Documentos de Académico
Documentos de Profesional
Documentos de Cultura
Indicates a strong possibility of severe personal injury or death if instructions are not followed.
CAUTION: Indicates a possibility of eqiupment damage if instructions are not followed.
NOTE: Gives helpful information.
Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. It is
important to note that this manual contains some warnings and cautions against some specific service methods which
could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand
that those warnings could not cover all conceivable w ays in which service, whether or not recommended by Honda,
might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda investigate all
such ways. Anyone using service procedures or tools, whether or not recommended by Honda, must satisfy himself
thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected.
HOW TO USE TH IS MANUAL CONTENTS
Follow the Maintenance Schedule (Section 3)
recommendations to ensure that the vehicle is GENERAL INFORMATION
in peak operating condition and the emission
levels are within the standards set by the U.S. LUBRICATION
Environmental Protection Agency and Califor
nia Air Resources Board. Performing the first MAINTENANCE
scheduled maintenance is very important. It
compensates for the initial wear that occurs FUEL SYSTEM
during the break-in period.
COOLING SYSTEM
Sections 1 through 3 apply to the whole
motorcycle, while sections 4 through 1 9
ENGINE REMOVAL/INSTALLATION
describe parts of the motorcycle, grouped ac
w
cording to location.
CLUTCH/GEARSHIFT LINKAGE
Find the section you want on this page, then
turn to the table of contents on the first page
of that section.
orii ======
.
ALTERNATOR/STARTER CLUTCH
CYLINDER HEADIVALVE
Most sections start with an assembly or
system illustration, service l nformtion and CYLINDER/PISTON
troubleshooting for the section. The subse
quent pages give detailed procedures.
CRANKSHAFT/TRANSMISSION
REAR WHEEL/BRAKE/SUSPENSION
ALL INFORMATION, ILLUSTRATIONS, DI ======
0
RECTIONS AND SPECIFICATIONS INCLUDED IN HYDRAULIC DISC BRAKE
THIS PUBLICATION ARE BASED ON THE LATEST
PRODUCT INFORMATION AVAIL ABLE AT THE
BATTERY/CHARGING SYSTEM
TIME OF APPROVAL FOR PRINTING. HONDA
MOTOR CO., L TO. RESERVES THE RIGHT TO
MAKE CHANGES AT ANY TIME WITHOUT
NOTICE AND WITHOUT INCURRING ANY OBLI
GATION WHATEVER. NO PART OF THIS PUBLI ELECTRIC STARTER
CATION MAY BE REPRODUCED WITHOUT
WRITTEN PERMISSION.
LIGHTS/METER/SWITCHES
INDEX
GENERAL SAFETY
If the engine must be running to do some work, make sure the Gasoline is extremely flammable and is explosive under certain
areals well-ventilated. Never run the engine in an enclosed conditions Work in a well ventilated area with the engine
area. The exhaust contains posisonous carbon monoxide gas stopped. Do not smoke or allow flames or sparks in the work
that may cause loss of consciousness and lead to death. area or where gasoline is stored.
The battery generates hydrogen gas which can be highly explo The battery electrolyte contains sulfuric acid. Protect your
sive. Do not smoke or allow flames or sparks near the battery, eyes, skin and clothing. In case of contact, flush thoroughly
especially while charging it. with water and call a doctor if electrolyte gets in your eyes.
CAUTION :
Inhaled asbestos fibers have been found to cause respiratory Used engine oil may cause skin cancer if repeatedly left in con
disease and cancer. Never use an air hose or dry brush to clean tact with the skin for prolonged periods. A lthough this is
brake assemblies. Use an OSHA-approved vacuum cleaner or unlikely unless you handle used oil on a daily basis, it is still
alternate method approved by OSHA designed to minimize adviseable to thoroughly wash your hands with soap and
the hazard caused by airborne asbestos fibers. water as soon as possible after handling used oil.
SERVICE RULES
1. Use genuine H O N DA or HON DA-recommended parts and lubricants or their equivalents . Parts that don ' t meet H O N DA ' s
design specifications may damage to the vehicle .
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the vehicle . Metric bolts, nuts, and screws are not i nterchangeable with English fas
teners.
4. I nstal l new gaskets, 0-rings, cott e r pins, and lock plates when reassembling .
5. When tightening bolts or nuts, beg i n with the larger-diameter or inner bolts first. Then tighten to the specified torque diag-
onally in 1-5 steps, u nless a particular sequence is specified .
6. Clean parts in non-flammable or h i gh flash point solvent upon disassembly.
7. Lubricate a ny sliding surfaces before reassembly.
8. After reassembly, check all parts for proper installation and operation .
1 -1
GENERAL I N F O RMATION
The frame serial number i s stamped o n the right side o f the The engine serial number is stamped on the right crank
steering head. case below the rear cylinder.
The carburetor identification numbers are on the carbure The color label is attached on the frame under t h e seat.
