND LINE INSPECTION Disconnect the relay 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 connector. Shift the transmission into neutral. Measure the voltage between the Yellow/Red wire H) and ground at the starter relay switch connector. There should be battery voltage only when the starter switch button is depressed with the ignition switch is ON. 18'10 STARTER RELAY SWITCH ELECTRIC STARTER DIODE CONTINUITY INSPECTION Disconnect the starter cables from the starter relay switch. Connect an ohmmeter to the starter relay switch largelerminals. Check for continuity between the starter relay switchterminalst There should be continuity while the starter switch button is depressed and should be no continuity when the starter switch botton is released. REMOVAL Remove seat (page 2-2), Open the fuse box and remove the diode. INSPECTION Check for continuity with an ohmmeter. Normal direction: Continuity Reverse direction: Nu continuity INSTALLATION Install the diode in the reverse order of removal, 18-11 STARTER RELAY SWITCH FUSE BOX DIODE LIGHTS/METERS] SWITCHES SYSTEM LOCATION IGNITION SWITCH FRONT BRAKE LIGHT SWITCH CLUTCH SWITCH OIL PRESSURE SWITCH STARTER RELAY SWITCH TURN SIGNAL RELAY rm’é’ FAN MOTOR SWITCH NEUTRAL SWITCH REAR BRAKE LIGHT SWITCH SIDE STAND SWITCH 19 19. LIG HTS/ M ETERS/ SWITCH ES SYSTEM LOCATION 19-0 OIL PRESSURE SWITCH 19-1 2 SERVICE INFORMATION 19-1 IGNITION SWITCH 19-13 HEADLIGHT 19~3 HANDLEBAR SWITCHES 19-14 POSITION LIGHT 19-4 BRAKE LIGHT SWITCH 19-15 TURN SIGNAL 19-4 CLUTCH SWITCH 19-15 TAIL/BRAKE LIGHT 19-5 NEUTRAL SWITCH 19-15 COMBINATION METER 19.5 SIDE STAND SWITCH 19-16 TACHOMETER 19-9 HORN 19-17 COOLANT TEMPERATURE GAUGE/ TURN SIGNAL RELAY 19-17 SENSOR 19-10 COOLING FAN MOTOR SWITCH 19-11 SERVICE INFORMATION GENERAL AWARNING I A halogen headlight bulb becomes very hot while the headlight is ON, and remains hat for a while after it is turned OFF. Be sure to let it cool down before servicing. I Use an electric heating element to heat the water/coolant mixture for the fan motor switch inspection. Keep all flammable materials away from the electric heating element. Wear prone-tin 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 is to fall. —If 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 CDndItIon 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 following color codes are used throughout this section. Bu=B|ue G=Green Lg=Light Green H=Red Sb=Sky Blue BI: Black Gr=Gray O=0range W=White Er=Brown Lb=Light Blue P=Pink Y=Yel|ow 19—1 LIGHTS/METERS/SWITCHES SPECIFICATIONS ITEM SPECIFICATIONS Bulbs Headlight [Hi/Lo) 12V760/55W Position lightlExcept Utype) 12V~4W Brake/taillight 12Vi21/5W X 2 Turn signal light 1ZVE21W>< 4 Instrumentlight 12V*1.7W X 3 Turn signal indicator 12Vi1.7W X 2 High beamindicatqr 12v7117w Neutral indicator 12V—1.7W Oil pressure indicator 12V—1t7W Fuse Main fuse 30 A Sub fuse 10 A X 4 Fan motor Startto close (ON) 9877102 ”C(208i216°F)¥_ switch Stop to open 93-97 °C [199*207 °F) Coolant temperature sensor resistance at 80 “C/176 “F , 45 , 60 Q, at 120 °CI24B ”F 10*20 Q TORQUE VALUES Oil pressure switch Oil pressure switch terminal screw Neutral switch Side stand pivot bolt Side stand pivot lock nut Side stand switch mounting bolt ignition switch mounting bolt Coolant