HOW TO USE THIS MANUAL This service manual describes the service procedures Follow the Maintenance Schedule (Section 3) recom- mendations to ensure that the vehicle is in pesk Operating condition and the emission levels. are Within the standards sot by the U.S. Environmental Protection Agency, California Air Resources Board Performing the first scheduled maintenance is very important. It compensates for the initial wear that ‘occurs during the break-in period. Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for ramoval/ ‘sallation of components that may be required to perform service described inthe fallowing sections. Sections 4 through 19 describe parts of the motoreyela, grouped aasarding to location. Find the section you want on this page, then turn to the table of cantents on the first page ofthe saction. Most sections have an assembly or system iilustration, service information and troubleshooting forthe section, The subsequent pages give detalled procedures. If you don't know the source of the trouble, go to ‘veution 22 Troubleshooting, ALL INFORMATION, ILLUSTRATIONS, DIREC- TIONS AND SPECIFICATIONS INCLUDED IN ‘THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING HONDA MOTOR CO,, LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY | OBLIGATION WHATEVER. NO PART OF THIS | | PUBLICATION MAY BE REPRODUCED WITHOUT | WRITTEN PERMISSION. THIS MANUAL IS | WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON HONDA MOTORCYCLES, MOTOR SCOOTERS | on arvs. CONTENTS GENERAL INFORMATION [-cenenatinronwarion SYSTEM. MAINTENANCE El | LuBRIcaTion system Ei FUEL SYSTEM i ENGINE REMOVAL/INSTALLATION Ea CYLINDER HEAD/VALVE | 3] [ actennaror/starrerciutcH ER CRANKCASE/TRANSMISSION | 11 | | ORANKSHAFT/PISTON/CYLINDER a REAR WHEEL/SUSPENSION | 14 | BATTERY/CHARGING SYSTEM a IGNITION SYSTEM Ea LIGHTS/METERS/SWITCHES { wirine DIAGRAMS El [TECHNICAL FEATURE ENGINE AND DRIVE TRAIN al CHASSIS | LECTRICAL, | | | | TROUBLESHOOTING SHOOTING face Date offssue: January, 1868SYMBOLS ‘The symbols used throughout this manual show specific service procedures. If supplementary information is required potting tu Urese syniluly, it wuuld Ue enpleined specifically in the tent without Ure use ofthe aymbuls, |g | eplcoshe part with new ont btore assembly foes mene oo | | Use recommended engine oil, unless otherwise specified. [TR encores oni ot somes sees | oe — ee [ eaeqy | Use mut purpose grease (Lithium based mut purpose grease NLGI #20 uve) | use molybdenum disulfide graase (containing more than 3 % molybdenum Fie equivalent yo Example: Molykote” BR-2 plus manufactured by Dow Corning, U.S. A Use molybdenum disulfide paste {containing more than 40 % molybdenum disulfide, NLGI #2 or equivarent, Example: Molykote® G-n paste, manufactured by Oow Corning, U.S.A, Honda Moly 60(U. S.A. oniy) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Apply sealant. Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified. Se Dye | Aonivatocking agent. Use a mite srangth locking agent uniess otherwise specified. sa a Use Fork or Suspension Fluid1. GENERAL INFORMATION GENERAL SAFETY WW LUBRICATION & SEAL POINTS 1-16 ‘SERVICE RULES 12 CABLE & HARNESS ROUTING 1:18 MODEL IDENTIFICATION 13 EMISSION CONTROL SYSTEMS 1-29 ‘SPECIFICATIONS 14 EMISSION CONTROL INFORMATION | LABELS 1-32 TORQUE VALUES 111 | TooLs 14 GENERAL SAFETY CARBON MONOXIDE USED ENGINE OIL, sure the atea is well ventilated, Never run the engine in an enclosed area BS The exhaust contains poisonous carbon monoxide gas ‘that ean eauce lose af consciousness and may lead to death. Fun tne engine in an open area or wn an exnaust ‘avacuation 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. Gasoline is extremely flammable and is explosive under certain conditions, KEEP OUT OF REACH OF CHILDAEN. BS SSS Engine ana exnaust system parts become very not ana remain hot for some time after the engine is run. Wear insulated gloves or wait until the engine and exhaust ‘system have cooled before handlina these parts. oo Used engine oil may cause skin cancer if repeatedly let in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, itis ‘stil advisable to thoroughly wash your hands with soap and water as soen ae possible after handling ueed oil. KEEP (OUT OF REACH OF CHILDREN. Never use an air hose or dry brush to clean the brake assemblies. Use a vacuum cleaner or alternate method to ‘minimize the hazard caused by air borne asbestos fibers. Bg Inhaled asbestos fibers have bee respiratory disease and cancer. found to cause BRAKE FLUID cautl 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 conditions, the ethylene glycol in engine coolant is combustible and its flame is not visible. If the you can be burned, be “Avoid spiling 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 lame. ‘Coolant (ethylene glycol) can cause some skin irritation and is poisonous if swallowed. KEEP OUT OF REACH OF (CHILDREN, The coolant is under pressure and could scald you. + Koop hands and clothing away from the cooling fan, as it starts automaticaly, CAUTION Using coolant with silicate corrosion inhibitors may cause premature wear of water pump seals or blockage of radia~ torpassages. Using tap water may cause engine damage. SERVICE RULES BATTERY HYDROGEN GAS & ELECTROLYTE a + Tho battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. = The baciery comatns sulrurle wend fetectrotyee). Coma with skin or eyes may cause severe burns. Wear protec- tive clothing and a face shield. =Ifelectrolyte gets on your skin, flush with water. =f electrolyte gets in your eyes, flush with water for at least 15 minutes and calla physician immediately + Electrolyte is poisonous. =i ewallowad. chink large quantities of wator or milk and follow with milk of magnesia or vegetable oil and calla physician. KEEP OUT OF REACH OF CHILDREN. 1.Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents, Parts that don't meet HONDA'S design specifications may cause damage to the motorcycle. 2.Use the soecial tools desianed for this product to avoid damaae and incorrect assembly. 4.Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners. 4 Install new gaskets, O-rings, cotter pins, and lock plates when reassembling, E.When Sighteoning belts or mute, begin with the larger diameter er innar halt frst Thon tighton to the epesified torque diagonally in incremental steps unlese a particular sequence is specified, 6.Clean parts in cleaning solvent upon disaseembly. Lubricate any sliding surfaces before reassembly 7.After eeassembly, check all parts for proper installation and operation. @.Route al electrical wires as show on pages 7-18 through 1-25, Cable ang Harness routing. 1-2MODEL IDENTIFICATION GENERAL INFORMATION VEHICLE IDEN IIHIUAION NUMBER (VIN) ‘The Vehicle identification Number (VIN) is located on the lft side ofthe frame. ) FRAME SERIAL NUMBER ENGINE SERIAL NUMBER ‘The frame sorial number is stamped on the right side of the steering head. ‘The engine serial number is stamped on the rear side cof the upper erankcase, (CARBURETOR IDENTIFICATION NUMBER / 1 oy dX ‘The carburetor Identification number Is stamped on the intake side of the carburetor body, ‘The color label is aflached on the rear fender under the seat. When ordering color-coded parts, always specify the designated color code. 1-3GENERAL INFORMATION SPECIFICATIONS GENERAL —— em SPECIFICATIONS DIMENSIONS | GveralTengin 2085 mm BIT | Overai with 886 mm (27. vera en 11190 mm (485i | Wheelbase | 11390 mm (47 in) | Seatheight | stammtain) Footpeg height |. 360.mm 14.2in) Ground clearance | 135mm 6.3) Ory weight 49.tateCanada ype | 16049 (973 be California tyoe | 170K9 75 tbs) Curoweight — GGetateamaratvnn | 197 kyle ihe) California type | 198 (437 es) Maximum weight capacity 49 state/California type | 175 kg (386 Ibs) canada ype 379.ny (999 bs) Frame pe mon Front suspension Tolescopic fork Front axle travel | 120 mm (4.7 in) || Rear suspension Swingarm | || Rear axle travel | 120 mm (4.7 in} Fronttie size 1207702R17 (S8W) Roertie eixe | 20786 2817 (raw) | Fronttire brand | BRIDGESTONE BTSEF RADIAL E, DUNLOP D207FJ, MICHELIN TX18C | Rear tire brand BRIDGESTONE BTSGR RADIAL G Front brake Hydraulic double disc |, eae brake Hydraulic single ise Caster angle | 2 ‘rail length 96 mm (3.8in} | Fueltankeapacity {17.0 0(4.49 US gal 3.74 imp gal) ENGINE Cylinder arrangement “cylinders inline inclined 31° from verical | Bore and etroke 67.0 ¥ 42.5 mm (2.64 1.67 in) \ | Displacement | 899 em? 196.5 cu-in) | Compression ratio | 12031 | | Vatve train Chain driven, DOHC [ iisevatve opens 22 810 1a | MAT 08 48° ABDC (At 1 mm if) Exhaust velve opens | 36° 88DC fat 1 mm itt closes | TPaToC (att mm ify Lsbrcation system Forced pressure and wet sump | | Giipump ype Trochoid | Gosling system | Uquid cooled | Engine dry weight | 59k (130 bs) | Firing order 1243GENERAL INFORMATION GENERAL (Cont'd) Trem CARBURETOR Carburetor type rote bore lutch system Clutch operation system Transmission Primary reduction Final reduction Gear ratio. tst 3rd ath sth eh Gearshift pattern SPECIFICATIONS. Constant Velocity Soo mm 1.84 in} Multi-plate, wet Cable operating Constant mesh, 6-speeds 4.822 (82/45) 2.812 (45/16) 2.893 (34/12), 2002 (23/10) 1.887 (28/17) 4.421 (27/19) 1.250 (25120) 1.130 (26/23) Left foot operated return system, 1-N-2-3-45.6 ELECTRICAL Tgnition system Charging system Regulatoriecttier Lighting system Fall ransistorized ignition Eloctrie etertor moter Triple phase output alternator SCR shorted, triple phase full wave rectification BatterGENERAL INFORMATION [~ LUBRICATION SYSTEM TEM Unit: mm tin) srannano [sete ua Enaine oil canacity Recommended engine oil Oil pressure (atoll main gallery) 3301 ayuesusa.osimpal Honda GN4 4stroke oll of equivalent meter ail ‘API sorvice classification SF or SG Viscosity: SAE 10 W-40 “490 kPa (6.0 kgficm?,71 psi) at «| SS 6,000 rpmia0C/176) [oleump | ipstearanes 0.15 0.06), aes [Body elearanea 0,150.29 (0006—0008). “03s 0.018) Sit sean Sip =Nay Waar =HnNe) Ep rote sos) FUEL SYSTEM SPECIFICATIONS. Carburetor idantifeation |G atate/Canada type Wee umber Caifornia ype 8 Main iet 49 sate/Canoda We No. Wa carbureign 2122, No.2 carburetor #105 | Caifomistvoe 2 198 (all carburetors) Siow jet 240 inilalfinal opening See page 539 as} igh skitude adjuetn anes Boo page 6 34 — 37 0.5 mm (064 = 002i) Idle speed ‘ saterCanada type 4,300 = 100 rpm California type “1,400 + 100 rpm ‘Cargufator vacuum aifrance base carouretor: No.3) “Throttle grip free play uel pump flow capscity (minimum) TUS of , 24.6 imp oz) (minute, 2=8 mm (i/16—V/¢ in) 1 COOLING SYSTEM: TEM SPECIFICATIONS. Bra SUSE. [Resorve tank T 33141033 US af,027 imp) Radiator cap relat pressure T TOE=137 KPa (1.11.4 kgflem?, 16-20 psi) Thermostat Begin to open. T T3=T7 °C 116317128) lly open Valve lift Recommended antifrosze Pro Honda HP Coolant or an equivalent high quality ethylene tlycol antifeare containing silieate-frna corrosion inhihitoreGENERAL INFORMATION [7 CYLINDER HEAD/VALVE TEM Cylinder compression at 360 rpm ‘STANDARD 1,226 kPa [12.5 kafiom®, 178 psi) Unit: rar te) SERVICE LIMIT (0.28 # 0.03,(0.011 + 0.001) | Camsha’ | Cam | a9 state/Canada '36,600~ 36.760 (1.4409 1.427) 3657120) | tobe |_type eas: 35.380— 35.540 (1.3929 — 1.3992) "35.35 (1.392) height | Calforaia type 34.640 34,720 (1.3628 1.3669), [ar (1-369) '33.820= 36,000 (7.3954 1.3986) 33.691.) Runout 1 0.06 10.002) Oil less 3.958 0.80F 0.9600 _a.08a) 3.106.003) Valve ifr — [Valve iter OD. [28.978 25.999 1.0998~ 1.0295) 125 971.022) Valve lifer bore 1D. {726.010 26.026 1.0240 1.0248) [26.08:1.025) Valve, Valve stem 0.0. IN| 3.975=3.990 (0.1565 0.1571 (0.1581) valve guide [Ex] 965 = 3.960 01861 0.1560), 3.985 (0.1867) Waive guide 0. INEX—|4.900— 4.072 (0:1875~ 0.1580), £04 (0.158) Stemto-guide clearance 9100.07 000400015) | 0.075 0.0030 78.=0 94718 0 % 3.006 16.3872) |" Waive gui projection 16.1 16.4 (0.83 0.65) above cylinder nead 143-146 (0.56—057) t Valve seat with 0.90.10 (0,035 0.063) ETO Valve spring | Free length IN [Saw IU) $27 307] l EX | 36.23 (1.426) 275 (1.367) Cylinder head warpage I ——— [0.10 (0.004) [— CLUTCH/GEARSHIFT LINKAGE Unite Cr Tem ‘STANDARD | service unart Soe Tee ay — io aoe TSG) t Cluteh [Spring fea length | 465 (1.8) ITB) Disc thickness 292-308 (0118-0120) 2510.10) Plate warpage 0.30 (0.010) Cluteh outer guide 1D, DOI= OT (OSES OSESTY 25.03 10.985), OD. [34.975 —34.991(1.3770—1.3776) 3497 (1.377) ‘WinshattO.D-at dutch outer guide {24.960 — 24,995 (0.9835 0.9840) 24:96 (0.983) p> ALTERNATOR/STARTER CLUTCH rie. nee fn rem STANDARD SERVICE LIMIT ‘Slanar ven gearboss OD. Sra a ZT Se IGENERAL INFORMATION 0,025 —0.075 (0.0010—0.0030) [> CRANKCASE/TRANSMISSION nie mn inh TEM STANDARD SERVICE LiMT Saitek [EDR [Glaw thickness | B83-600(0233-0.708) | 8910.23) ‘Shift fork shaft_| 0.0. f ‘11.957 = 11.968 (0.4707 — 0.4712) 1711.95 (0.470) Transmission | Gear. 8, Me 102611082) [2s.06 1.108) | a,c3, gare) enoa tase) Gear bushing OD. ME, M6 1016) [27.94 (100) | @ 30.955=30,980/1.2187— 1.2197) | 086 1218) 3, cx 30.950—30.975 1.2185—1.2195), 30.93 (1.218) ["Gearte-bushing —[MS, Me~———|"0.020 0.062 (0.0008 0.0024) .10(0.00) clearance 2 0.020=0.070 (0.0008 0.0028) 10 (0.008) (o.008) [~ CRANKSHAFT/PISTON/CYLINDER —— ‘24.9R8 — 25.006 (0.987 —0 9R¢5) Dame 9 BRAS) 3.1018 1.1026), 28.021 (1.1032) 980 (0.9830 0.8835) 24.96 (0.883) i shat © ‘27.967 27.980 (1.1011 —1.1016) 27.96(1.101) J Bushing-wrsia '9.005~0.059 (0.0002 —0.0075) 0.09 (9.0021 clearance, [ez "0.005 — 0.039 (0.0002 ~0.0015) 0,06 (0.002) Unit: mm tin) ‘STANDARD ‘SERVICE LIMIT a.075 01086 0.0008 ~0.0020) — Crankshaft 070=0.25 (6.004—0.0101 [ian une beating lt cleranee ["Runout __ 0.05 (0.002) Piston, Piston O.D. at 15 (6) frombotom | 66.965 ~ 66.985 26364-26372) (66.90 2.638) piston pin, [Piston pin hal [7.wu2= 17.008 (W.pe86 Ube 1.02 (05/0) piston ring [Piston pin 16.984 ~17.000 0.669) “Piston-te-piston pin learance Piston rina end 0.4 0.021 ap 0.5 0.02), 1.0 (0.08h, 0.08 (0.003), | 0.08 10.003), Gylindsr 102.64) | ‘Connecting rod small end 1.0. [C17.016= 17.034 (0.6699 0.6708) 17.04 (0.6717, Connecting roviseupiston pia rlaaranea “aoe =0.d0 i.00n = 4.0036) BGA in oA 1-8GENERAL INFORMATION [~ FRONT WHEEL/SUSPENSION/STEERING Lit mm tind STANDARD 1 SERVICE LIMIT ‘Minimum tire tread depth [7.510.08), ‘Culu ure pressure [Uy w 50 Ky (200 ibs) uaa Bowe ZoUNBTET 38 BA Up to maximum weight capacity 250 kPa (2.50 kal/cm?, 36 psil Aa runout —_ ozo | Wheel rim runout | Radial 7 2.010.081 Axial 2.0(0.08) | Wheel Balance weight 60g 2.1 odmax| Fork ‘Spring free length 3361321 228.3 12.86), Tubs runcut (0.20 (0.008) Recommended fluid |_ProHonda Suspension Fluid SSB I [Fluid ievel 118 (4.6) Fluid capacity | 0.0908. 475 = 25 cm (16.1 = 0.08 US oz 187 Steering head bearing preload 1.0= 18 kgfi22—3.3 16H) ;~ REAR WHEEL/SUSPENSION it me tn} ITEM STANDARD SERVICE LIMIT inimum tire tread aepmn az Coldire pressure |_Upto 90 kg 200 bs) load ‘Upto maximum weight capacity 290 kPa 12,90 kgfiem?, 42 psi) z0To0e 10 kPa (2.90 kaflem®, 62 psi) _ [ ‘Axle runout Tezeon__| Wheel rim runout [Radial = 12.00.08), ‘Axial = 2.0 (0.08), ‘Wheel balance weight [60 9 (2.1 o7imax. Brive hig slack 35-1 3a) HYDRAULIC BRAKE i emf TEM STANDARD ssenvicc unarr Front [Specified brake uid bora = — [Brake disc thickness 44— 45 (017-078) Tawi Brake dise run 9.20 (6.0°3) ‘Master cylinder ‘Master piston 0.0. 35.870— 15.91 0.6248 0.6265) i 118.525 (0.5270), 95.827— 15.854 (0.6231 = 0.6242) [5.8165 (0.6226) x 34.01 (1.387 ~ 1.339) [302 1.339) 5 = 32.080 (7.2610 1.2630) 32,09 (1.263) A 38,895 — 33.978 (1.5344 —1,3957) 33.87 (1.333) & [31,985 ~ 31,98 (1.2585~ 1.2599), 1731.96 0.257) Rear | Specified brake Auld ors = Brake disc thickness 48-63 10.10-020) 4010.16), Brake disc runout 7 0.30 (0.012) ‘Master cylinder 10. 44,000 ~ 18.043 (0.55120 5529) 14,055 (0.5533). Master piston 0.0. 13.997 13,208 (0.0490—0.95001 13.989 (U.5490) Caliper cylinder LD. 36.18 38.23 (1.503 1.605) 38.24 (1.506) Caliper piston 0.D. '38.098— 38.148 (1.4999 ~ 1.5078) 38,09 (1.500)GENERAL INFORMATION [~ BATTERY/CHARGING SYSTEM TEM ‘SPECIFICATIONS Battery : oN Voltage Fully charged a (206) _["Needs charging | Charging current” [_Normal 1 aig Fema a ‘Alternator | Capacity == ‘343 W/5,000 min” (rpm) Charging boil resistanes [20°C)65 7) 01-100 IGNITION SYSTEM Trem SPECIFICATIONS Spark plug] #9 satelCanada type CASES INGK) UZTFER.9 (DENSO) E California pe — CROEHVX9 (NGK) ~ Spamoloa as Tae=USU MM (UUs LOST ignition col primary peak voltage 100 V minimum, ignition pulse generator peak voltage 0.7 V minimum ing |"F” mark) (0° BTDG a ile Resistance (20 °C)68) 46k input voltage a7 53V, TEM ‘Starter motor brush length [— ELECTRIC STARTER — unt mm an ‘STANDARD 120-13.010.7-051) | ‘SERVICE UMIT | 65026} p~ LIGHTS/METERS/SWITCHES TEM ‘SPECIFICATIONS Bulbs [Headlight Highview bear) Tay — SoBe Brake/ailight 32V = 2YSW Xo License light 12V~ ace. = urn signal running ight TV Scr 5a) x 2 "12V=32CP (23) <2 - Instrument light = WaV=1.1W x3 Turn signal indicator Wav = tawx<7 = High beam indicator 32 = 14 Ne 12V = 1.4. Fuse 308 — _ TAX’ ‘Thermasensor resistance 7 a8 0 14-189 Fan motor switch ‘Starts to close (ON) 38— 102 °C 208-216 Fh ‘Stops to open (OFF) ‘99=97 °C (189207 *F) 1-10GENERAL INFORMATION TORQUE VALUES STANDARD | FASTENER TYPE ‘onaue ronaue | 5mm bolt and mut BI05 26) Bem seraw 404,29) | @mmboltand nut 1011.0,7) mm screw 9(09,65) | Siym bottand ut 2122.18) | Smmfengebot(@mmneed, | TOL10.7 | som botand nt 335/29) | smaltnge "eimm eo ana nt S2185:2) | Stamnange oot mm nso, ven | ig tango | Crm fenge bok tommners) | 12012.8) | rant | | Stim lange bot and ut 2127.29 | tOmm flange board 59160, 29 * Others should be tightened to standard torque values listed above. NOTES: 1. Apply sealantto the threads. 2. Apply lacking agent tothe threads. 3. Stske. 44. Apply oilto the threads and seating surface. 5. Usnut 6. ALOC bol/screw: replace with a new one. 7. Apply grease to the threads. 8. Apply molybdenum oil solution to the threads and seating surface, — ENGINE - | ow THREAD TORQUE ro OT DIA mm) | Nem (kat, tote) | REMARKS ee | | MAINTENANCE: | ‘Spark plug } 4 | 10, 1241.2,9) Ting holecap 1 ie worwa,10) | Note? Engine ol iter coridge 1 20 novio.7) | NOTES Engine oll drain bolt 1 | 2 29(3.0,22) LUBRICATION SYSTEM: Ly 1 == | ‘Oil main gallery sealing bot 0 (20,2 2 Oitpressure sich |oa | erie 12(02,9) | NOTE Oil pressure switch terminal screw \4 ‘ 2102, 1.4 Oil pump cover bolt oe 6 | 910.9, 6.0) Oil cooler bolt (filter boss) } 4 20 | 64 (6.5, 47) NOTES FUEL SYSTEM: | Starting enrichment (SE) valve nut ‘ — 2102,14 Gltburster connecting nt rant 2 ° sis 8) | rear 2 5 5105.36) Reed valve cover bolt a] oa 13013, NOLING SYSTEM: | Water pump assem bolt ae | ec | ‘Thermostat cover bol 2 1201219) ENGINE MOUNTING: | | | CYLINDER HEAD/VALVE: | | | | Cylinder head bot | w | s | aaa | notes CCamahatt holder bot » | 6 12(12,9) | NOTES Cam sprocket bot pep og 2020.14) | NOTE? Cylinder head cover bot 3 6 1010.7) CCamehain tensioner iter mourtng bolt 2 | 8 10110.) = = J 1-11GENERAL INFORMATION [~ ENGINE (conra) ‘CLUTCH/GEARSHIFT LINKAGE: | Clutch bolt fs | | eos | Gearshift stopper arm bolt boa} 6 | Raz | Gearshift spindle return spring pin . | a | 2323/17 ALTeRnATOR/STARTER CLUTCH | (See i... | cantiSaettnansmssion Gears rum Soon ander att an bot Ble i east liners San cnew ieee GT eaain| mores Crankcase bolt a 10 | 39(4.0, 23) cataecray setonscrinnes | | | agin canes | | uaitonnctens owen, Neutral switch 1 | 10 12(1.2.9) [ee ] | Tunean ‘Tonaue | -_ on | DIA. (mm) N-m (kgt-m, Ibf-ft) Lelactale Fusenoovpacisenuustersre | Erno ha |7 aa..0 Upper fairing-to-side firing bolt oo 5 210.2, 1.4) | ‘Muffler band bolt ; 2 8 2312.3, 17) | Passenger footpeg bracket bot Ja 8 warm | Trant engine hanger bolt | 2 10 39(60,29) pager | Center engine hanger adjusting bolt (right side) 1 20 4(0.8,29) ~| | | Rearengine hanger nut 1 10 | 39¢40,20) -| ‘Shock fink bracket nut | 2 | © 3914.0 , 28) FRONT WHEEL/SUSPENSION/STEERING: | | | Front axle holder bolt os | ees | 4-12GENERAL INFORMATION FRAME (Cont'd) rem HUNT WHEEL/SUSPENSIUIS IEERING: Front fender bolt Fork socket bolt Fork cap Fork top bridge pinch bolt Fork bottom bridge pinch bolt Steering bearing adjustment nut Steering beating aujusuinent ut ivek nut Steering stem nut Front brake hose clamp bolt (steering stem) REAR WHEEL/SUSPENSION: Rear brake disc bolt Final driven sprocket nut Rear axle nut Shock arm-to-swingarm nut Shock arm-to-shock link nut Shock link-to-bracket nut Drive chain slider bolt Swingarm pivot adjusting bolt ‘Swingarm pivot lock nut Swingarm pivot nut, HYDRAULIC BRAKE: Brake caliper bleed valve Front master cylinder reservoir cap screw ‘Roar brake reservulr niouriiny Bult Pad pin Pad pin plug Brake hose oil bolt Front brake lever pivot bolt Front brake lever pivot nut Front brake light switch screw Front mastor eyiindor mounting bolt Front brake caliper assembly bolt Front brake caliper mounting bolt Rear master cylinder joint nut Rear master cylinder mounting bolt Rear brake calipar bolt Rear brake caliper pin bolt HT /METERS/SWITCHES: Side stand switch bolt Ignition switch mounting bott Fan motor switch OTHERS: Side stand pivot bolt Side stand pivot lock nut Side stand bracket bolt Driver footpeg bracket bolt 4 2 2 2 2 i 1 1 10 10 10 ‘TORQUE Nem (kgf-m, tot 12012,9) 34(3.5,25) 232.3, 17) 232.3, 17), 39(4.0, 29), 252.5, 18), 103 (10.5, 76) — 10(1.0,7) 42143,.31) 8819.0, 65) 939.5, 69), aan.) 44185, 33), 4414.5,.33), 44145 ,33) 710.7,5.1) 64165 47) 93 (95,69) 6108, 43) 202, 1.8) a2 (8,9) 1811.8, 13) 303,22) 34138, 25) 1(0.1,0.7) (08,43) 140.107) 1202.9) 23123, 30(8.1,22), 19 (1.8, 13), 910.9,05) 23(2.3,17) 27(2.8, 20), 1011.0,7) 2512.5, 18) 18118, 13) 2912.9,97) 10(1.0,7) 2913.0,22), 44(45/ 33) 262.7, 20), > page 14-17 REMARKS. page 13.28, NOTES NOTES NOTES NOTES NOTES NOTES NOTES Notes NOTE 2 NOTES NOTES 1-13GENERAL INFORMATION TOOLS DESCRIPTION | Toot numeen ALTERNATIVE TOOL TooL NUMBER | Fostievergauge——} —"trao-aoro00o —} Oil pressure gauge 07506.2000000 —- Equivalent commercially available | Oi pressure gauge attachment orstonyro100—| in S.A | Cluten center hater 07724-0060002 | Equivalent commercially avalabie| ins | Fiywheel holder 07725-0040000 | Equivalent commercially available Rotor puller | or7ss-0020001 | Rotorpuiter 07933-3950000 Astachment, 3238 mm | o7746-0010100 fctachment 37 % &0 mm | o7746-0010200 ‘Attachment, 42 X 47: mm | o7746-o010300 | Attachment, 52 * 58 mm | o77es-2010400 Atachmert. 22 24 mm 07746.00%0800 | fner aren errsecoa0%09 | ‘tachment, 25 mm |. 077489030200 Astachmert, 30 mm 0 | orrasccanaoo | | Flot, 17 mm 07748.a040400 | Pilot 20 mm o774e.a040s00 Pilot 35 mm 07748.0040800 Pilot, 28 mm 0746.0081100 | | Baring omover shaft 7748.0050100 —1 equivalent commercially avaiable | | Bearing remover head, 20 mm 7746-0080600 —] in USA Driver 97749-0010000 | Valve spring compressor 07757-01000 | | Vaio seateuter, 223mm ex.s) | 07790-0910100 —r} Equivalent commercially avaiable Valve seat cutter, 27.5 mm(INaé*) | 07780-0010200 {| in USA Flat etter, 24 mim (EX 32) 07780-0012500 — | | et etter, 27 mm (N32) 07780-0013300 — Interior cutter 2 mm (EX 60 rreo-0014202 — | Interior exter 26 mm IN 60") 07750-0014500 | Cutter holder 8.0 mm o778-0010500 — | Lock nut rah 07000 4000009 | Lock nut wrerni 27200-4oso002 Snap ring piers o7sta-Saso0o1 | Steering stom sockst 079163710101 | Steering stem socket ore163710100 ‘Attachment, 28 30mm 07946-1870100 Ball rae remover set 730s «M90001 —- Not avalble in USA | “Driver attachment A | arsasxatgoi00—] (scene 19-2) | ~Driver attachment B | 07946-90200 | ~briver shay | thsue xeoaa — \ | Bearing vomover trsao-cnosot — Bearing remover 8 t73ae-ch0s00 | ~Assembly bove | orsas-xmsos00— seston 27920.0000900 1-14GENERAL INFORMATION | DESCRIPTION TOOL NUMBER ALTERNATIVETOOL | TOOLNUMBER [ain bearing driver attachment 7846. EDOIOO - | Driver snate o7et6.Joo100 | | | Dewar head (07946-00200 | | Fork seal driver attachment, &8mmLD. | — 07947-KA80200 | | | Fork seal driver weight 07987-KAS0%00 | | Driver attachment handle 7ag9.a7 10001 | | Valve spring compressor attachment 07959-KM30101 | | Oil seal driver 07965-80000 Oil finer wrench o7Ha-P70100 Peae vonage sdapror rmiGu-uuesivy | eax vonage tester (U9. oniy) Needle bearing remover co7inac-naR70%100 Tappet hole protector ‘O7HMG-MR70002 Drive chain tool set O7HMH-MR10103 Drive chain too! sat O7HMH MR T0108 | (US.A only) Valve guide driver o7sMo-kY20100 | Pilot serew wrench | O7KMA‘MINGO100 Piet serew wrench | o7kMaswssor01 Valve guide reamer, 4,008 mm | o7MMH-mvsoro0 Compression gauge tachment | O7RNU-MMY50100 } Lock nut wrench O7VMA-MBB0100 | instaer shat 7VMF-KZ30200 | | instatter attachment A | orvwF-maTotoo | | Installer attachment 8 | o7vie-ntatoz00 | Remover attachment A | orvie-nato200 | Remover attachmant B (O7VME.MATo40O | 1-15GENERAL INFORMATION LUBRICATION & SEAL POINTS p7 ENGINE Leeanion, | MATERIAL ‘il pan mating surface Cylinder head sem-circulor area Crankcose mating surfces (ight side) | Crankcase mating surfaces lot side) Crankease mating surface | Sitpressure suit threads | See page 9-14 See page 10-2 See page 11.11 See page 4-4 | Comshattjournais and car lobes ‘iuten autor guige sting surraces Starter reduction gear shaft outer surface | 1Ma/4, C5, C8 gear shift fork grooves Connectina rod small end inner surface Piston pin outer surface Crankpin bearing sliding surface Grankshatt main journal bearing sliding surface Primary drive oub-gear sliding surfaces Crankshaft thrust surfaces Thermosonsor threads Do not apply to the sensor head. ‘Water pump shaft spindle and thrust washer siding surfece | Molybdenum oll solution | See page 6-13 | Cylinder head @ mm boit threads and seating surface | (a mixture of 1/2 engine | Valve stem sliding surface cil and 1/2 molybdenum Valve lifter outer surface isulfide grease) Engine oil fer cartridge threads and seating surface | Engine oll Oil cooler bot (fiter boss) threads and seating surface Cylinder head bolt threads and seating surface Camshaft holder bolt threads and seating surface Clutch disc lining surfaces Guteh eentar lark nit threads and seating surface Starter sprag clutch contacting surfaces Flywheel bolt threads and seating surface | Piston outer surface Fision ring waote surtace Connecting rad bearing cap nut threads and seating surface Crankcase bolt (main journal 8 mm) threads Each gear teeth and rotating surface Each bearing rotating area Each O-ring and packing whole surface | Other rotating and sliding area ‘Timing hole cap threade ~) Moni parpoce oreaee Carburetor synchronization adjusting screw tip Each oil seal lips —_ __ il pump driven sprocket bolt threads Cam sprocket bolt threads Gearshift cam bolt threads Gearshift spindle oll seal plate bolt threads Startar clutch bat threads Mainshaft bearing sat plate bol threads Gearshift drum bearing and fork shaft set bolt threads Cam chain tensioner pivot boi threads Gil main gallery 20 mm sealing bolt threads Locking agent 1-16GENERAL INFORMATION 7 FRAME $$$ Location (MATERIAL REMARKS Seat catch hook sidin Front whee! dust seal lips, ‘Steering head bearings Steering head bearing dust seal lips Final driven flange-to rear whect hub mating curface and O-ring Rear wheel dust seal Roar wheel side collarinner surfaces Shock absorber needle bearings ‘Shock absorber dust seal lips ‘Shock link and shock arm (swingarm) needte bearings [Shock link and shock arm (swingarm) dust seal line ‘Swingarm pivot bearings ‘Swingarm pivot dust seal lips Throttle grip pipe flange Guten iever pivot Rear brake pedal Gearshift pedal link tie-od ball joints Gearshift pedal oivot Driver footpeg sliding aree Passenger footpeg sliding eree TMuitepurpose grease Clutch cable outer inside Choke cable outer inside Cabie lubricant Handlebar grip rubber inside Fonda bond Aor equivalent ‘Steering bearing adjustment nut threads gine oil Front brake lever-to-master piston contacting area Front brake lever pivot Fear brake master piston-o-push rod contacting area ‘and push rod boot groove Fear brake caliper boot inside (collar outer surface) ‘ear brake caliper pin bolt boot inside “Y"Silicon grease Brake master piston and cups Brake caliper piston and piston seals. DOT 4 brake fluid oi voir hose joint screw threads iper assembly bolt threads Rear brake caliper pin bolt threads Fork fluid Locking agentGENERAL INFORMATION CABLE & HARNESS KOUTING ‘TURN SIGNAL CONNECTORS BRAKE HOSE LEFT HANDLEBAR SWITCH WIRE HEAULIGH! LUNNEC IU” IGNITION SwiTcH WIRE RIGHT HANDLEBAR SWITCH WIRE ‘OUTER AlR VENT HOSE (California type: No. 8) LEFT TURN SIGNAL WIRE RIGHT TURN SIGNAL WIREGENERAL INFORMATION CLUTCH CABLE E CLUICH SWIICH ~ CONNECTORS \\ Uf x Kay EHUN SHAKE LIGH SWITCH CONNECTORS xm Sey 4 ro 4 / / NN Leer sansa 5 Wee ‘SWITCH WIRE, 4 o \\ SWITCH WIRE on ware | Za SSS rinorre casies (CHOKE CABLE SUB-AIR CLEANER. cLUTCH CABLE waren “eg x eS F\ wa SUB-AIR CLEANER SIPHON TUBE RESERVE TANK BREATHER TUBEGENERAL INFORMATION AIR VENT CONTROL SOLENOID VALVE IGNITION swiTcH EVAP CAV SOLENOID VALVE (California type only) a IGNITION COIL 6 (Back) COMBINATION METER CONNECTOR Tonttinn caiteh 4 (White) Leithandiebar switch 13? (Black) Right handleber switch 4P and 3P Red) Heedlight and turn signal 9P (White) — AIR VENT CONTROL BRAKE HOSE ‘SOLENOID VALVE 2 FAN MOTOR SWITCH 2P CONNECTOR VALVE" (Black! CONNECTOR (California type only) CONNECTORS: Alternator 3 White) Side stand switch 2° (Green) Ignition pulse gonorator 2° (Red) AN re eee | \ peers \S Recreruracyt fox = Speed Sensor G U NEUTRAL SwTCH (Cay Ce BESTA use SREATHER ‘SIDE STAND SWITCH FUEL TANK {49 state/Canade type) \ BREATHER TUBE rue, TANK FUEL TANK DRAIN TUBE oD a 1-20GENERAL INFORMATION 49 state/Canada type shown: FLOAT CHAMBER ie in eNO AIR VENT CONTROL SOLENOID VALVE Wf Lo ‘SUB-AIR CLEANER: i Ale _ \ _ROATcHauses caankcase / ; BSE HAMEE 000 Sree hose .y > W. CN crore ate cuamesn AINVENT HOSE IGNITION cols: THROTTLE CABLES vay rHROTTLE |, SENSOR ‘GnouNo rownr: \\ \ MA af Ry // CARBURETOR HEATER WATER TUBES: \\ NS re iT) A {| / FueL TuRe 1-21GENERAL INFORMATION ‘AIR SUPPLY HOSES (California: No. 16) vacuum Tuoc \ (Biteent Noy é Ss PULSE SECONDARY a AIR INJECTION (PAIR) CONTROL an ‘AIR SUPPLY HOSE. . (California: No. 15) THROTTLE SENSOR WIRE GROUND CABLE ‘SPEED SENSOR 3. (Black) CONNECTOR, 1-22GENERAL INFORMATION FUEL RESERVE SENSOR CONNECTORS FUEL TANK BREATHER TUBE (49 state/Canaca type) Ss) \ \ h 4 / \h LR \AES \) f FUEL TANK DRAIN TUBE STARTER MOTOR CABLE- I wmamvswor_| -——_—— ce / FUEL PUMP 2P (Black) CONNECTOR L Fy | ly (ae ee reno, STOP SCREW ~~ FueL PUMP: REAR BRAKE LIGHT SWITCH 2P (White) CONNECTOR, 1-23GENERAL INFORMATION SEATLOCK CABLE BRAKETAIL LiOnT CONNECTORS: IRN SIGNAL, AIR VENT CONTROL SOLENOID VALVE RELAY CONNECTORS ts ae only) 8, IGNITION CONTROL MODULE (ic), _ REAR BRAKE LIGHT SWITCH WIRE egouno Soe { uct puve fuer Ly Tupnsiend, g mae : ie Re ee a R wane Sel) REGULATOR) Lae ower iL oan sda oneke UGHT STE 1-24GENERAL INFORMATION California type only: AIR VENT CONTROL SOLENOID VALVE VACUUM CHAMBER AR VENT HOSE | No. Hose No.8 HOSE EVAPORATIVE EMISSION (EVAP) PURGE CONTROL VALVE IN. 7 (From EVAP canister) (From air cleaner housing) EVAPUNAIIVE EMISSION Mt CARBURETOR AIR VENT. (EVAP CAV) SOLENOID VALVE CRANKCASE BREATHER HOSE Mra airiaaner housing) No. 15 HOSE 1-25GENERAL INFORMATION California type only: EVAP PURGE CONTROL VALVE No. &HOSE No. 2HOSE \ EVAPORATIVE EMISSION (EVAP) CANISTER ES | No.2HOse FUEL TANK ORAIN TUBE 1-26GENERAL INFORMATION No, 4 HOSE FUEL TANK DRAIN TUBE \ ee \ No, 2 HOSE MAIN WIRE HARNESSGENERAL INFORMATION FUEL TANK, / EVAP PURGE CONTROL VALVE EVAP CANISTER, x 7 Open ee No.5 cL vas EVAP CAV SOLENOID VALVE pea aie 1.92GENERAL INFORMATION EMISSION CONTROL SYSTEMS ‘The U.S. Environmental Protection Agency, Transport Canada and California Air Resources Board (CARB) require manufac- turers to certify that their motorcycles comply with applicable exhaust emissions standards during their useful life, when ‘operated and maintained according to the instructions provided, and that motorcycles built after January 1, 1983 comply with applicable noise emission standards for one yaar or 6,000 km (3,730 miles) after the time of sale to the ultimate pur chaser, when operated end maintained sccording to the instructions provided. Compliance with the terms ofthe Distributor's Limited! Warranty for Handa Matoreycla Emission Control Systems ie necessary in order to keep the emissions system warranty in effect. SOURCE OF EMISSIONS The combustion process produces carbon monoxide and hydrocarbons. Controlling hydrocarbon emissions is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon ‘monoxide does not react in the same way, but itis toxic. Honda Motor Co.,Ltd, utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydrocar bons. CRANKCASE EMISSION CONTROL SYSTEM ‘The engine is equipped with closed crankcase system to prevent discharging crankcase emissions into the atmosphere, Blow-by gas is returned to the combustion chamber through the ai cleanet and carburetor. _AIRCLEANER CARBURETOR <== FRESHAIR — slowayaas 1-29GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (PULSE SECONDARY AIR INJECTION SYSTEM) ‘The exhaust emission control system consists ofa secondary air supply system which introduces fiterad air into the exhaust ‘System. This charge of Trash air promotes burning of the unburned exhaust gases and charges a considerable amount of hy¢rocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor. ‘This model has the pulse secondary air injection (PAIR) control valve and PAIR check valves. PAIR check valve prevents reverse air low through the systui, The PAIR conti valve rests Wy high inlake manifold vaguurn aad will ext off che Supply of fresh air during engine deceleration, thereby preventing afterburn inthe exhaust system, 'No adjustment to the pulse secondary air injection system should be made, although periodic inspection of the components is recommended, AIR CLEANER, PAIR CHECK VALVE ween \ [AIR SUPPLY HOSE (California: No. 15) VACUUM TUBE (California: No. 10) PAIR CONTROL VALVE p> u_f tener Connect the water hoses tothe oll cooler. Install tha ail fitar (page 3-12) Fill and bleed the cooling system (page 6-4). LUBRICATION SYSTEM5. FUEL SYSTEM SERVICE INFORMATION TROUBLESHOOTING | AIR CLEANER HOUSING CARBURETOR SEPARATION CARBURETOR DISASSEMBLY/ INSPECTION CARBURETOR ASSEMBLY CARBURETOR COMBINATION 53 55 514 5.15 5-16 518 5-22 5-26 CARBURETOR INSTALLATION PILOT SCREW ADJUSTMENT HIGH ALTITUDE ADJUSTMENT DIRECT AIR INDUCTION (D.A.1) SYSTEM FUEL PUMP ‘SECONDARY AIR SUPPLY SYSTEM EVAPORATIVE EMISSION CONTROL ‘SYSTEM (California type only) 5-30 5:33 5:34 5.36 | 5-37 | 5 5 31 5-38 "i ,| DIRECT AIR INDUCTION (0.A.L) SYSTEM AIR FLOW PATTERN. 