tor body i ntake side. When ordering a color coded part, always specify its desig
nated color code.
1 -2
G E N ERAL I N FO R MATIO N
SPECIFICATIONS
1 -3
G E N ERAL I N FO RMATIO N
----
B attery capacity 1 2V BAH
S pa rk plug -----------------------------------,------------------- NGK N I P PO N D ENSO
Standard D PR B EA-9 X24 E P R - U 9
For cold climate D P R 7 EA-9 X22EPR-U9
( B elow 5" C,4 1 " F)
For extended high speed D P R 9 EA-9 X27 E P R-U 9
riding
Spark plug gap 0.8-0.9 m m ( 0.03 1 -0.03 5 i n )
Fuse Main 30 A
Sub 1 0 AX3, 1 5 AX 1
Starting system Electrical starter
H eadlight 1 2 v 60/ 5 5 w
Turn signal light Front 1 2 V 32/3 C P (23/8 W )X2 S A E No. 1 034
Rear 1 2 V 32 C P(23 W)X2 SAE N o. 1 0 7 3
B ra ke & taillight 1 2 V 32/3 C P (23/8 W)X2 S A E No. 1 034
M eter light 1 2 v 3.4 w
Indicator light Neutral 1 2 V 1 .7 W
High beam 1 2 V 1 .7 W
Tu rn signal 1 2 V 1 .7 W
Licence light 1 2 V 4 CP
Firing o rder Front(2)- R ear( 1 )308"
1 -4
G E N ERAL I N FO RMAT IO N
TORQU E VALU ES
ENG I N E
1 -5
G E N E RA L I N FO RMATIO N
FRAM E
Thread dia. Torque
ITEM O'ty Remark
(mm) N m ( Kg-m,ft-lb)
Steering stem nut 1 24 1 05 ( 1 0.5,7 6 )
Steeri ng bearing adjustment n ut 1 26 25 (2.5, 1 8 ) See page 1 2-23
Fork top pinch bolt 2 7 1 1 ( 1 . 1 ,8 )
Fork bottom pinch bolt 2 10 5 0 ( 5 .0,3 6 ) Apply o i l t o the threads
Front axle 1 18 7 5 ( 7 . 5,54)
Front axle pinch bolt 2 7 22(2.2, 1 6)
Rear axle nut 1 16 90(9.0, 6 5 )
B ra ke torque rod nut 8 27 (2.7,20)
'88, ' 8 9, ' 9 1 - ' 93, After '94: 2 8 22(2.2, 1 6)
'94.: 2 8 27 (2.7,20)
Middle brake a rm 1 8 27 (2.7,20)
M id d le rod joint n ut After ' 9 4 : 2 6 9 (0.9, 6 . 5 )
Caliper mounting bol '88,'89,' 9 1 -'93: 2 8 27 (2.7,20)
After '93: 2 8 3 1 (3. 1 ,22)
B ra ke hose oil bolt '88,'89,'9 1 -'93: 2 10 30(3.0,22)
After '93: 2 10 3 5 (3 . 5,25 )
B leed valve 1 8 5 . 5 (0. 5 5,4)
B ra ke master cylinder holder bolt 2 6 1 2( 1 .2,9)
B ra ke master cylinder cover screw 2 4 1 . 5 ( 0. 1 5, 1 . 1 )
B rake lever pivot bolt 1 6 1 (0. 1 ,0. 7 )
nut 1 6 6 ( 0. 6,43 )
B ra ke d isc mounting bolt 5 8 40(4.0,29) Apply locking agent
Caliper pin bolt 1 8 22(2.2, 1 6) Apply locking agent
Caliper bracket pin bolt 1 8 1 2( 1 .2, 9 ) Apply locking agent
Pad pin 1 10 1 8 ( 1 .8, 1 3 )
Pad pin plug 1 10 2.5 (0.25, 1 .8 )
Shock a bsorber u pper mounting bolt 1 10 4 5 (4.5,33 ) Socket bolt
Shock a bsorber lower mounting bolt 1 10 45 (4.5,33 )
Gearshift arm bolt 1 6 1 2( 1 .2, 9 )
Foot p e g bracket bolt 4 10 40(4.0,29 )
Swingarm pivot bolt 1 14 90(9.0, 6 5 )
Front u pper engine mounting bolt 1 10 5 5 ( 5. 5.40)
Front u pper engine bracket bolt 2 8 27 (2.7,20)
Front lower engine mounting bolt 1 10 5 5 ( 5. 5,40)
Rear u pper engine mounting bolt 1 10 5 5 ( 5. 5.40)
Rear u pper engine bracket bolt 2 8 27 (2.7,20)
Exhaust pipe joint n ut 4 8 25 (2.5, 1 8 ) Flange nut
Fuel tan k mounting bolt 1 8 1 9 ( 1 .9, 1 3 . 7 ) Flange bolt
Ignition switch mounting bolt 2 6 1 1 ( 1 . 1 ,8} Shear bolt
Exhaust pipe cover bolt 3 6 1 2( 1 .2,9)
Exhaust m uffler bracket bolt/nut
' 88 , ' 8 9 , ' 9 1 -' 93 : 1/1 8 27 (2.7,20)
After '93 1 /4 8 20(2.0, 1 4)
Helmet holder mounting bolt 2 6 1 3 ( 1 .3,9) Shear bolt
Side stan d pivot bolt 1 10 1 0( 1 .0,7.2) Socket bolt
nut 1 10 30(3.0,22)
Driven sprocket nut 5 10 6 5 ( 6.5,47 )
Fork tube cap 2 34 22(2.2, 1 6)
Front socket bolt 2 10 30(3.0,22) Apply locking agent
Damper rod lock nut '88,'89,'9 1 ,'92: 1 14 7 0 ( 7 .0,5 1 )
Spokes 1 08 4 4(0.4,2.9 )
Handlebar mounting nut 2 8 25 (2.5, 1 8)
Ha ndlebar upper holder bolt
After ' 9 4 : 2 8 3 0 ( 3 . 0, 22)
H a ndlebar lower holder n ut
After ' 9 4 : 2 8 23 (2. 3 , 1 6)
Fuel valve body 1 22 23 (2.3, 1 6 )
Throttle l i n k cover stay screw 2 4 2. 1 (0.2 1 ' 1 . 5 )
Rear ignitio n coil stay bolt 2 6 9 (0.9,6. 5 )
Battery cover mounting bolt 2 6 9 (0.9, 6 . 5 )
F u e l p u m p stay mou nting nut 1 6 9 (0.9,6 . 5 )
1 -6
GEN ERAL I N FORMATION
Torque specifications listed above are for specific tightening points. If a specification is not listed, follow the standard torque
values below .
1 -7
G E N ERAL I N FO RM ATIO N
TOOLS
SPECIAL
re Attachment
Fork seal driver , 3 9 m m 07947 - 4630 1 00 12
Ball race remover 07953 - MJ 1 0000 0 7 9 5 3 - MJ 1 OOOA , 12
- driver attachment 07953 - MJ 1 0 1 00 D river 0 7 9 5 3 - MJ 1 OOOB or
- driver handle 07953 - MJ 1 0200 D river handle 07 949- 3 7 1 000 1 and
Attachment,
32X35mm 07746- 00 1 0 1 00
Main bearing d river attachment 07H M F - M M 90400 11
Valve guide reamer, 5 . 5 1 0 mm
(IN) 07984 - 200000 1 9
Valve guide reamer, 6 . 6 1 2 mm 07 9 8 4 - 2 00000 D
(EX) 07984 -ZE2000 1 0 79 84 - ZE2 000 D 9
Attachment, 28 x 30 mm 07746 - 1 870 1 00
* Drive chain cutter 07 H M H - MR 1 01 03 N ot available 0 7 H M H- M R1010B
* Shock absorber compressor at- 07JM E - M R 1 0 1 00 in U . S .A. 13
tachment
* : New for this mode l .
1 -8
G E N ERAL I N FO RMATIO N
COMMON
1 -9
G E N ERAL I N FORMATI O N
X
does not interfere with any moving or sliding parts .
After routing, check that the wire harnesses are not twisted
or kinked.