temperature sensor unit 12 N-m [1.2 kgt‘rn , 9 lbf-Iti Apply sealant to the threads 2 N-m [0.2 kgf-m , 1,4 lbf-ft) 12 N-m [1.2 kgf—m , 9 lbf-ftl 15 N-m [1.5 kgf—m ,11Ibf-ft) 39 N-m (4.0 kgf-m , 29 Ibf-ft) 10 N-m [1.0 kgt‘m , 7 lbf~ftl ALOC bolt 25 N-m [2.5 kgf-m,18|bf‘ft) Apply a locking agent to thsthreads 10 NM (1.0 kgf-m , 7 Ibf»ftl Apply sealant to the threads 19-2 LIGHTS/M ETERS/ SWITCHES HEADLIGHT BULB REPLACEMENT M A halogen headlight bulb becomes very hot while the hudllght is ON, and remains hat for a while after it is turned OFF. 85 sure ta let it can] down before servicing. Hemove the screws and headlight unit. Remove the headlight bulb socket and dust cover. Unhook the bulb retainer and remove the headlight bulb. CAUTION: Avoid touching hulnyen headlight bulb. Finger prints can create hat spats that cause a bulb to break. If you touch the bulb with your bare hands, clean it with cloth moistened with denatured alcohol to prevent early bulb failure. Install a new bulb into the headlight unit. Install the headlight bulb aligning its tabs with the grooves in the headlight unit. Hook the bulb retainer. install the dust cover tightly against the headlight with its "TOP” mark facing up. Connect the headlight socket. Install the headlight unit and tighten the screws securely. 19-3 DUST COVER “TOP" MARK RETAINER HEADLIGHTUNIT LIGHTS/M ETERS/SWITCHES POSITION HEADLIGHT CASE REMOVAL/INSTAL- LATION Remove the headlight unit (see precious page). Disconnect the connectors and remove the wires from the headlight case, Remove the rubber plugs from the headlight case mounting bolts. Remove the headlight case mounting bolts/nuts and headlight case. installation is in the reverse order of removal. LIGHT BULB REPLACEMENT Remove the headlight unit (see previous page). Pull out the position light bulb socket. Push the bulb in and turn it counterclockwise. then remove the bulb and replace it with a new one Install the position light bulb in the reverse order of removal, TURN SIGNAL BULB REPLACEMENT Remove the screw, turn signal lens and packing, Push the bulb in and turn it counterclockwise, then remove the bulb and replace it with a new one. install the bulb in the reverse order of removal. 19-4 BU LB SOCKET SCREW LENS BULB LIGHTS/METERS/SWITCHES TAIL/BRAKE LIGHT BULBS BULB REPLACEMENT ‘ Remove the screw and tail/brake light lens. Push the bulb in and turn it counterclockwise. then remove the bulb and replace it with a new one. Install the bulb in the reverse order of removal. SCREWS LENS COMBINATION METER 5W -' REMOVAL L ‘ ‘ - Remove the headlight unit (see previous page). Disconnect the combination meter 6? (Natural! and GP (Red! connectors. kl ,splN Disconnect the speedometer cable from the speedometer. Remove the two socket bolts and combination COMBINATION METER‘ meter assembly. 19-5 LlGHTS/METERS/SWITCHES DISASSEMBLY/BULB REPLACEMENT Remove the screws and lower cover. Remove the bulb sockets. Replace the bulb with a new one if necessary. Remove the sub-harness clamp screwt Remove the three nuts and combination meter bracket, Remove the front cover mounting screw. 