49 state/Canada type: Under 20 kev (18 mph FLOAT CHAMBER, INNER SIRUENT HOSE VACUUM CHAMBER AIR VENT HOSE CARBURETOR AJR CLEANER HOUSING AIR INTAKE DUCT FLOAT CHAMBER ‘OUTER AiR VENT HOSE AIR VENT CONTROL SOLENOID VALVE 5-1FUEL SYSTEM cattornia type: Under 20 krvh (18 mph: {AIR CLEANER HOUSING [AIR INTAKE DUCT VACUUM CHAMBER, (Over 20 km/h (18 mph: AIR VENT HOSE No, 4 HOSE (FLOAT CHAMBER CARBURETOR j OUTER AIR VENT LY HOSE) No.7 HOSE i ‘ (FLOAT CHAMBER INNER AIR VENT No. HOSE EVAP CAV SOLENOID VALVE AIR VENT CONTROL SOLENOID VALVEFUEL SYSTEM SERVICE INFORMATION GENERAL COS ‘+ Gasoline is extremely flammable ands explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. = When the engine must be running to do some work, make sure the area ix well-ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area, * Bending or twisting the control cables will impair smooth operation and could cause the cable to stick or bind, resulting moss of venicie controt. + Work in a well ventilated area. Smokina or allowina flames or sparks in the work area or where nasoline 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. + For fuel tank and air intake duct removal and installation, see page 2-3, + For throttle sensor inspection and replacement, see page 17-7. + For carburetor synchronization, aaa page 21 * Before disassembling the carburetors, place an approved fuel container under the carburetors, loosen the drain screws ‘and drain the carburetors. ‘After removing the carburetors, cover the intake ports of the cylinder heads with a piece of tape to prevent any foreign ‘material rom aropping into the engine, ‘= When disassembling the fuel system parts, nate the locations ofthe O-rings. Replace them with new anes on reassembly. ‘* The vacuum chamber and float chamber can be serviced with the carburetors combined. 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FUEL SYSTEM SPECIFICATIONS: mem ‘SPECIFICATIONS Carburetor Wentification | 49 state/Canada type = Vee number California type. VP5AE Main jet 49 state/Canada type No. Wearburstor #182 , No. 23 carburetor 2136 - California ype 2 128 (all carburviurs) — Slaw et 240 Pilot screw Taitiainal opening See page 533 = high altitude adjustment ‘See page 5-34 = Float level 737 =05 mm (0.54 = 0.02in) Idle speed 48 state/Canada ype 1,300 == 100 rpm = [California tyoe 1.400 + 100 rpm Tarburetar vacuum diferene (nage carburetor Noa) ‘Within 30 mmm Hg (12 in Hah Fuel pump flow capacity (minimum) Throttle grip free play —FOW-em (23.7 US 02, 246 imp o2) minute 2- Emm (/i6~ ¥/4in) TORQUE VALUES Startina enrichment [SE) valve nut Carburetor connecting nut (8 am) (mm) Reed valve cover bolt TOOL Float level gauge Pilot screw wrench 2Nem (02 katm. 1.4 bf) Nom (0.8 kgiim 6.5 bf 5N-m (0.5 kghm, 3.6 Ib.) 13Nem (1.3 kgm , 9 IbE-A) 07407-0010000 DO7KMA-MINGOTOU oF O7KMAMSBO101FUEL SYSTEM. TROUBLESHOOTING Engine cranks but won't start * No fuel in tank *# No fuel to carburetor ~ Clogged fuel fiter Clogged fuel line — Clogged fuel tank breather tube ‘Too much fuel getting tothe engine = Clogged air cleaner = Flooded carburetor + Contaminated/deteriorated fuel ‘Improper choke operation ‘Improper throttle operation * Fuel pump system malfunction ‘No spark at plug (faulty ignition system—section 17) * Rastvicted fuel lina * Fuel mixture too leanvtich + Contaminated/deteriorated fuel Intake air leak * Misadjusted idle speed * Misadjusted pilot screw * Restricted fuel tank breather tube * Clogged air cleaner + Clogged slow circuit * Starting enrichment valve open uel pump system maitunetion *DAL system malfunction ‘Faulty EVAP CAV and/or EVAP purge control system (California toe) + Faulty ignition system (section 17) Atterbuen when engine braking is used * Lean mixture in slow circuit + Faulty aie cutoff valve * Faulty pulse secondary air injection (PAIR) system + Faulty ignition system (section 17) Backtiring or misfiring during acceleration * Lean mixture = Foulty ignition eyeter {esotion 1) Poor performance (driveability) + Clogged fuel system ‘Fue! pump system maitunction *D.ALL system malfunction + Faulty EVAP CAV control system (California type) 1 Fauity ignitinn systar (section 17) Lean mixture * Clogged fuel jets * Faulty float valve * Float level too low * Restricted fuel line « Rastricta fuel tank breather the ‘Intake air leak + Faulty vacuum piston ‘Fuel pump system malfunction + Fauity evar CAV contro! system (Cautrornia type) Rich mixture * Starting enrichment valve open * Clogged air jets * Faulty float valve * Float level too high ety air cleaner * Faulty vacuum piston + Faulty EVAP purge control system (California type) 5-5FUEL SYSTEM. Direct Air inauction (U.A. System mamtunction (44 31 A1E/GANAUA type} Turn the ignition switch ON with the enaine stop switch to RUN and check the solenoid valve for ‘operational sound located under the front side of the fuel tank (i.e. poping sound). Sound | Romove the seat cow! |page 2-2). Raise the rear wheel off the ground and suppor the motorcycle securely with @ hoist or equi lent Start the engine, shift the transmission into gear ‘and check for continuity between the Pinkiwhite and Blackiwnite #2 terminals of the solenoia valve relay. There should be continuity when the ‘speedometer is below 20 krnvh (18 mph) and no continuity when the speedometer is 20 krv (18 ‘mph) or more. |-No sound—= (Go to following pace! AIR VENT CONTROL [Normal —= « Check the induction ducts and hoses, and the Solenoid valve operation (page 526) FUEL PUMP. SOLENOID VALVE FUELPUMP. ay FELAY Abnormal rane Disconnect the fuel pump transfer relay connec ‘or. Measure the voltage between the Blackiwhite #1 (+) terminal of the solenoid vaive relay and ‘ground (-~) with the ignition switch ON, na Blackiwhite #2 Blackiwhite #1 [No voltage “= # Open circuit in Blackiwhite #1 wire Voltage I Measure the voltage between the Pinkiyellow (+) terminal of the solenoid valve relay and around (=) with the ignition switch ON, L.No voltage -= « Faulty solenoid valve relay Voltage ‘Connect the tanster relay connector. Start the engine, shift the transmission into gear land measure the voltage between the Pinkiy low (=) terminal of the salancid valve relay and ‘ground (=). There should be battery voltage when the speedometer is below 20 kavyh (18 ‘mph and no voltage when the speedometer is 20 Kendle (10 aphid ur wee: Linormai—e « rautty solenoid valve relay Abnormal {Go te following page)FUEL SYSTEM. From previous page: Abnormall Remove the combination meter without discon- necting the connector (page 19-8), ‘Start the engine, shift the tranemiesion into gear and measure the voltage between the Pinkiyel- low (+) and Green (~) terminals ofthe meter. ‘There should be battery voltage when the spoed- Cometer 1s below ZU kmin {18 mph} and no vortage when the speedometer is 20 kmh (18 mph) or [Normal —> * Open circuitin Fink/yellow wire Abnormal ‘Faulty combination meter (From provious pai COMBINATION METER Disconnect the solenoid valve 2P (Black) connec tor and measure the battery voltage between the Pink’white (+) and Green (—) terminals at the harness side connector with the ignition switch ON. No voltage SOLENOID VALVE Remove the seat cow! (page 2-2. Moaoure the voltoge batwaon tha Blackohi (=) terminal of the solenoid valve relay and ‘ground {~} withthe ignition switch ON. CONNECTOR [No voltage * Open circuit in Blackiwhite #2 wire SOLENOID VALVE RELAY Voltage ‘Check for continuity between the Pinkiwhite and Blackiwhite #2 terminals of the solenoid valve rulay wh tne itu swe ON. "Pink/yeliow Black white £2 Blackiwhite #1 Continuity ~ + Open vineuit in PinAvwhite oF Gree wie No continuity (Cote following page! 5-7FUEL SYSTEM {From previous page: No continuity) ee Measure the voltage betwaen the Blackiwhite #2 |-Novvoltago—> « Faulty solencid valve relay (+) and Pink/yellow (—) terminals ofthe solenoid valve relay withthe ignition swe ON. \ Voltage Disconnect the combination mater connector | Continuity = # Shor circuit in Pinky (page 19.6), Check for continuity between the Pinkyellow ter ‘minal of the meter connector and ground. No continuity + Faulty combination meter COMBINATION METER CONNECTOR 5-8FUEL SYSTEM. Direct Air induction (D.A.,) system malfunction (CALIFORNIA type] Remove the combination meter without discon- necting the meter connector (page 19-4) Raise the rear wheel off the ground and support the motoroyele securely with @ hoist or equiva- ‘Start the engine, shift the transmission into gear land measure the voltage between the Pinkiyel low (+) and Green (~) terminals of the meter connector. There should be battery voltage wnen the speedometer is below 20 kmilh (18 mph) and ro battery voltage when the speedometer is 20kmih [18 mph ar more. |— Normal—= (Goto following page! ‘Abnormal COMBINATION METER CONNECTOR Disconnect the meter connector and measure the voltage betvicen the Pinkiyellow (+) and Green (=) terminals of the meter connector with the ignition switch ON. [Voltage —» « Faulty combination meter No voltage Remove the seat cowl (page 2.2). Disconnect the air vent control solenoid valve 2° (black) connector and measure the voltage be- tween the Blackiwhite (+) torminal at the har- ness side connector and body ground () with the ighition arity ON, |_o vatage-> * Open circuit in Blackiwhite wire Voltage ‘AIR VENT CONTROL SOLENOID VALVE 2P CONNECTOR (Cheek for continuity hatwnen the Pinkiyallowy ta: minals of the combination meter and solenoid vvalve connectors, | wa continity-= « Open or short circuit in Pink'yellow wire Continuity ‘+ Faulty air vent control solenoid valveFUEL SYSTEM (From previous page: Normal) Disconnect the EVAP CAV solenoid valve 2P (black) connector. Measure ue voltage burween une Brack (F) ane Green (~} terminals at the harness side connec: tor with the ignition switch ON. [-No voltage—* « Open circuit in Black or Green wire EVAP CAV SOLENOID VALVE 2P CONNECTOR T | Voltage ‘Check the induction ducts, hoses, andthe sir vent Control solenoid valve and EVAP CAV solenoid valve operation (page »-36 ana -1) 5-10FUEL SYSTEM Fucl pump cyetem malfunetion Remove the seat cow! (page 2.2) Raise the rear wheel off the ground and support the motoreycle securely with @ hoist or equiva lent. Start tha angina, shift the transmission into gear ‘and measure the voltage between the Finkiyel low (+) terminal of the fuel pump transfer relay ‘and ground (|. There should be battery voltage Wwnen tne speeaometer is below 20 Riv (18 mph and no voltage when the speedometer is 20 kmh (18 mph) or more. Normal —= (Go tofellowing page) souzyowo vauve SSS BOPMIES AS Prt FUEL PUMP TRANSFER RELAY Blackibiye Abnormal | Black/yel Black/white #1 Measure the battery voltage between the Black! white #1 (+) terminal of the transfer relay and ‘ground (~) with the ignition switch ON. [No voltage- * Open circuitin Blackiwhite #1 wire Vottage ‘Measure te battery vortage Detween tne Fink yellow (-+) terminal of the transfer relay and ‘ground (~) with the ignition switch ON, | —vorage—— > rauity tui pump uanster relay Novolage Remove the combination meter without discon- ‘acting the connector (page 19-6). Start the engine, shift the transmission into gear ‘and measure the voltage between the Pink/yel low (+) and Green (—) terminals of the meter. ‘Thore chould be battary voltage when the epaed ‘ometer is below 20 krn/h (18 mph) and no voltage when the speacometer is 20 km/h (18 mph) or more. [Normal —= + Open or shor circuit in Pink/yellofy wire Abnormal * Faulty combination metor, COMBINATION METER 5-11FUEL SYSTEM (From previous page: Normal) Disconnect the fuel pump transfer relay connec- ‘ana iackiyaliow terminals of ne transfer relay. ‘There should be no continuity while the 12V bat tery is connected to the Blackwhite #1 (+) and Pinkivellow (—) terminals of the relay and conti- nity when the battery is disconnected. Normal ‘Check for continuity between the Siackibiue ana Blackiwhite #2 terminals of the transfer relay. ‘There should be continuity while the 12V battery is connected ta the Black/white # 1 (+) and Pink! yellow {~) terminals of the relay and no Continuity when the battery is disconnected. Normal Measure the battery voltage between the Black! white 2 (+) terminal of the transfer relay con- octane and ground (=) with the ignitinn switch oN. Voltage Check for continuity between the Blackiblus terminal of the transfer relay connector and ground. Continuity ! Check for continuity between the Blackiyellow terminals of the fuel cutoff relay and transfer rolay connectors Continuity {Go to following page! ] | — abnormal = « Faulty uel pump transfer relay tor. Check for continuity between the Black/blue | |_— abnormal = # Faulty tual pump cranster ralay |— No voltage = * Open circuit in Blackiwhite #2 wire 1 No continuity-~ * Open circuit in Black/blue or Green wire + Faulty fuel pump |- No contiauity--* Open ciccuit in Black'yellow wire 5-12FUEL SYSTEM (From previous paye: Continuity) | Measure the battery voltage betwoen the Black’ white (+) terminal of the fuel cut-off relay and | ground (withthe ignition ewiteh ON, [No voltage * Open circuitin Blackiwhite wire ‘Measure the battery valtage between the Blue) [No unltage—= « Open circuit in Rlua/lack win black (+) terminal of the fuel cutoff relay and ‘ground (—) with the ignition switch ON. Voltage ‘Faulty fuel cutoff relay K-12FUEL SYSTEM AIR CLEANER HOUSING HARNESS CLIP VACUUM TUBES. REMOVAL/INSTALLATION \ Remove the fuel tank (page 2-3). Califoria type Remave the evaporative emission (EVAP) purge ‘nly. control valve from the ar cleaner housing. Remove the wire harness clip from the air cleaner housing, Be carefulnot 9 Disconnect the four vacuum tubes and secondary i ‘break thepasic air supply hose (California: No. 15) EvaP PURGE lugs. CONTROL VALVE Disconnect the crankcase breather hose from the air cleaner housing. Loosen the two connecting tube band screws of the air intake duets Lanne the four eannecting tuba hand seraws Remove the air cleaner housing off the carburetor Intake ports and air intake ducts, Disconnect the float chamber inner air vent hose ‘California: No. 7) andthe vacuum chamber air vent hose. Installation is in the reverse order of removalFUEL SYSTEM CARBURETOR REMOVAL Drain the coolant (page 6) Remove the air cleaner housing (page 5-14), CCatforniaype Disconnect the No. 11 tube. ony: CCalforniatype Disconnect the No. § tubes. Disconnect the float chamber air vent hoses and te tue tubes trom the carburetor. Remove the choke cable from the cable holder and disconnect It from the starting enrichment (SE) valve arm, 5-15FUEL SYSTEM Loosen the four carburetor insulator band screws at the engine side, using a long screwdriver through the hale in bath eidas ofthe frama. Face aclean shop Remove the carburetor assembly off the cylinder fowe/ over tne head intake ports, Intake ports to prevent any Disconnect the throttle sensor connector. fromaropping into. wore: {the engine, Mone Do nat remove the throtle sensor unless it is tor. For sensor inspection and replacement, see page 17-7. Loosen the throttle cable lock nuts, then remove the cables from the cable holder and disconnect them from the throrle deur, Disconnect the water tubes from the carburetor. 5-16FUEL SYSTEM CARBURETOR SEPARATION Se WADVe Arta SCREWS) WASHERS NOTE: The vacuum chamber and tloat chamber can be serviced without separating the carburetors. Remove the following: throttle stop screw with spring and washer carburetor insulators by loosing bend screws SE valve arm and return spring —two collars INSULATORS ~front connecting nut, serew and throttle sensor. CAUTION: Do nat remove the throttle sensor from the brack- ‘et unless it requires replacement. It may cause the Sensor to move out of position resulting in improp- er ignition timing. connecting nut, boltand join retainer ~ air vent hase joint with O-ring ~sorew and throttle cable holder {joint retainer) dowel pin air vent hose joint with O-ring, Loosen the synchronization adjusting screws to reduce the spring tension and remove the synchroFUEL SYSTEM Remove ine rear connecting muss and bo. NO. 4INO.2 No. No. 4 Separate the No. 1/2 and No. 9/4 carburetors Remove the dowel pins. Aefertodiagram Separate the No. 1 and No. 2 carburetors then re- ‘on page 5-26 for move the thrust spring. 2: air vent hase joint water tube joint —dowel pins. Separate the No. 3 and No, 4 carburetors then re. ‘ove the thrust spring Remove the following: ~ehoke cable holder joint collar fuel tube joint air vent hose water tube joint dowel pins. No. No. # 5-18FUEL SYSTEM CARBURETOR DISASSEMBLY/ INSPECTION AIK FUNINEL Remove the following: “four sevewe funnel holder air funnel O-ring. STARTING ENRICHMENT (SE) VALVE Resnuve the full valve nut valve spring ‘SE valve. ‘Check the SE valve for scarina, scratches or wear, ‘Check the sat atthe tip of the SE valve for stepped AIR CUT-OFF VALVE Piscrnnact tha varuuim tube fram the vacuum Dive. Romove the attaching screw and the air cutoff valve, Remove the O-rings and joint pipe. HOLDER, FUNNEL eo =~ Oo hin cuTioee valve |” scaew 5-19FUEL SYSTEM ‘Apply vacuum tothe vacuum tube. RS The vacuum should maintained, {ir chonld not fou through tha value pnts when ‘ the vacuum is applied, and should flow when the vacuum is not applied, vacUUM TUBE VACUUM CHAMBER ‘compression cover. spring's very ong, when the cover is romoved, ‘VACUUM CHAMBER COVER Ramus the eomnrascian snring and diaphengm! vacuum piston from the carburetor body. DIAPHRAGM PISTON. / SPRING Be careful net to Serew one of the vacuum chamber cover (4 mm} ‘damage the screws int the jet needle holder. iaptragm. Pull the screw and remove the jet needle holder from the vacuum piston Do not remove the jet needle holder by pushing the jet needle 5-20Romeve the spring, jt needle and washer fram the vacuum piston. Check the jet needle for stepped wear ‘Check the vacuum piston for wesr or damage, ‘Check the diaphragm for pin hole, deterioration or damage. Note Air leaks out of the vacuum chamber if the dia playin is Gained in ony way, even a pi hile FLOAT CHAMBER Remove the three eerewe and the float chamber. Remove the float pin, float and float valve. (Check the float for damage or fuel inthe float. Check the float valve and valve seat for scoring, scratches, clogging or damage. Check the tip of the float valve, where it contacts Une valve sea fr stepped meet oF contarainatins Check the operation of the float valve. FUEL SYSTEM WASHER JET NEEDLE J so \ ee DIAPHRAGMIPISTON \ FLOAT CHAMBERFUEL SYSTEM Remove the main jt, needle jet holder and slow jet. NiSSOTER OER CAUTION: Handle the jets with care. They can easily be scored or scratched. ‘Turn the pilot crew in and carefully count the num: ber of turns untiit seats lightly. Make a note of this to use as & reference when reinstalling the pilot TooL: Pilot screw wrench O7KMA.MIN90100 or o7KMA-MS60101 cauTion: Damage to the pilot screw seat will occur if the pilot screw is tightened against the seat. O-RING $$ WASHER Remove the pilot serew, spring, washer and O-ring oe PLOT ‘SCREW. Cheek each jot for woor of domage NEEDIE JET. Check the pilot screw for wear or damage. HOLDER Clean the jets with clesning solvent and blow open with compressed ai. CARRURETOR CLEANING Remove the following: air funnel SE valve air cut-off valve ~diaphragm/vacuum piston, ~main jet, needle jet holder and slow jet. pilot gerew. CAUTION: leaning the air and fuel passages with a wire will damage the carburetor body. Blow open all air and fuel passages in the carbure. tor body with compressed air. 5-22FUEL SYSTEM CARBURETOR ASSEMBLY VACUUM CHAMBER COVER HOLDER ‘SE VALVE <= NUT 2 SPRING: HOLDER \3 f—sowr ee S a ‘Soar CUT-OFF VALVE dala PILOT SCREW FLOAT CHAMBER By ‘TOOL: NEEDLE JET HOLDER O7KMA-MS60101 MAIN JET Perform the pilot screw adjustment if new pilot serew is installed caution. Damage to the pilot screw seat will occur ifthe pi- ut screw is tightened against the seat Install the needle jet holder, main jet and slow jet.FUEL SYSTEM CAUTION: Handle the jets with care. They can easily be Hang the float valve onto the float arm lip. Install he float vaive, float anus neat pi. FLOAT LEVEL INSPECTION Nore: Sot the float level gauge that itis perpendicular to the float chamber face at the highest point of the float. With the flost valve seated and the flost erm just touching the valve, measure the float level withthe float level gauge. Too: Float level gauge 07401-0010000 FIQATIEVEL- 12.7 + 5 mm (OBA + 0.92 in) “The float cannot be adjusted. Replace the float assembly ifthe float level is out of specification Install a new O-ring into the float chamber groove, Install the float chamber and tighten the three VACUUM CHAMBER Coat a new O-ring with oil and install it into the Was UR Cen eee eae nee ees on ee Install the washer onto the jet needle. i Intl te ja eae and nee elder the vas oes ‘uum piston. Sh Press the needle holder until you feel @ click indicating that the O-ring is seated into the groove inthe vacuum piston. ip t HOLDER i / F Bom DIAPHRAGM/PISTON 5-24FUEL SYSTEM Install and compress the compression spring into the spring hole in the vacuum chamber cover using a screwdriver asa guide as shown. ‘VACUUM CHAMBER COVER. > SPRING Be careful not to Install the diaphragm/vacuum piston into the carbu- damage tnejet retor body, then insert the jet needle into the Lift the bottom of the piston with your finger to set the diaphragm rib into the groove in the carburetor body, and install the spring and vacuum chamber {Be careful not to Install and tighten the three screws. pinch taphragm under tho chamber cover AIR CUT-OFF VALVE Install new O-rings onto the air cut-off valve and joint pipe. Install the joint pipe inta the cutoff valve with the stepped side facing the air cut-off valve. Install the air cutoff valve and secure it with the Connect the vacuum tube to the vacuum pipe of the carburetor body. AIR CUT-OFF VALVE VACUUM TUBE 5-25FUEL SYSTEM SE VALVE Install the spring over the SE valve and install it Into the SE valve hole in the enrburetor. Install the valve nut and tighten it. TORQUE: 2N-m {0.2 kghm ,1.4 IDF) VALVE NUT AIR FUNNEL, Install @ new Oing into the groove in the carbure tor body. shown and install them by aligning the cut-outs in the funnel withthe lugs of the carburetor body. Becaretul not to. nstall the four sorews and tighten them. pinon ne ning, CARBURETOR COMBINATION JOINT RETAINER, AIR VENT HOSE JOINT INSYLATOR WATER TUBE JOINT. THRUST SPRING Nout f SeVALVE ARN : : i 7 E aa CHOKE CABLE HOLOER JOINT COLLAR s anvenrvosesont X72 UN © < . - Tiros co.eno.cen ruectuse sont, / = DOWEL PINS” Ss THROTTLE STOP SCREW RORFUEL SYSTEM Note: Nos ‘Always replace the O-rings with new ones and coat them with ol ‘Apply grease to the synchronization agjusting serow tips. No. 8 and No. 4 carburetors: Install the following onto the carburetor: —dowel pins tote Cube iil wrth ew Ovinngs air vant hose joint with new O-rings —fuel tube joint with new O-rings joint collar —choke cable holder, aligning groove with stopper —thrust spring (place over the synchronization nut) 2 THRUST SPRING Accomble the No. 2 and No, 4 carburetors Install the synchronization spring, No. 1 and No. 2 carburetors: Install the following onto the carburetor: dowel pins water tbe joint wth new O-rings air vant hoee joint with now O-rings fuel tube joint with new O-rings —joint collar —thrust epring (place aver the synchronization nut) Assemble the No. 1 and No. 2 carburetors. Install the aynchennization aneing No, 1/2 and No. 3/4 carburetors: Install the dowel pins onto the carburetor. ‘Assemble the No. 1/2 and No. 3/4 carburetors. Install the synchronization spring.FUEL SYSTEM be sure there 1s no clearance atthe joint area of the carburetor bodies. Install the rear connecting bolt and nuts, and terpo- ravily tighten them. Install new O-rings into the tube joint grooves. Install the air vent hose joints into the carburetors. Inctall the dowel pin Install the throttle cable holder {joint retainer aligning its groove with the joint lug and secure it withthe screw. Install the connecting bolt, nut and tube joint retain er, aligning the cetainer groove with the joint lug, Install the throttle sensor by aligning the tabs of the throttle sensor with the flat ofthe shaft as shown, CAUTION Install tne throttie sensor property. improper installation can cause damage to the throttle senFUEL SYSTEM Tighton the oach connecting nute gradually and alternately, be sure the bolt threads projections are ‘equal height (within 0~3 mm) Hold the nut and tighten the nut on other side. TORQUE: 6 mm nut: $ Nom (0.9 kgm 6.5 Ibf-) Simm nut: 5N-m (0.5 kgim, 3.6 IbF-) Install the arm return spring over the boss on the No. 2 carburetor. bosses of the carburetors, Install the SE valve arm over the SE valves and ‘onto the carburetors and attach the return spring. Install the plastic washers and screws and tighten them. Install the throttle stop serew with the washer and spring. UT] Turn the throttle stop screw to align the throttle valve with the edge of the outside by-pass hole in the No. 4 carburetor. ‘Align each carburetor (No. 1, No. 2 and No. 3) throttle valve with the outside by-pass hole by turning the synchronization adjusting sermw. Rotate the throttle drum and be sure that each throttle valve opens and closes smoothly. 5-29FUEL SYSTEM Install the carburetor insulators with the “CARB! mark facing the carburetor and the band screw heads facing the outside as shown, ‘Align esch insulator groove with each carburetor Jug to seat tho insulators securely. Align the band hole with the insulator boss. Tighten each band screw until the clearance be ‘swoon the band ende ie 11-12 mm (0.40.5 in). CARBURETOR INSTALLATION NoTE Route the tubes and cables properly (page 1-18). Connect the throttle cables to the throttle drum and install them into the cable holder, Connect the throttle sensor connector.FUEL SYSTEM Install the carburetor assembly over the intake ports by pressing the assembly against the cylinder head surface securely sides of the frame and tighten the insulator band screws as shown. Install the throttle stop serew into the cable holder. Connect the choke cable to the SE valve arm and install it into the cable holder. Connect the fuel tubes and the float chamber air vent hoses.FUEL SYSTEM cara ype Connectine No,» TUDES. oniy Calfornatype Connect the No. 11 tube. 5-32 only Perform tne following inspections and adjustment: Throttle operation page 3-4) Carburetor choke (page 35) Install the air cleaner housing (page 5-14). Fill and bleed the cooling system (page 6-4) stouretor aynchronication ifthe corbure isassembled (page 3-13} No. 11 TUBEFUEL SYSTEM PILOT SCREW ADJUSTMENT IDLE DROP PROCEDURE NOTE: * Make sure the carburetor synchronization is with- in specification before pilot screw adjustment. *# The pilot screws are factory pre-set and no adjust- ‘ment is necessary unless the pilot screws are re placed. see 2 tachometer with graduations of 50 -pm or smaller that will accurately indicate a 60 rpm change 1. Raise the fuel tank and supportitipage 2). ‘Turn each pilot screw clockwise until it seats light- Mesa Mea) Iv. than back’ aut ta the specification oiven. This bi eX is an initial setting prior to the final pilot screw ¢ adjustment. ‘CAUTION: Damage to the pilot screw seat will occur if the pilot screw is tightened against the seat. TOOL: Pilot serew wrench 07KMA-MIN80100 oF O>wMA naseoro% INITIAL OPENING: 49 state/Canada type: 3-1/8 turns out California type: zeystums out 2. Warm up the engine to operating temperature. ‘Stop and go driving for 10 minutes is suficient. 3,St0p the engine and connect a tachometer ac- cording to the tachometer manufacturer's instruc tions. 4, Siar the engine and adjust the idle speed with the throttle stop sorew. IDLE SPEED: 49 state/Canada type: 1,300 + 100.rpm California type: 11400 = 100 ep 6.Turn the No. 4 carburetor pilot screw in or out 6.Perfarm step 5 for al carburetor pilot screws. 7 Lightly open the throttle 2 or 3 times, then adjust the idle speed with the throttle stop screw. 8,Turn the No. 4 carburetor pilot screw in unt! te engine speed drops by 50 ¢pm. 9.Turn the No. 4 carburetor pilot screw out to the final opening fear tha position ahtainad ia stan FINAL OPENING: 49 state/Canada type: 3/4 turns out California type: Turns out 10.Adjust the idle speed with the throttle stop screw. 11.Perform steps 8, 9 and 10 forall carburetor pilot 5-33FUEL SYSTEM HIGH ALTITUDE ADJUSTMENT When the vehicle is to be operated continuously above 2,000 m (6,500 feet), the carburetors must be readjusted as described below to improve driveability and decrease exhaust emissions. Remove the sarburstor assembly from the intake ports of the cylinder head ipage 5-15) Drain the carburetors and remove the float cham- bers. Change each main jet for a high altitude one. HIGH ALTITUDE MAIN JET 49 state/Car 120 MAIN JET No.2and3 carburetors: 2 132 California type: = 125 Install the float chambers. Install the carburetor assembly (page 5-30). Install the fuel tank and support it withthe wrench (page 2-3 let Warm up the engine to operating temperature. Stop and go driving for 10 minutes ie eufficiont ‘Turn each pilot serew in to the specification given, ToL: Pilot serew wrench O7KMA-MINGO100 oF O7KMA-MS60101 HIGH ALTITUDE SETTING: 1/2 turn in ‘Adjust the idle speed withthe throttle stop screw. 49 state/Canada type: 1,300: 100 -pm California type: 1400 + 100 cpm ‘Attach the Vehicle Emission Control Information Update label on the rear fender under the seat as shown, Nore: Do not attach the label to any part that can be easily ‘Sustained operation at an altitude lower than 1,500 m (5,000 feet) with the carburetors adjusted | for high altitude may cause the engine to idle roughly and the engine to stall in traffic. It may also cause engine damage due to overheating. EMISSION CONTROL INFORMATION Urbare Lagel 5-324FUEL SYSTEM These adjustment ‘must be made at fow altitude to ensure proper iow ange opera, When tha vehicle is t0 be operated continuously below 1,500 m (5,000 feet, readjust the carburetors as follows {change each main jot for ure susttdara one ‘STANDARD MAIN JET: 49 state/Canada type: No. 1 and 4ecarburetors: #132 No. 2and3 carburetors: = 135 California type: #128 (al carburotors) Warm up the engine to operating temperature Stop and go driving for 10 minutes is sufficient Turn each pilot arrow aust V9 ten to it ariginal position, PILOT SCREW WRENCH Too: O7KMA-MS60701 ‘Adjust the idle speed withthe throttle stop screw. IDLE SPEEI 49 state/Canada type: 1,300 ~ 100 rpm California type: 11400 = 100 rem NOTE These adjustment must be mede ot ow altitude to ensure proper low altitude operation. Remove the Vehicle Emission Control Information Update label that is attached to the rear fender Under the seat after adjusting for ow altitude. 5-35FUEL SYSTEM DIREC! AIR INDUCTION (D.A.