0: C O RRECT
x: INCORRECT
1 -1 0
GENERAL INFORMATION
( 3) LEFT HANDLEBAR
SWITCH W I RE
( 7 ) HORN
W I RE
(4) SPEEDOMETE R
CABLE
1-11
GENERAL INFORMATION
' 94:
(1 ) THROTTLE CABLES
(4) SPEEDOMETER
CABLE
After '94:
( 1 ) TH ROTTLE CAB LES
( 3 ) LEFT HAN D LE B A R
SWITC H WI R E
).::;1t::::
:i ::::=- ( 1 ) TH ROTTL E
, CAB LES
(9) R I G HT HAN D LE B A R
SWITCH WI R E
\-1-'7"'77T---t-- (4) SPE ED O M ETER
CAB LE
(2) CLUTCH CAB LE
(9) R I G HT HAN D LE B A R
SWITC H WI R E
( 8 ) H O R N WI R E
11@fo ,:....\-mTt-t--+----
,_
(6) H EA D Li G HT
-(7) H O R N
C O N N ECTO R
1-12
GENERAL INFORMATION
'88-'89 '9 1 :
'
(2 ) HANDLEBAR SWITCH
W I RE BANDS
(9)
(6) I G N ITI O N P U LS E
GENERATOR
(7) CLUTCH CABLE W I RE
(2) C RANKCASE
(11 ) ENGINE B REATHER
B REATHER
TUBE
SE PA RATO R
(10 ) STARTER
M OTO R
(8) G RO U ND
CABLE ( 5 ) A I R CLEANE R
(7) CLUTCH CABLE
(6) I G N ITI O N P U LS E
GENE RATO R W I R E
HOUSING
1 - 13
G E N E R A L I N F O R MAT I O N
' 94 :
( 13) CRANKCASE BREATHER ( 1 ) HANDLEBAR SWITCH
TUBE WIRE BANDS
( 1 1 ) ENGINE B REATHE R
TUBE
(2) CRANKCASE
BREATHER
SEPARATO R
---l-1<:::.;..1--l-#-;.+---(3)
EVA PORATIVE
(9) STARTER EM ISSION
M OTOR PURGE CONTROL
CABLE VALVE (California
model only)
(4) SUB-AIR
CLEANER
( 1) HANDLE BAR
SWITCH WIRE
BANDS
( 1 0) STA RTE R
MOTO R
( 9 ) STA RTE R
MOTO R
CA BLE
:
0
'
'
'
:: ]
------- After' 9 5 : G
________
1 -1 4
GENERAL INFORMATION
( 1 ) THROTTLE
CABLES
'88-'89, '91-'93:
( 1 1 ) I G N ITI O N PULSE GENERATOR
4P WHITE CONNECTOR
( 1 2) HORN/FAN MOTOR
2P BLA CK CONNECTOR
:JID
(13)
-(0
.- -----
T U RN SIGNAL
9P WHITE CONNECTOR
( 1 4) INDICATOR PANEL
6 P GREEN CONNECTOR
( 1 5) SPEEDOMETER
6P BLACK CONNECTOR
(16) RIGHT HANDLEBA R SWITCH
9P RED CONNECTOR
1-1 5
GEN ERAL I N F O RMATION
'94 :
( 2) FRONT B RA K E H O S E
(3) I G N ITI O N P U LS E G E N E RATO R
4 P WH ITE CO N N ECTO R
(4) H O R N/FAN M OTO R
2 P B LA C K C O N N ECTO R
After '94 :
( 9 ) C RAN K CASE B R EATH E R D RAI N TU B E
(10) MAI N WI R E HAR N ESS
( 11 ) FAN MOTO R WI R E
1-16
GENERAL INFORMATION
-----;of-41-_17) REGULATOR/
RECTIFIER
( 1 9 ) IGNITION SWITCH
OIL PRESSURE
SWITCH
(21 I S I DE STAND SWITCH
1 -17
GENERAL INFORMATION
(7) THERMOSTATI C
SWITCH W I RE
( 6 1 RIGHT
( 5 ) IGNITION P ULSE CRANKCASE
GENERATOR
( 1 1 I BRAKE/TA ILLIGHT
CASE
( 1 21 TU RN SIGNAL
LIGHT
W I RE
( 1 3) LI CENCE LIGHT
WIRE
1 -1 8
G E N E RA L I N F O R MATI O N
After '93 :
( 1 ) ALTE RNATO R WI RE
1-19
GENERAL INFORMATION
NOTE
The hoses shown below are n u mbered as they appear on the Vacu u m Hose Routing Diagram Labe l .
( 1 ) @TUBE
( 1 5 ) ENGINE
BREATHER
TUBE
(FROM REAR
CYLINDER
HEAD )
@TUBE
AIR VENT CONTROL VALVE
(5)
( 1 21 EVAPORATIVE
EMISSION
CANISTER ( 1 1 l EVAPORAT IVE EM ISS ION CANISTER
OPEN
AIR TUBE ( 1 31 REA R SHOCK ABSORBER TUBE
1 - 20
G E N ERAL I N FO RMATIO N
SOURCE OF E M I SS I O N S
The combustion process p roduces carbon monoxide and hydrocarbons. Control o f hydrocarbons i s very important because,
under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not
react in the same way, but it is toxic.
Honda Motor Co . , Ltd . utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydro
carbons.
EXHAUST E M I S S I O N C O N T R O L SYST E M
The exhaust emission control system is composed o f a l e a n carburetor setting, and no adjustments should be m a d e except
idle speed adjustment with the throttle stop screw. The exhaust emission control-system is separate from the crankcase
emission control syste m .
CRA N K C A S E E M I S S I O N C O N T R O L S Y S T E M
The engine is equipped with a closed crankcase system which routes crankcase emissions through the air cleaner into the
combustion chamber.
c::::> FRESH A I R
-+ BLOW-BY GAS
1 -21
G E N ERA L I N FORMATION
This model complies with California Air R eso u rces Board evaporative emissio n requirements.
Fuel vapor from the fuel tan k and carbureto r is d irected into the evaporative emission canister where it is adsorbed a n d sto red
while the engine is stopped.When the engine is running and the evaporative emissio n purge control diaphragm valve is o pen,
fuel vapor i n the evaporative emissio n canister is d rawn i nto the engine through the carbu retor.
TO
OPEN
AIR
I (3) DRAIN
(4) EVAPO RATIVE EMISSIO N
CAN I STER
-- ( 5 ) EVAPO RATIVE E M I S S I O N
CAR B U R ETO R
IT AI R VENT CONTRO L VALVE
'
( 7 ) TO OPEN ( 6 ) EVAPO RATIVE E M I S S I O N
AIR CAR B U R ETO R
AI R VENT CO NTROL
VALVE
( E N G I N E STO P)
TAM PE R I N G WITH THE NOISE CONTROL SYSTEM IS PRO H I BITED : Federal law prohibits the fol lowing acts or the causing
thereof: ( 1 ) The removal or rendering inoperative by any person , other than for purposes of maintenance, repair, or replace
ment, of any device or element of design i ncorporated into any new vehicle for the purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is in use; or (2) the use of the vehicle after such device or element of design has
been removed or rendered inoperative by any person .
AMONG THOSE ACTS PRESU MED T O CONSTITUTE TAMPERING A R E T H E ACTS LISTED BELOW:
1 . Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust gases .
4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified
by the manufacturer.
1-22
G E N ERAL I N F O RMATI O N
The Vacuu m Hose Routing Diagram label is on the inside of the left side cover. Route the vacuum hoses as shown on this
label.
1-23
L U B R I CATIO N
'88, '89:
(1) ROCKER A R M
( 2 ) O I L PIPE
( 1 2 ) PISTON
l MAIN SHAFT
( 5 ) O I L STRA I N E R
( 6 ) PRESSU R E
(7) OIL FILTER R E L I E F VALVE
2-0
2. LU B R I CATI O N
After '89:
(1) ROCK E R A R M
(12) CAMSH A FT
(11) PISTO N
(10) O I L JET
(9) C R A N KSH A FT
( 2) MA I NSH A FT
( 8) CO U NT E R S H A F T
(7) O I L P R ESSU R E
SW ITCH
(@n
( 3) O I L PUMP
(4) O I L ST R A I N E R
( 5) P R ESSU R E
R E L I E F VALVE
2- 1
L U BRICATI O N
O I L FILTER C H A N G E 2-5
SERVICE I N FO RMATION
If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.
CAUTION
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. A lthough this is unlikely
unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possi
ble after handling used oil.
G E N ERAL
The o i l p u m p c a n be serviced a f t e r r e m o v i n g the e n g i n e from the fra m e .
S P E C I F I CATI O N S
Engine oil
Other viscosities s h o w n i n t h e c h a rt m a y
be u s e d w h e n the average tem perature
i n your riding area i s w i t h i n the i n d i cated
range .
0 20 40 60 80 100 F"
-20 -10 0 10 20 30 40 c
Oil pump
ITEM STA N DA R D S E R V I C E LI M I T
T O R Q U E VALU E S
O i l pressure s w itch 1 2 Nm ( 1 . 2 kg-m, 9 ft-lb)
Engine o i l d r a i n bolt 3 5 Nm ( 3 . 5 kg-m, 25 ft-l b )
Oil filter 1 0 N m ( 1 . 0 k g - m , 7 . 2 ft- l b )
2-2
L U BRICATIO N
T O O LS
Special
Oil filter wrench 07HAA - PJ 70 1 00
0 7 5 1 0- 4220 1 00 J
Oil pressure gauge 07 506 - 3000000 or equivalent commercially available in U . S . A .