19-6 LlGHTS/METERS/ SWITCHES Remove the front cover from the combination meterease‘ fierhove the six terminal screws and tachometer/ TERMINAL SCREWS Indicator unit. Remove the screw and trip meter knob. Remove the two speedometer gearbox screw, then remove the speedometer uniL 19-7 LlGHTS/METERS/SWITCHES ASSEMBLY SFEEDOMETEH GEARBOX METER CASE TRIP METER KNOB SPEEDOMETER FRONT COVER SU B-HARNESS TACHOMETER/COOLANT METER BRACKET TEMPERATURE GAUGE Assemble the combination meter in the reverse order of removal, NOTE. Route the combination meter wires properly, INSTALLATION Install the combination meter in the reverse order of removal. NOTE Route the combination meter sub—harness properly (page 1722). 19-8 LlGHTS/METERS/SWITCH ES TACHOMETER INSPECTION Remove the headlight unit (page 19-3), Check for loose or poor contact terminals of the combination meter connectors Disconnect the combination meter 6P (Natural) connector, connect the peak voltage adaptor to the tachometer Vellow/Green terminal and ground, TOOLS: Imrie diagnostic tester (model 625) or Peak voltage adaptor D7HGJ-0020100 with commercially available d'gital multimeter (impedance 10 M £2 IDCV minimum) CONNECTION: Yellow/Green [+)and Ground (, ] Stan the engine and measure the tachometer Input voltage. PEAK VOLTAGE: 10.5 Vminimum If the value is normal' replace the tachometer. If the measured value is below 10.5 V, replace the lCM. if the value is 0 V, perform the following: Remove the seat [page 2-2) and disconnect the ICM multi—connectcr. Check for continuity between the tachometer connector terminal and the ICM multi—connector Vellow/Green terminals. 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 194; combination meter disassemblv and assembly. 19-9 DIGITAL MULTIMETER PEAK VOLTAGE ADAPTOR 6P (NATURAL) CONNECTOR PEAK VOLTAGE ADAPTOR 6? (NATURAL) CONNECTOR ICM MU LTl—CONNECTOR LlGHTS/METERS/SWITCHES COOLANT TEMPERATURE GAUGE/SENSOR THERMO SENSOR CONNECTOR INSPECTION Disconnect the thermo sensor wire connector from the sensor. Ground the thermo sensor wire with a jumper wire. JUMPER WIRE Turn the ignition switch 0N and check the coolant temperature gauge. Disconnect the thermo sensor wire connector from the ground immediately it the gauge needle moves fully to H. CAUTION: Immediame 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. It the needle does not move, check for voltage between the sensor wire connector and ground. If the voltage is measured, the coolant temperature gauge unit is faulty. if there is no voltage, check for voltage between the Black/Brown and Green/Blue wire terminals. If there is no voltage between the terminal, coolant temperature gauge unit is faulty If a voltage is measured, check the wire harness. THERMO SENSOR UNIT INSPECTION 0 Wear insulated gloves and adequate eye protection. IKeep flammable materials away from the electric heating element. Drain the coolant (page 64). Disconnect the wire connector from the coolant temperature SEI’ISDI’ and remove the SBI’iSOl’X Suspend the thermo sensor in a pan of coolant (50—50 mixturei an electric heating element and measure the resistance through the sensor as the coolant heats up. 19 10 LlGHTS/METERS/ SWITCH ES NOTE' THERMO SENSOR ISoak 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, Temperature 50 ”C (68 ‘F) 120 “C (248 “Fl Resistance 2.1 —2t6 k9 i D,62*D.76 k9 Replace the sensor if it is out of specification by more than 10% at any temperature listed. CONNECTOR