| SYSTEM ) AIR VENT CONTROL SOLENOID VALVE INSPECTION Raise the fue tank and support it (page 2-3 ‘Check ths Induction aut an connecting Lubes For damage or loose connection. Remove the air cleaner housing (page 5-14), Remove the front fairing (page 25). Check the induction hoses for deterioration, dam- age oF loose connections. Check the eub-air cleaner for clogging. Ricennnart the air vant hose (California: Na. 6) from the 3-way joint that goes to the carburetor. Disconnect the No, 4 hose (California type) Blow ait into tie inner air vent hose (California: No. 7) with the ignition switch OFF. Blow air into the outer air vent hose (California: No. 4) with the ignition switch ON. Air should flow through the solenoid valve and out the air vent hose (California: No. 6) that goes to the carburetor 49 state/Canada type shown: FLOAT CHAMBER INNER. AIRVENTHOSE ruoay cuawace auires Sin VENT HOSE Eeo|\, \\ SUaAR <\\ eLeanea 47 VACUUM CHAMBER AIR VENT HOSE 49 stote/Canata type OUTER AIR VENT HOSE SOLENOID VALYE Tocarbiretor California type: SOLENOID VALVE No 7 HOSE 5-36FUEL SYSTEM FUEL PUMP 49 sate/Canaa ype shown DISCHARGE VOLUME INSPECTION nos Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area, Smoking oF allowing flames or sparks in the work area or where the gasoline is stored can cause a fire or explosion. Raise the fuel tank and support it (page 2-3) Remove the seat cowl page 22), Short the Blackiwhite and Blsck/biue terminals at the fuel pump transfer celay withthe jumper wire Disconnect the fuel tube from the 3-way tube joint ‘that goes tothe carburetor Hold the a gradusted beaker under the fuel tube. ‘Turn the ignition switch ON (engine stopped) with the engine stop switch to RUN and let the fuel flow into the beaker for § seconds, then turn the ignition switch OFF. ‘Multiply the amount in the beaker by 12 to deter rine tia fuel pump ow vapatity jx sate FUEL PUMP FLOW CAPACITY (minimum: "700 cm? (28.7 US o, 24.6 Imp o2)/minute SECONDARY AIR SUPPLY SYSTEM ‘SYSTEM INSPECTION Start the engine and warm it up to normal ‘operating temperature Remove the air cleaner housing cover (page 35). Check that the secondary air intake port is clean Check the pulse secondary sir injection (PAIR) check valves ifthe port is carbon fouled. Disconnect the air supply (air cleaner housing-to- PAIR control valve} hose (California: No. 15) from the air cleaner housina. Disconnect the PAIR control valve vacuum tube (California: No. 10) from the 3-way joint and plug the 3-way jointFUEL SYSTEM Connect a vacuum pump to the PAIR control valve vacuum tube (California: No, 10) [ ancien “Apa the theemie eighty raha | AIR SUPPLY HOSES certain that ait is sucked in through the alr supply hose (California: No. 18) Ifthe airs not drawn in, check the sir supply hoses for clogging. With the engine running, gradually apply vacuum te the PAIR control valve vacuum tube. Check that the air supply hose stops drawing air, and that the vacuum does not bleed, SPECIFIED VACUUM: 100 mm Hg (75.7 in Hg) Iv the air is drawn in, or ifthe specified vacuum is ot maintained, install a now PAIR control valve. aRerpurn occurs on deceleration, even wnen tne secondary air supply system is normal, check the air cut-off valve qt = AIR SUPPLY HOSE \. PAIR CONTROL VALVE VACUUM TUBE PAIR CHECK VALVE INSPECTION Remove the cadistor without disconnecting the water hoses (page 36) Remove the bolts and PAIR check valve cover from the eylinder head cover. Remove the PAIR check valves.FUEL SYSTEM Check th rand fr damage or fn, Replace fF necessary, REED STOPPER, Replace the PAIR check valve if the seat rubber is cracked, deteriorated or damaged, or if there is, Clearance oetween tne reeu ana seat Install the PAIR check valves and cover onto the cy!- indor head cover. Install the cover bolts and tighten them. TORQUE : 13 Nim/(1.3 kgt:m 9 IDF) Install the radiator (page 3-7. PAIR CONTROL VALVE REMOVAL/ INSTALLATION Remove the radiator without disconnecting the water hoses (page 36) rsconnect hw air supply Hoses wind vacuure tube 10 remove the PAIR control valve Installation is in the reverse order of removal EVAPORATIVE EMISSION CONTROL SYSTEM (California type only) Note: and Cable & Harness Routing (page 1-18) for the tube connections and routing, EVAPORATIVE EMISSION (EVAP) CANISTER REMOVAL/INSTALLATION Disconnect the No. 1, No. 4 and No, 2 tubes from the EVAP canister. Remove the 8 mm mounting halt Remove the side fairing socket bolt and fairing stay, the EVAP canister with the bracket. Hemove tne two nots, colars ana bracket Install the EVAP canister in the reverse order of removalFUEL SYSTEM EVAPORATIVE EMISSION (EVAP) See aS PTET PURGE CONTROL VALVE INSPECTION Dede cali ands ‘The EVAP purge control valve should be inspected ithot restart is dificult Reise the fuel tank and suppor it (page 23) Remove the EVAP purae control valve. Connect @ vacuum pump to the No. § tube fitting (output port that goes tothe carburetors. Apply the specified vacuum to the EVAP purge control valve. ‘The specified vacuum should maintained, (uonpou meee BO) Remove the vacuum pump and connect it to the C # 4 carburetor. J) control valve. x rose gunar® ‘The specified vacuum should maintained. Replace the EVAP purge control valve if vacuum is. Connect a pressure pump to the No. & tube fitting {input port) that goes to EVAP canistor. caution: Damaae to the EVAP purae control valve mav result from use of a high pressure ar source. Use a ‘hand-operated air pump only. While applying the specified vacuum to the EVAP purge control valve vacuum port, pump air through VACUUM PUMP ‘the input port. ‘SPECIFIED VACUUM: 250 mm Hg (8.8 in Hoh VACUUM PUMP Air should flow through the EVAP purge control valve and out the output port that goes to the carburetors. Replace the EVAP purge control valve if air does ot flow out Remove the pumps and install the EVAP purge con- trol valve,EVAPORATIVE EMISSION CARBURETOR AIR VENT (EVAP CAV) SOLENOID VALVE INSPECTION Nore ‘The EVAP CAV solenoid valve should be inspected hot reatac isnt ‘Remove the air cleaner housing (page 5-14). fReruve te Lule gitl sulviuid valve stay fun dhe frame. Disconnect the No. @ and No. 4 hoses, Blow air into the No. 4 hose fitting that goes to the VAP canister withthe ignition switch OFF. Blow air into the No. & hose Fiting withthe ignition witch OM. Air should flow through the EVAP CAV solenoid valve and out the air vent port (No. 4 hose fitting) that goes to tne air vant contro! soienoia vaive. FUEL SYSTEM — EVAP CAV SOLENOID VALVE No. 4 HOSE FITTING: (From air vent contro solenoid valve) 7 No. 8 HOSE FITTING (Opan air) No. 4 HOSE FITTING (Ta EVAP canister) 5-41COOLING SYSTEM CARBURETORS SIPHON TUBE RADIATOR, CYLINDER HEAD: Sp CYLINDER: 6-06. COOLING SYSTEM ‘SERVICE INFORMATION 61 THERMOSTAT 66 TROUBLESHOOTING 62 RADIATOR/COOLING FAN 68 SYSTEM TESTING 63 RADIATOR RESERVE TANK en | | COOLANT REPLACEMENT 6-4 WATER PUMP 612 SERVICE INFORMATION GENERAL * Wait until the engine is cool before slowly removing the radiator cap. Removing the cap while the engine is hot and the + Radiator coolant is taxi. 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 Many coolant is swallowed, induce vomiting, gargle and consutt a physician immediatel = Hany coolant gets on your skin or clothes, rise thoroughly with plenty of water. ‘KEEP OUT OF REACH OF CHILDREN. CAUTION: Using coolant with silicate corrosion inhibitors may cause premature wear of water pump seals or blockage of radiator passage. Using tap water may cause engine damage. + Add coolant at the reserve tank. Do not remove the radiator cap except to refi or drain the system. Allcooling system service can be done with the engine inthe frame. + Avoid spilling coolant on painted surfaces. + After servicing the system, check for leaks with a cooling aystom tector, ‘ Reter to section 19 for fan motor switch and thermosensor inspection, SPECIFICATIONS Te [ SPECIFICATIONS | Redistar and engine oie Reserve tank I ae Pein a 9310 (0.33 US at, 0.27 Imp qd 37 KPa (1.1— 1.8 kotlern®, 16~20 pall Thermostat — ‘open 73-7750 (163~171"F) n rete Valve lift ‘mm (0.3 in} minimum Recommended antiresz | Pro Honda HP Coolant or an equivalent high qualliy ethylene alvcol antifreeze containing silicate-free corrosion inhibitors, TOMQUE VALUES Water pump assembly bolt 12N-m (1.2 kgf, 9IbF ft) Thermostat cover bolt 12Nem (1.2 kgf-m, 9 IE) 6-1COOLING SYSTEM TROUBLESHOOTING Engine temperature too high ‘Thermostat stuck closed ‘* Feulty radiator cap * Insufficient coolant ‘ vassenges blocked in raaiator, noses or water jacket ‘Airin system ‘Faulty cooling fan motor “= Faulty fan motor switch * Faulty water pump Engine temperature too low Faulty tamparature gouge or thermosensor ‘ Thormostat stuck open * Faulty fan motor switch Coolant feaks * Faulty water pump mechanical seal * Deteriorated O-rings Faulty eadiatar ean * Damaged or deteriorated cylinder head gasket ‘Loose ose connection or clamp * Damaged or deteriorated hosesCOOLING SYSTEM SYSTEM TESTING BS ‘ne engine must be coo! perore removing tne raaia- tor cap; or severe scalding may result Remove the right air intake duct (page 25). Remove the radiator cap. COOLANT (HYDROMETER TEST) “Toot the coolant gravity using s hydromater, ‘STANDARD COOLANT CONCENTRATION: 50% ‘Look tor contamination and replace tne coolant it necessary. RADIATOR CAP | «a =. rn Coolant ratio \ | 700s 7.005. wo | as | 20 | 25 (50) | 69) 8) | 77) 7008 | 1.008 | 7,007 | 7,006 (ee 1005 7.003 40 | | 50 | (104) | 113) | 2) | {007 | 0569 | 0587 Fora 11.017, 1.028 | 1.027 ow F016 1.015 | 1.014 | 4.026 | 1,025 1.024 | 1.022 fois ort 1.020 | 1.018 7.0087|1.007"| 1,008 | 4.016 | 1.014 | 1.012 | 096.085 3.0347] 9.033 01.031 101.008 027.025 Ros (cho2T 9.019) a 1.045 | 1.044 4.043 | 1.042 | 1.040 1.038 EEA 3.051 [7,049 [7.047 17,085 1.036. | 1.034 4.031 | 1.028 | 1.025. 3.043 [7,081 | 1.038 [7.095 032 40 ara [1970 "Vea [des tose" |"ea62" ro 45 | 1.080, 1.078 1.076 | 1.074 | 1.072 | 1.069 08 06 50 7.036 1.080 i082 | ogo. o77 [07 3.079.068 17.065) [A000 [9.086 [7.092 1089 [1.086 7.088113 980. 1.077 [5.074 1.077]COOLING SYSTEM RADIATOR CAP/SYSTEM PRESSURE INSPECTION Botoreinstaling Pressure test the radiator cap using the taster. thecap in the Replace the radiator cap if it does not hold pressure, tester, wet ite oF if relief pressure is too high oF 100 low, it must sealing urfaces. hold specified pressure for atleast 6 seconds. RADIATOR CAP RELIEF PRESSURE: 108137 kPa (1.1 1.4 kgHfem?, 16~20 psi) Pressure the radiator, engine and hoses using the tester, and check for leaks. CAUTION Excessive pressure can damage the cooling sys- tem components. Do not exceed 137 KPa (1.4 kol/ nr, 20 pil Repair or replace components ifthe system will not hole enacifiad peaectira for at lnnet Rcaennee COOLANT REPLACEMENT PREPARATION a ‘+ 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 coneult a doctor immediately, if any coolant is swallowed, induce vomiting, FAN MOTOR FAN MOTOR SWITCH 8 sHRoUD coouaran ¢ SIA. / Install the fan motor onto the shroud as shown. Install and tighten the nuts. Install the fan motor connector onto the shroud and ‘secure the wire with the clamp. Install the cooling fan onto the motor shaft by align- ing the flat surfaces. Install and tighten the nut COOLING FAN 6-10COOLING SYSTEM RADIATOR RESERVE TANK [ Resravg Tan ROIT_-AUIRRER ‘Alia the focstira pin wit ne noe in the stay. Install the fan motor assembly onto the radiator TERMINAL fand tighten the mounting bolts with the ground terminal ‘CONNECTOR FAN MOTOR ASSEMBLY Install the air guide rubber over the raciator stays "ip Gyipe AUBBER properly. left grommet. Install the radiator (page 6-8). REMOVAL/INSTALLATION Drain the coolant from the rasarue tank (page 6-5) Remove the bresther tube from the reserve tank stay, Remove the mounting bolt, and the reserve tank ‘and heat guard rubber from the stay. Installation is in the reverse order of removal. NOTE: Route the tubes property (page 1-10) Fill the reserve tank with recommended coolant to the upper level line ipage 3-14), 6-11COOLING SYSTEM WATER PUMP MECHANICAL SEAL INSPECTION Inspect the telitale hole for signs of coolant leakage. there is leakage, the mechanical seat is defective and replace the water pump as an assembly. REMOVAL LDrain tne coolant trom tne system by removing the drain bolton the water pump (page 6). Disconnect the water tube end hoses from the water pump cover. Remove the O-ring. Disconnect the water hoses. Remove the pump body from the crankcase.INSTALLATION Pour the molybdenum cil salution into the hole in the water pump as shown. Apply molyuueriui ull sululon whe uirust washer. Apply engine oil to @ new O-ring and install it onto ‘the stepped portion of the water pump. Install the water pump into the crankcase while aligning the water pump shaft groove with the oil Align the bolt holes in the water pump and crankcase and make sure the water pump is secure: Connect the water hoses to the pump body. Install 8 new O-ring into the groove in the water pump body. Install the water pump cover and tighten the bolts [~~ agggg TUBE COVER with a new sealing washer. TORQUE :12 Nem (1.2 kgf, 9 loft) Connect the water hoses and tube. Fill and bleed the cooling system (page 6-4) COOLING SYSTEM 6-13ENGINE REMOVAL/INSTALLATION 44. (45 kgm , 33106: 20.N mm (HL0kgf m, 20 IbF A 7-07. ENGINE REMOVAL/INSTALLATION | SERVICE INFORMATION 7-2 ENGINE INSTALLATION 76 | ENGINE REMOVAL 73 29. Nem (4,0 kgtim , 28 It) f Ze S10 Nem (1.0 kgf , 7 IBF) 54N-m 6.5 katim, 40 Ib] 10 X Bo mm @ 10 X 50 mm 3 10 X 60mm 7-1ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION GENERAL + Ahoist or equivalents required to suppor the motorcycle when removing and installing the engine, +4 floor jack or other adjustable suppor is required to supgort and maneuver the engine. CAUTION Do not use the oil fter as a jacking point. ‘When using the lack nut wranch for the adjusting bot lock nut, use a deflecting beam type torque wrench 20 inches long. The lock nut wranch increases the torque wrench's leverage, so the torque wrench ceading will be less than the torque {tually applied to tha look nut. The epacifieation given ia the actual torquo applied tothe lock nut, nt the reading on the torque wrench, Do not overtighten the lock nut. The specification later in the text gives both actual and indicated, * The following components require engine removal for service: transmission (section 11) ~ crankshatypistonicylinder (section 12) ‘*When installing the engine, be sure to tighten the engine mounting fasteners to the specified torque in the specified sequence. If you mistake the tightening torque or sequence, loosen all mounting fasteners, then tighten therm again to the specified torque in the correct seauence, ‘SPECIFICATIONS ITEM | SPECIFICATIONS | —s9kg 130 )bs)__ —37H7BSUS at, 331m a 1 112.9 US qt, 2.4 Imp qu | [Engine dry weight Engine oil capacity a [Costantcapsetty (adstorand engine] TORQUE VALUES. Front engine hanger bolt 39 N-m (4.0 kgf. , 29 Ib) Center engine hanger bolt 39.Nim (4.0 kgf. 29 IDF‘) Cerne eriging nanger acjusung wore cight suey Nea .8 Kye, £9 IE Center engine hanger lock nut (right side) BEN-m (6S kgf, 40 IDFA) Roar engine hanger nut 38 Nem (4.0 kgfim , 29 bt) Rear engine hanger adjusting bolt right side) 4Nim (0.4 kafim 2.9 Ibe) Rear engine hanger lock nut (right side) BENem 5 kghm, 40 IDEA) Shook lnk bracket nut 39 Nem (4.0 kgf:m , 29 bt) Shock link-to-bracket nut 44 Nem (45 kgf , 33 lof) Drive sprocket bolt 5A Nim (8.8 kgm 40 be) Starter motor terminal nut 1ON-m (1.0 kgm, 7 IbF. Oil pressure switch terminal screw 2Nm (0.2 kgf, 1.4 bf) TOOL Lock nut wreneh o7vma-me80100ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Drain the engine oll page 3-12), Hemove tne totlowing: radiator (page 6-8) radiator reserve tank (page 6-11) exhaust system (nage 2-7) carburetor (page 8-15) ~pulse secondary air injection {PAIR} control valve (page 5:39) A EVAP const nia wily, waye 9-39) direct ignition coil connectors. Remove the two bolts and radiator stay. Remove the cable holder bolt and disconnect the clutch cable from the clutch arm, g Remove the two bolts and thermostat housing. Remove the O-ring.ENGINE REMOVAL/INSTALLATION cetanaer Sr ieuee conecte | ‘alternator 3P (White) connector ~side stand 2P (Green) connector — gearshift arm by removing bolt neutral switch connector (CONNECTION ZEN I | NaS | Remove the two bolts, sprocket cover and guide plate.ENGINE REMOVAL/INSTALLATION ‘Supcort the Loosen the left and right swingarm pivot lock nuts onsen the rear axle nut and drive chain adjusters. move the drive sprocket bolt, washer and the ive sprocket with the drive chain from the coun- tershaft ‘Support the motoreyele securely with a hoist or equivalent Remove the following ‘shock link-to-bracket nut and bolt shock link bracket nuts and bolts — shook link brackets from engine and shock link —four dowel pins. age 1131 Remove the pivot nut and washer, and the pivot bolt Place a floor jack or other adjustable support under the engine. NOTE ‘The jack height must be continually adjusted to relieve strss for ease of batt removal Remove the following: ~fronthanger bolts and spacers (both sides) ‘sontar hangar halt laf idaENGINE REMOVAL/INSTALLATION Hold ine cerer nanger Gott right side) ana loosen <= ‘the lock nut using the special ool Too: Lock nut wrench 07VMA-MBBO100, Hold the rear hanger nut and loosen the lock nut | Ling tho came too Remove the following: ‘center hanger bot (right side) Fear hanger nut, bolt and spacers lock nuts and adjusting bolts engine from the frame, ENGINE INSTALLATION Note ‘= When tightening the lock nut with the lack nut wrench, refer to torque wrench reading informa ‘tion on page 7-2 "SERVICE INFORMATION = The jack height must be continually adjusted to celieve stress from the mounting fasteners. res and cables properly (page 1-18) CAUTION: Be sura to tighten all angine mounting taetanars 19 the specified torque in the specified sequence described following page. if you mistake the tightening torque or sequence, loosen all ‘mounting fasteners, then tighten dem again 10 the specified torque in the specified sequence,ENGINE REMOVAL/INSTALLATION Caretuly align the hanger batt holes Inthe frame and Install the engine into the frame and swingarm. Install the following: center hanger bolt (8) front hanger bolts (Al and (0! with spacers 1. Tighten the center hanger bolt (6). TORQUE :39 N:m (6.0 kgtim, 29 bt) 2. Tighten the front hanger bolt (A) TORQUE £29. m (1.0 kof mn, 29 bt 43. Tighton the front hanger bolt (0). VORQUE £39 Nm (4.0 kgm, 29 IDF) 4.Install the center adjusting bolt (€} until it just contacts to the enaine. Tiahten the adiustina bolt {E) tothe specified torgue, then turn it out 180" TORQUE :4 Nm (0.4 kgm, 2.9 IDE) 5. Install the lock nut (). Hold the adjusting bott(E) and tighten the lock aut () ToL: Lock nut wrench G7VMA-MBB0100 TOROUE: Acirtial: 84 Num (5 Bg 40 hE) Indicated: 49 Nm (5.0 kofim , 36 Ibtt) 6.Set the right spacer (F) between the frame and engine (Temporarily install the rear hanger bolt (C) to align the spacer). Install the adjusting bolt {until ijust contacts tothe spacer. Remove the hanger bolt (C) and tighten the rear adjusting bolt (F) to the specified torque, then turnit out 180" TORQUE +46 m [0.4 kgf m, 2.0 IBF AY 7.tnstall the lock nut (F). Hold the adjusting bot (F) ‘and tighten the lock nut TooL: Lock nut wrench O7VMA-MBB0100 TORQUE : Acutual: 54 Nm (5.5 kgm , 40 Ib) Indicated: 49 Nom (5.0 kgfsm , 38 Ibf-t) Basal oe oeiter Hanger LUI (Eat yh TORQUE : 39 Nim (4.0 gm, 29 Ib) .install the rear hanger bolt (C) from the left side withthe left spacer. Install the rear hanger nut (F) and tighten it TORQUE : 39 Nim (4.0 gh, 29 bf.) 10, Install the swingarm pivot bolt (page 14-17) ® 7-7ENGINE REMOVAL/INSTALLATION Install sne four dowel pins Into tne oracKet BOI holes in the engine. Install the link brackets onto the enaine and set the shack link between the brackets, Caratully align tha. nstall the bracket bolts and shock link-to-bracket ‘bolt roles in he bott from the left side. ‘Shock link. Install the bracket and shock link-to-bracket nuts Tighten the bracket nuts, then the shock link-to- bracket nut TORQUE : Bracket nut; 39.N-m (4.0 kgfim 29 ib) Shocklink-to-bracket: 4 N-m (15 kgf | 33 loft Instaiiwith he Install the drive sprocket with the drive chain onto sprockets mark the countershaft. acing out. Install the washer and bolt, and tighten the bolt TORQUE :54 Nn (6.5 kgf m, 40 Ib) Install the drive spracket cover with the guide plate and tighten the two bolts.ENGINE REMOVAL/INSTALLATION Install the gearshift arm onto the spindle by aligning the silt of the arm with the punch mark on the spindle, Tighten the pinch bolt Connect the fallowing neutral switch connector side stand 2P (Green) connector alternator 3P (White) connector starter motor cable STARTER MOTOR OIL PRESSURE SwiTcH TORQUE : 10 N:m (1.0 kgf. 7 bt carly ground cable } | oi pressure switch wie TORQUE :2.N.m (0.2 kgfim, 1.4 IbF ft) speed sensor 3P (Black! connector “ignition pulse generator 2° (Red) connector —thermosensor connector Install a now O-ring into the thermostat housing groove, Install the thermostat housing onto the cylinder hhead and tighten the two bolts.ENGINE REMOVAL/INSTALLATION install the cable holder, then tighten the holder bolt. Install the radiator stay and tighten the two bolts. Install the following: direct ignition coil connectors EVAP canister ( California only: page 5-39) pulse secondary air injection (PAIR) conteol valve (page 5-39) carburetor (page 6-30) exhaust system (page 2-7) — radiator reserve tank (page 6-11) radiator (page 6-8) Adjust the following: “onive enain siace (page 5-10) clutch lever free play (page 3-23). Fill the crankcase with recommended enaine oil (page 3-12) 7-10McMOCYLINDER HEAD/VALVE YON (1.0 kghm 7 bf) See oy V 2 ae ergs ser Na g 47 Nim (4.8 katirn .35 Ibe)8. CYLINDER HEAD/VALVE | SERVICE INFORMATION 81 VALVE GUIDE REPLACEMENT a2 TROUBLESHOOTING 82 VALVESEATINSPECTION/REFACING 8-13 | | CYLINDER COMPRESSION 83 CYLINDER HEAD ASSEMBLY a6 | | CYLINDER HEAD COVERREMOVAL = &3._—«CYLINDER HEAD INSTALLATION a7 CAMSHAFT REMOVAL 8-4 CAMSHAFT INSTALLATION 819 CYLINDER IICAD REMOVAL 0-7 — cyLINDEnHIcaD coven INSTALLATION 821 CYLINDER HEAD DISASSEMBLY 38 SERVICE INFORMATION GENERAL | 3 | ‘This section covers service ofthe camshafts, cylinder head and valves. ‘tne camsnatts, cylinder neag ano valves can De servicea witn the engine instavieg in tne trame. '* When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations. ‘*Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before ‘* Camshaft lubricating oil is fed through oll passages in the eylinder head. Clean the oil passages before assembling cylinder head. + Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head. SPECIFICATIONS Unie men tn) ( TM l ‘STANDARD ] seavice unary Gyinder compression S505m a 1306 We 7S iglom?, 178 pai = Vaive clearance iN_—[0.30 = 0.03 (0.008 + 0.001) : : bey —[naes nasiant = nang) Camshat | Cam | aSatateiCanada IN | 36.600~ 36.760 (1.4408 ~ 1.4472) Bera) lobe _type. Cex [ss. 35.35 (1.292) height | California ype [IN x [332903950 —J Tonout | = {0s 0.002). —| Ol clearance 1 soa0= 0.989 0:5008—00029 0.100.004) —] Valve iter) Valve iter 0.0 | 25 978—25.909 1.0228— 1.0235), “Fas97 1.022) Meno INS' | Valve liter bore. | 26.010~26-026 1.0240= 1.0246), 28.06(.025) Valve Vaive stem 0. IW |73.975—3.990 (0.1866 - 0.7571) 3.965 (0.1584) valve guide eg ——— Eas 3 80 sso. 3.955 (0.1557) [Cises-“:800 Steric guide daarancs [IN| 0.010=0.097(.0004=0,0018) ae ex, 0.020—0.07 (0,0008—0.0018), | Valve guide projection [IN |_soowseylinderhead | _Walve seat width INX | 0.80= 1.10 0.035 0.083) si006) Valve spring | Free length “(738.87(:570)_ 39.27 (1.5% ex 3629 11.426) 373 3601 [Ginger head warpage. a.1010 004)CYLINDER HEAD/VALVE TORQUE VALUES Cam chain tensioner pivot bolt Cam chain guide washer holt Cylinder head bolt (9 mm) Camshaft holder bolt Cam sprocket bor Cylinder head cover bolt Cam chain tensioner lifter mounting bolt Spark plua TOOLS Compression gouge attachment Valve spring compressor Valve spring compressor attachment Tappet hole protector 7AM MY60100 07757-0010000 07959-KM30101 o7HMG-MA70002 Valve guide driver 07 JMD-KY20100 Valve guide reamer, 4.008 mm O7MIMH.Av90100 Valve seat cutter, 27.5 mm (IN 45°) 07780-0010200 Valve gant outar. 24 8 mm (FX £52) nv7ao-onsa100 Fiat cutter, 27 mm (IN 32") 07780-0013300 Flat cutter, 24 mm {EX 32°) 07780-0012500 Interior cutter, 26 mn (IN 60") 07780-01450 07781-0010500 Inwertor euuer, 22 mm (EX 00") Cutter holder, 4.0 mm 4 TROUBLESHOOTING 10Nem (1.0 kgf ,7 otf) 12Nim (1.2 kgten 9 HFA) 47 Nem (4.8 kgf , 35 IbF A) 12Nem (1.2 kgf, 9 bE) 20m (2.0 geen 30Nom (1.0 kgém, 7 Es) 1ON-m (1.0 kgm, 7 Ibe) 12m {1.2 kam 9 bE Apply locking agent tothe threads Apply molybdenum cil solution to the threads and seating surface Apply cil tothe threads and seating surface “M1or-) AppIy looking agent co ine tnreaas. fr equivalent commercially available in U.S.A. Engine top-end problems usually affect engine performance. These can be diagnosed by @ compression test, or by tracing top ond noize with » sounding rod or etethoecops, Compression too low, hard starting or poor perfor- ‘mance at low speed Valves Incorrect valve adjustment Burned or bent valves Incnract valve timing Broken valve spring Uneven valve seating + Cylinder head Leaking or damayed cylinder head gasket —Warped or cracked cylinder head ~Loose spark slug ‘*Cylinder/piston problem (section 12) Compression too high ‘Excessive carbon build-up on piston head or Excessive smoke '* Worn valve stem or valve guide ‘ vamagea stem seat + Cylinder/piston problem (section 12) Excessive noise * Incorrect vaive clearance * Sucking valve or broken valve spring ‘Worn or damaged camshaft ‘Worn or damaged vaive liter Worn eam chain jorn or damaged cam chain tensioner * Worn cam sprocket teeth * Cylinder/piston problem (section 12) Rough idle ‘* Low cylinder compression R-2CYLINDER HEAD/VALVE CYLINDER COMPRESSION Warm up the engine to normal operating tempera: ture. ‘Stop tne engine ana remove tne airect ignition cos, (page 36), Install the compression gauge with the gauge at- tachment, Tool: Compression gauge attachment 07RMJ-MY50100 Shift the transmission in neutral. Open the throttle all the way and crank the engine with the starter motor until the gauge reading stops fising. The maximum reading is usually reached within 47 seconds, compreesion PRESSURE: 1,226 kPa (12.5 kaflom®, 178 psi) Low compression can be caused by: “blown eyiinger head gasket improper valve adjustment valve leakage —worn piston ring or evlinder High compression can be caused by: carbon deposits in combustion chamber or on pisior Wee CYLINDER HEAD COVER REMOVAL, Remove the carburetor (page 5-15). Dieconnest the ignition eoil 2P connectors and remove the direct ignition coils, Disconnect the air supply hoses and the vacuum tube to remove the pulse secondary air injection (PAIR) control valve.CYLINDER HEAD/VALVE Remove the three bolts and the cylinder head cover. NOTE: Do not remove the dowel pins and the breather plate from the head cover. CAMSHAFT REMOVAL Remove the cylinder head cover (page 8-3). ond sealing washer. This tool can easily be made from a thin (1 mm of thickness) piece of steel as shown below. 15mm 19mm am MATERIAL THICKNESS: 1.0 mm $5 2 3 Remove the two bolts and cam chain guide plate from the camshaft holder. 4Be caratul not to op the sprocket sprockets ita ne Remove the timing hala rap Remove the cam sprocket bolts from the intake and exhaust camshafts remove the other cam sprocket bolts, Remove the cam sprockets from the camshafts, ‘and suspend the cam chain with a piece of wira to prevent it from falling into the crankcase. To replace the cam chain, remove the cam chain tensioner and guide (page 8-11), Loosen the camshaft holder bolts in a crisscross pattern in several steps from the outside to inside to prevent damage the camshaft holder and camshafts Remove the camshaft holder. Remove the camshafts. NOTE: Do not forcibly remove the dowel pins from the Remove the valve liters and shims, * Be careful not to damage the valve liter bore. Shims may stick to the inside of the vaive lifter. De nat allow the shims to fal nto the erankeaoe: + Mark all valve lifters and shims to ensure correct, reassembly in their original locations. ‘sThe valve liter can be easily removed with @ valve lapping tool or magnet. ‘The shims can be easily removed with tweezers ora magnet. mim eee i, SN CYLINDER HEAD/VALVECYLINDER HEAD/VALVE INSPECTION j ‘CAMSHAFT ‘Check the car and journal surfaces ofthe camshaft for scoring, seratches of evidence of insuicient lu brication, LUneck re ot! notes in tne camsnan ror ciogaing. Measure the camshaft runout using a dial incicator. SERVICE LIMIT: 0.05 mm (0.002 in) Measure each cam lobe height using a micrometer. SERVICE LIMITS: 49 state/Canada type: IN:36.57 mm (1.440 in} X:36.35 mm (1.392 in} Calitornia typo: INF 2489 mon 11 in) EX: 23.89 mm (1.334 in) (CAMSHAFT JOURNAL Check the camshaft journal surfaces of the eam- shaft holders and cylinder head for scoring, ‘eratches or evidence of insufficient lubrication, CAM CHAIN GUIDE PLATE Check the guide plate for excessive wear or dam-CYLINDER HEAD/VALVE CAMSHAFT OL CLEARANCE NOTE {Vo not rotate ine camsnar curing inspection. The camshafts Wipe any oil from the journals of the evlinder head, have tha identi. camshaft and camshaft holder. ‘cation mark: Put the camshaft onto the cylinder head and lay a IN: intake strip of plastigsuge lengthwise on each camshaft Carefully install the camshaft holder onto the ‘camshafts Apely engine oll te the threads snd essting surfaces of the camshaft holder bolts. Install the twenty holder bolts with the eight washers as shown, ‘The camshaft holder have the number "1 thru. 20” Temporarily tighten the four bolts of the center ‘area gradually in the sequence 6-5-8-7 until the dowel pins on the camshaft holder inserts into the pin holes in the cylinder head properly (The clearance between the holder and head is 1-5 Next, tighten the all bolts in numerical ordar cast ‘on the camshaft holder (1 thru. 20) in several stops. Toraut 2N-m (1.2 kgm , 9b) Remove the camshaft holder and measure the comprocead plactigauge at ite widost point on tho camshaft to determine the ol clearance. ‘SERVICE LIMIT: 0.10 mm (0.004 in) If the oil clearance exceeds the service limit, replace the camshaft and recheck the oil clearance. Renlaca tha cylindar haad and camehatt holdars a= fst if the oll clearence still exceeds the service lint CYLINDER HEAD REMOVAL Drain the coolant (page 6. Remove the following: —two bolts and thermostat housingCYLINDER HEAD/VALVE —two bolts, washers and cam chain tensioner lifer. Remove the two 6 mm cylinder head bolts. Loosen the ten 9 mm cylinder head boits in a criss- cross peitern in 2 or 3 steps, and remove them. Remove the cylinder head. Remove the gackot and dowel pins. CYLINDER HEAD DISASSEMBLY Toot: Tappet hole protector _7HMG-MR70002CYLINDER HEAD/VALVE Remove the valve spring cotters using the special to9ls Toots: Valve spring compressor u///-wviuubu Compressor attachment — 07959-KM30101 To prevent loss of tension, do not compress the valve springs more than necessary to remove the Remove the following: ~spring retainer valve stem seal ~ spring seats Note Mark all parts during disassembly so they can be placed beck in their original locations. INSPECTION CYLINDER HEAD Remove the carbon deposits from the combustion surface. Check the spark plug hole and valve areas for cracks. Check the cylinder head for warpage with a straight edge end fesler gauge. SERVICE LIMIT: 0.10 mm (v.0U8in) ‘SPRING COMPRESSOR, 4 VALVE SPRING RETAINER, \ 6 gO seme STEM SEAL «CYLINDER HEAD/VALVE ‘uneok tne valve imer nore ror scoring, seratcnes oF damage. Measure the each valve lite bore 1.0. ‘SERVICE LIMIT: 26.04 mm (1.025 in) VALVE LIFTER Check the valve lifter for scoring, scratches or samage. Measure the each valve lifter 0.0, SERVICE LIMIT: 25.97 mm (1.022 inl Val VE SPRING “Measure the valve spring free langth. ‘SERVICE LIMITS: IN: 38.27 mm (1.507 in) EX: 38.73 mm (1.307 In) VALVE/VALVE GUIDE Check thatthe vaive moves smoothly in the guide. Chark tha waive far handing, huirning ae abnormal ‘Measure each valve stem 0.0. and record it EX : 3.985 mm (0.1857 in} 8-10CYLINDER HEAD/VALVE teeta race antec om PU va ve oye real Tool: EET Valve guide reamer o7MMH-aveot00 Measure each valve guide I. and record it. SERVICE LIMIT: IN/EX: 4.04 mm (0.159 in) Subtract each valve ster 0.D. from the correspond ing guide L.D. to obtain the stern-to-guide clearance. ‘SERVICE LIMIT: IN: 0.075 mm (0.0030 in) EX ; 0.085 mm {0.0033 in) It the stem-to-guide clearance exceeds the service limit, determine if new guide with standard dimen sions would bring the clearance within tolerance. fit If the stern-to-guide clearance exceeds the service limit with a new guide, also replace the valve, Nore Inspect and reface the valve seats whenever the valve guides are replaced (page 8-12). ‘CAM CHAIN TENSIONER/GUIDE Remove the right crankcase cover (page 9-3) Remove the socket bolt and the cam chain Tensioner, than the washer {between the engine and tensioner) Remove the washer bolt and the cam chain guide,CYLINDER HEAD/VALVE {Check the eam chain tensioner and guide for oxeoe- Ggy CHAIN TENSIONER sive wear of damage and replace them if necessary \ Install the cam chain tensioner and guide in the AN reverse oraer ot removal \ ‘Aoply locking TORQUE: Tensioner: 19 N-m (1.0 kgm, 7 bff), agent tote tan- Guide: 12 Nem (1.7 kgm INE) sioner (socket \ ‘bolt threads. Install the right crankcase cover (page 9-14). \ A CAM CHAIN GUIDE VALVE GUIDE REPLACEMENT refrigerator for about an hour. Heat the cylinder head to 130 140°C (275 ~290 °F) with a hot plate or oven, cog Wear heavy gloves to avoid burns when handling the heated cylinder head. os Using a torch to heat the cylinder head may cause warpage. 108 ‘Support the cylinder head and drive the valve guides out of the cylinder head from the eombus- tion chamber sie. VALVE GUIDE DRIVER Tool: Valve guide drive o7JMD-KY20100 While the cylinder head is still heated, drive new valve guides in the cylinder head from the camshaft side until the exnosed height is fallawing dimensions, Tool: Valve gue river orumb-wr20100 VALVE GUIDE PROJECTION: IN: 16.1~ 16.4 mm (0,630.85 in) EX: 14.3- 14.6 mm (0.56~0.57 in} Letthe cylinder head coo! to room temperature. 