Oil pressure gauge attachment
Snap ring pliers 079 1 4 - 323000 1 - or equivalent commercially available in U . S . A
TROUBLESHOOTI NG
Oil level too low
Oil contamination
Oil leaks
No oil pressure
Oil leaks
2-3
LUB R I CATIO N
Stop the engine, remove the oil fi ller cap/di pstick and wipe it
clean.
Check the oil level with the oil filler cap/d ipstick by inserting it
without screwing it in.
NOTE
Do not screw the cap in when making this check.
If the oil level is below the lower level mark on the di pstick, fill
to the upper level mark with the recommended oil .
Check the 0-ring for damage.
Change the engine oil with the engine warm and the motor
cycle on its side stand to assu re complete and rapid drain
ing .
( 1 ) DRA IN BOLT
R emove the o i l f i l ler cap/d ipst ick and d rain bo lt.
W ith the engine stop sw itch OFF, push the starter button for
a few seconds to drain any o i l which may be left in the eng ine.
( 1 ) D RA IN BOLT
NOTE
Do not operate the motor for more than few seconds.
After the oil has drained, check that the drain bolt sealing
washer is in good condition, and instal l the bolt.
OIL CAPACITY:
\
( 2 ) SEALING WASHER
2. 8 lit (2.94 US qt, 2.46 Imp qt) after disassembly
2.25 lit (2.36 US qt, 1 .98 Imp qt) at oil filter and oil change
2.1 lit (2.21 US qt, 1 . 85 Imp qtl after draining
Stop the engine and wait a few m inutes, then check that the
oil level is at the upper level mark with the motorcycle upright.
2-4
LUB R I CATION
O I L FI LTER CHANGE
Drain the engine o i l ( page 2-4) .
CAUTION
Do not replace the oil filter when the exhaust system is hot.
TOOL:
Oil filter wrench 07HAA - PJ70 1 00
(2) OIL FILTER WRENCH
Apply oil to the new oil filter 0-ring and install the new oil filter. (1 l OIL F I LTER
Tighten the oil filter with a filter wrench .
O I L P RESSU R E CHECK
Remove the following:
- drive sprocket cover (page 1 3 - 1 4)
- drive sprocket cover bracket (2) 0-RING
- switch cover and switch screw
Disconnect the wire from the oil pressure switch, remove the
switch and connect an oil pressure gauge to the switch hole.
TOOLS :
Oil pressure gauge 07506 - 0 7 506 - 3000000
Attachment 07 5 1 0 - 4220 1 00 or
equivalent commercially
available in U . S . A .
Connect the oil pressure switch wire and pull the dust cover
over the switch body securely.
Start the engine and check that the oil pressure warning light
goes out after one or two- seconds.
NOTE
Route the oil pressure switch wire properly ( page 1 - 1 5)
2-5
LU BRICATION
PRES S U R E R E L I E F V A L V E D I SA S S E M B LY
TOOL:
Snap ring pliers 079 1 4 - 323000 1
or equivalent commercially
available in U . S.A.
I N S PECTI O N
Check the spring, 0-ring and valve for fatigue, wear or dam
( 1 ) 0-R I N G
( 2 1 BOOY
Q
age. ( 3 ) VALVE
Check the body for clogging or damage .
Replace the relief valve as an assembly.
Clean all the parts and assemble them i n the reverse order of
disassembly.
( 5 ) SNAP R I N G
2-6
L UB R I CATIO N
Remove the oil strainer and oil pipe from the oil pump. (1 l O I L STRA I N ER
Check the 0-rings and oil seal for fatigue or damage. ( 1 l O I L SEAL (21 OIL STRA I N E R
Clean the oil strainer and oil pipe w ith non-flammable or high
flash point solvent.
/
0
(31 0-R I N G S
O I L PUMP I N S P ECTI O N
2-7
LUBRICATI O N
Remove the oil pump shaft from the oil pump and measure the
pump end clearance.
O I L PU M P A S S E M B LY
'88 , '89 , '91 -93:
(1 I PU M P BODY
( 1 0 1 0-RI N G
( 1 1 I O I L STRA I N E R
2-8
LUB R I CATI O N
After '93:
( 2 ) 0 UT E R R OTO R
(3 ) 1 N N E R R OTO R
(8)WASHER
(9)SPRING
I
( 1 4) D R IVE P I N
( 1 3 ) PU M P SHAFT
1 1 ) O I L STRAI N E R
I nstal l the outer rotor in the pump body with the punch mark
facing the cover, then i nstall the inner rotor.
I nstall the drive pin and spacer on the shaft.
I nstall the shaft i n the body, aligning the drive pin with the
inner rotor groove.
(6)
I N N E R ROTOR
2-9
LABRICATION
After '93:
( 1 ) O I L P U M P B O DY
I nstall the dowel pins on the p u m p cover,then i nstall the pump
body.
( 3 ) 0 1 L P U M P COVER
Install the 0-rings, oil seal, oil strainer and oil pipe on the oil
pump. (2) 0-R I NG (3) 0-R INGS
CAUTION
Install the 0-rings on the oil pipe with the tapered side facing
out as sho wn, or the engine will be damaged.
After '93:
( 1 ) 01L S EAL ( 2 ) E DG E
Insta l l the oil seal on the oil pump.
Align the edge of oil strainer with the g roove of the pump
cover,then i nstall the oil strainer as shown.
(4) 0 1 L STRAI N E R
2-10
L UB R I CATI O N
O I L PU M P I N STALLAT I O N
( 2 ) DOWEL PIN
I nstall the pressu re relief valve cover with the bolt. (1 l PRESSU R E RELIEF VALVE COVER
Assemble the crankcase (Section 11 ).
2- 1 1
LUBRICATI O N
(1 l
,
CLUTCH AND BRAKE
LEVER
( 2 ) TH ROTTLE
GRIP
- ----
(11 l STE E R I N G
HEAD BEAR I N G
..
I
I
I
I
I
- ---- -
( 7 ) BRAKE PEDAL ( 5 ) SWI NGARM
-
PIVOT PIVOT BALL
AND N EEDLE
BEARINGS
,
(4) DRIVE CHAIN
- lijiVft
(8) ( PR O HO N DA CHA I N LU B E )
BRAKE & CHANGE
CALI PER PIVOTS (6) S I D E STAND
(SILICON G R EASE) PIVOT
2-12
3. MAI NTENANCE
S E R V I C E I N FORMAT I O N 3- 1 C Y LI N D E R CO MP RESS IO N 3- 1 2
Ill
< EN G I N E>
BRAKE F L U I D 3-1 5
FUEL LINE 3-6
BRAKE S H O E/PAD WEAR 3-1 6
T H ROTTLE OP E RATIO N 3-6
BRAKE SYSTEM 3- 1 6
CA R B U R ETO R C HO K E 3- 7
BRAKE L I G HT SWITCH 3-1 7
A I R C LEAN E R 3- 7
H EADLIGHT AIM 3- 1 8
C RA N KCAS E B R EAT H E R 3-8
CLUTCH SYSTEM 3-1 8
S PA R K PLUGS 3-8
S I D E S TAND 3-1 9
VALV E CLEARANC E 3-8
S US PE N S IO N 3-1 9
CAR B U R ETO R S Y N C H RO N IZATIO N 3- 1 0
N UTS, BO LTS, FASTENERS 3 -20
CA R B U R ETO R I D L E SP E E D 3- 1 1
W H E E LS/TIRES 3 - 20
RADIATO R COO LA N T 3- 1 1
S T E E R I N G H EAD BEA R I N G S 3-21
C OO LI N G SYSTEM 3- 1 2
SERVICE I N FORMATION
If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.
Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area with the engine stopped.