THERMO SENSOR Apply sealant to the thermo sensor threads. Do not apply sealant to the sensor head. Install and tighten the thermo sensor. TORQUE: 10 N-m (1.0 kgfvm , 7 Ibf-fti Connect the thermo sensor connector. Fill the system and bleed the air (page 674). COOLANT FAN MOTOR SWITCH FAN MOTOR SWITCH CONNECTOR INSPECTION Check for a blown fuse before inspection. Fen motor does not stop Turn the ignition switch OFF, disconnect the connector from the fan motor switch and turn the ignition switch 0N again. If the fan motor does not stop, check for a shorted wire 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 JUMPER WIRE CONNECTOR Disconnect the connector trom the fan motor switch and ground the connectorto 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. 19-11 LlGHTS/METERS/SWITCHES If the mutor does not start, check for voltage between the fan motor switch cunnectur and ground. If battery voltage is measured, replace fan motort If there is no battery voltage, check for pour connection of the connector or broken wire harness. REMOVAL/ INSTALLATION Disconnect the fan motor switch connector and remove the switch. Install a new O—ring onto the fan motor switch, Apply sealant to the fan motor switch threads and O»ring. Install and tighten the fan motor switch to the specified torque. TORQUE: 18 Nm (1.8 kgfvrn , 73 Ibf-fti 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. OIL PRESSURE INDICATOR If the indicator does not come on, inspect as follow: TERMINAL SCREW Remove the dust cover. Remove the screw and oil pressure switch terminal. 19-12 DUST COVER OIL PRESSURE SWITCH IGNITION SWITCH 19-13 LlGHTS/METERS/SWITCHES Short the oil pressure switch wire terminal with the OIL PRESSURE SWITCH TERMINAL ground using a Iumper Wire. The oil pressure warning Indicator comes on with the ignition switch in ON. if the light does not comes on, check the sub-ruse lIOA) and wires for a loose connection or an open circuit. Start the engine and make sure that the light goes out. If the light does not go out, check the oil pressure (page 4-3). If the oil pressure is normal, replace the oil pressure switch (page 4-3)t INSPECTION Remove the headlight unit (page 19-3). Disconnect the ignition switch wire 4P (Black) connector. Check for continuity between the wire terminals of the ignition switch connector ‘in each switch position. Continuity should exist between the color coded wires as follows: IGNITION swn'cn . FAN IG BAT1 KEY ON 0 KEY 0N OFF " KEY OFF KEV OFF LOCK LOCK PIN come Bu/O RIBI R — REMOVAL/INSTALLATION Remove the headlight unit (page 19-3). Disconnect the ignition switch wire 4P (Blackl connector. Remove the headlight case (page 194). Remove the bolts and ignition switch. Install the ignition switch in the reverse order of removal. NOTE‘ Apply a locking agent to the mounting bolt threads. i LlGHTS/METERS/SWITCH ES HANDLEBAR SWITCHES Disconnect the handlebar swnch connectors. Check for continuity between the wire terminals of The handlebar swimh conneclon Continuity should exist between the color Coded wire terminals as follows: STARTER SWITCH ENGINE STOP SWITCH (Except u type) ;\ ”JG IRATz j\\ ST IG OFF __ FREE ,- ;- ~ ' _~, .. ,_ RUN CPfi) PUSfi C~v0 ‘ STARTER SWITCH LIGHTING SWITCH COLOR Bl EI/w COLOR Y/R BI/W ' ' ' STARTER