8-12CYLINDER HEAD/VALVE Ream the new valve guides. Insert the reamer from the combustion chamber VALVE GUIDE side of the head and always rotate the reamer clockwise, TOOL: Valve guide reamer, 4.008mm O7MIVH-Mve0100 NOTE: ‘* Take care not to tit or lean the reamer in the ale wile rearing. ‘+ Use cutting oll on the reamer during this oper tion. fer head thoroughly to remove any metal particles after reaming and reface the valve seat (page 8 141 VALVE SEAT INSPECTION/REFACING INSPECTION Clean all intake and axhauist valves thoroughly to r= move carbon deposits, Apply alight coating of Prussian Blue to each valve ‘Tap the valve against the valve seat several times without rotating the valve, to check for proper valve seat contact. Remove the valve and inspect the valve seat face. ‘The valve seat contact should be within the spe fied width and oven al around the siroumforenee. = ‘STANDARD \ IN/EX: 0.90~ 1.10 mm (0.035~0.043 in) ‘SERVICE LIMIT: IN/EX: 1.5 mm (0.08 in} Ifthe valve seat width is not within specification, rafare the vale eaat nage 18) sraT Mint Inspect the valve seat face for: ‘Uneven seat width: Replace the valve and reface the valve seat + Damaged face: Replace the valve and reface the valve seat. DAMAGED FACE UNEVEN SEAT wibTH 8-13CYLINDER HEAD/VALVE ‘Contact area (too high or too low) Reface the valve seat, The valve cannot be ground, If the valve face is burned or badly womn or if it contacts the seat un- evenly, replace the valve. REFACING NOTE: ‘Follow the refacing manufacturer's operating in- + Be careful not to grind the seat more than neces sary. Ie the contact area is tou highs on the valve, the seat must be lowered using a 32" flat cuter. If the contact area is too low on the valve, the seat must be raised using a 60" interior cuter. Using 2 45° soat cutter, remove any roughness or irregularities from the seat Toots: Seat cutter, 275mm _07780-0010200 Seat cutter, 265 mm 07780-0010100 Cutter holder, 4.0mm 07781-0010500 or equivalent commercially available in U.S.A. TooLow TOO HIGH | | CONTACT TOO HIGH { : | ~ OLD SEAT CONTACTTOO LOW OLD seat wot or fk —. ROUGHNESSUsing 2 32° flat cutter, eomove 1/4 of the exiting valve seat material Tools: Flat cutter, 27 mm (IN) U7 /40-0UTS30U Flat cutter, 24mm (EX) 07780-0012500 Cutter holder, 4.0mm 0781-0010500 or equivalent commercially available in USA. Using @ 60° interior cutter, remove 1/¢ of the oxisting valve seat material. Toots: Interior cutter, 26mm 07780-0014600 Interior cutter, 22mm 07780-0014202 Cutterholder, 4.0mm 07781-0010500 or equivalent commercially available in USA, Using 2 45° seat cutter, cut the seat to the proper width, After cutting the seat, apply lapping compound to the valve face, and lap the valve using light pres- CAUTION: “+ Excessive lapping pressure may deform or dam- age the seat. ‘+ Change the angle of lapping tool frequently to + Do not allow lapping compound to enter the guides, After lapping, wash any residual compound off the ‘vlinder head and valve and recheck the seat con- CYLINDER HEAD/VALVE ~ ae wiDTHCYLINDER HEAD/VALVE CYLINDER HEAD ASSEMBLY VALVE LIFTER ce sHim—___{—) OTTERS, SPRING RETAINER. OS EXHAUST VALVE SPRING: —-2 STEMSEAL— —— f sonnases EXHAUST VALVE GUIDE™ & EXHAUST VALVE! Blow thraugh all oi! paesagee in the eylindar head with compressed air. Install the spring seats and new ster seals. rn Lubricate the valve stom slicing surtace with motyb- denum oil solution, Insert the valve into the guide while turning it slow- ee ly to avoid damage tothe stern seal revanen | Be sores stew sea. Install the valve spring with the tightly wound coils facing the combustion chamber. Install the spring retainer. Combustion cnamoer sige Q4eCYLINDER HEAD/VALVE Install Une lappet hole protector into the valve lifter APPET HOLE PROTECTOR, bore. Toot: Tappet hole protector O7HMG-MR70002 Grease the cotters. Install the valve spring cotters using the valve toease installa- spring compressor. Toots: Valve spring compressor 07757-0010000 Comoressor attachment 07959-KM30101 ‘SPRING COMPRESSOR, CAUTION: To prevent loss of tension, do not compress the valve springs more than necessary to install the | cotters. ‘Suppor the cylinder head so that the valve heads will not contact anything that cause damage. Tap the valve stems gently with two plastic hammers as show to seat the cotters firmly. Install and tighten the spark plugs. TORQUE :12.N.mn(1.2kaf-m. 9 bf) CYLINDER HEAD INSTALLATION Inetll the dow pine and a new gachatCYLINDER HEAD/VALVE Install the eylinder head onto the eylinder, Apply molybdenum oil solution to the threads bolts and install ther. Tighten the 8 mm bolts ina erisseross pattern in 2or3steps. TORQUE :47 Nim (4.8 kgf, 35 br) Install and tighten the two 6 mm bolts. ofthe frame, do groove, rot instal the. Install thermostat housing onto the cylinder head thermostat yet. and tighten the two bolts. ‘Turn the cam chain tensioner lifter shaft clockwise fully to retract the tensioner lifter and secure it with 8-12CYLINDER HEAD/VALVE CAMSHAFT INSTALLATION The camshatts have the ‘entication =I: intake EX: exnaust Install 9 new gasket anta the tensioner lifter Install the tensioner lifter onto the cylinder head and tighten the two boits with new sealing washers TORUUE :1U Rie (TU KgEM, / OE cauTION Do not get molybdenum oil solution to the cam- shaft holder mating surfaces and holder bolt holes. It may fal to tighten the camshaft holder bolts for ‘correct torque Install the valva shims in their original lncations. Coat the outer surfaces of the valve lifters with mo: Iybdenum oil solution. Install the valve lifters in their original lifter bores, being eateful not to damage the sliding surfaces of the liftera and borea. Apply molybdenum oil solution to the camshaft IDENTIFICATION MARKS -CAMSHAFTS: journals and cam lobes. Install the camshafts onto the cylinder head with oth No. 1 cam lobes facing up diagonally as shown,CYLINDER HEAD/VALVE ‘Gost now 0 singe with oil and inetall thors into the ‘grooves inthe camshaft holder, Locsely install he camshatt holcer. Apply engine oil to the throads and seatin Suilaces ol the camshalt holder bolts. Install tho twenty bots with wight new washers as shown. Finger tighten the bots The camshalt holder nas the numbers "1 through 20" east nto te Graguay rghten the aignpropeny wine #8, #5, #8, 87, #2 and #1 bolts (in th the rows nthe créer) 1/2 tum at a time to draw the holder ‘plnder head. Gown evenly until the clearance betwaen the Sylindr hl ai he hla fs 2-Sen al the ‘way around e sre te ome! 11 the holder tits toward the 41 eylinder during and #1 as necessary to keep the holder ievel. ‘When the holder is parallel with the oylinger head, resume tightening the bolts in the Once the clearance is within 2-3rmm, begin lightening al the bolts in numerical order (#1 23.89. 290) 4/4 to 1/2 turn at atin stl tae holder is tully seated against the cylinaer head. ‘TORQUE +12 Nim'1.2kotn. 9 Ibt Be cartu nat to Turn the erankshat clockwise aed align “T” mark {am ita cam rain on the ignition pulse generator rotor with the index tenen uring he ‘rankahal!_ Install the cam sprockets onto the cam chsin and cam sprocet flanges so that the timing marks sprockets are flush wth the cylinder head surface and facing outward as shown, diagonally, align the bolt holes in the cam sprockats and camehats 8-20 Revised March, 2000, 1999-2000 CBREGOF4 (©2000 American Honds Motor Co. Inc, ~ Al Rights Reseved ‘MSV 8757 (0001)CYLINDER HEAD/VALVE Apply locking agent to the cam sprocket bolt threads. Install the cam sprocket bolts. turn tne crankshatt clockwise one turn and install the remaining cam sprocket bolts. ‘Tighten the cam sprocket bolts. TORQUE :20 Nim (2.0 kgfim 14 bf) ‘Turn the crankshaft clockwise one turn and tighten Install the cam chain guide plate and tighten the two bolts. Remove the stopper tool from the cam chain ten- sioner liter and install the sealing bolt with a new sealing washer. Install the Fiming hla nap {nage 3-19) Install the cylinder head cover. CYLINDER HEAD COVER INSTALLATION Install a now gaskat in tne head cover groove. Apply sealant to the cylinder head semi-circular casket GP 8-21CYLINDER HEAD/VALVE Install the head cover onto the cylinder head. Install the special washers onto the head cover | balte with tha "IP" mark faring the halt head Install the three head cover bolts by aligning them with the bott hole inthe cylinder head property. Tighten the bots in 2 or 3 steps. TORQUE : 10 Nem (1.0 kgf 7 bf) Connect the air supply hoses and the vacuum tube te install te PAIR control valve Install the diroct ignition coils onto the spark plugs. The cyinder Connect each 2P connector to the correct ignition numbers are oil printed on e3ch ‘gnition coll wie. Install the carburetor (page 5-30). Fill and bleed the cooling system if the cylinder head wae removed (page &- 8-22MEMOCLUTCH/GEARSHIFT LINKAGE 18 Nem (1.5 kgm, 11 IbFt) 12Nem (1.2 kghm, 9 IDEA 12N.m (1.2kgtm, 9 oF A 9-09g. CLUTCH/GEARSHIFT LINKAGE ‘SERVICE INFORMATION 91 GEARSHIFT LINKAGE a | TROUBLESHOOTING 9-2 RIGHT CRANKCASE COVER INSTALLATION 9-14 RIGHT CRANKCASE COVER REMOVAL 9-3 | cuuron 4 | SERVICE INFORMATION GENERAL ‘The clutch and gearshift linkage can be serviced with the engine installed in the frame, + Engine oil viscosity and level and the use of oil additives have an effect on clutch disengagement. Oil additives of any kind are specifically not recommended. When the clutch does not disengage or the motorcycle creeps with the clutch Lisengeye inspec the engine oll ad vil level before servicing the clutch system. '= The crankcase must be separated when the transmission, shift drum and shift forks require service (section 11) SPECIFICATIONS STANDARD is Spring freelength | 46.5(1.83) Disothickness | 2,923.08 (0.115; [asaii7e)—_) O21) 2.6:0.10) | . Plate warpage — = F930 0.01, Caan oer uae it 2000 =PSUT OHH OSE 2503 0385) | wes Po [13i975=3h991 1.3770~ 1.3776) Tsaarisi7 Mainahe ai cuich outer aude [24 980 24 999 (0.98350. 9640) 2960 985) —) TORQUE VALUES ‘clutch center lock nut Clutch bolt Gil pump driven sprocket bott Gearshift cam bolt Gearshift stopper arm boit Right crankcase cover bolt TOOLS Clutch center holder Driver Attachment, 37 x 40 mm Attachment, 42 * 47 mm Pilot. 17 mm Pilot, 35 mm. 127 Nem (19.0 kgm , 94 bE) 12N-m (1.2 kgfm SIDE) 18 Nem (1.5 kgm, 11 IBF) 23N-m (2.3 kgbm, 17 Ibht) TaN (1.2 kgém 9 Ibtf) T2Nem (1.2 kgm, 9 tot A) Apply cl tothe threads and seating aurfoce and stake Apply locking agent to the threads Apply locking agent tothe threads page 9-15 07724-0050002 or equivalent commercially available in U.S.A 07749-0010000 07746-0010200 07746-0010300 07746-0040400 07746-0040800CLUTCH/GEARSHIFT LINKAGE TROUBLESHOOTING Clutch lever too hard * improperly routed clutch cable * Damaged clutch liter mechanism * Faulty clutch lifter bearing Clutch will not disengage or motorcycle creeps with clutch disengaged * Too much clutch lever free olav '* Warped clutch plates, * Loose eluteh lock nut * Engine oil level too high, improper il viscosity or oil additive used Clutch slips * No clutch lever free play ‘*Worn clutch dises ‘Weak clutch springs * Clutch liter sticking * Engine oil level to0 low or cl additive usod Hard to shite ‘Improper clutch operation * Incorrect engine oil viscosity Incorrect clutch adjustment * Bent or damaged gearshift spindle Damaged gearshift cam * Bont fork shaft or damaged shift forks and shift drum (section 11) ‘Transmission jumps out of gear *# Broken shift drum stopper arm ‘Worn oF damaged gearshift cam * Bent fork shaft or worn shift forks and shift drum (section 11) Worn gear dogs or slots ‘section 11)CLUTCH/GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL Drain the engine oil (page 3-121 Remove the right side fairing (page 2-4), Reise tre fuel kon end support it (page 29) Remove the cable holder bolt and clutch cable hold: ‘er, and disconnect the clutch cable from the clutch liter arm. Disconnect the ignition pulse generator 2P connec- tor. Remove the crankcase cover bolts. Thelifter arm Remove the crankcase cover while turning the spinaio is engaged clutch litter arm counterclockwise to disengage the with the clutch lifter arm spindle from the lifter piece inter piece inside the eight crankcase cover. Remove the four dowel pins. Clean any sealant from the crankcase cover mating surfaces.CLUTCH/GEARSHIFT LINKAGE CLUTCH LIFTER ARM Remove the clutch lifter arm, return spring and ‘washer from the right crankcase cover. ‘Check the lifter arm spindle for wear or damage. Check the return spring for fatique or damage. Check the liter arm oll seal and needle bearings for ‘wear or damage. Install the clutch liter arm with the ‘spring and ‘washer as shown, CLUTCH DISASSEMBLY Romove the right erankeaeo cover [page 8 3). Remove the clutch bolts, springs and pressure plate. Remave the clutch titer pisce. Remove the seven clutch discs and six plates. The two dises (8) on both ends ave different fram the five discs (A). Do not confuse the discs A and 8. a4CLUTCH/GEARSHIFT LINKAGE Hold the clutch center with the special tool and ra- move the clutch center lock nut Tool: Clutch centerholder _07724-0050002 or equivalent commercially available in USA, Remove the special washer, plain washer and clutch center Remove the thrust washer.CLUTCH/GEARSHIFT LINKAGE Raise the fuel lank and support (page 2). Loosen the cam chain tensioner (page 8-4), ‘Be careful not to Align the gear teeth ofthe scissors gears (primary bend the ignition drive gear and sub-aear) by inserting a 5 mm steet pulse generator pin or screwdriver atleast 61 mm in length into the rotortangs. gear hole through the hole in the crankcase, and femove the clutch outer. ‘The ignition pulae genorater rotor must be aligned as shown, PRIMARY DRIVE. Geng IGNITION PULSE GENERATOR ROTOR Remove the oil pump driven sprocket bolt and washer. Remove the oil pump driven sprocket, drive chain and drive eprockor ac a eat Remove the elutch outer guide. INSPECTION UFTER BEARING “Tune Ue er sate UF dhe ler beating wilt your finger. The bearing should turn smoothly and quietly ‘Also check that the outer race of the bearing fits tightly in the pressure plate. Replace the bearing if the inner race does not turn smoothly, quietly, or f the outer race fit loosely in the pressure pate Drive the bearing out of the pressure plate. Unive @ new nearing into the plate witn its mark side facing out. Toots: Driver 07749-9010000 Attachment, 32 35 mm _07748-0010100 Pilot, 17 mm 07746-0040400 CLUTCH SPRING Foplace the clutch Measure the clutch spring ree length, ‘springs as set. SERVICE LIMIT: 45.2 mm (1.78 in)CLUTCH/GEARSHIFT LINKAGE CLUTCH CENTER CLUTCH CENTER: Check the clutch center and pressure plat for nicks, indentations or abnormal wear made by the plates. CLUTCH LIFTER PIECE Check the lifter piace for damage ar abnormal wosr CLUTCH DISC Replace he clutch Check the clutch discs for signs of scoring or iecs and plates discoloration. a8s01. Mansure the clutch dite thickness, ‘SERVICE LIMIT: 2.6 mm (0.10 in} CLUTCH PLATE Replace the clutch Check the plates for discoloration ‘ises and plates Chock the plate warpage on a surface plate using a aseset. feeler gauge.CLUTCH/GEARSHIFT LINKAGE CLUTCH OUTER GUIDE Measure the clutch outer guide I.. and 0.D. SERVICE LIMITS: LD.:_ 25.03 mm (0.985 in) 0.0: 34.87 mm (1.377 in) MAINSHAFT Measure the mainshaft O.D. st the clutch outer uid. SERVICE LIMIT: 248 men 1 9R2 in) cuutcH ouTER Check the slots in the clutch outer for nicks, indentation oF abnormal wear made by the clutch ‘isos, Check the needle bearing for wear or damage. Ralaca the haaring #f aacessay. Press the needle bearing out of the clutch outer us- ing the special toots pniven: Toots: Driver 07749-00100 Attachment, 37 x 40mm 07746-01020 ot, $5 mm oy 7a0-uuauauythe gearshift linkage (page 913), Becaretul not to bend the lgrtion pulse generator ‘rotor tangs. CLUTCH/GEARSHIFT LINKAGE LUsing the special tonls, pease the naedla bearing in the clutch outer until the depth below the raised portion of the clutch outer surface (oil pump drive i DRIVER sprocket side) is 0.40.6 mm. Toots: Driver 07749-0010000 Attachment. 42 x 47 mm 07748-0010300 Pilot, 35 mm 07745-0040800 ASSEMBLY solution and install it onto the mainshaft with the flange side facing the crankcase. Install the oll pump drive sprocket (with the pins facing out) drive chain and driven sprocket as @ set with the “OUT” mark on the drivan sprocket facing Apply to bolt threads. Insta ee HOI wid ane waster ae gti agent to the oll pump driven sprocket TORQUE : 15 N.m (1.5kgf:m, 11 Ib) ‘Align the gear teeth of the scissors gears (primary drive gear and sub-goar) by prying the gears with a screweriver, then instal the clutch outer. ‘Align the holes in the clutch outer with the pins on the oll pump drive sprocket by turning the oil pump driven sprocket while pushing in the clutch outer.CLUTCH/GEARSHIFT LINKAGE Make sure that the primary driven gear of the clutch outer is flush with the primary drive sub- gear. Release the cam chain tensioner lftar (nage 8-21), Install the theust washer. Install the clutch center. Install the plain washer and special washer with the "OUI" mark on the special washer facing out. Apply engine ol tothe throads and seating aurface ‘of a new clutch center lock nut and install it onto the mainshat Hold the clutch center with the special tool and tighten the lock nut Tool: Clutch cantar holder —07724.008N002 ar equivalent commercially available in USA, TORQUE: 127 Nem (1S.0KgEM 94 1ET ‘Be careful not 10. Stake the clutch center lock nut into the mainshaft damage the groove. a.1nCLUTCH/GEARSHIFT LINKAGE Insta the outside clutch aise (8) 203 int the shallow slots of the ciuteh outer Note: Do not confuse the clutch discs A and 8. Coat the clutch discs with lean engine ol Sy Install the seven clutch discs and six plates See | alternately, satin wth the dae). The we dses (Bloreinglaled ono bot ends) Install the clutch lifter piece into the lifter bearing. Install the pressure plate and the clutch bolts with the springs. Tighten the bolts in a crisserose pattern in 2 or 3 stops. TORQUE :12.Nim (1.2 kgm, 9 IDFA Install ne rignt crankcase cover (page 9-14). 9-11CLUTCH/GEARSHIFT LINKAGE GEARSHIFT LINKAGE REMOVAL Disassemble the clutch to the clutch outer (page 8- 4, Remove pint boll and the georshift arm. Remove the gearshift spindle assembly and thrust washer. Remove the gearshift cam bolt and gearshift cam Remove the dowel pin from the shift drum. Remove the stopper arm bott, arm, washer and re- turn spring, INSPECTION Check the gearshift spindle for bending, Check the spindle plate for wear or damage, Check the spindle return spring for fatigue or dam- age. ‘SPINDLE PLATE i i RETURN SPRING a,CLUTCH/GEARSHIFT LINKAGE INSTALLATION Install the return spring, washer (between the spring and arm}, stopper arm and bolt, and tighten TORQUE :12.N-m(1.2kgtm 91bF) Install the dowel pin into the shift drum. Lift the stopper arm with a screwdriver and install shift cam by aligning tha nin hole in th Apply locking agent to the gearshift cam bolt tnreaas. Install and tighten the bolt. TORQUE :23 N.m (2.3 kotm 17 Ib Install the thrust washer onto the gearshift spindle, ‘and insert the spinal into the crankcase, aligning the return spring ends with the spring pinCLUTCH/GEARSHIFT LINKAGE inca tne gearsni arm onto tne spina, aigning am the slit of the arm with the punch mark on the BEGEARSH spindle Trahten the pinch bot securely ‘Assemble the clutch (page @8), RIGHT CRANKCASE COVER INSTALLATION Install the four dowel pins Apply sealant to the crankcase mating surfaces as | shown. 3 em 10- 15mm (0.4-0.6in) 10-15 mm | (04-08 in} ‘Apply sealant to the right crankcase cover mating surface, Install the right crankcase cover while turning the Titer arm clockwise to engage the liter arm groove withthe lifter piece flangeCLUTCH/GEARSHIFT LINKAGE Donor pinch the ‘ignition puso Deneratnn wie between the water ‘hose and engin. Connectthe ignition pulse generator 2P connector. cgnynie TOR! Connect the clutch cable to the lifter arm and install the cable holder withthe bolt, ‘Tighten the four cover bolts fist in a numerical or der an the erankcase cover in 2 or 3 step, TORQUE : 12 Nim (1.2 kgm 9 IDE) ‘Tighten the other cover bolts to the same torque. Fill the crankcase with recommended engine oil page 3-12), ‘Adjust the clutch cable (page 3-23). Install the side fering (page 2-4. 9-15ALTERNATOR/STARTER CLUTCH a J2NM (1.2 kotem 9 HbA 10-010. ALTERNATOR/STARTER CLUTCH ‘SERVICE INFORMATION 10-1 FLYWHEEL REMOVAL. 10-3 TROUBLESHOOTING 10-1 STARTER CLUTCH 10-4 ALTERNATOR STATOR 10-2 FLYWHEEL INSTALLATION 10-6 | SERVICE INFORMATION GENERAL + This section covers service of the alternator stator, flywheel and starter clutch, These parts can be removed with the en: gine installed in the frame. + Rafer to section 16 far alternator stator inspection. ‘Refer to section 18 for starter motor servicing, SPECIFICATIONS nit: mm (in rem ‘STANDARD SERVICE LIMIT arte driven gear boss FS 10s 5 1.71. 038E=ZOBET) Be OF TORQUE VALUES | 10 | Stator wire clamp bolt 14 Nem (1.4 kgm , 10 IDE) Alternator stator bolt 12N-m (12 kgm, SbF) Stanter eluten Bort TAU ILO KGEM, 12106) Apply ocking agent o ine mnreaas Flywheel bolt 103N-m (10.5 kgm, 76 bf) Apply oll tothe threads and seating surface TOOLS Flywheel holder (07725-0040000 or equivalent commercially available in USA. Rotor puller (07733-0020001 or 07933-3850000 TROUBLESHOOTING Engine does not turn * Faulty starter clutch * Damaged reduction gearishaft 10-1ALTERNATOR/STARTER CLUTCH ALTERNATOR STATOR LEFT CRANKCASE COVER REMOVAL Remove the left side fairing (page 2-4) Disconnect the alternator 3P (White) connector. Remove me ler crankcase cover bolts ana tne ler. ‘erankease cover. The left crankcase cover (stator) is magnetically attached to the flywheel, be caroful during removal. Nore: The engine oi! will run out when the lett crankcase cover is removed. Set a clean oil pan under the en- dine and add the recommended oil to the specified level aftar installation, Remove the gasket and dowel pi. STATOR RFPIACEMENT Remove the clamp bolt and clamp. Remove the four bolts, grommet and stator from the left crankcase cover. Install a new stator onto the left crankcase cover. Apply sealant to the arommet seating surface and install it into the cover groove properly, Set the wire properly and install the wire clamp with the bolt TORQUE :14 Nim 1.4 kgm, 10 bt STATOR Install and tighten the stator bolts. TORQUE :12.Nim {1.2 kgm, 91bhf = 15mm fs ry LEET CRANKCASE COVER Rime hy INSTALLATION Z Apply sealant to the crankcase mating surfaces as 10-2ALTERNATOR/STARTER CLUTCH Insta the dowel pin and a new gasket Install the left crankcase cover and tighten the cov- cer bolts securely, Connect the alternator 3P (White) connector. Install the left side fairing (page 2-4), oil if necessary (page 3-11). FLYWHEEL REMOVAL REDUCTION: GEANSLA Remove the laftcrankcase cover page 10-2. ae Remove tha start eaduction gear and shaft Hold the flywheel with the special too! and loosen the flywhes! bolt. Tool: Flywheel holder 07725-0040000 or equivalent commercially available in USA Remove the flywheel bolt and special washer. Remove the flywheel using the special tool. Tool: Rotor puller 07733-0020001 or (07932-39000 ROTOR PULLER 10-3ALTERNATOR/STARTER CLUTCH Remove the woodruff key frorn the srauhalitt STARTER CLUTCH REMOVAL Remove the flywheel (page 10:3), Remove the starter a counterclockwise. fen gear while turning it Hold the flywhee! with the special tool and remove the starter clutch bolts Toot: Flywheet holder (07726 0040000 or equivalent commercially available in U.S.A, Remove the starter clutch assembly from the fy: wheel Remove the sprag clutch from the starter clutch out- 10-4INSPECTION ‘Check the starter driven gear, reduction gear and sprag clutch for abnormal wear or damage. Measure the starter driven gear 0.D. SERVICE LIMIT: 51,684 mm (2.0348 in} Check the inner contact surface of the clutch outer for damage. INSTALLATION ‘Apply engine oil to the sprag clutch contacting sur- faces. Inotall the oprag eluteh into tho etartor clutch outor as shown, Apply locking agent to the starter clutch bolt threads. Install the starter clutch assembly onto the flywhee! and install the bolts Hold the flywheel with the special tool and tighten Tool: Flywheet holder 07725-0040000 or equivalent commercially available in US.A, TOROUIE. 1A Non (1 Beghrn. 19 ALTERNATOR/STARTER CLUTCHALTERNATOR/STARTER CLUTCH Install the starter driven gear while turning it coun- rerclockwise STARTER DRIVEN GEAR Maka sure thar tha starter drivan nar hurns counter clackwise smoothly and does not turn clockwise. Install the fywhee! {see below. FLYWHEEL INSTALLATION Apply oll tome neeaie bearing, Clean any ol from the tapered portion of the crank: shaft and flvwheel, Install the woodruff key In the crankshaft key groove. Install the flywheel aligning the key way in the flv- ‘whoo! withthe woodruff key on the erankshaft, Apply engine oil to the flywheel bolt threads and seating surface. Install the special washer and flywheel bolt. Hold the fywheel with the special tool and tighten the bot, Toot: Flywheetholder —_07725-0040000 or ‘equivalent commercially avallagie in U.S.A TORQUE : 1031N-m {10.5 kgFm,,76 lof) 10-6ALTERNATOR/STARTER CLUTCH Apply oil to the stariar reduction gear and gear ™, shaft Install the reduction gear and shaft. Install the ert crankcase cover (page 1 10-7CRANKCASE/TRANSMISSION 39.Nem (4.0 kgf. , 29 IDE) 25 Nem (26 kgm, 19 IbF) ~ i io Nem (2.6 kgm, 18 IDFA) Ted 25 Nim (2.8 of mm, 18 TBF) T2Nm (1.2 kgf, Sib 50N-m (8.0 kghm 43 1bF-) 1ON-m (1.0 kgm 7 Ibe 11-011. CRANKCASE/TRANSMISSION SERVICE INFORMATION 11-1 SHIFT FORK/SHIFT DRUM. 14 | TROUBLESHOOTING 11-2 TRANSMISSION 16 CRANKCASE SEPARATION 11-3 CRANKCASE ASSEMBLY Wt SERVICE INFORMATION GENERAL ‘The crankcase must be separated to service the following ‘transmission —crankshatt (section 12) ~piston/connecting rod (section 12) + The following components must be removed before separating the crankcase: angina (gestion 7) ‘il pan, oil pump and oil cooler (section 4) water pump (section 6) ~eylinder head (section 8) clutetvgearehint linkage Isection ¥) —fiywhee! (section 10) starter motor (section 18) “Be careful not to damage the crankcase mating surfaces when servicing. ‘Prior to assembling the crankcase halves, apply sealant to their mating surfaces. Wipe off excess sealant thoroughly. a SPECIFICATIONS ITEM STANDARD ‘SERVICE LIMIT Shi fork 1D. — cigs | Claw thickness ["$.83—6.00 (0.233— 0.236) 5.9 (0.23), Shiterkstalt | 00. 11957-11968 (0470704772) 11,95 (0479) Transmission | Gearl i, 2.021 (1.1024 1.1032) 78.04 (1.108 = ___ [eres cr 31.095 17208-12919) angi 799) | 1" Gear Bushing OD, "NS, M6 —|~27.985--27.880(7.1007 1.1018 71.94 (1.100) | 2 [a0s65=20.se0(12167—1 2167) a0.94 1.718) | __Pexea—~T30.s50= 20.575 .2185—1.2105) 30.93 1.218) Geartopishing [Ms Me | ~u.020—. 082 0.0005 0.0024) 8.100.904) clearance c2 0.0200 — 0.100.008] | ___¢3.te (0.025~ 0.075 (0.0010—0.0030), a=/s0) 7 | Gaarbushing iB 7 = —T 35.016 0.98097 _— 27.985 ~26.006 1.1018 1.1026) [aao2t (1.1032) [Mancha 013. — 24,967 = 24,980 (0.9830—0.9835) | 24.96 0.983) [Fcountershaft 0. [727 967=27-980 (1.1011 = 1.1016) [276 (1.101) | [eusiig 9.005 0.099 (0.0008 0.0015) 0.60.08) clearance [ee 0.005 0.039 (0.0002 0.0015) 11-1CRANKCASE/TRANSMISSION TORQUE VALUES Mainshaft bearing set plate bolt 12Nem(1.2kaf-m, Gib) Apply locking agent to the threads Gearshift drum bearina and fork shaft set bolt 12Nen(1.2kaf-m, SbF) Apply lockina agent to the threads Cam chain tensioner pivot bolt JON-m (1.0 kgtm, 7 btR) Apply locking agent to the threads Cam chain guide washer bolt YAN (4.2 kgim , 9IbF A Ignition pulse generator rotor bolt 591N-m (6.0 kgf , 43 fbf.) Grankeaae bott {Main journal! DEN m (2.6 kgf m, 10 bff} Crankcase boit (10 mm} 39.N.m (4.0 kgf , 29 IDE Crankcese bolt (Upper side) 25 Nim (2.5kgfm 18 IDF) TOOLS Inner driver © (07746-0030100 Attachment, 25mm|.D. _07746-0030200 TROUBLESHOOTING Hara to shit, ‘ Improper clutch operation (section 9) ‘Incorrect engine oil weight “*Bontshift forks ant shift fork shaft * Bent shift fork claw ‘Damaged shift drum cam grooves Transmission jumps out of gear Worn gear dogs worn gear sniner groove *# Bont shift fork shaft * Broken shift drum stopper arm + Worn or bent shift forks ‘Broken drum stopper arm spring + Broken gearshift spindle return spring **Worn or damaged transmission gears * Worn or damaged transmission bearings 11-2CRANKCASE/TRANSMISSION CRANKCASE SEPARATION Reter to Service Information (page 11-1) for remov- al of necessary parts before disassembling the eronikease, Remove the bolts and water hose joint. Remove the oil pressure switch Remove the bolts and speed sensor. CAUTION: case with the speed sensor installed, Dono! use the Remove the bolt, washer and ignition pulse genera- faniton auice tar rar. eneraior rotor Remove the washer bolt and cam chain guide. tangs tool it in Remove the cam chain and timing sprocket. place while Remove the pivot bolt, cam chain tensi "er and Remove the three bolts and bearing set plate Loosen the seven 6 mm bolts and five 8 mm bolts ina crisscross pattern in 2 or 3 steps. Remove the bolts and sealing washers,CRANKCASE/TRANSMISSION ace tne engine witn ine upper siae Gown, Loosen the eight 6 mm bolts, ten 8 mm batts and 10 ‘mm bolt ina crisscross pattern in 2 or 3 steps. Remove the bolt, Separate the lower crankcase from the upper erank- Remove the dowel pins and oil orifices. [PI On ges [ ~~ Be ins Clean any sealant from the crankease mating Sur faces. SHIFT FORK/SHIFT DRUM REMOVAL Remove the bearing set bolts Remove the shift fork shaft and shift forks. Remove the shift drum and bearing. BEARING 11-4CRANKCASE/TRANSMISSION INSPECTION Check the shift fork guide pins for abnormal wear fr damage. ‘SERVICE LIMIT: 12.03 mm (0.474 in) ‘Measure the shift fork claw thickness, SERVICE LIMIT: 5.9 mm (0.23 in) ‘Measure the shift fork shaft 0.0. [SERVICE FINMIT- 11.05 ene £70 in} Check the shift drum guide groove for abnormal SEPSHiieP nati wear or damage. CCheck the shift drum bearing for smooth rotation. BEARING INSTALLATION Install the shift drum and bearing into the lower crankcaseCRANKCASE/TRANSMISSION ‘The shine forks ave qe following Iaenamestion Ri ARR 2S MARK SARL MARK marks: FL: right and loft shift forks Ceenter shift fork Install the shift forks into the shift drum guide ‘groove with the identitication marks facing toward ‘he right sige of the engine and Insert he fork shat. Apply locking agent the hearing sat holt thads Install the set bolts and tighten them, TORQUE :12 Nm (1.2 kafim 9 loft) ‘Assemble the crankease halves (page 11-11) TRANSMISSION DISASSEMBLY Separate the crankcase halves (page 11-2). Remove the mainshaft and countershaft assem: Disassemble the mainshaft and countershatt. Clean all disassembled parts in solvent thoroughly. CCheck the mainshaft and countershatft needle bear- = 2 Inge for abnormal wear or damage. 