Do not smoke or allow flames or sparks in the work area or where gasoline is stored.
G E N ERAL
S P E C I F I CATI O N S
E N G I N E
Ignition timing Initial '88 . ' 8 9 ,'9 1 - ' 9 3; 6 . 2 BTDC at idle
After ' 93; 6 . 5 BTDC at idle
Full advance 30 BTDC at 6 , 000 rpm
Spark plug N I PPON DENSO
NGK
Standard DPR8EA-9 X24EPR-U9
For cold climate ( below 5 C/4 1 F) DPR7 EA-9 X22EPR-U9
For extended high speed driving DPR9EA-9 X27 EPR-U9
Spark plug gap 0 . 8 - 0 . 9 mm (0.03 1 - 0.035 in)
Valve clearance IN 0 . 1 5 0.02 mm (0.006 0 . 0008 in)
(COLD) EX 0 . 20 0.02 mm (0.008 0 . 0008 in)
Idle speed 1 , 200 1 00 rpm
Cylinder compression 1 , 324 98 kPa ( 1 3 . 5 1 .0 kg/cm2, 1 92 1 4 psi)
Throttle grip free play 2 - 6 mm ( 1 / 1 6 - 1 /4 in)
3- 1
MAINTENAN CE
C H A S S I S
Rear brake free play 20 - 30 mm (3/4 - 1 -3/1 6 in)
Brake pedal height 43 mm ( 1 . 7 in)
C l utch lever free play 1 0 - 20 mm ( 3/8 - 3/4 in)
D rive chain slack 20 - 30 mm ( 3/4 - 1 -3/ 1 6 in)
Tires
Front Rear
Tire size 1 00/90- 1 9 57S 1 70/80- 1 5 7 7 S
Cold tire pressures U p to vehicle capacity load 200 ( 2 . 00, 29) 2 50 ( 2 . 50, 3 6 )
kPa (kg/cm2, psi) Up to 90 kg ( 200 lbs) load 200 ( 2 . 00, 29) 2 0 0 ( 2 . 00, 2 9 )
M aximum weight capacity 1 6 1 kg ( 3 5 5 lbs)
Tire brand Bridgestone L309 G 546
Dunlop F24 K555
TO R Q U E VALU E S
T O O LS
Special
Valve adjusting wrench 07 908 - KE90000 N ot available in U . S . A .
07908 - KE90 1 00 U . S . A . Only
Vacuum gauge 07404-0030000 or N ot available in U . S . A .
07 LMJ - 00 1 000A U . S . A . Only
Drive chain cutter 07HMH- M R 1 0 1 00 or
07HMH- M R 1 0 1 0 B U . S . A . Only
Spoke wrench 07J MA- M R 6 0 1 00 N ot available in U . S . A .
3-2
MAINTENANCE
WHICHEVER
FREQU E N CY
COMES ODOMETER READI N G ( N OTE 1 )
FI RST ..
*
z CARBU RETOR-
I I I I 3- 1 0
0 SYNCHRO N IZAT I O N
U5
en * CARBURETOR-IDLE SPEED I I I I I I I 3- 1 1
w RADIATOR COOLANT 2 YEARS * R I I *R 3- 1 1
* COOLING SYSTEM I I I 3- 1 2
* EVAPO RATIVE E M I S S I O N
(NOTE 4) I I 3-1 3
CONTROL SYSTEM
DRIVE CHAIN EVERY 600 mi ( 1 ,000 km) I. L 3- 1 3
en BRAKE FLU I D 2 YEARS * R I I *R I I *R 3-1 5
w BRAKE SHOE/PAD WEAR I I I I I I 3- 1 6
!::::
0 BRAKE SYSTEM I I I I 3- 1 6
I-
w
* BRAKE LIGHT SWITCH I I I 3-1 7
<{
...J
* HEADLIGHT A I M I I I 3- 1 8
a:
w
w
* SUSPE N S I O N I I I 3-1 9
z * NUTS, BOLTS, FASTEN ERS I I I I 3-20
0
z ** WHEELS/TIRES I I I I I I I 3-2 0
** STE E R I N G HEAD BEA R I N G S I I I I 3-2 1
* Should be serviced by a n authorized Honda dealer, unless the owner has proper tools and service data and is mechanically
qualified .
** I n the interest of safety, we recommend these items be serviced only by an authorized Honda dealer.
NOTES : 1 . At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3 . Service more frequently when riding in rain or at full throttle.
4 . California model only.
3-3
MAINTENANCE
O D O METER READ I N G ( N OTE 1 )
x 1 ,000 mi 0.6 4 8 12 16 20 24 REFER TO
M
NOTE x 1 ,000 km 1 6.4 1 2 . 8 1 9 . 2 2 5 . 6 32.0 38.4 PAG E
* FUEL LINE I I I 3-6
* THROTTLE OPERATION I I I 3-6
* CARBU RETOR CHOKE I I I 3-7
(/)
A I R CLEANER ( NOTE 2 ) R R 3-7
:2
w C RA N KCASE BREATHER ( N OTE 3 ) c c c c c c 3-8
!:::
c
SPARK PLUG R R R R R R 3-8
1- * VALVE CLEARANCE
w
I I I I 3-8
<(
....J
ENG I N E O I L R R R R 2-4
a:
w
<(
I I I 3- 1 7
w * HEADLIGHT AIM
....J
a:
I I I 3- 1 8
z CLUTCH SYSTEM I I I I I I I 3-1 8
0
U5 S I DE STAND I I I 3- 1 9
(/)
w
* SUSPENSION I I I 3- 1 9
z * N UTS, BOLTS, FASTENERS I I I I 3-20
0
z ** WHEELS/TI RES I I I I I I I 3-20
** STEERING HEAD BEARI N G I I I I 3-2 1
* SHOU L D BE SERVICED BY AN AUTHORIZED HONDA DEALER, U N LESS THE OWN ER HAS PROPER TOOLS A N D SER
VICE DATA AND IS M ECHANICALLY QUALI FIED.
** I N THE I NTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED O N LY BY AN AUTHORIZED HONDA
DEALE R .
NOTES : 1 . A t higher odometer readings, repeat a t the frequency interval established here .
2 . Service more frequently when riding in unusually wet or dusty areas.
3 . Service more frequently when riding in rain or at ful l throttle.
4 . California type only.
5 . Replace every 2 years, or at indicated odometer interval , whichever comes first . Replacement requires me
chanical skill.
3-4
MAI NTE N A N C E
w
* VALVE C LEARAN CE I I I I 3-8
ENGINE OIL R R R R 2 -4
a:
w
z
E N G I N E O I L F I LTER R R R R 2-5
0 * CAR B U R ETO R SYN C H R O N IZATIO N I I I I 3- 1 0
en
(/) * CAR B U R ETO R I D LE S P E E D I I I I I I I 3- 1 1
:2:
w R A D I ATO R COOLANT ( N OTE5) I I R 3- 1 1
* C O O LI N G SYSTEM I I I 3- 1 2
* EVAPO RATIVE E M I SS I O N C O N -
( N OTE4) I I 3- 1 3
T R O L SYSTEM
D R IVE CHAI N I , L EVERY 500mi (80 0 km ) 3-1 3
(/) B RA K E F LU I D ( N OTE5) I I R I I R 3- 1 5
:2:
w
!:::
B RA K E S H O ES/ PADS WEAR I I I I I I 3- 1 6
c B RA K E SYSTEM I I I I 3- 1 6
w
* B RA K E LI G HT SWITC H I I I 3- 1 7
* H EA D L I G HT A I M I I I 3- 1 8
a:
w
z C LUTCH SYSTEM I I I I I I I 3- 1 8
0
en S I D E STA N D I I I 3- 1 9
* SUSPENSION I I I 3- 1 9
:2:
w * N UTS , B O LTS , FASTEN E R S I I I I 3-20
z
I
0 ** W H E E LS/TI R ES I I I I I I I 3-20
z
** STE E R I N G H EAD B EAR I N G I I I I 3-2 1
* S H O U LD B E S E RVICED BY YO U R AUTH O R IZ E D H O N DA D EALE R , U N LESS TH E OWN E R HAS P R O P E R TOO LS AN D
S E RV I C E DATA AN D IS M EC H AN I CALLY QUALI F I E D .