SWITCH (u I pe) LIGHTING SWITCH (Except u type) \\ ST IG HL gHLI \ aATal TL BAT4 HL FREE O~-C . PUSH o-—o P O__O COLOR Y/R Bl El/R BuNV H C ,7 COLOR IBI/Br Br Bl/Fl Bu/W TURN SIGNAL SWITCH I w R L R 07—0 *‘W' " ’1 L 074-0 COLOR Gr I Sb 0 PASSING SWITCH \\ BAT2 HI FREE DIMMEH SWITCH PUSH w—o COLOR EUR 0 DlMMER SWITCH HL Ln HI LO V O——O lNl 0—0770 Hi o———o COLOR Bu/W w Bu- TURN SIGNAL SWITCH HORN SW Glad HORN SWITCH \ Ho BAT3 FREE PUSH ” COLOR ; lBl/Br 19-14 LIGHTS/M ETERS/SWITCHES BRAKE LIGHT SWITCH FRONT Disconnect the front brake light switch connectors. There should be continuity with the brake lever applied, and there should be no continuity with the brake lever is released. REAR Remove the rear cowl (page 23). Disconnect the rear brake light switch connectors and check for continuity between the terminals. There should be continuity with the brake pedal applied, and there should be no continuity with the brake pedal is released. CLUTCH SWITCH Disconnect the clutch switch connectors. There should be continuity with the clutch lever applied, and there should be no continuity with the clutch lever is released. NEUTRAL SWITCH Remove the left side cover (page 2-2), Disconnect the engine sub-harness 3P (Red) connector. Shift the transmission into neutral and check for continuity between the Light Green wire terminal and ground. There should be continuity with the transmission is in neutral, and no continuity when the transmission is into gear. 19-15 LlGHTS/METERS/SWITCHES SIDE STAND SWITCH INSPECTION Remove the left side cover (page 2-2). Disconnect the side stand switch 3P (Green) connector. Check for continuity between the wire terminals of the side stand switch connector. There should be continuity with the side stand UP and there shomd he no continuity with the side stand DOWNt REMOVAL/INSTALLATION Disconnect the side stand switch 3P (Greenl connec- tor. Remove the bolt and side stand switch. install the side stand switch by aligning the switch pin with the side stand hole and the switch groove with the return spring holding pin. Install and tighten a new side stand switch bolt. TORQUE: 10 NR! (1.0 kgf‘m , 7 Ibf-ft) 19-16 SIDE STAND SWITCH LlGHTS/METERS/SWITCHES Connect the side stand switch 3? (Green) connector. HORN Disconnect the wire connectors from the horn. Connect the 12 V battery to the horn terminal directly. The horn is normal if it sounds when the 12 V battery is connected across the horn terminals. TURN SIGNAL RELAY INSPECTION Check the following: - Battery condition , Burned out bulb or newspecilied Wattage 7 Burned fuse — Ignition switch and turn signal switch function 7 Loose connectors if the above items are all normal, check the following: Disconnect the turn signal connectors from the relay. 1. Short the Black/Brown and Gray terminals of the turn signal relay connector with a iumper wire. Stan the engine and check the turn signal light by turning the switch 0N. Light comes on Light does not come on 0 Broken wire harness 2. Check for Continuity between the Green terminal of the relay connector and ground. Continuity No continuity I Broken ground wire I Faulty turn signal relay. O Poor connection of the connector. 