5 mesegonINSPECTION ‘Check the gear shifter groove for abnormal wear or damage Check the gear dogs and teeth for abnormal wear ‘or damage, ‘SERVICE LIMITS: M5, M6: 28.08 mm (1.104 in) 2, 65, Ua51.U8 mm (1-222 I) Measure the gear bushing 0.0. ‘SERVICE LIMITS: (MS, ME: 27.94 mm (1.109 in} 3,64: 20.83 mm (1.218 in} G2 20.94 gun 1.240 0) Caleulate the gear-to-bushing clearance. ‘SERVICE LIMITS: "MBS, MI: 0.10 mmn (0.004 in) €3, C4: 0.11. mm (0.004 in) 2: 0.10 mm 0.004 in) Measure the gear bushing ID. SERVICE LIMITS: IMB: 25,016 mm (0.9849 in) €2: 28.021 mm (1.1022 in} Chock ure seinahaf end euunterstiat for obs wear or damage. ‘Measure the mainshaft 0.D. at the MS gear. SERVICE LIMIT: 24.96 mm (0.983 in} Measure the countershatt 0.0. atthe C2 gear SERVIGE LIMIT: 27.96 mn (1.101 in} Calculate the gear bushing-to-shat clearance. SERVICE LIMITS: 'MB: 0,08 mm {0.002 in) (62- 0.08 som (0.092 ini CRANKCASE/TRANSMISSION 2 11-7CRANKCASE/TRANSMISSION Install withthe roave side facing op. 11-8 ‘Tun the ball bering JuLer rave with your Anger ‘The bearing should turn smoothly and quietly. ‘Also check thatthe bearing inner race fits tightly on the shatt Replace the bearing ifthe outer race does not turn ‘smoothly, quietly, or ifthe inner race fs loosely on the chat. Nore: {ihe countersnatt ball pearing cannot be replaced. It the countershatt bearing is faulty, replace the coun tershatt MAINSHAFT BEARING REPLACEMENT MAINSHAET. Press the mainshatt out of the bearing, BEARING eZ Press a new bearing onto the mainshaft with the special tool. Tool: ‘Attachment, 25mm LD. 07746-0030200CRANKCASE/TRANSMISSION ASSEMBLY Apply molybdenum oil solution to the gear teeth, sliding surface, shifter grooves and bushings. Assemble the mainshaft and countershatt, Se a WASHEK ANU SNAP HING DINECHON: Desa Me DUCHING Ms Gear a MaMa GEAR (17/197), wancened’ "90 ~~ M6 GEAR (23T}- > M2 GEAR (167) OUTER RACE Lock wasHER. NEEDLE BEARING ‘COUNTERSHAFT: WASHER AND SNAP RING DIRECTION: SPLINE WASHER Cee NEEDLE BEARINGS i C3 GEAR (267) O} 1 C1 GEAR (347) C5 GEAR (257) C2 GEAR (337) 2 BUSHING cacéan en @ ~~ SEALCRANKCASE/TRANSMISSION NOTE Align the oil holes in the M6 bushing and mainshatt, and the C3, C4 soline bushinas and countersha. Note ' auign tne 1ocx washer tabs win ine spline washer grooves, ‘Always install the thrust washer and snap ring with the chamfered (rolled) edae facina awav from the thrust load ‘ Install the snap ring so that its end gap aligns withthe groove inthe splines. + Mako euro thatthe anap ring ia fully aoated in the shaft groove after installing i. Install the mainshaft assembly hy aligning tha hola inthe needle bearing outer race with the dowel pin. Install the countershaft assembly by aligning tha hole in the needle bearing outer race with the dowel pin. and the ring groove with tha eat ring Rest the pin on the ball bearing into the pin groove. Assemble the crankcase halves (page 11-11), 11-10CRANKCASE/TRANSMISSION CRANKCASE ASSEMBLY Apply sealant to the crankcase mating surfaces as shown, Install the three dowel pins and the two oil orifices by aligning the flat surfaces. Apply molybdenum oil solution to the main journal bearing surfaces on the lower crankcase, Install the lower crankcase onto the upper crank- case, aligning tne shirt rorks win tne gear snimier grooves. Apply engine oil to the 8 mm bol threads and seat- ing surfaces. Install the 10 mm bolt, ten 8 mm bolts and eight {6 mm bolts and tighten them in a crisscross pattern in2 or 3 stops. TORQUE: 10 mm bolt: 29 Nom (4.0 kgm , 29 IDF) Smmbolt: 25 Nm (2.6 kgf-m, 19 loft) Instat! tne sealing Install the five 8 mm bolts and seven 6 mm bolts vwashersingicated_ with new sealing washers. bythe". marks. Tighten the bolts in a crisscross pattern in 2 or 3 steps. TORQUE: 8 mm bolt: 25 N-m (2.5 kgf-m, 18 f#) s0mm BOLT 6mm BOLTSCRANKCASE/TRANSMISSION Apply locking agent tothe aet plate bolt threads. Install the bearing set plate with "OUT SIDE” mark facing out and tighten the three bolts. TORQUE :12.Nim(1.2kgf:m, 9lbf Install the timing sprocket and the ignition pulse generator rotor, aligning the wide groove with the install the bolt with the washer and tighten it TORQUE :58 N.m (6.0 kgf-m, a3 bf.) Install the cam chain. ‘Apply locking agent tothe pivot bolt threads. Install the cam chain tensioner, washer (between the tensioner and crankcase) and pivot bolt. TORQUE : 10 N-m (1.0 kgfim, 7 Ibf Install the cam chain guide and washer bot. ‘Tighten the bot. TORQUE :12 Nin (1.2 kafion 9 et Install a new O-ring into the groove in the water hose joint. Install the hose joint with the spout facina down and tighten the bolts.CRANKCASE/TRANSMISSION Cust « new O-ring with oil end instal onto the speed sensor. Install tha speed sensor and tighten the bolts, Install the following —oil pressure switch (page 3) oil pump, oil cooler, cil strainer, pressure relief water pump (section 6) starter motor (section 18) ~flywhee! (section 10) —gearsnirtunkage ana ciuten secon ») cylinder head, camshafts and head cover (sec- tion 8) engine section 7) 11-13CRANKSHAFT/PISTON/CYLINDER 25 Nem (2.6 kgém, 19 Ibe 12-012. CRANKSHAFT/PISTON/CYLINDER SERVICE INFORMATION 124 ‘TROUBLESHOOTING 122 CRANKSHAFT 123 MAIN JOURNAL BEARING CRANKPIN BEARING PISTON/CYLINDER 126 128 12-10 SERVICE INFORMATION GENERAL ‘= The crankcase must be separated to service the crankshaft and piston/connecting rod. Refer to section 11 for crankcase saparation and assambly. + Mark and store the connecting rods, bearing caps, pistons and bearing inserts to be sure of their correct locations for reassembly. The crankpin and main journal bearing inserts are select fit and are identified by color codes. Select replacement bear Ings from tie cous tables. After selecting ew Leatinys, reclieck Une vil clestanue with @ plastigeuye. Incorrect il clearance can cause major engine damage. ‘SPECIFICATIONS vst nt we svanoaro serwee une ‘Crenkohatt ae ido elear 910) (0.20 10,013) fese — Sessa — piston ring [Piston pin 0.0. Piston-to:piston pin clearance | 0. Se 7.000 0.6651=0.6693) | 18.981 [718.38 (0.689) Piston ring end gap | Top. [T0:10~0.20 (01004—0.008) 0,410.02) [Second 08 (0.02) Gil (side rail 1.0 (0.08), [Piston ingroving ~Peog0 “0.0 ont 0.09 (0.005) | ‘groove clearance ~0.015=0.050 (0.0008—0.0020) 0.08 (0.003) Cylinder 1. an |"67.000—67.015 2.6378~2.6384) 67.10 2.682) (Outofround - —— [70.10,0.008) — Taper = | Warpage, [Cylinder te-piston clear ‘OT = 0,650 015006 — 0.0020) oo1008 —| Connecting red small end LD. Tar aa=17 nae (0 enea 087085 (Carne (oReaT Connecting rod-te-pston pin clearance 2.076 0.040 (0.0008 — 0.0076) 0.060.002) 12-1CRANKSHAFT/PISTON/CYLINDER Tonaucr VALUES Connecting rod bearing cap nut 25N-m(28kgfm, 19 lbEft) Apply oil to the threads and seating surface Cranicase bole (Main journal) 25N-m (2.6kgtm,19|bf-t) Apply oil tothe threads and seatina surface TOOLS Inner driver © 07746-0030100 ‘Attachment, 30mm 1.0. _-07746-0030300 Universal bearing puller _07631-0010000 TROUBLESHOOTING Worn, stuck or broken piston ring *# Worn or damaged cylinder and piston Compression too high, overheating or knocking * Excessive carbon built-up on piston head or combustion chamber Excessive smoke * Worn cylinder, piston or piston rings ‘Improper installation of piston rings 1 Senradl ne enratehar pletan or eylineer wal Abnormal noise '* Worn piston pin or piston pin hole orn eunnecaing rod sal end + Worn cylinder, piston or piston rings ‘+ Worn main journal bearings '* Worn crankpin bearings. 12-2CRANKSHAFT/PISTON/CYLINDER CRANKSHAFT ‘Separate the erankcase halves {page 11-3) SIDE CLEARANCE INSPECTION Measure the connecting rod side clearance. ‘SERVICE LIMI £30 mm (0.012 in) If the clearance exceeds the service limit, replace ‘me connecting roa. Recheck and if itis stil out of limit, replace the cerankshatt REMOVAL cau’ Be careful not to damage the crankpin, main journal and bearing inserts. NOTE move them to indicate the correct cylinder for re assembly. ‘Tap the side of the cap lightly ifthe bearing cap is Remove the connecting rod bearing cap nuts and bearing caps. Lower the pistons to the top dead center to avoid damaging the crankshaft by the connecting rod bolt Remove the crankshaft. INSPECTION Hold the crankshaft both end. Set a dial indicator on the center main journal of the cranksha Rotate the crankshaft two revolutions and read the runout SERVICE LIMIT. 0.69 11 (0.002 40) CCheck the primary drive gear and sub-gear teeth for abnormal wear or damage. SUB-GEAR REMOVAL/ INSTALLATION Remove the following snap ring cone spring ~sub-gear gear springs ~ stopper pinsCRANKSHAFT/PISTON/CYLINDER Install the stopper pins and gear springs ono the primary drive gear as shown, Apply molybdenum cil solution to the sub-aear sliding surface. Temporarily instal the sub-gear by aligning the punch mark withthe hole inthe primary drive gear. Install the cone spring onto the sub-gear Inatll the aub goor onto the primary drive goar co that it evenly touches the primary drive gear by prying the sub-gear with a 5 mm pin or screwdriver ‘while the stoppers on the reverse side of the sub- Sear are pushing against the gear springs. Intl tne Install news snap ring ing the ting groove in the, large tab facing crankshatt securely with the end gap at right angle ‘the right ard th to the erankshatt cut-outs by aligning the large tab ‘chamfered side edge with the sub-gaar groove as shown, facina the var ‘STARTER CLUTCH NEEDLE BEARING REPLACEMENT Remove the needle bearing with the bearing puller. Toot: Universal bearing puller 07531-0010000 ‘CAUTION To protect the crankshaft main journal from the ‘haaring puller claws. cover the mainshaft journal ‘properly; worn main journal bearings are usable as protectors. SmmPIN » sup-cean ‘enoove SNAP FING BEARING PULLER 12-4CRANKSHAFT/PISTON/CYLINDER Precewith the Pross a new needle hearing anta the crankshaft ie. ‘boaring’s marked ing the special tools until its edge is flush with the ‘ide acing up. groove in the crankshaft. INNER DRIVER Make sure that the height from the crankshaft end 182/.6-2/.9 mm (1.09 110M, aoe ATTACHMENT. Inner driver © 07748-0030100 Attachment, 30mm LD. 07746-0030300 om —— Groove INSTALLATION CRANKPIN BEARING Do not get the molybdenum oil solution to the con- necting rod bolts and bearing cap nuts. It may ‘cause the eap nuts to be tgntened to an incorrect torque value. ‘Apply molybdenum oil solution to the main journal bearing sliding surfaces on the upper crankcase land the erankpin bearing sliding surfaces on the connecting rods. ‘Apply molybdenum oil solution to the thrust sur- faces of the crankshaft as shown. Lower all the pistons to the top dead center to ‘avoid damaging the crankpin by the connecting rod bolts. Caretully install ne cranksnart onto tne upper crank ‘Set the connecting rods onto the crankpins.CRANKSHAFT/PISTON/CYLINDER ‘Apply molypaenum oll solution 10 ne erankpin bearing sliding surfaces on the bearing caps. Install the bearing caps by aligning the ID. code on the connectina rod and bearina cap. Be sure each partis installed ints original postion, as noted dur ing removal Apply engine cil to the bearing cap nut threads and seating surfaces and install the cap nuts. Tighter the nuts it 204 3 steps. TORQUE :25 Nim (2.8 kgf. 19 bt) Assemble the crankcase halves (page 11-19, MAIN JOURNAL BEARING Remove the crankshaft [page 12-3) BEARING INSPECTION Check the bearing inserts on the upper and lower crankcases for unusual wear or peeling Check the bearing tabs for damage. OIL CLEARANCE INSPECTION Donet rotate the Clean off any cil from the bearing inserts and main crankstalt during journals. Inspection. Install the crankshaft onto the upper crankcase. Put e strip of plastigauge lengthwise on each mein Journal availing tha oil aie 12-6Carefully install ¢ crankcase, Apply engine oil to the main journal 8 mm bolt threads and seating surfaces and install them. Tighten the bolts in a crisscross pattern in 2 oF 3 steps. lower crankcase on the upper TORQUE :25 Nim (2.8 kgfim 19 lb) Remove the lower crankcase and measure the compressed plastigauge at is widest point on each main journal to determine the oil clearence, ‘SERVICE LIMIT: 0.05 mm (0.002 in} I the oll clearance exceeds the service limit, select. the correct replacement bearings. BEARING SELECTION Record the crankcase bearing support 0. code let ters NOTE: Loners (A, B or C) on the left side of upper erank case are the codes for the bearing support LD. s ‘rom laftto right. Record the corresponding main journal 0.0. code numbers. Nore Numbers (1, 2 oF 3) on the crank weight are the cede for the main journal 0.0. «from loft to right. CRANKSHAFT/PISTON/CYLINDER 12-7CRANKSHAFT/PISTON/CYLINDER LLross rererence ine main journal ana pearing sup- port codes to determine the replacement bearing color code, — Unit: mm tin} Bearing support A 8 c \ ["Bao00-3a008 | Sa008~SanT2 | 3012-8078 (1:2992~ 1.2994) | (1.2984~1.2897) | (1.2997 ~ 1.2998), ‘30.000 30.008 = 3 € 1 rsii-1igi3) | ing | tvetiow) (Green) = | 29:994—30,000. | D C B [2 | (rigoo—11e11 | vellow | Green) | ttrown) 729.988 —28.998 | c T es A 3 (r1g08—1.1809 | __ (Green (Brown) | __ (Backs MAIN JOURNAL BEARING INSERT THICKNESS: COLOR cones ‘A: Black: 1.508 1.508 mm (0.0583 ~0.0884 in) 8. Brows 1:503~1.506 mi 0.0582 ~0.0583 in) Ci Green: 1.500 1.503 mm (0.0591-0.0882 in) : Yellow: 1.497—1.500 mm (0.0583—-0.0581 in) E:Pink: 1.494~1.687 mm (0.0588 ~0.0883 in) caUTION: After selecting new hearings, recheck the oil clear. ‘ance with plastigauge. Incorrect oil clearance can ‘cause major engine damage. BEARING INSTALLATION Clean the bearing outer surfaces and crankcase bearing supports. Inatall tho main journal bearing i crankcase bearing suppor, aligning each tab with each groove. CRANKPIN BEARING Remove the crankshaft (page 12.3) BEARING INSPECTION Check tha hearing inearts for unusual wear oF damage, Check the bearing tabs for damage. 12-8CRANKSHAFT/PISTON/CYLINDER OIL CLEARANCE INSPECTION Donet rotate ne Clean off any cil from the bearing inserts and crank: crankshaft auring pin, ‘inspection. Carefully install the crankshaft onto the upper erank- Set the connecting rods onto the erankpin. pin avoiding the cil hoe. Carefully install the bearing caps by aligning the LD. code. rut threads and seating surfaces and install ther. ‘Tighten the cap nuts in 2 or 3 steps. TORQUE :25 Num (2.6 kgf , 19 bf.) Remove the bearing caps and measure the ‘compressed plastigauge at its widest point on the . peters a ‘SECOND RING ~~ ae OIL RING ) PISTON INSTALLATION Apply molybdenum oil solution to the connecting rod small end inner surfaces and piston pin outer Insta ine piston Install the piston pin into the piston and connecting so that the “IN rod, mark facing the Install new piston pin clips into the grooves of the sameairection as piston pin hole the ol ean the connecting rod. NoTE: ‘© Make sure thatthe piston pin lips seated secure. Wy. + Do not align the piston pin clip end gap with the piston cutout . (gma) menor vn SIDER 20mm ania) 20mm ~ ion} ¢ 0 lL HOLE og DP aston en curs 12-14Apply engine el to the cylinder wall, piston and pis. ton rings. (CAUTION: Be careful not to damage the piston rings and the cylinder wall by the connecting rod. Install the connecting rod/piston from the top of the ‘mark toward the intake side, pressor tool. Install the crankshaft (page 125) CRANKSHAFT/PISTON/CYLINDER 12-15FRONT WHEEL/SUSPENSION/STEERING 103.N.m (10.5 kghm , 76 Ibe 12Nem (1.2 kgf, 9 IDF 59 Nm (8.0 kgm , aie) 23 Wem (23 kgf, TT IbERD 39 Nem (80 kgf-m , 29 bef 12Nm (1.2 kgtm, 9 oF) 30 Nem (3.1 kgm, 22 IDFA) 13-013. FRONT WHEEL/SUSPENSION/STEERING | SERVICE INFORMATION 13-1 FRONT WHEEL 13.6 | TROUBLESHOOTING 13-2 FORK 13-12 | 133 STEERING STEM 13.21 | HANDLEBAR | SERVICE INFORMATION GENERAL ‘+ Riding on damaged rims impairs safe operation of the vehicle. ‘+A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. + A hoist or equivalents required to support the motorcycle when servicing the front wheel, fork and steering ster. + Refer to section 15 for brake system service. SPECIFICATIONS Unit me fin nem ] SIANDANY SERVICE Ut ‘Minimum tire tread depth — ~ is 0.06) Upto 50 Kg (300 bs] oad —— Up iomaxinum weit eal Cold tire pressure 260 KPa SO KGiiem*, 36 pall I “Aaleconout _—— — ‘oo ‘Wheel rim runout | Radi a (0.08) 113 | ‘Axial (2.0,0.081 |_Wheel balance weight = Fg 2. oni. | Fork Spring roe length 329.312. 961 Tube runout 0:20.0.008), Resorsmondad fuid —— | Fluid fevel | | Fluid capacity L (steering reo baseng (oad TORQUE VALUES Handlebar weight mounting screw Front brake dise bolt Front axle vole Front axle holder bolt Front fender bolt Fork socket bolt Fork cap Fork top bridge pinch bolt Fork bottom bridge pinch bott Stooring boaring adjuetment nut Steering stem nut JON-m (1.0 kgm ,7 IBF 20/N-m (2.0 kgf, 14 IF) 99 Ne (9.0 hyn 89 22Nem (2.2 kati , 16 ib) 321Nem (1.2 kgf , 9 IF) 34.Nem (3.5 kgf , 25 IF 231Nem (2.3 kgf. 17 IDF) 23N-m (2.3 kgf. , 17 Ibfth 39.N-m (6.0 kgtim , 29 bff) 26 Nim (25 kgm 78 BEA 103 N-m (10.5 kgf-m , 76 bf) ALOC screw: replace with @ new one ‘ALOC bolt replace with a new one Front brake hose clamp bolt (steering stern! Front master cylinder mounting bolt Front orake caliper mounting bolt TON. (1.0 kgf-m , 7 Ibe 12Nem (1.2 kgm 9 Ibe) 30 Nam (3.1 kgm 22 1BER) ALOG bolt replace with a new one 13-1FRONT WHEEL/SUSPENSION/STEERING TOOLS Bearing remover shaft Bearina remover head, 20 mm Driver ‘Attachment, 42 % 47 mm Pilot, 20mm Fork seal driver attachment, 43 mm LD. Steering stem socket Ball race remover sot Driver attachment A Driver attachment 8 Driver shaft assembly Bearing remover A Bearing remover B Assembly base Main bearing driver attachment Fork seal river weight Oil seal driver Installer shaft Installer stachment A Installer attachment 8 Remover attachment A Remover attachment B ‘Stoaring stem driver TROUBLESHOOTING Hard steering * Steering bearing adjustment nut too tight * Worn or damaaed steerina head bearinas * Bent steering stem * Insufficient tire pressure Steers one aide or docs not taok straight * Damaged or loose steering head bearings ‘Bent forks * Bent axle ‘= Wheel installed incorrectly ‘Bent frame ‘Worn or damaged wheel bearings {Worn ar damagad swingarm pivot bearines Front wheel wobbling ‘Bent rim ‘Faulty front tice ‘* Unbalanced front tre and whee! 13-2 07746-0050100 — or equivalent commercially avaiable in US.A 07746-05060 07748-00100 (07746-0010300 07746-04050 97047 KASOT00 07947-KAs0200 07816-3710101 or 07916:3710100 07946-KM90001—~ nat available in U.S.A. (07946-k1ag0100~ 7946-kM90200— ‘07866-kM90300—| o7946-kMg0401 ~ ‘07846-11900 — ‘o7946-KMg0600 — (07946-ME90200 —~ U.S.A. only (07847-KAGO100 (07865.MA60000 o7vMF-Kz30200 — ODVME-MATOTOO— ‘O7VMF-MATO200—| o7VMF-MaTo300—| OTVMF-MaTo«00 — ‘o7946-M1B00000 Front wheel turns hard * Faulty ront wheel bearings “Bent front axle ‘Front brake drag Soft suspension = Ineuffcient fluid in fork * Incorrect fork fluid weight * Weak fork springs ‘Insulficient tre pressure Hard suspension * Bent fork tubes *# Too much fluid in fork * Incorrect fork fluid weight * Clogged fork fluid passage * Insuficiant fluid in fork * Loose fork fastenersFRONT WHEEL/SUSPENSION/STEERING HANDLEBAR HANDLEBAR WEIGHT RIGHT HANDLEBAR REMOVAL Hold ie hawuleber Weigle ail remuve Une mounting screw and the weight. Disconnect the front brake light switch connectors. ‘Keep the brake master cylinder upright to prevent air from entering the hydraulic system. Remove the two bolts, holder and master cylinder from the handlebar. Remove the two screws and handlebar switch throttle housing. Loosen the pinch bol. Remove the stopper ring and the handlebar from the fork. Remove the throttle grip pipe from the handlebar. RIGHT HANDLEBAR INSTALLATION Apply grease to the throtle grip pipe flange and in- | stall the throtle grip pipe onto the right handlebar.FRONT WHEEL/SUSPENSION/STEERING insta me nanaieoar onto tne rork,atigning its Boss withthe groove in the fork top bridge. Install the stopper ring and tighten the handlebar pinch bot Inctall the right handlebar switeh/throtte housing ‘onto the hendlebar, aligning its locating pin with Uhe ble in the heieber Tighten the forward screw fist, then the rear screw. Install the front brake master cylinder and holder withthe "UP" mark facing up. Align the end of the master cylinder with the punch ‘mark on the handlebar, and tighten the upper bolt TORQUE :12Nom (1.2 kgm, 9b.) Connect the front brake light switch connectors Install the handlebar weight onto the inner weight ‘aligning the bosses and grooves each other. Install a new weight mounting screw and tighten it while holding the weight TORQUE : 10 Nem (1.0 kgm, 7 bt) Check the throttle grip operation and free play (page 2-4), 13-4FRONT WHEEL/SUSPENSION/STEERING LEFT HANDLEBAR REMOVAL CLUTCH LEVER BRACKET Disconnectthe clutch switch connectors. CONNECTORS, Remove the two bolts, holder and clutch lever bracket trom the nancletar. Remove the two screws and left handlebar switch housing. Disconnect the choke cable from the choke lever, Hold the handlebar weight and remove the mount ing serew and weight, Remove the left handlebar grip and choke lever from the handlebar. Loosen the pinch bolt. Remove the stopper ring and the handlebar from the fork LEFT HANDLEBAR INSTALLATION Install the handlebar onto the fork, aligning its boss with the groave inthe fork top bridge. Install the stopper ring and tighten the handlebar pinch bolt, Clean the inside surface of the left handlebar grip and the outside surface ofthe left handlebar. Apply Honda Bond A or equivalent to the inside surface ofthe left handlebar grip and to the outside surface of the left handlebar. Wait 3-5 minutes and install the choke lever and the grip. Rotate the grip for even application of the adhesive. NOTE Allow the adhesive to dry for an hour before using,FRONT WHEEL/SUSPENSION/STEERING Install the handlebar waight onto the inner weight, aligning the bosses and grooves each other. Install a new weight mounting screw and tighten it while holding the weight, TORQUE : 10 Nim (1.0 kgm, 7 bf Connect the choke cable to the choke lever Instll the tof hondleter avrtus tuwsiiny uny te handlebar, aligning its locating pin with the hole in the handlebar. ‘Tighten the forward screw first, then the rear screw. Install the clutch lever bracket and bracket holder withthe "UP" mark facing up. Align the end of the clutch lever bracket with the punch mark on the handlebar, and tighten the Connect the clutch switch connectors. FRONT WHEEL REMOVAL Support the motorcycle securely using a hoist or equivalent and raise the front wheel off the ground. Remove the mounting bolts and front brake cali pers. CAUTION: Support the brake from the brake haze. De not twist the brake hose. NOTE Do not operate the brake lever after removing the brake calipers. 13-6FRONT WHEEL/SUSPENSION/STEERING Loosen the right front axle holder bolts prea: eo 23 Remove the ront axle bot. Loosen the left front axle holder bolts. Remove the front axle and the front wheel. Remove the side collars. INSPECTION AXLE Set the front axle in V-blocks, ‘Turn the front axle and measure the runout using a dial indicator. Actual runout is 1/2 the total indicator reading, ‘SERVICE LIMIT: 0.2mm (0.01 in}FRONT WHEEL/SUSPENSION/STEERING WHEEL RIM Check the rim runout by placing the wheel in a Spin the wheel slowly and read the runout using a dial indicator. ‘Actual runout is 1/2 the total indicator reading ‘SERVICE LIMITS: Radial: 2.0 mm (0.08 in) Axial: 2.0mm (0.08 in) WHEEL BEARING ‘Turn the inner race of each beaning with your ringer. ‘The besrings should turn smoothly and quietly. ‘Also check that the bearing outer race fits tightiy in the hub, Replace the wheei Remove and discard the bearings if the races do bearings inpairs, nat turn smoothly and quietly, if they ft loosely in the hub, DISASSEMAI Vv Remove the dust seals from the wheel hub. Remove the dise bolts and brake discs from the wneet nub. Replace the whee! Install the bearing remover head into the bearing, ‘earings inpairs. From opposite side, install the bearing remover Donet rouse old shaft and drive the bearing out of the wheel hub, bearings Remove the distance collar and drive out the other bearing, Toots: Bearing remover shaft 07746-0050100 or equivalent commercially available n USA. Bearing remover head, 07746-0050600 or 20mm ‘equivalent commercially available in USA. 13-8FRONT WHEEL/SUSPENSION/STEERING ASSEMBLY DISC BOLT BEARING (6204) DUST SEAL BRAKE DISC Isc BOLT Drive in a new right bearing squarely with the ‘marking side facing up unt itis fully seated, Install the distance colar DRIVER Drive in a new left bearing squarely with the marking side facing up untl itis fully seated ATTACHMENT. Toots: Driver (07748-00100 Attachment, 42% 47mm 07746-0010300 Pilot, 20 mm (07748-00400 Big a nat get oraace an the brake dise ar stoning power will be reduced. rst ae rake sc ws ate stash Faia ie the normal rotating direction. Install new dise bolts and tighten them in a criss- cross pattern in 2 0r3 steps. TORQUE :20 Nim (2.0kgfm, 14 Ibe)FRONT WHEEL/SUSPENSION/STEERING Apply grease to new dust seal lips. Install the dust seals inta the wheel hub. WHEEL BALANCE Bg Wheel balance directly affects the stability handling and suarall eatery af tha motarryela Carefully check balance bofore reinstalling the wheel. NOTE * Mount the tire with the arrow mark facing in the normal rotating direction, ‘*The wheel balance must be checked when the tire is remounted For optimum balance, the tira balanoe mark (2 paint dot on the side wall) must be located next to the valve stern. Remount the tre if necessary. Mount the wheel, tire and brake disc assembly on ‘an inspection stand. Spin tha whoal. allow it to stan. and mark the lowest (heaviest part of the wheel with chalk. Do this two or three times to verify the heaviest Wavhett is balanced, i will ot stop Consistently i the same position. INSPECTION STAND To balance the wheel, install balance weights on the lightest side of rim, the side opposite the chalk ‘ad just enough weight so the wheel will ne longer stop in the same position when itis spun. Do not add more than 60 g (2.1 02) to the wheel GE GRAMS weit 12-1FRONT WHEEL/SUSPENSION/STEERING INSTALLATION mm, our si A Install the side collars. NOTE: The right side collar is longer than the left side collar Install the front wheel between the fork logs. Apply thin onst af resco ta the frant ale. Install the front axle from the left sid. Install the front axle bolt and tighten it while holding the axle, TORQUE : 59 N.m (6.0 kgf-m, 43 bff) Tighton the right axle holder botts. TORQUE :22 N.m (2.2kgtm, 16 lot) Install the brake calipers with new mounting bolts and tighten the bolts. ‘TORQUE : 30 N-mm (3.1 kgf , 22 Ib) Install the front fender. Inetll the four fender bolte with tho bralio hose clamp, 3-way joint and reflectors and tighten ther. TORQUE :12.Nim (1.2 kgm, 9Ibt-)FRONT WHEEL/SUSPENSION/STEERING [Wil the hon Leake applied, pump Une forks up and down several times to seat the axle and check brake operation Tighten the eft axle holder bolts. TOnGUE 22 14m (2.2 KUEN, 16 1OETY FORK REMOVAL enuve tie unt wlivel (pat 13-0) Remove the wire bandis) Loosen the handlebar pinch bolt and remove the stopper ring from the fork. When the fork is ready to be disassembled, loosen the fork cap, but do not romove it yet. emove the handlebar assembly and secure it 12-12FRONT WHEEL/SUSPENSION/STEERING Loosen the fork top and bottom pinch bolts and remove the fork tube from the fork bridges. DISASSEMBLY FORK CAP Remove the fork can from the fork tube. Hold the rebound damping adjuster and remove the fork cap from the damping adjuster. | FORK CaP Remove the Oving % Sd Do not remove the rebound damping adjuster from the damper rod, or fork damping force will change. DAMPING ADJUSTER Remove the joint plate, joint collar and spring seat. Remove the O-ring se JOINT PLATE a JOINT COLLAR SPRING SEAT 13-13FRONT WHEEL/SUSPENSION/STEERING Romove the fork spring, Pour out the fork fluid by pumping the fork tube === and the damper rod several times. Hold the fork slider in a vise with a soft jaws or shop towel and remove the socket bot. NOTE If the fork damper turns together with the socket bolt, temporarily install the fork spring, spring seat, joint collar and fork cap. Remove the fork damper from the fork tube. FORK DAMPER Remove the dust seal and the fork protector. FORK PROTECTOR 13-14FRONT WHEEL/SUSPENSION/STEERING Remove the stannar ring heing careful not to ‘scratch the fork tube sliding surface. Using quick successive motions, pull the fork tube ‘ut of the fork slider. Remove the oil seal, back-up ring and guide bushing trom the tork tube. GUIDE BUSHING BACK-UP Nore: RING Do not remove slider bushing unless itis necessary 10 replace itwith a new one, Carefully remove the slider bushing by prying the slit with @ screwdriver until the bushing can be pulled off by hand. lL Lock rece Remove the oil lock piece from the fork slider. SLIDER BUSHING Remove the O-ring 13-15FRONT WHEEL/SUSPENSION/STEERING INSPECTION Measure the fork spring free length, SERVICE LIMIT: 929.3mm (12.96 in) Check the fork tube, slider and damper piston for ‘score marks, and excessive or abnormal wear. ‘Check the rebound spring for tatique or damage. Replace the component if necessary. Sct the fork tubo in V blooks and measure the fork {tube runout with a dial indicator. ‘Actual runout is 1/2 the total indicator 1 SERVICE LIMIT: 0.20 mm (0.008 in) Visually inspect the slider and guide bushings. Replace the bushings if there is excessive scoring or seratching, or ifthe teflon ia worn 20 thet the copper surface appears on more 3/¢ of the entire surface. Check the backup ring; replace it if there is any distortion at the points shown. | Fork DAMPER |EBOUND SPRING. DIAL INDICATOR e | 12.418FRONT WHEEL/SUSPENSION/STEERING ASSEMBLY Before assembly, wash all parts with a high Nash point or non-flammable solvent and wipe them off Eomoletely. DUST SEAL Ss; FORK CAP o1 seat Ss Guibe ausHiNG stopren, RING commie. HAH SOCKET BOLT OILLOCK PIECE FORK DAMPER. wv / 8 cm S-—sonr rate FORK SPRING Install a new slider bushing if it has been removed. cauTioN: = Be careful not to damaye te coating of the bushing. * Do not open the bushing more than necessary. NOTE Romeve tho burra from the buching mating curfaeo, being careful not to peel off the coating. Coat new O-ring with fork tluid ari insta it nto the ‘groove inthe ol lock piece, Install the oil lock piece into the fork tube. eee Install the fork tube into the fork sli Install the fork damper into the fork tube.FRONT WHEEL/SUSPENSION/STEERING Hold the fork ser a vis witha 0% J8¥8 OF aay seas NG WASHER shop towel oS Install the socket bolt with a new sealing washer and tighten it TORQUE :34.N-mn (2.8 kgf ,25 bf) NOTE: If the fork damper turns together with the socket bolt, temporarily install the fork sprina, sprina seat, joint collar and fork cap. Place the guide bushing over the fork tube and rest it on the slider. Put the back-up ring and an old nuisTsral < ti | iii 1 if hi |i + Ht Vv il MI i i I Sushing or equivalent tool on top oF the Gu bushing Drive the bushing into place and cemove the old STOPPER RING hhching av onus tat gg OILSEAL rap vinyl tape around te ork be top end o | $7 } avoid dameging the il ea ip. Coat a naw ol seal wih fork hud we instal over BACK-UP ING. the forctube with the marke sie facing up GUIDE BUSHING Drive the oil seal until the stopper ring groove is visible, 1 driver weight 07047 KAsO100 I driver attachment, 43 mmi.D. 07947-KA40200, Install the stopper ring into the groove in the fork slider. 12-12FRONT WHEEL/SUSPENSION/STEERING Apply fork fie to.a naw dust sal ip and install the dust seal into the fork slider Install the fork protector over the fork slider by aligning the tab with the slider groove. Pour the specified amount of recommended fork fluid in the fork tube. RECOMMENDED FORK FLUID: Pro-Honda Suspension Fluid S$-8 FORK FLUID CAPACITY: 475 = 25 om (16.1 = 0.UB US 07, 16./ = U.UY 02) Pump the damper rod several times until the fork fluid flows out of the oll hole in the rebound damp ing adjuster. Slowly pump the fork tube several times to remove trapped air. ‘Compress ie fork we fully. Measure the oll level from the top ofthe fork tube. OIL LEVEL: 118mm (4.6 in) Pull up the damper rod fully Install the fork spring with the tightly wound end facing down, Coat new O-ring with fork fluid and install itinto the {groove in the rebound damping adjuster. Install the sprina seat, joint collar and joint plate. ote DOWN, Ss a as Fl ene g i JOINT COLLAR _— SPRING SEAT 13-19FRONT WHEEL/SUSPENSION/STEERING ‘Coat new o-ring wit rork mula ana instal Ingo te groove in the fork cp. FORK CAP oING Install the fork cap onto the rebound damping = os ee Pon] g adiuster. beets Hold the rebound damping adjuster and screw in the fork cap, Install the fork cap into the fork tube FORK CAP. ye Note: Tighten the fork cap after installing the fork tube into the fork bridges. ory Tune, INSTALLATION Fovte the cables, Install the fork tube into the fork bridges so that the wire nernesses height from the top bridge upper surface to the fork end moves reper tale end a 28.men (1.2 in) Iy (page 1-18). Tighten the fork top bridge pinch bolt. TORQUE :23 Nim (2.3 kgtim , 17 bff) Tighten the fork bottom bridge pinch bot. TORQUE :39 N:m (4.0 kgfim, 29 IDF) 13-20FRONT WHEEL/SUSPENSION/STEERING Tighten the forkeap to the specified torque ifitwas ESESEREEaTaa removed, Sole i TORQUE :23 Nim (2.3 kgf'm , 17 Ib) Install the handlebar. Install the stopper ring ‘Make sure that the handlebar boss is positioned in the fork top bridge groove. ‘Tighten the handlebar pinch bolt. Fight fork: Secure the handlebar switch wire with the wire band. atttort: Secure the handlahar switch and horn wires with the wire bands (page 1-18). Install the front whee! (page 13-11) STEERING STEM REMOVAL Ramava the front wel foae 12-6 Ramave the left air intake duct (page 2-6) Release the wire band and disconnect the ignition “switch 4? (White) connector. Remove the bolt and front brake hose clamp. Disconnect the horn connectors, Remove tne belt an nore, Remove the forks (page 13-12).FRONT WHEEL/SUSPENSION/STEERING emia te steering ster tu ea, ‘Temporarily install the forks into the fork bridges. | Loosen the steering stem nut. Remove the forks, stem nut and fork top bridge. Straighten the lock washer tabs. Remove the steoring bearing adjustment nut lock nut and lock washer. Remove the steering bearing adjustment nut using the special tool Toot: ‘Steering stem socket 079163710101 or (07916-3710100 13-22FRONT WHEEL/SUSPENSION/STEERING Remove the dust seal Remove the upper bearing inner race, steering SoA SEREI ‘stem, upper and lower steering bearings. ‘ STEERING BEARING REPLACEMENT Except US.A, ‘Always replace Replace the steering bearing outer races using the Toots: Ball race remover set 07946-kMs0001 Driver attaclnnent A(3) _07946-KM90700 —Driver attachment B (2) _-07946-KM90200 Driver shaft assembly (3) 07946-KN90300 \gremover A(é} _07946-KM90401 igremover (5) 07948-KM90500 Assembly base (6) ‘07946-KMe0600 a6) 13-23FRONT WHEEL/SUSPENSION/STEERING [Note the inattia Inatall the ball race remover into the steering head tion direction of pipe as shown, the assembly base, Align bearing remover A with the groove in the | {Note the natalie tion direction of tne assembly base, steering head, Lightly tighten nut B. While holding the driver shaft, urn nut A gradually toremove the upper bearing outer race. Install the ball race remover into the steering head pipe as shown, Align bearing steering head. Lightly tighten nut ©. While holding the driver shaft, turn nut A gradually to remove the lower bearing outer race. mover 8 with the groove in the \ ATTACHMENT 8 ATTACHMENT A “_ UPPER BEARING | ‘OUTER RACE | suaer ATTACHMENT A (ae) Ss LOWER BEARING OUTER RACE 13-24FRONT WHEEL/SUSPENSION/STEERING Install a new upper bearing outer race and the ball face remover as shown ATTACHMENT A Wile holding the driver shaft, turn aut A gradually nfl the groove in diver atachment A aligns with Ate upwer end ut the steciny Heo Tis nl lve Sa you 6 instal the upper bearing outer race. | = i a oN 1 | UPPER BEARING ae | | OUTER RACE } Sa J|\| 3 | ( La p | | | |) arracinenre | ance wir Ia ano loner eae ad te bat abr Sea ura Tite tr ht um ut Agra wn tae ne ac as wi asse out ln the lowe beating outer rca g Ul ATTACHMENT | Lowen ocanine | OUTER RACEFRONT WHEEL/SUSPENSION/STEERING 05.4. onty Always replace Replace the steering bearing outer races using the UPPER NUT i] the earings end special tools listed below. \ roots: DavER AAS ment Main bearing diver attachment 07945:ME80200 Stes —— Sravemaccewe | BRAGS aur ba inal shat rune czs0200 Installer attachment A OTVMEMATOTOD Installer tachment ——-OTVME-NATO200 — Remover attachment A O7VMF-MATO300 Beran BEAnIN Remover attachment B O7VMF-MATO400 