* * I N TH E I NT E R EST O F SAF ETY , W E R E CO M M E N D THESE ITEM S B E S E RVI C E D O N LY BY YO U R AUTH O R IZ E D
H O N DA D EALE R .
N OTES : 1 . At higher odometer readings, rep eat a t the frequency interval established here .
2 . Service more frequently when riding in u nusually wet or d u sty a reas .
3 . Service more frequently when rid i n g in rain or at fu ll throttle .
4 . California type only .
5 . Replace every 2 years , or at indicated odometer interva l , whichever comes first . Replacement requ i res me
chanical skill .
3-5
MAI NTENAN C E
FUEL LI N E
Remove the seat .
F U E L F I LTER
Pul l the fuel filter out, clip the inlet line closed and remove the
filter.
Replace the fuel filter with new one, if necessary (page 4-3 ) .
TH ROTTLE O P E RATION
Check for smooth throttle grip full opening and automatic full
closing in all steering positions.
C heck the throttle cables and replace them if they are deterio
rated , kinked or damaged .
Adjust the free play by loosening the lock nut and turning the
adjusting nut. Tighten the lock nuts .
3-6
M A I NTENANC E
Direction Friction
A Increase
B Decrease
Loosen the choke valve nut and remove the choke valve from
the carburetor.
Pull the choke knob all the way out to fully open position and
recheck for smooth operation of the choke knob.
There should be no free play.
Check the valve seat on the choke valve for damage. Reinstall
the choke valve in the reverse order of removal .
AI R CLEANER
Remove the a i r cleaner housing cover bolt and cover.
3- 7
MAINTENANCE
Remove the drain plug from the tube to empty any deposits .
Reinstal l the drain plug.
NOTE
Disconnect the spark plug cap and remove the spark plugs.
VALVE CLEARANCE
NOTE
3 -8
MAINTENAN CE
Remove the valve adjusting covers from the cylinder head cov
ers.
NOTE
F R O N T C Y L I N D E R H EA D
VALVE CLEARANCES :
Intake : 0 . 1 5 0 . 02 mm (0.006 0 . 0008 in)
Exhaust : 0 . 20 0 . 02 mm (0.008 0 . 0008 in)
TOOL:
Valve adjusting wrench 0790 8 - K E90000
N ot ava i lable i n U . S . A .
07908- K E 9 0 1 00
3- 9
MAINTENANCE
R E A R C Y L I N D E R H EA D
TORQUE
Timing hole cap:
3.5 Nm (0.35 kg-m, 2 . 5 ft-lbl
Crankshaft hole cap:
1 5 Nm ( 1 . 5 kg-m, 1 1 ft-lb)
Remove the fuel tank mounting bolt. Carefully raise the tank
and support it in the frame using a suitable base (see page 3-
9) . .
Remove the air cleaner case ( page 4-4) . Remove the plugs from
the cylinder intake ports and install the vacuum gauge
adaptors as shown .
TOOL:
Vacuum gauge 07404 - 0030000
N ot ava i lable in U . S . A .
07 LMJ - 0 0 1 OOOA
Warm up the engine and adjust the idle speed with the throttle
stop screw.
3- 1 0
M A I NTENANC E
NOTE
The rea r cylinder carburetor is the base carburetor .
RADIATOR COOLANT
Check the coolant level of the reserve tank with the engine
running at normal operating temperature .
The level should be between the " U P" and " LOW" level lines.
If necessary, remove the right side cover and then remove the
reserve tank cap.
Fill up to the upper level line with 50/ 50 mixture of distilled
water and antifreeze .
3- 1 1
MAI NTENAN C E
COOLI NG SYSTEM
Remove the radiator shroud and check the radiator air pas
sages for clogging or damage . ..
llllf
Straighten bent fins or collapsed core tubes with a small flat
blade screwdriver as shown and remove insects, mud or any
-- --- -- -- . -
obstructions with compressed air or low pressure water.
Replace the radiator if the air flow is restricted over more than
20 % of the radiated surface .
For radiator replacement, refer to page 5-5.
NOTE
Check that there is no leakage at the gauge connection .
The maximum reading is usually reached within 4-7 sec
onds.
COMPRESSION :
1 ,324 98 kPa ( 1 3 . 5 1 . 0 kg/cm2, 1 92 1 4 psi)
3- 1 2
MAINTENAN CE
DRIVE CHAIN
CHAIN SLACK INSPECTION
Never inspect or adjust the drive chain while the engine is run
ning.
Turn the ignition switch off, su pport the motorcycle on its side
stand, and shift the transmission into n e utr a l .
Check slack in the d rive chain lower run midway between the
sprockets .
"'
CHAIN ADJ USTMENT
3- 1 3
MAINTENANCE
Check the chain wear label. If the red zone on the label aligns
with the arrow mark of the chain adjuster after the chain has
been adjusted , the chain must be replaced .
L U B R I CATI O N A N D C LE A N I N G
(1) W I PE D RY
When the drive chain becomes extremely dirty, i t should be
cleaned prior to lubrication.
Clean the drive chain with a non-flammable or high flash point
and wipe dry.
Lubricate the d rive chain with Pro Honda Chain Lube or equiv
alent chain l ubricant desig ned specifically for use on 0-ring
chains .
C H A I N R E PLAC E M E N T
TOOL:
Drive chain cutter 07HMH - M R 1 0 1 03
N ot ava i l a b l e i n U . S . A .
07 H M H - M R 1 0 1 0B
NOTE
When using the special tool, follow the manufacturer ' s op
erating instructions. (1) SWINGARM
CAUTION
Never reuse the old drive chain, master link, master link plate
and 0-rings.
3- 1 4
MAINTENANCE
Assemble the new master link, 0-rings and plate . (2) 0-RINGS
CAUTION
Insert the master link from the inside of the drive chain and in
stall the plate with the identification mark facing the outside.
Make sure that the master link pins are installed properly.
L
Measuring the master link pin length projected from the plate. MASTER (5) STAN DAR D
LI N K LEN GTH
1m
Standard length: R K: 1 .2-1 .4 m m (0.05 -0.06 i n )
D I D : 1 . 1 5-1 . 5 5 mm (0.05 -0.06 i n )
Stake the master link pins using the special tool. (4) D R IVE CHAI N CUTIER
D I A M ET E R OF TH E STA K E D A R EA:
5.50-5.80 m m (0.2 1 7-0.228 i n )
After staking, check the staked area of the master link for
cracks.
If there is any cracking , replace the master link, 0-rings and (3) N O G O O D
plate . ( 4 ) CRACKED
CAUTION
Drive chain with clip-type master link must not be used.
D R I V E A N D D R I V E N SPRO C K ET
NOTE
Never install a new d rive chain on worn sprockets or a worn
chain on new sprockets . Both chain and sprockets must be
in good condition, or the new replacement chain or sprock
ets will wear repidly. (2) NORMAL
I
BRAKE FLU I D
Check the front brake fluid through the sight glass; if the level
is visible, remove the cover, set plate and diaphrag m . Fill the
reservoir to the upper level with DOT 4 fluid from a sealed con
tainer. Check the system for leaks.