19-17 INDICATER 80x 12v 1.7wa 1, LEFT TURN SIGNAL INDICATOR / C 2, NEUTRAL INDICATOR STARTIER RELAY SWITCH 755733? C 3. III mm: 332° FUSE - INDICATOR 4. RIGHT TURN SIGNAL INDICATOR e 9 TAGHOMETER A IOA FAN MOTOR REAR BRAKE LIGHT BATTERY \ 8 10A HEAD LIGHT swrrcH 12v SAN I C 10A METER‘TAIL-HORN-POSITION U --——-. 'GNmON 5mm” D 10A IGNITION - STARTER [5—15 ”HI—“— I ' __. 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TROUBLESHOOTING ENGINE DOES NOT START OR IS POOR PERFORMANCE AT HIGH HARD TO START 21-1 SPEED 21-4 ENGINE LACKS POWER 21-2 POOR HANDLING 21~4 POOR PERFORMANCE AT LOW AND IDLE SPEED 21-3 ENGINE DOES NOT START OR IS HARD TO START Possible cause 1. Check the iuel flow to carburetor — Not reaching carburetor -—> - Clogged fuel line and filter 0 Pinched fuel valve vacuum tube Reaching carburetor I Clogged fuel tank breather 2. Perform a spark test — Weak or no spark - Faulty spark plug ' Fouled spark plug Good spark 0 Faulty ignition control module - Broken or shorted spark plug wire I Faulty ignition switch I Faulty ignition pulse generator I Faulty engine stop switch 0 Loose or disconnected ignition system wires 3. Remove and inspect spark plugs *' Wet plug ‘v I Flooded carburetor D SE valve ON position Good - Throttle valve open I Air cleaner dirty 4. Start by Iollowing normal procedure Engine starts but stops —> 0 improper choke operation ' Carburetor incorrectly adjusted Engine does not start - Intake pipe leaking I Improper ignition timing (Faulty ignltion coil or ignition pulse generator) ' Fuel contaminated 5. Test cylinder compression — Low compression ——> - Valve clearance too small ' Valve stuck open ' Worn cylinder and piston ring - Damaged cylinder head gasket 0 Seized valve 0 Improper valve timing 21-1 TROUBLESHOOTING ENGINE LACKS POWER Possible cause ‘l. Raise wheel off the ground and spin Wheels do no! spin freely—> I Brake dragging by hand 0 Worn or damaged wheel bearing Wheel pins freely 2. Check tire pressure Pressure low I Faulty tire valve l I Punctured tire Pressure normal 3. Accelerate rapidly from low to sec» Engine speed doesn't -——>I Clutch slipping ond change accordingly when I Worn clutch discs/plates l clutch is released I Warped clutch discs/plates Engine speed reduced when clutch IWeak clutch spring is released I Additive in engine oil 4, Accelerate lightly — Engine speed does not —> 0 SE valve ON position increase I Clogged air cleaner Engine speed increase I Restricted fuel flow I Clogged muffler I Pinched fuel tank breather 5. Check ignition timing Incorrect - Faulty ignition control module I Faulty ignition pulse generator Correct 6' Test cylinder compression Incorrect —— I Valve stuck open I Worn cylinder and piston rings Normal I Leaking head gasket I improper valve timing 7. Check carburetor for clogging—C Clogged —> I Carburetor not serviced frequently enough Not clogged 8. Remove spark plugs —— Fouled or discolored —’ I Plugs not serviced frequently enough I Spark plugs are the incorrect heat Not fouled or discolored range 9‘ Check oil level and condition ———-— Incorrect —> I Oil level too high I Oil level too low Correct I Contaminated oil 10. Remove cylinder head cover and Valve trein not lubricated —>I Clogged oil passage inspect lubrication properly I Clogged oil control orifice Valve train lubricated properly 21-2 11. Check for engine overheating Not overheating 