ou ane Remover Intl the speci ols nto the steering head pipe | AFPACHIENT A 4 shown Align romove attachment A withthe groove inthe storing hea Lower Nur ‘wile nalaing the instaner snam wan the wrench, turn the upper nut gradually to remove the upper bearing outer race, InsTaLen sharT as shown INSTALLER n Align remover attachment 8 with the groove in the | ATTACHMENT A steering head. ‘nite nolaing ine installer snare win tne wrenen, turn the lower nut gradually to remove the lower bearing outer race, Ls INSTALLER SHAFT ———-+| | J [UPPER NUT ~. . lo, reourn ATTACHMENT B— SB LOWER BEARING: OUTER RACE OIL SEAL DRIVER | Fork seat, | DRIVER WeicHT — MAIN BEARING DRIVER ATTACHMENT ~ LOWER NUT 129KFRONT WHEEL/SUSPENSION/STEERING Install new upper bearing outer race and the spe- cial tools as shown. UPPER NUT While holding the installer shaft with the wrench, tuen the lower nut gradually until the groove in | ywstaLten Installer attachment A aligns witn the upper end ot | ATTACHMENT A the steering head. This will allow you to install the upper bearing outer race. UPPER BEARING: ouTEn RACE INSTALLER SHAFT ——} ol INSTALLER ? ATTACHMENT 8. OL SEAL DRIVER FORK SEAL GRIVER WEIGH MAIN BEARING DRIVER AT TACHMENN oA LOWER NUT Install new tower bearing outer race and the spe- Cla tools as shown, urpernut While holcing the installer shat withthe wrench, turn the upper nut gredually unl the groove in | installoratachment € aligns with tho lower ent ot | MAN BEARING | the seering head Ths wl alow you to natal the | BRWERSATTAGHMENT lower bearing outer race. | FORK SEAL DRIVER WEIGHT: INSTALLER, ATTACHMENT A- | ve INSTALLER SHAFT. INSTALLER, ATTACHMENT B: Lower, ee ‘OUTER RACE, 13-27FRONT WHEEL/SUSPENSION/STEERING Install the stem nut onto the stem to prevent the threads from being damage when removing the lower bearing i ‘oF equivalent tool, being careful not to damage the stem, Remove the dust seal DUSTSEAL LOWER BEARING INNERRACE ste NUT Apply grease to 3 new dust seal lip and install it to the steering stem. Press a new lower bearing inner race onto the sxeering stem using the special tool. saaao oat Steering stem driver, 07946-w1800000, INSTALLATION out the cables, Apply grease to the steering bearings and bearing wires-and nose races ‘properly Install the lower bearing onto the steering stem. (page 1-18). Install the steering stem into the steering heed pipe Install the upper bearing and inner rac. Apply grease to @ new dust seal lip and install it. 12-92FRONT WHEEL/SUSPENSION/STEERING Apply oil to the steering bearing adjustment nut threads. Install and tighten the steering stem adjustment nut Steering stem socket 07916-3710101 oF (07916-3710100, TORQUE :25 N:mn (2.5 kgfim, 18 bff) ‘Tur the stering stem right and lt locktoviock at Fetighten the steering stem adjustment nut to the STEERING BEARITTG ADJUSIMENTNUT Se same torque ‘ ENENUTS Install a new lock washer and bend the two oppo: site tabs down into the grooves in the adjustment Install and finger tighten the lock nut all the way. Hold the steering adjustment nut and further tighten the lock nut, within 90° to align its grooves witn the tans oF tne ook wasner. Bend up the lock washer tabs into the grooves of the lock nut. Install the fork top bridge and steering stem nut. Temporarily install the forks into the fork bridges, Tighten the steering ster nut. TORQUE : 103 Num (10.5 kgf , 76 bf fe Make sure that the steering stem moves smoothly, without play or binding, Install the steering stem nut cap, Install the forks properly (page 13-20), 13-29FRONT WHEEL/SUSPENSION/STEERING Inctall the front brake hove clamp and tighten the bolt TORQUE : 10 Nim{1.0 kgm ,7 Ibe) Install the horn and tighten the bolt. Connect the horn connectors. Connect the ignition switch 4P (White) connector and secure the wires with the band (page 1-18) r' Install the front whee! page 13-11) Install the air intake duct (page 2-6) ‘STEERING BEARING PRELOAD Remove the front fairing (page 2-5), stands or a hoist and raise the front wheal off the ground, | Position the steering stem to the straight ahead po- Hook a spring scale to the fork tube between the fork top and bottom bridges. ‘Mako sure that there is no cable, wire harness oF hose interference, Pull the spring scale keeping it right angle to the steering stem, Feet die sale ie poli vere une steering steer just starts to move, ‘STEERING BEARING PRELOAD: 1.0~ 15 kgf (2.23.3 Ibf) lf the readings do not fall within the limits, readjust the steering bearing adjustment. Install the front fairing (page 2-5) 13-30MEMOREAR WHEEL/SUSPENSION * * 7 Nom (0.7 kgm 8.1 IBF) 64 Nem 6.5kgtm 47 Ibe) ee \ * Nem (0.7 kgf, 8.1 Ie) * 64 Nm (6.5 kgtem 47 Ibe) ~ ® * 93.N.m (9.5 kgm , 69 16F4) 9.N.m (9.5 kgm , 69 I-A)14, REAR WHEEL/SUSPENSION ‘SERVICE INFORMATION 14-1 SHOCK ABSORBER 149 ‘TROUBLESHOOTING 142 SUSPENSION LINKAGE a1 | REAR WHEEL 143° SWINGARM 14-13 | SERVICE INFORMATION GENERAL TE ‘Riding on damaged rims impairs safe operation of the vehicle. ‘+A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated dise with a high quality brake degreasing agent. += The shook absorber sontaine nitrogen gae under high procoure. De net allow fire or heat naar the shook aboorber * Before disposal of the shock absorber, release the nitrogen. * The damper unit is filed with nitrogen gas under high pressure, do not try to disassemble, ‘A hoist or equivalent s required to support the motorcycle when servicing the rear wheel and suspension. ‘Use genuine Honda replacement bolts and nuts forall suspension pivots and mounting points ‘* When using the lock nut wrench for the adjusting bolt lock nut, usa deflecting heam type torcqua wranch 20 inches long The lock nut wrench increases the torque wrenct’s leverage, so the torque wrench reading will be less than the torque actually applied to the lock nut. The specification given is the actual torque applied tothe lock nut, not the reading on the ‘torque wrench. Do not overtighten the lock nut. The specification later in the text gives both actual and indicated. ‘svinen iastating ure swingari, be sure io ugruet tie Seanigarin pivot fasteners to the spciteg torque In ine spectiea Se quence. If you ristake the tightening torque or sequence, loosen all pivot fasteners, then tighten them again to the speci fied torque in the correct sequence. + Refer to section 18 for brake system service. SPECIFICATIONS ' Unit: mm in Tem I SERVICE LMT Minimum tire tread depth Zo. | pressure | Up t6 30g 1200 Iba load 220 Ka ZSO gion? «2 pal] —— [Up to maximum weight capacity |~ 290 KPa (2.80 kat/em™, 42 psi) Axlerunot ‘Wheel rim runout [Radial [asia Wheel balance weight [drive chain slack 02 (0.0%) TORQUE VALUES Rear brake disc bolt 42.Nm (4.3kafm.31Ibff) ALOC bolt: replace with a naw one Final driven sprocket nut BBNmIG.kgtm, 65 IBF) Umut Rear axle nut 93N-m[9.5kgtm, 69 IbFA) U-nut Shock absorber mounting nut. 44Nem(4.5kgfm, 33 bf) U-nut Shock armto-sevingarm nut Ab tim iaSkgem /29IbE) Umut ‘Shock arm-to-shock link nut 44NemiaSkgtm, 33 Ib6A) Unut ‘Shock linkto-bracket aut 44Nm{45kgtm, 33 Ibe) Unaut Drive chain slider bolt Nom (0.9 kgfm, 6.5 bF-t) ALOC bolt replace with # new one ‘Swingarm pivot adjusting bolt 7 Nem (0.7 kgm, 8.1 IbfA) page 14-17 ‘Swingarm pivot lock nut 684 Nim (6.5 kgm, €7 Ibe) ‘Swingarm pivot nut 83.N.m (9.5 kgf:m, 69 bf A) U-nut 14-1REAR WHEEL/SUSPENSION TOOLS Bearing remover shaft 107746-0050100 ~ or equivalent commercially available in U.S.A, Bearing remover head, 20mm 07746-05060 — Driver 07748-0010000, Attachment, 22 % 24 mm 07746-0010800 ‘Attachment, 28 x 30.mm 07946-1870100 ‘Attachment, 22 8 mm 97740-0010100 ‘Attachment, 37 x 40mm 07746-01020 ‘Attachment, 42 47 mm (07746.0010300 Attachment, 52 85 mm 07746-0010400 Pilot, 17 mm 07746-0040400 Pilot, 20 mm, 07746-0040500 Pilot, 28 mm. 07746-0041100 Drivar attachment handle 07949-3710001 Bearing remover eet ‘OTLMC-KV30100 Lock nut wrench (07808-4690008 or 07908-4690002 Driver shaft 07346-MJo0t00 aver neaa uisae-msuuzvu Needle bearing remover ‘OTHMC-MR70100 TROUBLESHOOTING Soft suspension “+ Wook ahoek absorber spring ‘Incorrect suspension adjustment * Oil leakage from damper unit ‘Insufficient tire pressure Hard suspension * Incorrect suspension adjustment ‘+ Damage rear suspension pivet hearings Bent damper rod * Incorrect swingarm pivot fasteners tightening + Tire pressure too high Rear wheel wobbling * Bont rim # Worn or damaged rear wheel bearings + Faulty rear tire * Unbalanced rear tie and wheel ‘Insufficient rear tie pressure + Foulty owingorm pivot bearings Rear wheel turns hard * Faulty rear whee! bearings * Bent rear axle + Roar brake drag ‘Drive chain too tight Rear suspension noise ‘Faulty rear shock absorber + Loose rear suspension fasteners + Wor war suspension pivat bearings 14.9REAR WHEEL/SUSPENSION REAR WHEEL REMOVAL Raise the rear wneel of te ground and support te motorcycle securely with a hoist or equivalent. Loosen the drive chain adjusters and rear axle nut Remove the axle nut and washer. Push the rear wheel forward and derail the drive chain from the final driven sprocket. Remove the rear axle and the rear wheel Do not operate the brake pedal after removing the rear wheel. Remove the side collars. ee INSPECTION axe Place the axle in V-blocks and measure the runout. ‘Actual runout is 1/2 the total indicator reading, ‘SERVICE LIMIT: 0.2 mm (0.01 in)REAR WHEEL/SUSPENSION place the whee! bearings in pars 14-4 WHEEL CCheck the rim runout by placing the wheel in @ unout using a dial indicator. ‘Actual runout is 1/2 the teta indicator reading [SERVICE LIMITS: RADIAL: 2.0 mn 0.08 in) AXIAL: 2.0 mm/0.08 in) WHEEL BEARING urn the inner race at each bearing with your tinge. The bearings should turn smoothly and quietly. {Also check thatthe bearing outer race fits tightly in the huh, Remove and discard the bearings if the races do not turn smoothly and quietly, or i they fit loosely inthe hub, DRIVEN spROCKET CCheck the consition of the driven sprocket teeth Roplace the sprocket if worn ar damaged. Nore. #f the driven sprocket requires replacement, inspect the drive chain and drive sprocket, ‘sNever install 2 new drive chain on a worn sprocket or a worn chain on new sprockets. Both chain and eprosket mut be in good condition, or the replacement chain or sprocket will wear rapidly DISASSEMBLY Remove the right dust seal Remove the bolts and brake disc.REAR WHEEL/SUSPENSION Remove the laf ust sl NOTE: Ir you wil replace ane final ariven sprocker, ioosen the driven sprocket nuts Remove the final driven flange assembly from the leftwheel hub, Remove the damper rubbers and O-ring, Foplace the whee! Install the bearing remover head into the bearing, bearings inpairs. From opposite side, install the bearing remover ‘Doro reuse old shaft and drive the bearina out of the wheel hub, bearings. Remove the distance collar and drive out the other bearing Bearing remover shaft 077460050100 or equivalent commercially available in U.S.A, Bearing remover head, 07748.0050600 or 20mm equivalent commercially available in U.S.A,REAR WHEEL/SUSPENSION Pross thw driven flange collar out of the driven flange bearing. Toots: Driver 7749.0010000 Driver head (07946-J00200 ASSEMBLY Nore: Refer to page 13-10 for wheel balance. BRAKE DISC DUST SEAL, DRIVEN FLANGE BEARING (63/22), ’ COLLAR DUST SEAL WHEEL DAMPER RUBBER & DRIVEN FLANGE WHEEL BEARING (6208) Press the driven flange collar in a new driven flange bearing until itis fully seated, Toots: Driver 07749-0010000 Attachment, 28 30mm 07948-1870100 Plot, 20 mm 07746-0040800REAR WHEEL/SUSPENSION Drive in the driven flange bearing squarely with the ‘marking side facing up until itis fully seated. Toots: Attachment, 52 $5 mm _07746-0010400 Pilot, 20 mm (07748-0040500, Drive ina new right bearing squarely with the mark ing side facing up until its fully seated. Driva in a now left bearing squarely with the mark ing side facing up until its fully seated. ruts: Driver 07749-0010000 Attachment, 42 x 47 mm 07746-0010300 Pilot. 20 mm 07746-0040500 Install the damper rubbers into the eft wheel hub. Coat a new O-ring with grease and install it into the hub groove, Apply grease to the mating surface of the wheel hub (eide eurfacs) and final driven flange, Install the driven flange assembly into the left whee! hub, When the driven sprocket is replaced, install a new sprocket and tighten the nuts. TORQUE : 88 N-m (9.0 kgf, 65 IDF) Apply grease to @ new dust seal lip and instal it un- tilts flush withthe drivan flangeREAR WHEEL/SUSPENSION Install tne Brake aise onto tne nignt wneet nuo. Install new dise bolts and tighten them in a criss- cross pattern in2 or 3 steps. TORQUE :421Nim (4 3kgfm, 31 bE) ‘Apply grease to @ new dust seal ip and install tun. tile flush withthe hub, INSTALLATION ‘Apply grawse w the yrouve in Ue side cola inter surface. Install the side collars. Make sure that the rear brake caliper isin positon, Place the rear whee! ia the swingarm and instal the drive chain over the driven sprocket Insert the rear axle from the left side through the Install the washer and axle nut ‘Agjust the drive chain slack (page 3-16) 14-8REAR WHEEL/SUSPENSION SHOCK ABSORBER Set the lower joint inanyarauic rebound damping adjuster facing up wher pressing ia bearing rassin the Dearing with the marking side facing up. REMOVAL Support the motorcycle securely with a hoist or equivalent. Remove the fuel tank (page 2). Loosen the reservoir band screw and remove the shock absorber reservoir from the frame. ‘Support the swingarm securely. Remove the shock absorber mounting nuts and LUulta, en the shock aboorbor INSPECTION CCheck the damper unit, reservoir hose and reser- voir for leakage or other damage. ‘Check the upper joint bushing for wear or domege. Replace the shock absorber assembly if necessary. Remove the lower joint pivot collar. Check the needle bearing, pivot collar and dust seals for wear or damage. NEEDLE BEARING REPLACEMENT Remove the dust seals. Press the needle bearing out of the lower joint us- ing the special tools. ATTACHMENT HANDLE Toots: Driverattachment handle 07949-3710001 ‘Attachment, 22 24mm 07746-0010800 Apply grease tothe needle rollers of a new bearing. Carefully press the needle bearing n the lower joint Unt the depth from the lower joint outer surface is 7.88.2 mm (0.31~0.32 in), using the same tools. 14-9REAR WHEEL/SUSPENSION ‘Apply grease to new dust seal ips and install them tntil they are flush with the lower joint Ins he pvt cal oD an USrsEALS SHOCK ABSORBER DISPOSAL Center punch the center of the reservoir bottom to ‘mark the drilling point. Weap the shark ahenther inside 9 plastic hag and support the reservair in a vise as shown, Through the open end of the bag, insert a drill mo- ‘tor with a sharp 23 mm (5/64 1/8 in) dil it Big Do not use a dull drill bit which could cause @ build-up of excessive heat and pressure inside the reservoir, leading to explosion and severe personal injury. «The chook abeorbor containe nitrogen ga and oil under high pressure. Do not dril the side of the reservoir or the damper case, or you may dril into the oil chamber (bladder oll escaping under high pressure may cause serious personal jury. ‘+ Always wear eye protection to avoid getting imatal shavings in your ayne when the ane Pr ‘Sure is released. The plastic bag is only intended to shield you from the escaping gas. RESERVOIR BOTTOM 1 | “A Hold the bag around the drill motor and briefly run the drill motor inside the bag; this will inflate the bag with alr from the motor and help keap the bag fram the getting caught in the bit when you start. INSTALLATION Install the shock absorber in the frame and shock ‘arm with the rebound damping adjuster facing to the right Install the upper and lower mounting borts trom tne right side Install the mounting nuts and tighten them. TORQUE: 44 Nom (4.5 kgfm , 33 Ib.) 14-10REAR WHEEL/SUSPENSION Install the reservoir into. the reservoie band by aligning the label edge with the band and tighten the band screw securely Ingtau tne tue! rank (page Zs. SUSPENSION LINKAGE REMOVAL Support the motorcycle securely with a hoist or equivalent Remove the following: shock absorber lower mounting nut and bolt shack aem-te-swing arm nut and bolt shock arm-to-shock link nut and bolt, shock arm plates shock link-to-bracket nut and bolt ~shock lnk, Note: If the shock link can not be removed, loosen the shock link bracket nuts to get the clearance be- tween the shock link and brackets (page 7-5) INSPECTION DUST SEALS Remove the aivot collars Check the needle bearings, pivot collars and dust seals for wear or damage. Check the shock arm plates for deformation or ‘SHOCK LINK PIVOT BEARING REPLACEMENT Remove the dust seals. 14-11REAR WHEEL/SUSPENSION Press in the bearing withthe marking side acing wp. Pross the needle b using the special toots ring out of the shock link pivot | ° : 82-8. mm (0.20~0.22 in) raa1s: ver attachment handle 07949-3710001 Attachment, 22 * 26mm 07748-0010500 Pilot, 17 mm (07746.0040400 Apply grease to the needle rollers of a new bearing, Carefully press the needle bearing in the link pivot Until the depth from the shock link outer surface is. Apply grease to new dust seal lips and install them into the shock lnk pivots until they are seated. Install the pivot collars. INSTALLATION Install the shock link into the link brackets and the bolt from the let side. the left and front side and the bolts from the right sige, Install the nuts. Tighten the link bracket nuts if they were loosened Ipage7 8. Tighten the all suspension linkage nuts. TORQUE : 44 Nem (4.5 kgtm , 33 bt) 14-12REAR WHEEL/SUSPENSION SWINGARM REMOVAL Hemove me rear wneet (page 144). Remove the two bolts and drive chain cover. Remove the bolts and brake hose clamps. from the swingarm. ‘Support the swingarm securely, Remove the shock arm-to-swingarm nut and bolt. Loosen the left and right pivot lock nuts. TooL: Lock nut wrench 07908-4680003 or 97908 4690002 Remove the swingarm pivot nut and washer. Remove the pivot bolt.REAR WHEEL/SUSPENSION Lecaen the pivot adjusting bolts and remave the swingarm. DISASSEMBLY Reniuve the tr uit eval ive leis aden fet essary. Remove the pivot collars and dust seals, COLLAHS AND DUST SEA PIVOT BEARING REPLACEMENT Remove the snao rina. Drive ball bearings and distance collar out of the right pivot 14-14REAR WHEEL/SUSPENSION Pressin the Dearing with the ‘marking side acing up Draw inthe bearing with he ‘marking sido facing the flange rote the noodle bearing out of the left pivot using the special tools. Toots: Driver shaft o7946-w1J00100 Needle bearing remover O7HMC-MR70100 Pack naw ball hearing eavitias with grease Press the inner bearing into the right pivot with the ‘marking side facing up until its fully seated, using the special tools. Toots: Driver 07749-01000 ‘Attachment, 22 X36 mm 07748-0010100 Pilot, 20 mm (07746-0040500 Install the distance collar. Peeve the vuter Leoring int the sight pives with the marking side facing up until its seated, using the ‘special tools, Toots: Driver 07749-00100 ‘Attachment, 37 40mm _07746-0010200 Pilot, 20 mm 07748-0040500, Install the snap ring, Apply grease to the needle rollers of a new bearing. Carefully press the needle bearing into the left piv. ‘of until the depth from the swingarm outer surface is 56 mm (0.20~0.24 in), using the special tools Toots: Driver 07749-00100 ‘Attachment, 37 X 40. mm _07748-0010200 Pilot, 28 mm (07746-0041100, ‘SHOCK ARM BEARING REPLACEMENT aw the nasdla hearing nuit of the wingarm ising the special too REMOVER SET Tool: ‘Bearing removersex —o7LMC-Nv30100 ‘Apply grease to the needle rollers of a new bearing, Install the needle bearing into pivot until the depth from the swingarm outer surface is 55~6.0 mm (0.20.24 in), using the same toolREAR WHEEL/SUSPENSION ASSEMBLY LEFT PIVOT INNER DUST SEAL RIGHT DIUOT LIST SEALS LEFT PIVOT OUTER DUST SEAL COLLAR ‘COLLAR CHAIN SLIDER——» COLLAR a ‘SHOCK ARM PIVOT OUST SEALS Apply grease to new dust seal lips and instal them as follows: “shock arm pivot and swingarm right pivot dust ‘seals until they are flush with swingarm outer sur- “left pivot outer dust seal unti it is seated onto bearing “left pivot inner dust seal until depth from swing- ‘armouter surface is & mm (0.2 ink Install the pivot collars as shown, Install the drive chain slider if removed, aligning the hole withthe boss ofthe swingarm, Install new slider bolts and tighten them, TORQUE :9.N-m (0.3 kgtm, 6.5 Ibtt) Alan 14-16REAR WHEEL/SUSPENSION INSTALLATION NOTE: nen vigntening «me lock mUE With he 1ock AU wrench, refer to torque wrench reading information fon page 14-1 "SERVICE INFORMATION”. CAUTION the specified torque in the specified sequence described below. If you mistake the tightening torque or sequence, loosen all pivot fasteners, then tighten them again to the specified torque in the specified sequence. ‘install the left and right adjusting bolts so that they do not project out ofthe frame inner surface, 2.Uptain a spare pivot ott (HIN SzTUT-MesW-LUU) for this model or use a 20 mm (0.8 in) 0.0. shaft. Set the swingarm into the frame and the shock ‘arm platas and temoorarily insert the spare pivot bolt or 20 mm 0.0. shaft from the left side to support the swingarm. Be sure that the swingarm is properiy aligned. 3.Tighten the right adjusting bol. ToRQU H12Nem (1.2 kgm , 9 bh) Loosen the right adjueting bolt and retighten it to the specified torque. TORQUE :7 Nom (0.7 kgm ,5.1 IDE) 4. Install the right lock nut Hold the right adjusting bolt and tighten the right lock nut ToL: Lock nut wrench (97908-4690003 or TORQUE: Actual: 64.N-m (6.5 kgf:m,, 47 IbFt) Indicated: 58 N.m (6.9 kgf-m , 43 IbF-REAR WHEEL/SUSPENSION S.insert the other pivot bolt from tne right side ‘gradually pushing the left side pivot bolt out from the left side, 6. Tighten the let adjusting bott. TT TORQUE :12.N-m (1.2kgtm 9 1oER) Loosen the left adjusting bolt and retighten it to tha enacifind tar TORQUE £7 N-m (0.7 kgm, 5.1 It Install the left lock nut Hold the left adjusting bolt and tighten the left lock nut Toot Lock nut wrench (07908-4690003 or 07808-4680002 TORQUE: Actual: 64.N-m (6.5 kgfim 47 Ibft) Indicated: 58 N:m (6:9 kgm , 43 bff) 8, Push in the pivot bole until itis seated, Install the pivot nut with the washer and tighten it. TORQUE : 93 Nm (9.5 kgf , 68 lb) 4A12REAR WHEEL/SUSPENSION Install the shock arm-to-swingarm bolt and nut Tighten the nut TORQUE : 44 N.m (4.5 kof, 33 Ib) Install the brake caliper/bracket assembly onto the boss of the swingarm Install the brake hose clamps with the bolts Install the enaln cover by aligning the nole with the boss of the swingarm, and tighten the two bolts Install the rear wheel (oaae 148)HYDRAULIC BRAKE 1 Nay (0.1 kgf 0.7 IE) 12m (1.2 kgm , 9 IDE) yy Nm (3.5 kgf. , 25 IDE 12Nem (1.2 kgf, 9 bE) 34 Nom (3.5 kgm , 25 bff) 34N.m 35 kat Nom (0.9 kgtm 6.5 bt. 30 Nm (3.1 kgf , 22 IBF) 18N.m (18kghm,, 13 1bE) 28Nim (2.3 gfe 17 IBF 15-015. HYDRAULIC BRAKE SERVICE INFORMATION 15-1 FRONT MASTER CYLINDER: 15-8 ] TROUBLESHOOTING 15-2 REAR MASTER CYLINDER/ | pate ie | BRAKE FLUID REPLACEMENT/ AIR BLEEDING 15-3 FRONT BRAKE CALIPER 15-16 BRAKE PAD/DISC 15-5 REAR BRAKE CALIPER: 15-19 SERVICE INFORMATION GENERAL A contaminated brake dive or pad reducce stopping power. Dissard contaminated pads and aloan a sontemi with a high quality brake degreasing agent. * Spilled brake fluid wil severely damage the plastic parts and painted surtaces. It is also harmtul to some rubber parts. Be careful whenever you remove the reservoir cap; make sure the reservoir is horizontal ist + Never allow contaminants (dirt, watar, tc) to get into an open reservoir. * Onc the hydraulic system has been opened, or ifthe brake feels spongy, the system must be bled * Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of flue id as they may not be compatible. + Always chack brake operation before riding the motoreycle. ‘SPECIFICATIONS om ] ‘STANDARD Unit: mm tin} SERVICE Limir Front [Specified brake fluid Brake disc thickness — BOTs 44—4610,17-0.18) 510.14) Caliper cylinder LD. 78.815 10.6226) | ae Brake disc thickness Brake discrunout___ Master eylinder 0, A 39) 34.02 (1.335) _ 5 1.26301, '32.0911.263) Caliper piston O.. [3387 0.333) 31.94(1.257) — 9001-083 (0.5 1a 0589] 14.055 055 14.055 (0.5533) | ‘master piston 0.0. is.9b/= 15.968 U.De¥o—U.9DV0) Ts38 (U.3a80) Caliper cylinder LD. (38.18=38.23 38.24 (1.506) Caliper piston 0.0. 36.098 — 38, 148 (1.4999 ~ 1.5019) [38.09 (1.500) | 15-1HYDRAULIC BRAKE TORQUE VALUES Brake caliper bleed valve Pad pin Pad pin plug Brake hose oil bolt Front brake lever pivot bolt Front brake light switch screw Front brake caliper assembly bolt Rear master cylinder joint nut Rear master cylinder mounting bolt Rear brake caliper bolt Front master cylinder reservoir cap screw Front master eylinder mounting bolt Front brake caliper mounting bolt Rear brake reservoir mounting bolt Rear brake caliper pin bolt Driver footpeg bracker bolt TOOLS Snap ring pliers TROUBLESHOOTING Brake lever/pedal soft or spongy ‘Air in hydraulic system Leaking hydraulic system * Contaminated brake padidise + Worn caliper piston seals ‘Worn master cylinder piston cups ‘Worn brake padiise * Contaminated caliper * Contaminated master cylinder * Caliper not sliding properly + Low brake fuia evel * Clogged uid passage + Warpedideformed brake disc * Stickinalworn caliver piston * Sticking/worn master piston * Bent brake lever/pedal Brake lever/pedal hard * Cloggadirestricted hydraulic system * Sticking/worn calipar piston * Sticking/worn master piston * Caliper not sliding properly + Bent brake lever/pedal 8Nm (0.8 kgf, 43 IDE YBN. (1.8 kaf-m 13 Ibe 3Nsm (0.3 kgf, 2.2 IDF 34 Nim (3.5 kgf, 25 IDF) Nem (0.1 kgm , 0.7 bf 1.Nem {0.1 kas 0.7 bf. 23 Nim (2.3 kgm 17 IDF) TENm (1.8 kgm, 13 Ib) 8 Nem (0.9 kgtm 85 IbFt) 23N.m (2.3 kgtim 17 IDFA) 2Nom (0.2 kgfm 1.4 IDE) 32Nom (1.2 kgfm 9 IEA) 30.N-m (3.1 kgf. | 22 IbF A) T2Nem(1.2kgtm, 9 lof A) 27 Nem (28 kgf. , 20 IBF A) 2oN-m (2. kghm | 20 10t-) 07814850001 Apply locking agentto the threads ALOC bolt: replace with a new one Brake drag Contaminated brake pad/dise ‘ Misaligned wheel ‘Badly worn brake pad/dise +s Warped/deformed brake dise ‘Caliper not sliding properly ‘*Cloggedirestricted fluid passage ‘Sticking caliper piston 15-2HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/ AIR BLEEDING MS A contaminated brake dise or pad reduces stopping power. Discard contaminated pads and lean a contaminated dise with a high quality brake degreasing agent. ‘CAUTION; * Do not allow foreign material to enter the sys- tem when filling the reservoir. * Avoid spilling fluid on painted, plastic or rubber parts, Place a rag over these parts whenever the * Use only DOT 4 brake fuid from a sealed contain- * Do not mix different types of fluid. They are not compan BRAKE FLUID DRAINING Remove the reservoir cap, set plate and diaphragm {page 8-20 for front, page 3-21 for rear) Connect the bloed hose to the blaed valve. Loosen the bleed valve and pump the brake lever 6 pedal until no more fluid flows out of the bleed valve. BRAKE FLUID FILLING/BLEEDING Close the bleed valve. Fill the reservoir with DOT 4 brake fluid from 2 sealed container. Connect a commercially available brake bleeder to the bleed valve Pump the brake bleeder and loosen the bleed valve. ‘Add brake fluid when the fluid level in the reservoir is low. ‘Check the fluid level often while bleeding the ‘brake to prevent air from being pumped into the system. When using a brake bleeding tool, follow the ‘manufacturer's operating instructions.HYDRAULIC BRAKE 15-4 Repeat the previous procedures until air bubbies {do not appear inthe plastic hose. If airis entering the bleeder from around the bleed valve threads, seal the threads with teflon tape. Clase the bleed valve and operate the brake lever fr pedal. If it still feels spongy, bleed the system again I¥.a brake bleedor isnot available, use the following procedure ump up the system pressure wn the brake lever ‘or pedal until lever or pedal resistance is felt. Connect a bleed hose to the bleed valve and bleed the system as follows: 1.Squeeze the brake lever or depress the brake pedal, open the bleed valve 1/2 turn and then Note Do not release the brake lever or pedal until the bleed valve has been closed. 2,Release the brake lever or pedal slowly and wait several seconds after it reaches the end of its travel Repeat the steps 1 and 2 until air bubbles do not ap- pear in the bleed hose, Tighten the bleed valve. TORQUE :6 Nim (0.6 kgfm, 4.3 IbF-t) Fill the reservoir tothe upper level fine with DOT 4 brake fluid fram a sealed container Install tne giaphragm, set plate and reservoir cap (page 3-20 for front, page 3-21 for rear).HYDRAULIC BRAKE BRAKE PAD/DISC Aways piace the brake pads in patrs to ensure ‘oven dise ares- FRONT BRAKE PAD REPLACEMENT Loosen tne paa pins. Femave the bolts and brake caliper. Push the ealiper pistons all the way in to allow in- stallation of new brake pads. NOTE: CCheck the brake fluid lovel inthe brake reservoir as this operation causes the level to rise, Remove the pad pins wi spring, then remove the pa pushing in the ped pring and brake pads. Install new brake pads and the pad spring with the arrow facing up. Install the pad pin while pushing in the pad spring, Install the front brake caliper so the disc is posi- tioned between the pads, being careful not to dam- & ‘age the pads, Install and tighten new mounting bolts. TORQUE :30 Nim (3.1 kgfsm , 22 bf) ‘Tighten the pad pins. TORQUE : 18 N:mn (1.8 kgf , 13 bt) Operate the brake lovar to seat the caliper pistons against the pads.HYDRAULIC BRAKE REAR BRAKE PAD REPLACEMENT ‘Always ceplace the Push the caliper piston all the way into allow instal- brake oads in Intion of new brake oads, pals to ensure even dise pressure. oye, Chock the Lake fui level ine brake reoer vole as this operation causes the level to rise Remove the pad pin plug and loosen the pad pin Remove the rear brake caliper bol Pivot the caliper up, and remove the pad pin and brake pads. Be careful not 10 Install new brake pads so that their ends are PEE ‘ose the pad spring. positioned on the retainer on the caliper bracket as SAKE PADS 15.8HYDRAULIC BRAKE | owar the calipar and install the nad pin. Install and tighten the rear brake caliper bol. TORQUE :23 Nm (2.3 kgfm 17 IbF-t) Tighten the pad pin. TORQUE 12m (1.8 kam, 12166 Install and tighten the pad pin plug TORQUE :3.N-m (0.3 kgm, 22 bt) Operate the brake pedal to seat the caliper piston against the nade. BRAKE DISC INSPECTION Visually inspect the disc for damage or cracks. Moaaure the brake die thicknose st several points SERVICE LIMITS: Front: 3.5mm (0.14 in) Rear: 4.0mm (0.16 in) Measure the brake disc warpage with a dial indica- tor. SERVICE LIMIT: 0.20 mm (0.012in) Check the wheel bearing for excessive play, if the | Replace the brake disc ifthe wheel bearings are nor- mal. 15-7HYDRAULIC BRAKE FRONI MASTER CYLINDER Ol BOLT CAUTION ‘= Avoid spilling fluid on painted, plastic or rubber parts, Place a rag over these parts whenever the system is serviced. ‘ vinen removing tne ou vor, cover tne ena ot tne hose to prevent contamination. DISASSEMBLY Drain the brake fluid from the front brake hydraulic system (page 15°). Disconnect the front brake light switch connectors. Disconnect the brake hose from the master cylinder by removing the oil bolt and sealing washers. Remove the master cylinder holder bolts, holder and the master eylinder. Romove tho pivot nut, bolt and broke lover sagem biy. Remove the screw and front brake light switch, Remove the piston boot from the master piston and master cylinderRemove the snap ring usina the special tool Tool: ‘Snap ring pliers 07914-SA50001 Remove the master piston, cup and spring from the master cylinder. Clean the master cylinder and master piston with clean brake fluid. INSPECTION CCheck the cups for wear, deterioration or damage. Check the spring for damage. Check the master cylinder and piston for scoring, scratches or damage, Measure the master cylinder LD. SERVICE LIMIT: 15,995 mm (0.6230 in} Measure the master piston 0.0. SERVICE LIMIT: 15.615 mm (0.8226 in) HYDRAULIC BRAKE SNAP RING: ‘SPRING cup “he, 15-3HYDRAULIC BRAKE ASSEMBLY BF _vesenvoin car tL 4 ZA SET PLATE 7 DIAPHRAGM SPRING s Le = te \ : oo svar. RING MasTFR CVI NER ~ BRAKE LIGHT SWITCH Coat the master piston and piston cups with clean brake fluid Install the spring, cup and master piston into the ‘master cylinder. MASTER CYLINDER cAUTION: cur Do not allow the piston cup lips to turn inside out A ‘SPRING i MASTER PISTON’ Install the snap ring into the groove in the master eq cylinder, using the special too). Too: Snap ring pliers 07914-Sas0001 Be certain the snap ring is firmly seated in the groove. | SNAP RING PERS 15-10Intl the boot onto the piston and int the master finder opty alicono grease to the brake lever corteting area ofthe master piston, ae Apply silicone grease to the pivot bolt sliding Su BraKe LEVER face, Tighten the pivot bot TORQUE :1 Nim (0.1 kgf , 0.7 bt) Install and tighten the pivot nut TORQUE :6 Nim (0.6 kat . 