CAUTION
Do not remo ve the reservoir cover until the handlebar has been
turned so that the reservoir is level.
Do not mix different types offluid, as they are not compatible
with each other.
Do not allo w foreign material to enter the system when filling
the reservoir.
A void spilling the fluid on painted, plastic or rubber parts.
Place a rag o ver these parts whenever the system is serviced.
3- 1 5
MAINTENAN C E
CAUTION
A lways replace the brake pads as a set to assure even disc pres
sure.
After '93 :
Replace the brake pads if the wear grooves in the pads are visi
ble (page 1 4-5 ) .
CAUTION
A lways replace the brake pads as a set to assure even disc pres
sure.
B R A K E S H O E I N S P E CT I O N
BRAKE SYSTEM
I nspect the brake hoses and fittings for deterioration, cracks
and signs of leakage. Tighten any loose fittings.
Replace hoses and fittings as required .
BRAKE P E D A L H E I G H T
3- 1 6
MAINTENANCE
To Adjust :
Loosen the stopper bolt lock nut and turn the stopper bolt .
Retighten the lock nut .
NOTE
After a djusting the brake pedal height, check the rear brake
light switch and brake pedal free play and adjust if neces
sary.
B R A K E P E D A L F R E E P LAY
NOTE
NOTE
After adjusting the brake pedal free play, check the rear
brake l ight switch operation and adjust if necessary.
Adjust the brake light switch so that the brake light will come
on when the brake pedal is depressed 20 mm (3/4 in). and
brake engagement begins. Hold the switch body and turn the
adjusting nut. Do not turn the switch body .
3- 1 7
MAINTENANCE
NOTE
Adjust the headlight beam as specified by local laws and
regulations.
A n improperly adjusted headlight may blind oncoming drivers, (2) VERTICAL ADJUSTING
or it may fail to light the road for a safe distance. SCREW
----
CLUTCH SYSTEM
Measure the clutch lever free play at the lever end.
i
( 1 ) 1 0 - 20 mm
( 3/8 - 3/4 in)
\
Minor adjustments are made with the upper adjuster. ( 1 ) U PPER ADJ U STER
Pul l the lever cover back, loosen the lock nut and turn the ad
juster to obtain the specified free play.
After'9 5 :
M ajor adjustments are made with the lower adjuster.
Loosen the lock nut and turn the adjusting nut to obtain the
specified free play.
( 1 ) LOWE R ADJ U ST E R
3- 1 8
MAI NTENANCE
SI DE STAND
Check the spring for damage o r loss of tension.
Check the side stand assembly for freedom of movement.
Lubricate the pivot bolt and the side stand pivot area if neces
sary.
Tighten the pivot bolt and nut.
SUSPENSION
FRONT
Check the entire fork leg assembly for signs of leaks or dam
age .
Replace any components which are unrepairable.
Tighten a l l nuts and bolts to the specified torque value.
!
REAR
3- 1 9
MAI NTENAN C E
WHEELS/TI RES
TI R E P R E S S U R E
NOTE
Tire pressure should be checked when the tires are COLD .
Front Rear
Tire size 1 00/90- 1 9 5 7 S 1 70/80- 1 5 7 7 S
Up to
C o l d tire
pressures vehicle
200 ( 2 . 00, 29) 2 50 ( 2 . 50, 36)
kPa capacity
( kg/cm2, load
psi) U p to 90 kg ( 1 ) SPO K E
(200 lbs) 200 ( 2 .00, 29) 200 ( 2 .00, 29)
load
Maximum weight capacity 1 61 kg ( 3 5 5 lbs)
Tire Bridgestone L 3 09 G 546
brand Dunlop F24 K555
Check the front and rear wheels for trueness ( Section 1 2 and
13).
Measure the tread depth at the center of the tires .
Replace the tires if the tread depth reaches the following limit:
TOOL:
Spoke wrench 07JMA - MR601 00
N ot ava i l a b l e in U . S . A .
3 -20
M AI N T E N A N C E
3-2 1
FUEL SYSTEM
1 9 N m ( 1 . 9 kg-m, 1 3 . 7 ft-lbl
4-0
4. FU EL SYSTEM
S ERV I C E I N FO RMATIO N 4- 1 CARBU R ETO R I NS TALLATIO N 4- 1 5
SERVICE I N FORMATIO N
Gasoline is extremely flammable and is explosive under certain conditions work in a well ventilated area a with the engine stopped.
Work in a well ventilated area.
If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.
G E N ERAL
Refer to Section 3 for carburetor synchronization, throttle cable and choke cable adjustments .
When d isassembling fuel system parts, note the locations of the 0-rings; replace them with new ones on reassembly .
The carburetor float chambers have d rain screws that can be loosened to drain residual gasol ine .
For fuel pump refer to section 1 8 .
All hoses used in the evaporative emission control system are numbered for identification . When connecti ng one of these
hoses, compare the hose number with the Vacuum Hose Routing Diagram Label on page 4- 1 6 (California model only) . for
its routing.
CAUTION
Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind.
N OTE
If vehicle is to be stored for more that one month , drain the float bowls. Fuel left in the float blowls will cause clogged jets
resulting in starting and drivability complaints .
S P E C I F I CATI O N S
4- 1
F U E L SYSTEM
TO R Q U E VA LU E
TOOLS
Special
Vacuum/Pressure pump A937X - 04 1 - XXXXX or
Pressure pump ST - AH- 2 5 5 - M C 7 ( U S A . only)
. .
Common
Float level gauge 0740 1 - 00 1 0000
TROU BLESHOOTI NG
Engine cranks but won't start Misfiring during acceleration
No fuel in tank Faulty ignition system
No fuel to carburetor
Engine flooded with fuel Backfiring
No spark at plug (ignition system faulty) Faulty ignition system
Clogged air cleaner faulty carburetor
Intake air leak
Improper choke operation Poor performance (driveability) and poor fuel economy
Improper throttle operation Clogged fuel system
Faulty ignition system
Hard starting or stalling after starting Dirty air cleaner
Improper choke operation (California model only : )
Ignition malfunction : Faulty evaporative emissio n carbu retor a i r vent
Faulty carburetor control valve
Lean mixture
(California model only : )
: Worn/damaged emission system hoses
4- 2
F U EL SYSTEM
Disconnect the fuel tube from the fuel tank and fuel breather
tube (t o canister: California model only) .
I N STALLAT I O N
( 1 ) FUEL TAN K
(3) F U E L STRAINER SCREEN
The fuel filter with its narrow
pointing toward the outside .
l1i< (8) TO FUEL
t.
($.,
PU MP
'
171 FUEL VALVE K N O B . i .
4-3
FUEL S YSTEM
Remove the fuel tank mounting, and lift the tank and remove
the air cleaner housing mounting bolts .
'
Loosen the air cleaner housing -to-air cleaner chamber band .
Disconnect the crankcase breather tube from the air cleaner
housi ng.
I N STALLATI O N
S U B-A I R C L E A N E R E L E M E N T
4-4
F U E L SYSTEM
the excess .
(3)
Reinstal l the element and cover, and tighten the bolt.
Reconnect the air tubes from the carburetors . DRY
! J
! t
A I R C L EA N E R C H A M B E R
R E M OV A L/ I N STA LLAT I O N
----- ( 8 ) PLUG
(3) A I R CLEA N E R H O U S I N G
(6) HOLDER
4- 5
FUEL SYSTEM
CARBURETOR REMOVAL
Loosen the drain screws and drain the fuel into a container.