12.Accelerate or run at high speed Engine does not knock TROUBLESHOOTING Possible nause Overheating —> I Coolant level low Engine knocks -—> 0 Fan motor not working (faulty fan motor switch) 0 Thermostat stuck close I Excessive carbon build-up in combustion chamber I Use of poor quality fuel I Clutch slipping I Lean fuel mixture I Wrong type of fuel I Worn piston and cylinder I Wrong type of fuel I Excessive carbon build-up in combustion chamber I Ignition timing to advanced (faulty ignition control module) I Lean fuel mixture POOR PERFORMANCE AT LOW AND IDLE SPEED 1. Check carburetor pilot screw adjustment Correct 2. Check for leaking intake pipe Not leak 3. Perform spark test Good spark Incorrect Possible cause I See section 5 Leaking —> 0 Loose insulator clamps Weak or intermittent spark 4 Check ignition timing Incorrect 21-3 I Damaged insulator I Faulty carbon or wet fouled spark plug 0 Faulty ignition control module 0 Faulty ignition coil ' Broken or shorted spark plug wire 0 Faulty engine stop switch . Faulty ignition pulse generator ' Faulty ignition switch I Loose or disconnected ignition system wires I Improper ignition timing (faulty ignition control module) TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED 1,Disconnect fuel tube at carburetor and pumpthe vacuum line Fuel flows freely 2,Rarnova the carburetor and check for clogging Not clogged Fuel flow restricted Possible cause . Clogged ruel line 0 Clogged fuel tank breather 0 Faulty fuel valve I Clogged fuel filter CIogged—> 0 Clean 3. Check valve timing Incorrect Correct 0 Cam sprocket not installed properly 4 Check ignition timing lncorrect Correct 0 Faulty ignition control module I Faulty ignition pulse generator 5. Check valve spring Weak Not weak POOR HANDLING I Faulty spring Possible cause Hf steering is heavy t Steering stern adjusting nut too tight I Damaged steering head bearings 2‘ If either wheel is wobbllng — 0 Excessive wheel bearing play 3, if the motorcycle pulled to one side 21—4 ' Bent rim 0 Improper installed wheel hub U Swingarm pivot bearing excessively worn I Bent frame - Faulty shock absorber - Front and rear wheel not aligned - Bent fork - Bent swingarm I Bent axle AIR CLEANER AIR CLEANER HOUSING ALTERNATOR COVER INSTALLATION ALTERNATOR COVER REMOVAL ALTERNATOR INSPECTION BATTERY BODY PANEL LOCATIONS BRAKE FLUID BRAKE FLUID REPLACEMENT/AIR BLEEDING BRAKE LIGHT SWITCH BRAKE LIGHT SWITCH BRAKE PAD WEAR BRAKE PAD/DISC BRAKE PEDAL BRAKE SYSTEM CABLE KI HARNESS ROUTING CAM CHAIN TENSIONER LIFTER CAMSI—IAFT INSTALLATION CAMSHAFT REMOVAL CAREURETOR CHOKE CARBURETOR ASSEMBLY CARBURETOR COMBINATION CARBURETOR DISASSEMBLY CARBURETOR INSTALLATION CARBURETOR REMOVAL CARBURETOR SEPARATION CARBURETOR SYNCHRONIZATION CHARGING SYSTEM INSPECTION CLUTCH CLUTCH SYSTEM CLUTCH SWITCH COOLANT REPLACEMENT COOLANT TEMPERATURE GAUGE/SENSOR COOLING FAN MOTOR SWITCH COOLING SYSTEM COMBINATION METER CRAN KCASE COMBINATION CRAN KCASE SEPARATION CRAN KSHAFT CYLINDER COMPRESSION TEST CYLINDER HEAD ASSEMBLY CYLINDER HEAD COVER INSTALLATION CYLINDER HEAD COVER REMOVAL CYLINDER HEAD DISASSEMBLY CYLINDER HEAD INSPECTION CYLINDER HEAD INSTALLATION CYLINDER HEAD REMOVAL DIODE DRIVE CHAIN DRIVE CHAIN SLIDER ENGINE IDLE SPEED ENGINE INSTALLATION ENGINE OIL/OIL FILTER ENGINE REMOVAL