43 IbFf) Install the front brake light switch with the screw. TORQUE 1 Ni (0.1 Aen 27 WER) Install the master cylinder and holder with the "UP" mark facing up. Align the end of the master cylinder with the punch mark on the handlebar, and tighten the upper bolt fice, thon tighton the lowor bolt TORQUE :12.N.m (1.2kgf-m ,9 IDE HYDRAULIC BRAKE PIvoT NUT WASTER ~ CYLINDER ceo the bras howe te ovine wth Fear i te etary TT gy SANG Waseas GU ESTE TORQUE : 34 Nom (3.5 kgm , 25 Ibf ft) Connest the front brate light switch connectors Fill and bleed the front hydraulic system (page 18- aHYDRAULIC BRAKE REAR MASTER CYLINDER/ BRAKE PEDAL CAUTION: + Avoid spilling fluid on painted, plastic or rubber (parte, Place 2 70g over theee parte whonover the system is serviced. + When removing the oil bol, cover the end of the hose to prevent contamination, DISASSEMBLY Drain the brake fluid from the rear brake hydraulic system (page 15) by removing the oll bolt and sealing washers. Remove the screw and reservoir hose joint from the master cylinder. Remove the O-ing Loosen the master cylinder mounting bolts, Remove the foatoea bracket bolts and footoea bracket assembly, Remove the rear brake light switch spring and ‘brake pedal return spring, Remove the brake light switch from the footoea bracket. 15-12HYDRAULIC BRAKE Remove the master cylinder mounting halts and step guard ge. snap ring Remove the snap ring, washers and brake pedal from the footpeg bracket. Hemove tne cotter pin trom tne joint pin. Remove the joint pin and master cylinder from the brake pedal. Remove the boot from the master cylinder. Remove the snap ring using the special tool Tool: SNAP RING ‘Snap ring pliers o7914-Sas0001 Remove the master piston, cup and spring, Clean the master evlinder and master piston in clean brake fuid INSPECTION Check the cups for wear, deterioration or damage. Check the spring for damage.HYDRAULIC BRAKE 15-14 (Chowk te raster Uylender anid pitun for sour ot damage, Measure the mastar cylinder ID. SERVICE LIMIT: 14,085 mm (0.5523 in) SERVICE LIMIT: 13.945 mm {0.5490 in) ASSEMBLY 2 MASTER CVI INNER “4 PUSH ROD ‘SPRING: cur — MASTER PISTON eS” RING “9 PUSH ROD JOINT Coat the master piston and piston cups with clean brake lui. Install the spring, cu and master niston inte the master cylinder. ‘CAUTION: cur Do not allow the piston cup lips to turn inside out. SPRING Apply silicone grease to the push rod contacting ‘area af the master piston. AHYDRAULIC BRAKE Install the snap ring into the groove in the master SNAP RING cylinder, using the special tool Toot: ‘Snap ting pliers 07914-Sas0001 Be certain the snap ring is firmly seated in the groove, ‘Apply silicone grease to the boot groove in the ppush rod and install the piston boot into the master cylinder and the groove inthe push rod, If the push rod joint is reintalled, adjust the push rod length so that the distance from the center of ‘the master cylinder lower mounting hole to the cen ter of the joint pin hole is 100 mm (3.9 in). After ad- justmant,tightan the joint nut TORQUE :181N-m (1.8kgtm, 13 loft) Connect the master cylinder push rod joint to the brake pedal with the joint pin and a new catter pin. Apply grease to the brake pedal pivot, Install the brake pedal onto the pivot shaft, Install the wave washer, plain washer and snap ring ante tha pve ahaft Install the master cylinder with the mounting bolts and step guard. 15-15HYDRAULIC BRAKE 15-16 {Connect tne peal return spring as shown. Insta the rear brake light switch into the footpeg bracket and connect the rear brake light switch praelichngs Install the footpeg bracket assembly onto the frame and tighten the bracket bolts. TORQUE :26 Nim (2.7 kgfim 20 bt) Tighten the master cylinder mounting bolts. TORQUE :9 Nim (0.9 kgtim 65 IbFt) Apply brake fluid to @ new O-ring and instal it onto the reservoir hose joint a Install the hose joint into the master cylinder. Apply locking agent to the hose joint screw. Install the serew and tighten it. Connect the brake hose to the master cylinder with the oil bolt and new sealing washers, and tighten the oil bot. TORQUE :34 Nem (3.5 kgm, 25 bf) Fill and bleed the rear brake hydraulic system (page 16-3),HYDRAULIC BRAKE FRONT BRAKE CALIPER CAUTION: ‘Avold spiting Mui on patnced, plasite vr ruber arts Place a rag over these parts whenever the system is serviced. DISASSEMBLY Drain the brake fluid from the front brake hydraulic system (page 15-3) Disconnect the brake hose from the front brake cali- per by removing the oil bolt and sealing washers. Remove the brake pads (page 18-5) Install a corrugated cardboard or soft wood sheet between the pistons. Apply smal squirts of air pressure to the fluid inlet 10 remove the pistons. os Do not use high pressure air or bring the nozzle +100 close to the inlet. Remove the four caliper assembly bolts and sepa- rate the caliper body halves. CALIPER ASSEMBLY BOLTS 15-17HYDRAULIC BRAKE Remove tne ronowiny: joint seal caliper piston A ~caliper piston B Push the dust seals and piston seals in and lft them out CAUTION Be careful not to damage the piston sliding surface. Clean the seal grooves, caliper cylinders and piston INSPECTION Check the caliper cylinders and pistons for scoring, scratches or damage. ‘Measure the caliper oylinder LD, ‘SERVICE LIMITS: ‘Cylinder A: 36.02 mm (1.339 in) Cylinder B: 32.09 mm (1.263 in) Measure the caliper piston 0.0. ‘SERVICE LIMITS: Piston A: 33.87 mm (1.333 in) Piston B: 31.94 mm (1.257 in} CALIPER PISTON A JOINT SEAL % CALIPER PISTON 8 ‘SEALS 15-18ASSEMBLY BLEEDVALVE CALIPER PISTON 8 Xe LE ASSEMBLY BOLT Cost new piston and dust seals with clean brake flu- {and install them in the seal grooves inthe caliper. Coat the caliper pistons with clean brake fluid and install them into the ealiper cylinders with the open- ing toward the pade, Install a new joint seal into the fluid passage ‘groove inthe caliper body. Assemble the caliper body halves. ‘Apply locking agent to the caliper assembly bolt threads. Ingtall and tighten the assembly bots. TORQUE :23 Nim (2.3 kgfsm , 17 Ib) HYDRAULIC BRAKE JOINT SEAL CALIPER PISTON A DUST SEALS PISTON SEALS Joint sea PISTON A, Z oe ee 15-19HYDRAULIC BRAKE REAR BRAKE CALIPER ._ Remove the rear brake caliper from the bracket. Install ne brake pads (page 12 Connect the brake hose to the brake caliper with tha oil holt and new sealine washers. and tighten the oil bot. TORQUE : 34 Nim (3.5 kgf'm 25 Ibe) Fill and bleed the front brake hydraulic system (page 153), cauTion: Avoid spilling fluid on painted, plastic or rubber “Fi Place a rag over these parts whenever the system Ieserviced. DISASSEMBLY Drain the brake fluid from the rear brake hydraulic system (page 15-3), Disconnect the brake hose from the rear brake caliper by removing the oil bolt and sealing washers Remove the rear brake pads [page 15-8) Remove the pad spring, collar and boot from the caliper body. couan PAD SPRING. B0oT 15-20HYDRAULIC BRAKE Place a shop towel avar 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. Ce Do not use high pressure air or bring the nozzle t00 close to the inlet. Push the dust seal and piston seal in and lft them out SEALS CAUTION: Be careful not to damage the piston sliding surface. Clean the seal grooves, caliper cylinder and piston with clean brake fluid INSPECTION Check the caliper cylinder and piston for scoring, scratches or damage. Measure the caliper cylinder. ‘SERVICE LIMI 38.28 mr (1.506 in} Measure the caliper piston 0.D. SERVICE LIMIT: 28.09 mn (1.500 in} 15-21HYDRAULIC BRAKE PAD SPRING. 18.29 ASSEMBLY \ CALIPER PISTON PISTON Seat ChuPeR Pw Bou a. = Cont the caliper paton with coon brake Mud and in ? gS stall it into the caliper cylinder with the opening to ward wie pas, s fi CALIPER oy Install the pad spring onto the caliper body as GBiiki shown. . PAD SPRING CCheck the caliper boot and replace it fits hard, de teriorated or damaged, Apply silicone grease tothe inside of the boot Install the boot and collar into the caliperHYDRAULIC BRAKE Check the caliper pin boot and replace itif itis hard, deteriorated or damage, Apply silicone grease to the inside of the boot and install the caliper onto the bracket. Install the rear brake pads (page 15-6) Connect the brake hose to the brake caliper with the oil bolt and new sealing washers, and tighten TORQUE :34 N.m (3.5 kgtim , 25 bf) Ful ano bieea ine rear praKe nyaraulle system (page 15:3) 15-23CHARGING SYSTEM MAIN FUSE 308 REGULATORRECTIFIER ALTERNATOR R/WOSO— HD O MAIN FUSE aA eaTTeRY oY eee yo oG Rew L REGULAIOR/ RECTIFIER ALTERNATOR16. CHARGING SYSTEM SERVICE INFORMATION 16-1 CHARGING SYSTEM INSPECTION 165 TROUBLESHOOTING 16-3 ALTERNATOR CHARGING COIL 166 BATTERY 16-4 REGULATOR/RECTIFIER 167 SERVICE INFORMATION GCNENAL CO «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 o face ehiold. “if electrolyte gets on your skin, flush with water. =f electrolyte gets in your eyes, lush with water for at least 15 minutes and call a physician immediately. Electrolyte is polsonous. = it swallowed, drink large quantities of water or milk and follow with mux of magnesia or vegetapve ol! ana cait a physician, KEEP OUT OF REACH OF CHILDREN. ‘Always turn off the ignition switch before disconnecting any electrical component. CAUTION: ‘Some electrical components inay be danayed If corm ignition switch is ON and current is present. * For extended storage, remove the battery, give it full charge, and store it in a cool, dry place. * For a battery remaining in 2 stored motoreyele, disconnect the negative battery cable from the battery Nore ‘The maintenance free battery must be replaced when itreaches the end of its service life o ION ‘The battery caps should not be removed. Attempting to remove the sealing caps from the cells may damage the battery. ‘The battery ean be damaged if overcharged or undercharged, or if left to discharge for long period. These same conditions contribute to shortening the "life span” ofthe battery. Even under normal use, the performance of the battery deteriorates after 2~3 years. ‘= Battery vortage may rcuver after Uaery Chierylny, LL UM IWwavy bad, Wie battery voltage will drop quickly ond ‘eventually die out. For this reason, the charging system is often suspected as the problem. Battery overcharge often results from problems in the bartery itself, which may appear to be an overcharging symptom. If one ofthe battery cells is shorted and battery voltage does not increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions, he electrolyte level goes down quickly. + Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check ifthe battery is frequently under heavy load, such as having the headlight and taillight ON for long periods of time without riding the «The battery will self-discharge when the motorcycle is notin use. Far this reason, charge the battery every two weeks to prevent sulfation from occurring, Filling @ new battery with electrolyte will produce some voltage, but in order to achieve its maximum performance, always charge the battery. Also, the battery ites lengthened when itis intially charged. * When checking the charging system, always follow the steps in the troubleshooting flow chert ipage 16-3) * For alternator service refer to section 10. 16-1CHARGING SYSTEM + This model vores with # nisintwnrbe few (MF) battery. Remember the following about MF batteries —Use only the electrolyte that comes with the battery. —Use all ofthe electrolyte. Seal the batery oraperiy. Never open the seals again BATTERY TESTING Refer to the inotructions in the Operation Menu! forthe recommieruled battery teate fur Uetals abut dhe tery est. ‘The recommended battery tester puts 8 “load” on the battery so that the actual battery condition ofthe load can be meas- ured. Recommended battery tester —_BV-210-AH, 8M-210, or BATTERY MATE or equivalent CAUTION: For battery charging, do not exceed the charging current and time specified on the battery. Using excessive current or ‘extending the charging time may damage the battery SPECIFICATIONS rem SPECIFICATIONS | Battery [Capac I iav— aA - | [Current leakage 0.1 mA max. Voltoge ‘liy sharged - 730192 Li20"ciea °F) ___ | "Needs charging | = “Below 123) Charging current |_ Normal — Lo ae ‘Quick ‘Alternator | Capacity — 33 W000 min" pI cael [Charging col resistance (20 "C168 "71, 01-10 9 1h.CHARGING SYSTEM TROUBLESHOOTING Battery is damaged or weak Remove the battery (page 16-4. | Check the battery condition using the recom. | mended battery tester. RECOMMENDED BATTERY TESTER: BM-210-AH, BM210, or BATTERY MATE or equiv- (ee Correct 1 }-Incorrect--« Faulty battery Install the battery (page 16-4). Chock tho battery ourront lookoge (Look toot: page 165) ‘SPECIFIED CURRENT LEAKAGE: 0.1mAmax. | | SURES! et STANDARD: 0.1-1.0 2 (20 °C/68°Fi Correct digital multimeter (page 16-4. Start the engine. “Measure the charging voltage (page 16-5) Compare the measurements to result of the following ealeulation, MEASURED BATTERY VOLTAGE< MEASURED CHARGING VOLTAGE<15.5 V T spection (page 16-7). Correct 1 + Foulty regulatorirectifier Disconnect the regulator/rectifier SP (black) connec: tor and recheck the battery current leakage. Incorrect Correct Correct + Faulty regulatorirectfier {______- « shorted wire harness * Faulty ignition switch Check the alternator charging coil (page 16-6) |~Incorrect--« Faulty charging coil Measure and record the battery voltage using 2 |~Correct = « Faulty battery Perform the regulator rectifier wire harness in- [Incorrect * Open circuit in elated wire *# Loose or poor contacts of related terminal # Shorted wine hanes 16-3CHARGING SYSTEM BATTERY REMOVAL/INSTALLATION Remove the seat (page 2-2, (Open the battery case cover by releasing the two With the ignition switch OFF, disconnect the negative (—) cable frst, then discannect the posi tive (+) cable. Remove the battery from the battery case. Install the battery in the reverse order of removal positive (1) cable frat there rect the negative (—) cable ‘After connecting the battery cables, coat the VOLTAGE INSPECTION (Open the battery case cover. Measure the battery voltage using @ commercially avaliable aigkal multimeter. VOLTAGE (20 °C/68 °F): Fully charged: 13.0—13.2V Under charged: Below 12.3 BATTERY CHARGING oe ‘The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide ‘adequate ventilation when charging. = Turn die power ON/OFF at tie charger, HOC Ht the battery terminals. Remove the battery, 16-4CHARGING SYSTEM Connect the charger postive (+) eable to the bat tery positive (~) terminal ‘Connect the charger negative (—) cable to the bat- tery negative (—) terminal BATTERY (CHARGING CURRENT/TIME: ‘Standard: 09.8 x 5~10h Quick: §— 40% 10h CAUTION: = Quick eharyiny shouht only be done fran enver- gency; slow charging is preferred. ‘For battery charging, do not exceed the charging ‘current and time specified on the battery. Using excessive current or extending the charging time ‘may damage the battery CHARGING SYSTEM INSPECTION Open the battery case cover (page 16-4), CURRENT LEAKAGE TEST ‘Turn the ignition switch OFF, and disconaact the negative (=) cable from the battery. Connect the ammeter |-+) probe to the negative (~) cable and the ammeter (—) probe tothe battery (~) With the ignition switch OFF, check for current leak: age, Nore ‘* When measuring current using a tester, set itto.@ high range, and then bring the range down to an ‘appropriats level. Currant flow higher than tho range selected may blow out the fuse in the tester. ‘+ While measuring current, do not turn the ignition sswiteli ON. A sudden surge of currant may blow ‘out the fuse in the tester. If current leakage exceeds the specified value, a shorted circuits kely Locate tne snort ay alsconnecuing connections one by one and measuring the current, CHARGING VOLTAGE INSPECTION BS ‘work, make sure the area is well-ventilated. Never un the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause oss of consciousness and lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area. 16-5CHARGING SYSTEM Bo cure that the Start the engine and warm it up to the operating battery ingood temperature; stop tha engine. condition bofore Connect the multimeter between the positive and performing this negative tarminale of the harry. test. CAUTION ‘+ 10 prevent snort, make aosowtery certain wnren are the positive and negative terminals or cable. + Do not disconnect the battery or any cable in the charaina svstem without first switchina off the ignition switch. Fallure to follow this precaution can damage the tester or electrical components. With the headlight on Hi beam, restart the engine. Measure the voltage on the multitester when the engine runs at 6,000 rpm. STANDARD: Measured battery voltage (page 16-4)< Measured ALTERNATOR CHARGING COIL iron 3° CONNECTOR INSPECTION Remove the lat side faring ipage 2-4. Disconnect the alternator 3P (white) connector. Measure the resistance between the wire terminals of the alternator side connector. STANDARD: 0.1~1.0 2 (20°C) 08) Check for continuity between each wire terminal of the alternator side connector and around. ‘There should not be continuity, Replace the alternator stator if resistance is out of ground, Refer to section 10 for alternator stator replace- ment TRARCHARGING SYSTEM REGULATOR/RECTIFIER WIRE HARNESS INSPECTION Remove the seat cowl (page 2.2) Disconnect the regulaterirectfir SP (black) connec: {heck he connector for loose contacts or coroded terminals. BATTERY LINE ‘Measure the voltage between the red/white wire ter- minal and ground. ‘There should be battery voltage at all imes. ‘GROUND LINE ‘Check the continuity between the green wire termi- nal and ground. ‘There should be continuity tall times, CHARGING COIL LINE Measure the resistence between the yellow wire tor minals. ‘STANDARD: 0.1~1.0 2 (20°C/68 °F) Check for continuity between each yellow wire ter- minal and ground. 18-7IGNITION SYSTEM. ENGINE STOP SWITCH THROTTLE SENSOR MAIN FUSE 308 IGNITION swITcH IGNITION CONTROL BATTERY MODULE (ICM) J, he DIRECT IAITION COR sean nus igumon use orn Be ck NeuTeal swt use sioe stino sures a foe to ee wan rose sewrin we Seeeavon ae = a3 woo ved son 2 oe jeeet iT : coun Pb bg | omens t 417017. IGNITION SYSTEM SERVICE INFORMATION 17-1 IGNITION PULSE GENERATOR 77 ‘TROUBLESHOOTING 17-3 IGNITION TIMING 17-7 IGNITION SYSTEM INSPECTION 17-4 THROTTLE SENSOR 77 SERVICE INFORMATION GENERAL ARN When the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an ‘enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to ‘death. Fun the engine in an open area or with an exhaust evacuation system in an enclosed area, CAUTION ‘Some electrical components may be aamagea 1 terminals or connectors are connected or aisconnected 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 17-2, «The transistorized ignition system uses an electrically controlled ignition timing system, No adjustments can be made to the ignition timing + Tho ignition contra! module (ICM) verioa ignition timing aecording to the engine speed. The thraitle sensor signals the ICM to compensate the ignition timing according tothe throttle opening ‘= Tho ICM may be damaged if dropped. Also, if the connector is disconnected when current is flowing, the excessive voltage may damage the ICM. Always turn off the ignition switch before servicing, ‘© A faulty ignition system is often related to poor connections. Check those connections before proceeding ‘© Make sure the battery is adequately charged. Using the starter motor with @ weak battery results in a slower engine cranking speed as well as no spark at the spark plugs. ‘The diner ignitinn enil that tha ignitian anil and epaek plug ean are inagratad, ic aanted an thie mentary Use the spark plugs of the correct heat range. Using a spark plug of an incorrect heat range can damage the engine. + The California type's spark plug is equipped with platinum type electrodes. Do not use spark plugs other than specified (California type only. + For spark pluy inopoction and dict ignition cull emmuvalnstallation, see section 3 + See section 18 for following components: Ignition switch Engine stop switch =Neutral switch Side stand switch Clutch switen 17-1IGNITION SYSTEM SPECIFICATION Tem Sparkplug _|_49 state/Canada type California oe SPECIFICATIONS: z7FR-9 (DENSO} CRBEHVXSINGK) B0=1.90 pm (6.031—0038 in) 0-7 minimum "10" BTOC at idle Spark slug gap Tgnition col prisnany peak vohioge Ignition pulse generator peak voltage lanition timing ("P” mark) Throttle Resistance (20°C168"F) —_ — sensor Foley eee. 0.22 TORQUE VALUE Timing hole cap 18N.m (1.8 kgtm, 13 bf) Apply grease tothe threads TOOL Poak voltage tester (U.S.A. only) or Peak voltage adaotor O7HGJ-0020100 (not available in U.S.A) with commercially available dicital ‘multimeter (impedance 10 Ma1/DCV minimum) 17-9IGNITION SYSTEM TROUBLESHOOTING + Inspect the following before diagnosing the system. Faulty spark plug Loose alructiynitun cull eoneeciions —Water got into the direct ignition coll ignition coll secondary voltage leak) ‘*1f there is no spark at any cylinder, temporarily exchange the direct ignition coll with another good one and perform the ‘spark test. If there is spark, the exchanged direct ignition coli faulty. ‘initial voitage” of the Igsition primary cal is the battery voltage with the ignition switch ON and engine stop switch at FUN (when the engine is not eranking by the starter motor) NO SPARK AT SPARK PLUGS. UNUSUAL CONDITION T PROBABLE CAUSE (Check in numerical order) Torition coil | No intial voltage with the Tgnition | 7. Faully engine stop switch primary | switch ON and engine stop swtcn at | 2.An open circult in black/white wire between the direct voltage RUN, (Other electrical components ignition coil and engine stop switch. {are normal.) 3.Loose or poor connection of the ignition coil primary wire teeminal. oF an open circuit in primary coil. (Check at the ignition control module (ICM) connector.) 4.Faulty ICM when the initial voltage is normal while disconnecting ICM c [antar vonage nora batiediops | Teineorreut peak voltaye ova down to 24 V while cranking the | 2Battery is undercharged. (Large voltage drops when the ‘engine. engine is started.) | 3.No voltage between the black (+) and ground {—) of the | ICM connector, or loose or poorly connected ICM. 4.Poor connection or open circuit in green (ground) wire of the ICM. 5.Looge or poor cannections, or open circuit In blue/black, | yollowlwhite, red/blue and rediyellow between the direct ignition coils and ICM. 6 Faulty side stand switch or neutral switch. | ran open eeu or oars conacion No, © rem su + Side stand switch line: grean(white wire 4 Neutral switch line: light een wire | 8.Faulty ignition pulse generator. (Measure peak voltage.) L_ 8. Faulty ICM (when above No. 1 thru. 8 are normal) Tnital volage is normal, But no peak 1. Incorract peak voltage adaptor connections. | voltage exists while cranking the | 2.Faulty peak voltage adaptor. sngine __3.Faulty [CM hen above No. 1 and 2 are normal. inal voRage normal, bat peak | 1. The mutimeter impedance soo low below 10 MO/DCY. Voltage js lower than the standard | 2.Crankingspredis oo slow. (Batory i undercharged.) value. 5:The sampling timing ofthe tester and measured pulse were | not synchronized. (System is normal if measured voltage is over the standard voltage atleast once.) A BenityICR bwshon above Nv 1 thru 2are nner Tnitial voltage and peak voltage are | 1.Feulty spark plug or leaking ignition coil secondary current ‘normal, but no spark jumps at plug. ampere. ___ __| 2.Faulty direct ignition coils) [anion Peak Vorage lower Than The Sian | I. The multimeter Impeuance 100 Tow, Uelow TO MIG /OCY. pulse ard value, 2.Cranking speed is too slow. (Battery is undercharged) ‘generator 42, The sampling timing ofthe tester and measured pulse were not synchronized. (System is normal if measured voltage is ‘over the standard voltage atleast once.) | 4.Faulty ignition pulse generator (when above No. 1 thru. 3 | __ __| “are normal To peak voage: Tfoulty peok voltage adaptor. 2. Faulty ignition pulse generator. } 17-3IGNITION SYSTEM IGNITION SYSTEM INSPECTION { DIGITAL MULTIMETER 7 | limpedance 10 Ma/DCV minimum) sino spark jumps atte plugs, check al connee Rm tions for loase or poor contact before measuring | Yy \ cschoeskvetage, ay | Liman mca | | cere | | *The display value differs depending upon the | internal impedance of the multimeter. ass - Connect the peak voltage adaptor to the digital ‘multimeter, oF use the peak voltage tester. Toots: Peak voltage tester (U.S.A. only] or Peak voltage adaptor ‘O7HGJ-0020100 ‘with commercially available digital multimeter impedance 10 M2 /DCV minimum) IGNITION PRIMARY PEAK VOLTAGE NoTE ‘Chock all eyetom connections baforo thie inepoe tion, Poor connected connectors can cause incorrect readings ‘Check the cylinder compression at each cylinder ‘and check that the spark plugs are installed correctly in each cylinder. Disconnect the direct ignition coils from the spark! plugs ipage 38), Connect the 2P connectors to the direct ignition Connect good known spark plugs to the direct ignition cofls and ground the spark plugs to the cylinder head as done in a spark test. 17-4the peak voltage adaptor or tester probes to the nition coll primary wire terminal and ground. roots: Peak voltage tester (U.S.A. only] or Peak voltage adaptor ‘O7HGy-0020100 with commercially available digital multimatar impedance 10 Mo /DCV minimum} ‘CONNECTION: Viyniton wll, Dlucyblack we tesa (=U Ground (—) # ignition coll: Yellowiwhite wire terminal (+ to-Ground (~} # ignition coll: Rod/blue wire terminal (+)-t0- Ground (~) jon col: Rediyellow wire terminal (+}- te-Ground (-} #49 ‘Turn the ignition switch ON and engine stop switch to RUN. {eek ror me sniiat natery vorrage, If battery voltage is not present, follow the checks described in the troubleshooting on page 17-3. Shiftthe transmission into neutral Crank the engine with the starter motor and meas- ure the ignition col primary peak voltage. PEAK VOLTAGE: 100 V minimum Omg ‘Avoid touching the spark plugs and tester probes 10 prevent electric shock. Note Although measured values are different for each ignicion cot, say are swurmat as Yong as vorage 13 higher than the specified value. If the peak voltage is lower than standard value, follow the checks described in the troubleshooting chart (page 17-3) IGNITION PULSE GENERATOR PEAK VOLTAGE Note Check eylindar enmneassion at wach eylindar and check that the spark plugs are installed correctly in the eylinders Remove tte seat cow ipaye 2-2). Disconnect the ignition contral module (JCM) con- rector. IGNITION SYSTEM 6 CONNECTOR iIGNITION SYSTEM Connect the pesk voltage adaptor or tester probes tothe connector tarminals ofthe wire harness side. roots. Peak voltage tester (U.S.A. only) or Peak voltage adaptor 7HGJ-0020100 ‘with commercially available digital multimeter (impeaance 1 may! ULV minimum) ‘CONNECTION: Yellow wire terminal (+ Hto-White yellow wire terminal (~) Turn the ignition switch ON and engine stop switch to RUN. Shift the transmission into neuteal Crank the engine with the starter motor and meas: Ure the ignition coil primary peak voltage. PEAK VOLTAGE: 0.7 V minimum If the paak voltage measured at ICM connector is abnormal, measure the peak voltage at the pulse ‘generator connector. Rennuve the right side falling (peye 2), Disconnect the clutch cable (page 9-2) Disconnect the ignition pulse generator 2P (red) connector and connect the peak voltage adaptor or tester probes to the connector terminals of the Inthe game manner a8 at the ICM connector, meas- ure tho peak voltage and compare ito the valtago NCO ‘measured athe ICM connector. IGNITION PULSE GENERATOR ae! ‘If the poak voltage measured at the ICM is ‘abnormal and the one measured st the ignition pulse aenerator is normal, the wire harness hes fn open or short cireut, orloose connection. ‘If both peak voltages are lower than standard valu, follow the checks described in the trouble- shooting shen (page 17 2) Install the removed parts in the reverse order of tomoval 17-6IGNITION SYSTEM IGNITION PULSE GENERATOR REPLACEMENT Remove the right crankcase cover (page #3) Remove the wira setting washer bol Remove the two bolts and ignition pulse generator. ‘Apply sealant to the grommet seating surfaces. Install a new ignition pulse generator and the grom= mec imo tne cover yrouve properly. Tighten the bolts securely. Install the right crankcase cover (page 9-14) IGNITION TIMING Remove the right side fairing (page 2-4) ‘Start the engine and warm it up to operating tem perature. ‘Stop the engine and remove the timing hole cap. ‘Raed thainctrac- Connect the timing light to the #1 or #4 direct tions for timing ignition coll wire (black/white). light operation. ‘Start the engine, et it idle and check the ignition timing The ignition timing is correct if the F mark on the ignition pulse generator rotor aligns with the index ‘notch on the right crankcase cover at idle as shown Coat @ new O-ring with grease and install it onto the timing hole cap. Apply grease tothe timing hole cap threads. Install and tighten the timing hole cap. TORQUE :18 Nm (1.8 kgf, 13 IDE) Install the right side fairing (page 2-4), THROTTLE SENSOR SYSTEM INSPECTION Remove the seat cowl (page 2-2) Discreet te fysidon conta aude (EM) Lune rector. Measure the resistance between the yellowiblack and blue/green wire terminals of the wire harness side connector. ETANDARD: 46 ea (20 *C/83 °F) California type! BLUE/GREEN YELLOW/BLACK 17-7IGNITION SYSTEM. Check that the resistance between the yellow/biue and blua/groen wire terminals of the ICM connector ‘varies with the throttle position while operating the heatla grip Fully open—Fully closed position: Resistance decreases Fully closed rutly open position: Nesistance If the correct measurements cannot be obtained. raise the fuel tank (page 23), disconnect the throttle sensor 3° connector and perform the same inspections atthe sensor terminals ‘If the measurement at the ICM is abnormal and the one atthe throttle sensor is normal, check for ‘open ar short circuit, or loose or poor connections in the wiee harness, ‘If both measurements ara abnormal, replace the throttle sensor. Connect the ICM connecter Turn the ignition switch ON, Measure the input voltage between the yellow! black (7) anu biuuyyreen (—) wire terminals OF he wire harness side throttle sensor connector. STANDARD: 4.75.3 IF the input voltage is abnormal, or if there Is no input voltage, check for open or short circuit in the wire harnase, or looce or poor ICM connector contact. REPLACEMENT Remove the carburetor assembly from the eylinder head intake ports (page 5-18), Disconnect the throttle senor connector. Remove the two tore screws and the throttle sensor. Install the throttle sensor by aligning the tabs of the ‘sensor with the fat of the shaft as shown, ‘Apply locking agent to the torx screw threads and loosely install the screws. CAUTION: Install the throttle sensor properly. Improper instal- lation can cause damage to the throttle sensor. uf SensoR CONNEC 17-8IGNITION SYSTEM Adjust the throttle sensor position go thatthe resis. tance between terminals A and B is 490-5109, and tighten the torx screws. ‘Connect the throttie sensor connector. Install the removed pars in the reverse order of re moval 17-9ELECTRIC STARTER IGNITION swiTcH ENGINE STOP SWITCH STARTER SWITCH BATTERY MAIN ELISE 308 FUSE 10 A/DIODE Ty, “8 oe evra svré SIDE STAND SWITCH ‘STARTER RELAY SWITCH STARTER RELAY SWITCH MAIN FUSE 3 IGNITION t ef | Line oe EY ti GsR Br 2 21, eres STARTER SWITCH ENGINE STOP Bl: Black = NEUTRAL SWITCH 12018. ELECTRIC STARTER SERVICE INFORMATION 18-4 ‘TROUBLESHOOTING 18:2 STARTER MOTOR 18-4 STARTER RELAY SWITCH CLUTCH DIODE 18-10 18-11 SERVICE INFORMATION GENERAL Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing ‘serious injury. *# The starter motor can be serviced with the engine in the frame, += Whan checking the starter system, always follow the steps in the troubleshooting flow chart (page 18-2) * A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current. ‘ifthe current is kept flowing through the starter motor to turn Kt while the engine is not cranking over, the starter motor may be damaged. + See section 10 for starter clutch servicing, 1 See sectian 19 for following components ~lgnition switch Engine stop switch Starter switch ="Neutralewiten Side stand switch —Cluteh switch SPECIFICATIONS . a’ Ln mm fn) { rem =| ‘STANDARD SERVICE LIMIT Sieger maerBaR gh Tneaa eros) S5025) TORQUE VALUE Storer motorterminal nut ON (1.0kgim, Tbe) 18-1ELECTRIC STARTER TROUBLESHOOTING Starter motor will not turn Check for a hinwn main fa (90 Ad op sih-firn (10 A * Check thatthe battery is fully charged and in good condition, bie, and open circuit in battery cable. Normal 1 site terminal Normal ‘motor cable, and open circuit in starter motor ca- ble. Normal Cchevk (or louse or poorly connected bauury ca |-—Abnormal—= # Foony connected naxtery caple * Open circuit in battery cable Check for loose or poorly connected starter relay |— Abnormal —~ « Poorly connected terminals Check for loose or poorly connected starter |-—Abnormal = # Loose or poorly connected starter motor cable *# Open circuit in starter cable With the ignition switch ON and engine stop switch ot RUN. push the sterter switch and check for a “Click” sound from the starter relay switch. | = Clicks —=-| Connect the starter motor terminal directly to the battery positive terminal. (Because a large | amount of current flows, donot use a thin wire.) | Starter motor turns Starter motor does not turn No licks + Fauity starter motor ‘Faulty starter relay switch 1 Check the starter relay coil ground line (page 18- | —Abnormal —e- Faulty neutral switch 10} 1 To page 183 ‘Faulty diode «Faulty clutch switch + Faulty side stand switch Loose of poor connactor contact * Open circuit in wire harness 12.9ELECTRIC STARTER Fram page 18.9 tt ‘neck the starter relay voltage (page 16-1 “Apnormai—= « Fauity ignition switen * Blown fuse + Faulty engine stop switch Faulty starter switch * Loose or poor connector contact # Open circuit in wire harness Check the starter relay switch operation ipage 18- | —Abnormal— « Faulty starter relay switch 10. Le | Normal LL _________________~ « Loose or poor starter relay switch 4P connector contact Starter motor turns slowly ‘Weak battery * Poorly connected battery cable += Poorly connected starter motor cable * Faulty starter motor Starter motor turns, but engine dows ue turn * Faulty starter clutch (section 10) Starter relay switch “clicks”, but engine does net turn over '* Crankshaft does not turn due to engine problem + Faulty starter clutch (section 10) * Faulty starter reduction gear (section 10) 18-3ELECTRIC STARTER STARTER MOTOR REMOVAL Always turn the ignition switch OFF before ‘Servicmy the starcer motor. The motor could suddenly start, causing serious injury. Remove the fuel tank ipage 23) Drain the coolant from the system by removing the drain bolton tho water pump (page 6 §). Disconnect the water hose from the water pump. Remove the rubber cap, terminal nut and starter ‘motor cable. Pll the water hose aside. Remove the two mounting bolts and the starter mo: tor frre the eraninnen Remove the O-ring from the starter motor. DISASSEMBLY Remove the starter motor case bolts. Remove the O-rings from starter motor case bolts Record the Remove the following: location ard ~front cover lock washer ~ insulated washer shims FRONT CovER INSUL ATEN WASHER ‘SEAL RING «3 ay Lock wastien euine, 1QAELECTRIC STARTER seal ring ~shims armature ‘SEAL RING. REAR COVER ge ) INSPECTION damage. Check the oll seal and needle bearing in the front cover for deterioration, wear or damage. Pine NEEDLE BEARING Check the commutator bars of the armature for discoloration, “ARMATURE GOMMUTATOR AARS, NOTE: i Do not use emery oF sand paper on the commu: 18-5ELECTRIC STARTER ‘Check for continuity between pairs of commutator bars. There should be continuity Check for continuity between each commutator bar and the armature shaft, ‘There should be no continuity Check for continuity between the insulated brush ‘and cable terminal There should be continuity. INSULATED BRUSH Check for continuity between the cable terminal and motor case. “There shouldELECTRIC STARTER Bemave he flowing BRUSH HOLDER ~washer insulator washers o-ring brush holder —brushes Measure the brush length. SERVICE LIMIT: 6.5 mm (0.26 in) ASSEMBLY REAR COVER onING BAYSH HOLDER INSULATOR WASHERS WASHER — ARMATURE SEAL RING ‘SEALAING: sHIMS INSULATED WASHER Lock WASHER 18-7ELECTRIC STARTER Inctall tho brushes into the brush holder, Install the cable terminal and brush holder into the rear cover, aligning the holder tab with the rear cov- er groove. BRUSH HOLDER ALIGN Install the following: new O-ring = washer nut Install the armature in the motor case. When instaling the armature into the motor case, MOTOR CASE case from pulling the armature against CAUTION The coil may be damaged if the magnet pulls the armature against the case. ARINATURE Insta the same numberof shims in the same loca- tions as noted during disassembly, Ss ALIGN Install a new seal ring onto the motor case. ‘Apply thin coat of grease to the armature shaft end, Into the brush holder and aligning the brush holder tab with the motor case groove. suns EAR COVER a is nd re ne ono eS UAE armature sha g Insane aeal in onto the motor cas. cous FRONT cover Apply grease to the oll seal lip and needle bearing in the front cover. Install the lock washer onto the front cover. Inctall tho Front cover suims Loce WASHER 18-8ELECTRIC STARTER Install new O-rinas onto the motor case bolts. Install and tighten the motor case bolts. INSTALLATION Prat a naw Onring with oil and inetall inte the starter motor groove, Install the starter motor into the crankcase. Install the ground cable and mounting bolts, and tighten the bolts securely Connect the starter motor cable. Install and tightan the terminal at TORQUE : 10.N-m (1.0 kgm, 7 IbF ft) Install the rupber eap securely. Connect the water hose to the water pump. Install the fuel tank (page 23), Fill and bleed the cooling system (page 6-4)ELECTRIC STARTER STARTER RELAY SWITCH INSPECTION Remove the seat page 2-2. TPSPARIER RELAY switcH Shift the transmission into neutcal Turn the ignition ewiteh ON and engine stop owiteh toRUN, Push the starter switeh, ‘The coil is normal if the starter relay switch clicks. 1¥ you don’t hear the switch “CLICK”, inspect the re- lay switch using the procedure below. (GROUND LINE Disconnect the starter relay switch 4° connector. Check for continuity between the greenired wire (ground ine) terminal and ground. If there is continuity when the transmission is in ‘neutral or when the clutch is disengaged and the Side stand is retracted, the ground circuit is normal. (in neutral, there fe = clight resietance due to the ode.) STARTER RELAY VOLTAGE Connect the starter relay switch 4P connector. Shiftthe transmission into neuteal terminal (+) and ground ( Ifthe battery voltage appears only when the starter switch 1s pushed wit the ignition switch UN and en- gine stop switch at RUN, itis normal OPERATION CHECK Disconnect the starter relay switch 4P connector and eables Connect a fully charged 12 V battery positive wire to the relay switch yellow/ted wice terminal and negative wire ta the gran/ted wire terminal ‘There should be continuity between the cable terminals while the bettery is connected, and no eontiuity whe the Galery is disconnected 18-10ELECTRIC STARTER CLUTCH DIODE INSPECTION Hemove tne seatipage £2). ‘Open the fuse box cover and remove the clutch di- ode. Check for continuity between the diode terminals When there is continuity, a small resistance value Hf there is continuity in one direction, the diode is normalLIGHTS/METERS/SWITCHES FRONT BRAKE LIGHT SWITCH oe ll PRESSURE SWITCH TURN SIGNAL RELAY FAN MOTOR SWITCH THERMOSENSOR NEUTRAL swiTCH SIDE STAND swaTcHt REAR BRAKE LIGHT SWITCH 19-019. LIGHTS/METERS/SWITCHES ‘SERVICE INFORMATION 19-1 OIL PRESSURE INDICATOR 19-12 | HEADLIGHT 19-3 IGNITION SWITCH 19-12 | TURN SIGNAL LIGHT 193° HANDLEBAR SWITCHES 19-13 BRAKE/TAILLIGHT 194 BRAKE LIGHT SWITCH 19-44 LICENSE LIGHT 195 CLUTCH SWITCH 19-15 COMBINATION METER 13-6) NEUTRAL SWITCH wp SPEEDOMETER/SPEED SENSOR 19-8 SIDE STAND SWITCH 19-15 TACHOMETER 19-9 LOW FUEL INDICATOR/ FUEL RESERVE SENSOR 19-16 COOLANT TEMPERATURE GAUGE/ | TicRMosENSOR 19:9 HoRN 19-17 | | | | cooLinG FAN MOTOR SWITCH 19-11 TURN SIGNAL RELAY 19:18 I SERVICE INFORMATION GENERAL ————————————eeEe——————E—— * A halogen headlight bulb becomes very hot while the headlight is ON, and remains hot for a while after itis turned OFF. Be sure to let it cool down before servicing. ‘the water/coolant mixtura for the thermosensor inspection. Keep all flammable Wear protective clothing, insulated gloves and eye protection. += Note the following when replacing thy 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 ito fall — Ifyou touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early failure. Be sure to install the dust cover after replacing the bulb. * Check the battery condition before performing any inspection that requires proper battery voltage. * A continuity test can be made withthe switches installed on the motorcycle. Bu: Blue G:Green Lg:Light Green R:Red Bi Black Gr Gray 0: Orange W: White Br:Brown Lb: Light Blue Pink Y: Yellow 19-1LIGHTS/METERS/SWITCHES SPECIFICATIONS Tem | ‘SPECIFICATIONS: Bulbs Headlight Highiiow beam) | TV = Bose Brakefalight eemace sw “License light 1 1 ace = ron igiaunATg ng —| z= SzrscPesrewy 2 [CReertur signalight—-—T 12V~ 320° (23) 2 | sstument ight] tan "Tumm signalingicator BV LWx2 High bear indicator | wv — Law ‘TNeutatingieator i v= LW ~ “Oil pressure ingigator [rev nw t TED Fuse { 30a, | Subse = oA xa ‘Thermosensor resistance [At 80°C (T6F] a9 | AUTZO'C AF] ja 182 Fan motor switch [Starts to close (ON) 98 = 102 °C (208-216 °F) [stops to open 9397 °C (199207 F) TORQUE VALUES Trormrvsenous tore (unt, 7 it) Apply suaarn ws ees Fan motor switch Ignition switch mounting bolt Neutral switch Side stand switch bolt Fuel reserve sensor 19-2 18Nem (1.8 kghm 13 IDEA) 25 N.m (2.5 kgm , 18 bf 12N-m (1.2 kgm 9 bt) AON-m (1.0 kgf. 7 IBF) 2aN-m(23kgEm 17 lbERLIGHTS/METERS/SWITCHES. HEADLIGHT BULB REPLACEMENT A halogen headlight bulb becomes very hot while the headliaht is ON. and remains hot for a while after itis turned OFF. Be sure to let it cool down before servicing. Disconnect the headlight connector, Ramove the dust cover. Unhook the bulb retainer and replace the headlight bulb. Avoid touching halogen headlight bulb. Finger prints can create hot spots that cause a bulb to break. If you touch the bulb with your bare hands, clean it with @ cloth moistened with aleohol to prevent its early failure. Install Ue rerrioved parse une reverse Uruer OF ree moval REMOVAL/INSTALLATION Remove the front fairing Ipage 25) Remove the four screws, washers, two clamps and the headlight unit. outa the wices Install the headlight unit in the reverse order of re- ‘and hase properly moval (page 1-18) TURN SIGNAL LIGHT BULB REPLACEMENT Remove the screw and turn signal light lens. RETAINER DUST COVER HEASIIGHT AULA CONNECTOR WASHERS CLAMPS HEADLIGHT UNIT TURN SIGNAL LIGHT LENS 19-3LIGHTS/METERS/SWITCHES BRAKE/TAILLIGHT 10.4 ‘while pushing the bulb in, urn it counterctockwise to removeit, and replace it with @ new one. ‘Make sure that the lens aasket is installed in oosi- tion and is in good condition, and replace it with new one if necessary. Install the lens, aligning the slot with the tab of the REMOVAL/INSTALLATION ront: Hemove tne instrument panels ipage £9). Rear: Remove the seat Ipage 2-2) Disconnect the turn signal light connectors. Remove the nut, setting plate and the turn signal ligt. Install the turn signal ightin the reverse order of re= moval Nore Route the turn signal light wice properly (page 1-18) BULR REPLACFMFNT Remove the seat (page 2-2) from the brakefailight. TURN SIGNAL LIGHT BULB.LIGHTS/METERS/SWITCHES Pull the brake/tillight bulb out of the socket and re- place it with a new one. Install the socket by turning it clockwise Install the seat (page 2-2. LICENSE LIGHT BULB REPLACEMENT Remove the following: “two nuts and collars —tolte, wire lamp and wachere ~ number plate Bracket from the rear fender two nuts “tens, lens cover and license light base from the number plate bracket While pushing the bulb in, turn it counterclockwise to remove it, and repiace it with a new one position and is in good condition, and replace it ‘with new one if necessary. Install the removed parts in the reverse order of removalLIGHTS/METERS/SWITCHES COMBINATION METER COMBINATION METER ‘meter mayb damaged it the bub is removed or Ignition switen is ON, BULB REPLACEMENT Remove the instrument panels (page 25) Remove the bolt cap and meter mounting bolt Remove the amination mater frarn the fairing stay by sliding it downward, Remove the bulb hole cap from the meter lower omove the bull from the printed sirout board by turning it 45° counterclockwise. Install a new bulb and turn it clockwise to lockit Install the Dub note cap. Install the combination meter by aligning the two bosses with the grommets ofthe fairing tay. Install the mounting bolt and bolt cap. Install the inatrumant nanals (nage 9-8) REMOVAL/INSTALLATION Remove the combination meter from the fairing stay (see above) Disconnect the connector and remove the combina tion meter. Install the combination meter in the reverse order of removal 19-6LIGHTS/METERS/SWITCHES DISASSEMBLY/ASSEMBLY PRINTED CIRCUIT BOARD Bute wourmnbnussen | senew colle POWER/GROUND LINE INSPECTION Remove the combination meter (page 19-8) Check the following at the wire harness side connector of the combination meter. POWER INPUT LINE Moacurs the voltage batwoon the Bleck/brown wire terminal (+) and ground (~) There should be battery voltage with the ignition switch ON, It there is no voltage, check for open circuit in Black’orown wire RACK-UP VOLTAGE LINE Measure the voltage between the Red wire terminal (+) and ground (=I, There shuld be Letsry vollaye a al eves If there is no voltage, check for open circuit in red ‘SENSOR GROUND LINE CCheck for continuity between the Greer/black wire ‘There should be continuity at all times. If thore is no continuity, check for apan circuit in Groondblack wire. 19-7LIGHTS/METERS/SWITCHES SPEEDOMETER/SPEED SENSOR SYSTEM INSPECTION [Uneck that tne tachometer and coolant temperature ‘gauge function properly If they do not function, perform the power! ‘ground line inspection of the combination matar (soe above). * if they function, shift the transmission in neutral, disconnect the combination meter connector page 19-0) aid wun she igilon sween OW. Measure the voltage between the Pink/green (+) and Greeniblack (—) wire terminals of the wire harness side connector. Slowly turn the rear wheel by hand, ‘There should be 0V t0 5 V pulse voltage, =If pulse vokage appears, replace the printed circuit board, —If pulse voltage does not appet for short circuit in Pinkigreen wir If the Pink/green wire is OK, check the speed sensor. check for open SPEED SENSOR INSPECTION Raise the fuel tank (page 2.3) Turn the ignition owiteh ON and measure the voltage between the Black (+) and Green (—) wire terminals of the speed sensor 3P connector with the connector connected. ‘There should be battery voltage, Hf there is no voltage, check for open circuit in related wires Shift the transmission in neutral and turn the q bY ignition switch ON. ‘SPEED SENSOR 3P CONNECTOR Measure the voltage between the Pink (+) and — ‘Green |) wire terminal of the sensor connector with the connector connected. Slowly turn the rear wheel by hand, There should be 0t0 5 V oulse valtace, 19-8LIGHTS/METERS/SWITCHES. TACHOMETER SYSTEM INSPECTION ture gauge function properly. ‘if they do not function, perform the power! {ground line inspection of the combination mater (page 19-7, ‘If they function, disconnect the combination ‘meter connector (page 19-6) and turn the ignition cwiteh ON. Measure the voltage between the Yellow/green (+) and Green/black (~) wire terminals of the wire harness side connector. There should be battery voltage, If there is battery voltage, replace the printed cieeut hoard If there is no voltage, check for open or short circultin Yellow/green wire. COOLANT TEMPERATURE GAUGE/ THERMOSENSOR SYSTEM INSPECTION CCheck that the speedometer and tachometer func tion propery. if they do not function, perform the power {ground line ispection of tie combination meter (page 19-7) + If they function, raise the fuel tank (page 2), dis connect the thermosensor wire connector and ‘ground it with a jumper wire Turn the ignition anitsh ON ond check the coolant temperature gauge needle. The needle should move t0'"H". CAUTION: Immediately turn the ignition switch OFF when the naedla mouse to "Ht" that} ta pravant the gauge from being damaged. Ifthe needle moves, check the thermosensor. inne needle does not move, check for open clr- cuitin Greenvbiue wire Hf the Green/blue wire is OK, replace the printed circuit board:LIGHTS/METERS/SWITCHES 19-10 ‘THERMOSENEOR INEPECTION on ‘Keep all flammable materials away from the elec- tric heating element. Wear protective clothing, insulated gloves and eye protection. Remove the carburetor assembly (page 5-18) Disconnect the thermosensor connector and re ‘move the thermosensor. ‘Suspend the thermosensar in a pan af coolant {60-50 mixture) on an electric heating element ‘and measure the resistance through the sensor as SHERMONETER the coolant heats up. Nore Soak the thermosensor in coolant up to its threads with at least 40 mm (1.57 in) from the bot tom of the pan tothe bottom of the sensor. ‘* Keep the temperature constant for 3 minutes be- {ore testing. A audden change of temperature will result in incorrect readings. Do not let the ther- ‘mometer or thermosensor touch the pan, IMERMUSERSUH Temperate | BUCS | OC IEF] Resisince [47-870 1 1d= 180 Replace the thermosensor if it is out of specifica tions by more than 10% at any temperature listed. ‘Apply sealant ro ene thermosensor inreaas. Lo not apply sealant to the sensor head. Install and tighten the thermosensor. TORQUE : 10 Nm (1.0 kgf, 7 Ibf-t) Connect the thermosensor connector. Install the carburetor assembly (page 5-30). Fill and bleed the cooling system (page 6-<).LIGHTS/METERS/SWITCHES COOLING FAN MOTOR SWITCH Remove the left side faring (page 2-4) INSPECTION Fan motor does not stop Turn the ignition switch OFF, disconnect the | connector from the fan motor switch and tuen the ignition switch ON again, cuit between the fan motor and switch If the fan motor stops, replace the fan motor switch Fan motor does not start Before testing, check for a blown fan motor fuse. Disconnect the connector from the fan motor ‘switch and ground the connector with a jumper ‘Turn the ignition switch ON and check the fan mo- tor. ‘*1f the motor starts, check the connection at the fan motor switch terminal. If it OK, replace the fan motor switch. voltage between the Black/biue (+) and Green (=) wire terminals atthe fan motor 2P connector. ‘There should be battery voltage. If there is battery voltage, replace the fan motor. =if there is no voltage, check for open circuit in Blackiiaand Geaan wiras. REMOVAL/INSTALLATION Drain the coolant (page 6-5) Disconnect the fan motor switch connector and ce move the switch, Install and tighten the fan motor switch, TORQUE : 18 Nim (1.8 kgfim, 13 Ibf ft) Connect the fan motor switch connector. Fill and bleed the coolina svster (oaae 6-4) 19-11LIGHTS/METERS/SWITCHES OIL PRESSURE INDICATOR INSPECTION Indicator does not come on with the ignition switch turned ON Fomove the fuel tank page 23. Remove the rubber cap, and disconnect the oil pressure switch wire by removing the terminal Ground the wire terminal to the engine with a jumper wire. Turn the ignition switch ON and check the oi pressure indicator. + Ifthe indicator comes on, replace the cil pressure switch (page 43) ‘+ 1f the indicator does nat come on. check for oven circuit in BUR wire. Indicator stays on while the engine is running Remove the rubber cap, and disconnect the oil pres: ‘ure switch wire by removing the terminal screw. Check for continuity between the wire terminal and jrouna, ‘If there is continuity, chock for short circuit in Bu’ Rowire +#If here is no continuity, check the oil pressure (page £3). H the oll pressure is normal, replace the oi pressure ewiteh page 42) IGNITION SWITCH INSPECTION Remove the let air intake duct ipage 26) Disconncst the ignition awitch 4P (white) connoetor.LIGHTS/METERS/SWITCHES Check for continuity between the connector termi: nals in each switch position, Continuity should exist between the color coded wices as follows: Position ~~ | ON O==0 OFF. t “Tock = REMOVAL/INSTALLATION igcnnnaet tha ignitinn ewiteh AP fuhite) ennnen- tor (page 18-12), Remove the two mounting bolts (T80) and the ig Install the ignition switch and tighten the mount- ing bots. TORQUE :25 Nim (2.5 kgf, 18 bff) HANDLEBAR SWITCHS Remove the let sir intake duct (page 2-6). Disconnect the right handlebar switeh 2P and 4P (Red) connectors and left handiebar switch 12P connector Check for continuity between the connector termi- nals in each switen position, Continuity should exist between the color coded wires as follows: ENGINE STOP SWITCH —_ Color sw | Bw ‘OFF | RUN | STARTER SWITCH. —_ Color ~ vm | eww | ayn | au Position FREE PUSH | 19-13LIGHTS/METERS/SWITCHES | ow | uw | HORN swiTcH —_ Color DIMMER SWITCH _TURN SIGNAL SWITCH Position [Free = (rust BRAKE LIGHT SWITCH FRONT rectors and check for continuity between the switch terminals Tever squeezed and no continuity with the lever released REAR Remove the seat (page 2-2. Disconnect the rear brake light switch 2P (white) connector and check for continuity between the con: ector terminals. ‘There should be continuity with the rear brake ped: al depressed and no continuity with the pedal re Teoaes. 19-14LIGHTS/METERS/SWITCHES CLUTCH SWITCH GAGS smicicounectonsy Disconnect the clutch switch wire connectors and check for continuity between the switch termi ‘There should be continuity with the clutch lever ‘squeezed and no continuity with the lever re- leased. NEUTRAL SWITCH INSPECTION Disconnect the neutral switch wire connector. Check for continuity between the switch terminal sand engine ground There should be continuity with the transmission in neutral, and no continuity with the transmis: sion in gear except neutral REMOVAL/INSTALLATION Disconnect the neutral awitch wire connector Remove the neutral switch from the crankcase. Install the neutral switch with a new sealing wash- fer and tighten it. TORQUE :12.Nim (1.2 kgf-m, 9 IbF-) Connect the neutral switch wire connector. SIDE STAND SWITCH Remove the ltt side fairing (page 2-2), INSPECTION Riscnnneet the side stand ewitah 2P (green) cennee tor. Check for continuity between the connector termi- nals ‘There should be continuity with the side stana retracted and no continuity with the side stand low- ered. 2P CONNECT 19-15LIGHTS/METERS/SWITCHES REMOVAL/INGTALLATION Disconnect the side stand switch 2° (green) connec: tor. Remove the side stand switch bolt and the switch, Insta ine siae stana swaitcn by aligning tne swaten pin with the side stand hole and the switch groove with the bracket pin Install the side stand switch bolt and tighten it TORQUE : 10.N.m (1.0 kgf, 7 bf. Install the removed parts in the reverse order, Nore: Route the side stand switch wire properly (page v8) LOW FUEL INDICATOR/FUEL RESERVE SENSOR 19-16 INSPECTION Raise the ue! tank ipage 2). Low fuel indieator does not go off Disconnect the Browrvblack wire connector from the fual reserve sensor. “Turn the ignition switch ON and check the low fuel indicator. + Ifthe indicator does not come on, replace the fuel the indicator comes on, check for short circuit in Browniblack wire. {ows fal indicator does nat came on CCheck that the speedometer, tachometer and cool- {ant temperature gauge function properly. If they do not function, perform the power! groung tine inspection oF ine combination mecar (page 19-7), ‘sIF they function, disconnect the fuel reserve sen- sor connectors and short the connector terminals with a jumper wire ‘Turn the ignition switch ON and check the low fuel indicator. —I" the indicator comes on, replace the fuel reserve If the indicator does not come on, check for an open circuit in Brown/black and Green/black If they are OK, replace the printed circuit board [nage 19-71 SWITCH PIN JEERESEAVE SENSORLIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION CES Garvie is extremly Manabe ant Is expla 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, Remove the fuel reserve sensor from the fuel tank. Install @ new O-ring into the sensor groove properly {and install the reserve sensor, and tighten ft. TORQUE :23 Nim 12.3 kot. 17 bet CCheck for leakage from the reserve sensor. Install the fuel tank (page 2-2) HORN SSOP ornine connect Disconnect the wira connectors from the horn, Connect @ 12 V battery to the horn terminals. ‘The horn is normal if it sounds when the 12 V battery is connected across the horn terminals 19-17LIGHTS/METERS/SWITCHES TURN SIGNAL RELAY 19-18 Turn signal ight does not blink Remove the seat cowl (page 2-2. Disconnect the turn signal relay connector. Connect the Black’brown and Gray wire terminals Turn the ignition switch ON and cheek the turn sig nal light by operating the turn signal switch, Ifthe light does not come on, check for open cir cuitin Black/brown and Gray wires. ‘if the light comas on, check far eantinuity he- tween the Green wire terminal and body ground. If there is no continuity, check for open eireult in proce te If there is continuity, check the connector termi- nals for loose or poor contact. If the connector terminals are OK, replace the turn signal relay. 49 state/California type shown: ‘TURN SIGNAL RELAYL-0¢ 0029-MaWW-Z08C0 adh epeveg/oversey INVYSVIG ONIYIM “02WIRING DIAGRAM, California ype 030Z-MBW-7700 20-221. TECHNICAL FEATURE COIL-INTEGRATED SPARK PLUG CAP | (DIRECT IGNITION COIL) 214 | COIL-INTEGRATED SPARK PLUG CAP (DIRECT IGNITION COIL) ‘The direct ignition coil is the spark plug cap with the builtin ignition coil. The spark plug wire is omitted, and the light ‘weight and compact size ignition deviee is accomplished by the direct igrition col a — PRIMARY COIL, rtue terme 91-1MEMO22. TROUBLESHOOTING ENGINE DOES NOT START ORIS POOR PERFORMANCE AT HIGH | HARD TO START 22-1 SPEED 22-4 | ENGINE LACKS POWER 22-2 POORHANDLING 22-4 POOR PERFORMANCE AT LOW AND IDLE SPEED 22-3 ENGINE DOES NOT START OR IS HARD TO START Possible cause 1.Check the tual tow to carburetor [Not reaching carburetor ———= « Clogged tuet line and fiter *# Clogged fuel tank breather tube Reaching carburetor + Sticking float valve + Fauity fuel pump 2.Perform a spark test Weak or no spark ——=-« Faulty spark plug + Fouled spark plug system wires ‘+ Fauity ignition pulse generator * Faulty ignition coil * Faulty ignition control module (ICM) + Faulty engine stop switch aulty ignition switch 3.Remove and inspect spark plugs Wet plug = « Flooded carburetor * Starting enrichment (SE) valve ON Good condition position (open) 1 ‘+ Throttle valve open \ ‘Dirty ar cleaner 4, Start by following normal procedure Engine starts but stops ——- + Improper choke operation * Incorrectly adjusted carburetor * Lesking carburetor insulator Engine does not start ‘Improper ignition timing (Faulty ICM " ‘or ignition puloe generator! \ * Contaminated fuel 5, Test cylinder compression —— Low compression = # Valve stuck open *# Worn eylinder and piston rings + Damaged oylinder head gasket *# Seized valve f Imnrenar valve timing 22-1TROUBLESHOOTING ENGINE LACKS POWER 1. Raise whee! off the ground and spin by hand 2.Check tre pressure Pressure normal 3.Accelerate rapidly low to second Engine epaed reduced whon clutch isreleasea 4. acceterate ightly Engine speed increase ' t Correct | 1 6.Testevinder compression Normal camprassion 1 7. Check carburetor for logging: Not clogged 1 8, Remove and inspect spark plugs Not fouled or discolored 8, Chack ail level and condition Correct Topage 22-3 Possible cause ‘Wheel do not spin freely———r-« Brake dragging + Worn or damaged whee! bearings * Drive chain too tight Pressure low «Faulty tre valve Engine speed doesn’t ——= « Clutch slipping change accordingly when + Worn clutch dises/plates clutch is released ‘Warped clutch discs/plates *# Wook clutoh epring * Adltive in engine oil Engine speed does not ——= « starting enrichment (St valve UN, increase position (open! ‘Clogged sir cleaner + Restricted fuel flow ‘Clogged muffier « Restricted fuel tank breather tube covet = = Pauly ignition want smut JEM ‘Faulty ignition pulse generator + + Vaive clearance too small + Worn eylinder and piston rings 4s Damagad aylindar hand gackat + improper valve timing Clogged ——-——=« Carburetor not serviced frequently ssrougt Fouled or discolored = « Plugs not serviced frequently enough ‘Incorrect spark plug heat range Incorrect ————> «il evel 120 high * Oil level too low ‘Contaminated out 22-2TROUBLESHOOTING From page 23-2 Possible cause 10.Remove cylinder head cover and ——~ Valve train not lubricated —— « Clogged oll passage Tnigpect lubrication pevwerty + Glugyed vil uiiive Valve train lubricated properly 1 11. Check for engine overheating ——— Overheating > « Coolant level too low ‘+ Fan motor not working (Faulty fan motor Not overheating ‘Thermostat stuck closed ‘*Excessive carbon build-up in combus | tion chamber ‘Use ot poor quality uel ‘Clutch slipping ‘Loan fuel mixture 4 Wenng tyne af fun 12Accelerate or run at high speed Engine knocks > # Worn piston and cylinder '* Wrong type of fuel Texcesive taruun Uulleup tn eombus Engine does not knock tion chamber * Ignition timing too advance (Faulty ICM) Lean fuel mixture POOR PERFORMANCE AT LOW AND IDLE SPEED Possible cause 1.Check carburetor pilot screw adjust: — Incorrect 1 See section ment Correct + + Loose carburetor insulator bands ‘* Damaged carburetor insulator 2. Check for leaking carburetor insulator — Leaking Noman 1 4, Perform spark test Weak or intermittent ——» « Faulty spark plug spark + Fouled spark plug | * Loose or disconnected ignition system Quad spark wives * Faulty ignition pulse generator + Faulty ignition coil, * Faulty engine stop switch * Faulty ignition contral module (ICM) * Faulty ignition switeh 4. Check ignition timing Incorrect + Faulty ignition control module (ICM) + Faulty ignition pulse generator 22-3TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED Possible cause 1. Disconnect fuel tube at carburetor Fuel flow restricted ———> « Restricted fuel tube « Restricted fuel tank breather tube + Clogged fuel filter Fuel flows freely + Faulty fualvaivo + Faulty fuel pump 2. Check carburetor for clogging —— Clogged» «Carburetor not serviced frequently enough Notelogued 1 3. Check valve timing incorrect + « Cam sprockets not installed properly Correct 4, Check ignition timing —— Incorrect ——» Faulty ignition control module (ICM) ‘+ Faulty ignition pulse generator Correct 1 5. Check valve spring weak + Faulty valve spring Not weak POOR HANDLING Possible cause Alf steering is heavy + Steering stem adjustment nut too tight * Damaged steering head bearings 2.1f either wheel is wobbling + s excessive wheel bearing play * Bent rim Excessively worn swingarm pivot bearings * Bent frame 3.lfthe motorcycle pulled to one side» « Front and rear wheels not aligned ‘© Bent fork Bent axie ‘Bent frame 22-423. INDEX AIR CLEANER so ‘AIR CLEANER HOUSING ALTERNATOR CHARGING COIL... ALTERNATOR STATOR BATTERY wu BRAKE FLUID BRAKE FLUID REPLACEMENTIAIR BLEEDING... ONAKE LIGIIT SWITCH BRAKE LIGHT SWITCH BRAKE PAD/DISC. BRAKE PADS WEAR... BRAKE SYSTEM. BRAKEMTAILLIGHT CABLE & HARNESS ROUTING .. CAMSHAFT INSTALLATION, CAMSHAFT REMOVAL CARBURETOR ASSEMBLY CARBURETOR CHOKE... (CARBUNE | On COMBINATION CARBURETOR DISASSEMBLY/INSPECTION. (CARBURETOR INSTALLATION CARRUIRETOR REMOVAL CARBURETOR SEPARATION... CARBURETOR SYNCHRONIZATION CHARGING SYSTEM INSPECTION. cuuTcH CLUTCH DIODE... CLUTCH SWITCH. CLUTCH SYSTEM COILINTEGRATED SPARK PLUG CAP [DIRECT IGNITION COIL) COMBINATION METER COOLANT REPLACEMENT. COOLANT TEMPERATURE GAUGE/ THERMOSENSOR..... COOLING FAN MOTOR SwiTcH COOLING SYSTEM... CRANKCASE ASSENIBLY. CRANKCASE SEPARATION... GRANKPIN BEARING. CRANKSHAFT... CYLINDER COMPRESSION ... CYLINDER HEAD ASSEMBLY . EYLINDER MEAD COVER INSTALLATION CYLINDER HEAD COVER REMOVAL. CYLINDER HEAD DISASSEMBLY. CYLINDER HEAD INSTALLATION, CYLINDER HEAD REMOVAL... DIRECT AIR INDUCTION (D.A..) SYSTEM. DIRECT AIR INTAKE DUCT EMISSION CONTROL INFORMATION LABELS... EMISSION CONTROL SYSTEMS ENGINE IDLE SPEED. ENGINE INSTALLATION... ENGINE OIL es ENGINE OIL FILTER... ENGINE REMOVAL EVAPORATIVE EMISSION CONTROL SYSTEM (California type onty) EXHAUST SYSTEM. FLYWHEEL REMOVAL seven 10 FORK nn : 1342 FRONT BRAKE CALIPER 1015 FRONT FAIRING 25 FRONT INNER FAIR : 2a FRONT MASTER CYLINDER. 8S FRONT WHEEL . vse 137 FUEL LINE wratrnsnnn mae FUEL PUMP. : = 537 FUEL TANK. GEARSHIFT LINKAGE GENERAL SAFETY... HANDLEBAR. HANDLEBAR SWITCHES HEADLIGHT. HEADLIGHT AIM css HIGH ALTITUDE ADJUSTMENT. HORN. IGNITION SWITCH... IGNITION SYSTEM INSPECTION... IGNITION TIMING, LICENSE LIGHT. LOW FUEL INDICATOR/FUEL RESERVE SENSOR... 19-16 LUBRICATION & SEAL POINTS, : MAIN JOURNAL BEARING MAINTENANCE SCHEDULE MODEL IDENTIFICATION... NEUTRAL SWITCH. NUTS, BOLTS, FASTENERS OIL COOLER vernon OIL PRESSURE CHECK. OIL PRESSURE INDICATOR OIL PUMP... OIL STRAINER/PRESSURE RELIEF VALVE. PILOT SCREW ADJUSTMENT sensor PISTON/CYLINDER. RADIATOR COOLANT. RADIATOR RESERVE TANK. RADIATORICOOLING FAN. REAR BRAKE CALIPER, REAR FENDER/SEAT RAIL REAR MASTER CYLINDERIBRAKE PEDAL . REGULATOR/RECTIFIER RIGHT CRANKCASE COVER INSTALLATION. RIGHT CRANKCASE COVER REMOVAL, SEAT SEAT COWL... SECONDARY AiR SUPPLY SYSTEM SERVICE INFORMATION 318,837 ALTERNATOR, o 104 BATTERY/CHARGING SYSTEM 164 CLUTCH/GEARSHIFT LINKAGE vnnssnssnnsee 91 COULING SYSTEM ven CRANKCASE/TRANSMISSION : CRANKSHAFT/PISTON/CYLINDER 14 CYLINDER HEADIVALVE et ELECTRIC STARTER vvoscn sos TB ENGINE REMOVALIINSTALLATION vossesnee 7-2 FRAME/BODY PANELS/EXHAUST SYSTEM sss. 2-1INDEX SERVICE INFORMATION FUEL SYSTEM = 53 HYDRAULIC BRAKE 164 IGNITION SYSTEM... cara LIGHTS /METERS/SWiTCHES 184 LUBRICATION SYSTEM. a MAINTENANCE ae 3 REAR WHEEL/SUSPENSION SERVICE RULES... ‘SHIFT FORK/SHIFT DRUM. ‘SHOCK ABSORBER. SIDE FAIRING... SSIDE STAND asses SIDE STAND SWITCH... SPAKK PLUG. SPECIFICATIONS 'SPEEDOMETER/SPEED SENSOR. STARTER CLUTCH senso STARTER MOTOR STARTER RELAY SWITCH. STEERING HEAD BEARINGS Grecaine ore SUSPENSION... SUSPENSION LINKAGE SWINGARM sin SYSTEM TESTING TACHOMETER.. THERMOSTAT, THROTTLE OPERATION. THROTTLE SENSOR... = TOOLS verne TORQUE VALUES... TROUBLESHOOTING "ALTERNATOR vo 104 BATTERY/CHARGING SYSTEM worvnscnnsncns 163 CLUTCHIGEARSHIFT LINKAGE. 92 COOLING SYSTEM. . 62 CRANKCASE/TRANSMISSION wcarnunnannsnnone 12 CRANKSHAFTIPISTON/CYI INGER 2 CYLINDER HEADVALVE ELECTRIC STARTER ooo . ENGINE DOES NOT START OA IS HARD ENGINE LACKS POWER... FRAME/BODY PANELSIEKHAUST SYSTEM vornoue 2-1 FRONT WHEEL/SUSPENSIONSTEERING nnn 192 FUEL SYSTEM. a HYDRAULIC BRAKE wn 152 IGNITION SYSTEM... . 73 LUBRICATION SYSTEM = 42 POOR HANDLING ve POOR PERFORMANCE AT HIGH SPEED. POOR PERFORMANCE AT LOW ANO IDLE SPEED... 22:3 REAR WHEEL/SUSPENSION.. a2 ‘TURN SIGNAL LIGHT ied TURN SIGNAL RELAY wnssnssssssonsne aoe ele VALVE CLEARANCE 38 VALVE GUIDE REPLACEMENT. sa VALVE SEAT INSPECTION/REFACING ws cnncasnene 813 WATER PUMP enon en 6:12 WHEELSTIRES 327 23-2 WINDSHIELD. WIRING DIAGRAM, 26 2041