EMISSION CONTROL SYSTEMS FLYWHEEL INSTALLATION FLYWHEEL REMOVAL FORK FRONT BRAKE CALIPER INDEX 3-5 5-4 10-8 10-2 16-8 16-5 270 3-22 15-4 3-24 19-15 3723 15-6 15-24 3—23 1-22 8-25 8720 8-8 3-5 5-15 5-20 6711 5-24 5-8 579 3-14 1676 9-4 3-25 19-15 6-4 19-10 19-11 3-16 19-5 1 171 1 11-3 1273 8-17 8723 8-10 FRONT FENDER FRONT MASTER CYLINDER FRONT WHEEL FUEL LINE FUEL TANK FUEL VALVE GEARSHIFT LINKAGE GENERAL SAFETY HANDLEBAR SWITCHES HANDLEBAR HEADLIGHT HEADLIGHT AIM HORN IGNITION COIL IGNITION CONTROL MODULE IGNITION PULSE GENERATOR IGNITION SYSTEM INSPECTION IGNITION SWITCH IGNITION TIMING LUBRICATION SYSTEM DIAGRAM LUBRICATION 8L SEAL POINTS MAINTENANCE SCHEDULE MODEL IDENTIFICATION MUFFLER/EXHAUST PIPE NEUTRAL SWITCH NUTS, BOLTS, FASTENERS OIL COOLER OIL PRESSURE SWITCH OIL PRESSURE INSPECTION OIL PUMP OIL STRAINER/PRESSURE RELIEF VALVE PILOT SCREW ADJ USTMENT PISTON/CONNECTING ROD POSITION LIGHT RADIATOR RADIATOR COOLANT RADIATOR RESERVE TANK REAR BRAKE CALIPER REAR COWL REAR FENDER REAR MASTER CYLINDER REAR WHEEL REGULATOR/RECTIFIER RIGHT CRANKCASE COVER INSTALLATION RIGHT CRANKCASE COVER REMOVAL SEAT SERVICE RULES SECONDARY AIR SUPPLY SYSTEM SECONDARY AIR SUPPLY SYSTEM SERVICE INFORMATION (ALTERNATOR/STARTER CLUTCH) (BATTERY/CHARGING SYSTEMI (CLUTCH/GEARSHIFT LINKAGE) (COOLING SYSTEM) (CRAN KCASE/PISTON/CYLINDERI (CRAN KSHAFT/TRANSMISSIONI (CYLINDER HEADNALVES) (ELECTRIC STARTER) (ENGINE REMOVAL/INSTALLATION) 241 15-9 13-9 3-4 2—4 5-28 9-11 1-1 19-14 1373 1973 3-24 19-17 17-6 17—11 17-6 17-4 19-13 17-12 4-0 1719 3-3 1-3 2-5 19—1 5 3-27 4-10 19—12 3-16 6714 15721 2-3 15-13 14~3 SERVICE INFORMATION (FRAME/BODY PANELS/EXHAUST SYSTEM) (FRONT WHEEL/SUSPENSION/STEERING) (FUEL SYSTEM) (HYDRAULIC BRAKE) (IGNITION SYSTEM) (LIGHTS/METERS/SWITCHES) ILUBRICATION SYSTEM) (MAINTENANCE) (REAR WHEEUSUSPENSION) SHOCK ABSORBER SIDE COVER SIDE STAND SIDE STAND SWITCH SPARK PLUG SPECIFICATIONS STARTER CLUTCH STARTER MOTOR STARTER RELAY SWITCH STATOR STEERING HEAD BEARINGS STEERING STEM SUSPENSION SWINGARM SYSTEM DIAGRAM (BATTERY/CHARGING SYSTEM) (ELECTRIC STARTER) [IGNITION SYSTEM) SYSTEM FLOW PATTERN SYSTEM LOCATION SYSTEM TESTING TACHOMETER TAIL/BRAKE LIGHT THERMOSTAT THROTTLE OPERATION THROTTLE SENSOR TORQUE VALUES TOOLS TRANSMISSION TROUBLESHOOTING (ALTERNATOR/STARTER CLUTCH) (BATTERY/CHARGING SYSTEM) (CLUTCH/GEARSHIFI' LINKAGE) (COOLING SYSTEM) (CRAN KCASE/PISTON/CYLINDER) (CRANKSHAFT/TRANSMISSION) (CYLINDER HEAD/VALVES) (ELECTRIC STARTER) (ENGINE DOES NOT START OR IS HARD TO START) (ENGINE LACKS POWER) (FRAME/BODY PANELS/EXHAUST SYSTEM) (FRONT WHEEUSUSPENSION/STEERING) (FUEL SYSTEM) (HYDRAULIC BRAKE) (IGNITION SYSTEM) (LUBRICATION SYSTEM) (POOR HANDLING) (POOR PERFORMANCE AT HIGH SPEED) TROUBLESHOOTING 2-1 (REAR WHEEL/SUSPENSION) 13-1 TURN SIGNAL 5-1 TURN SIGNAL RELAY 15-2 VALVE CLEARANCE 17-1 VALVE GUIDE REPLACEMENT 19-1 VALVE SEAT INSPECTION/REFACING 4-1 WATER PUMP 3-1 WHEELS/TIRES 14-1 WIRING DIAGRAMS 14-10 2-2 3-25 19-16 3-5 1-4 10-5 18-4 18-10 10-3 3-28 13-25 3-26 14-12 1 6-0 1 8-0 1 7-0 6-0 1 9-0 6-3 1 9-9 1 9-5 6-6 3-5 17-1 0 'I -‘l 3 1 -1 7 1 2-7 1 0-1 1 6-3 9-2 6-2 'I 1 -2 1 2-2 8-3 1 8-2 22-1 22-2 2-1 13-2 5-3 15-3 17-3 4-2 22-4 22-4 (POOR PERFORMANCE AT Low AND IDLE SPEED) 22-3 21-6 14-2 19-4 19-17 3-7 8-14 3-15 6-14 3-27 20-1