Remove the left choke valve from the carburetor and loosen
the carburetor insulator bands.
.
CARBURETOR DISASSEM BLY (2) C H O K E
'
CABLE
NOTE LOCK
Remove the choke cable and right choke valve from the carbu
retor by loosening each lock nut.
VAC U U M C H A M B E R
4-6
FUEL SYSTEM
Remove the spring, and diaphragm/vacumm piston. ( 1 I D IAPHRAG M/PISTON (2) SPRING
Inspect the vacuum piston for wear, nicks, scratches or other
damage.
Make sure the piston moves up and down freely in the cham
ber.
(1 I NEEDLE J ET HOLDER
Then remove the needle holder, spring, jet needle and washer (1 ( 2 ) J ET (3) HOLDER
from the piston . N EEDLE
Inspect the needle for excessive wear a t the tip, bending or
other damge .
Inspect the diaphragm for damage, fatigue or pin holes.
Inspect the vacuum piston for wear or damage.
I
(4) SPRING
4- 7
F U E L SYSTEM
Check the float valve and valve seat for scratches, clogging or
damage.
Remove the main jet, needle jet holder, slow jet and valve seat/
filter.
(2) MAIN
Check each part for wear or damage . J ET
Blow open all jets with compressed air.
Inspect the float valve seat and filter for grooves, nicks or de
posits .
/ lt. ow '
Clean the filter with low-pressure compressed air. ( 5 ) F I LTER
(4) VALVE SEAT
/''' ,..,
SLOW J ET
(3)
PILOT SCREW
NOTE
4-8
FUEL SYSTEM
Center punch the pilot screw plug to center the drill point.
Drill throug h the plug with a 4 mm ( 5/32 in) drill bit. Attach a
drill stop to the bit 3 m m (1/8 i n ) from the end to prevent
drilling into the pilot screw .
CAUTION
Be careful not to drill into the pilot screw.
Both pilot screws must be replaced even if only one requires it,
for proper pilot screw adjustment (page 4-15).
Use compressed air to clean the p ilot screw area and remove
metal shavings.
CAUTION
Damage to the pilot screw seat will occur if the pilot screw is
tightened against the seat.
0
Remove the pilot screws and inspect them. Replace them if
they are worn or damaged . /
(4) WASHER
(3) PILOT SCREW /
A I R C U T O F F V A LV E
Remove t h e two screws, t h e set plate and t h e air cut off valve
cover.
NOTE
The air cut off valve cover is under spring pressure. Do not
loose the spring and screws.
4-9
FUEL SYSTEM
cl
- 0-ring for damage.
(4)
/
S PR I N G
( 5 ) HOLDER
( 1 4) PISTON
4- 1 0
F U E L SYSTEM
P I LOT S C R EW ER
I nstall the pilot screws and return them to their original posi
tion as noted during remova l .
Perform pilot screw adjustment if n e w pilot screws are in
stalled .
Do not install new plugs on new pilot screw holes until after
1 /
adjustment has been made.
CAUTION
Damage to the pilot screw seat will occur if the pilot screw is
tightened against the seat.
I nstall the valve seat, slow jet, needle jet holder and main jet.
Install the float with float valve i n the carburetor body, then in
stall the float arm pin through the body and the float.
FLOAT L E V E L GAUGE
Measure the float level with the float tang just contacting the
float valve.
TOOL:
Float level gauge 0740 1 - 00 1 0000
4- 1 1
FUEL SYSTEM
NOTE
VAC U U M CHAM B E R
(1 l J ET NEEDLE
HOLDER (4) F I N G E R
The vacuum piston with the tab of the diaphragm aligned with ( 2 ) CAVITY
the groove of the carburetor.
I nstall the chamber cover with the spring, aligning the cover
cavity with the hole i n the carburetor, and secure with at least
two screws before releasing the vacuum piston.
4- 1 2
FUEL SYSTEM
(21 CHOKE KNOB
FUEL TUBE;:,p:s .
....--.......
Install the fuel and air tubes as shown. ( 1I
.lib
CARBU RETOR
SEPARATIO N / ASSEM BLY
SEPARATION
NOTE
(2) SYNCHRON
. ..
IZATION SPRING
4- 1 3
FUEL SYSTEM
Install the synchronization spring and synchronization adjust 121 SYN C H RON IZATION
ing screw. ADJUSTING SCREW
Turn the throttle stop screw to align the rear cyli nder carbure
tor throttle valve with the edge of the by-pass hole.
Align the front cylinder carburetor throttle valve with the by (1 ) SYN C H RO N IZATION ADJUSTIN G
REW
pass hole edge by turning the synchronization adjusting
screw.
4- 1 4
FUEL SYSTEM
NOTE
Damage to the pilot screw seat will occur if the pilot screw is
tightened against the seat.
6 Turn each pilot screw 1 /2 turn out from the initial setting .
0
1 3 0 Drive new pilot screw plugs i nto the pilot screw bores
with a 7 mm valve guide driver (P/N 07 942 - 8230000 ) .
W h e n fully seated the plug surfaces w i l l b e recessed 1 ( 1 I PLUG
mm.
4- 1 5
F U E L SYSTEM
H I G H ALTITU D E S ETTI N G :
Adjust the idle speed to 1 , 2 00 1 00 rpm , with the th rottle
stop screw . LE E M ISSION CONTROL
Drive new pilot screw plugs i nto the pilot screw bores ( page 4- I N FOR MATI O N UP DATE LAB E L
1 5) .
NOTE
NOTE
Do not attach the label to any part that can be easily re
THIS VEHICLE HAS BEEN ADJUSTED TO
IMPROVE EMISSION CONTROL PERFORMANCE
WHEN OPERATED AT HIGH ALmUDE.
.
moved from the vehicle. ALmuDE PERFORMANCE ADJUSTMENT INSTRUCTIONS
ARE AVAILABLE AT YOUR AUTHORIZED HONDA DEALER.
''51111d
Sustained operation at an altitude lower than 1, 500 m
(5, 000 feet) with the carburetors adjusted for high alti
tude may cause the engine to idle roughly and engine
may stall in traffic and may cause engine damage due to
overheating.
When the vehicle is to be operated continuously below
1 , 500m (5 , 000 feet), turn each pilot screw to the specificatio n
below, its o riginal position .
LOW A LTITU D E S ETTI N G : 1/2 turn out
Adjust the idle speed to 1 , 2 00 1 00 rpm with the th rottle
stop screw .
D rive new pilot screw plugs into the pilot screw bores ( page 4 VACUUM HOSE ROUTI NG DIAGRAM
- 1 5) .
ENGI NE FAMI LY- ';:;-;-;-; ==----
EVAPORAT I VE FAMILY;r: :: ------,:J
Be sure to make these adjustments at low altitude . Remove
L =:::
____
the Vehicle Emission Control U pdate Label that attached to
the inside of the left side cover after adjusti ng for the low CAL l FORNIA VEHI C L E
altitude .
EVAPORATIVE E M ISSION
P U RG E CONTROL VALVE INSPECTION
(Ca l iforn ia mod e l o n l y) "'
NOTE ..:
z
w
The evaporative em1ss1o n p u rge control valve should be
"-
0
inspected if hot restart is d ifficult.
Check all fuel tan k, Evaporative Emission Purge Control Valve
( EVAP P U R G E CONTROL VALVE),and evaporative emission
canister hoses to be su re they a re not kin ked and a re secu rely
connected. Replace any hose that shows signs of damage or EVAP CAN I ST E R
d eterioration. MZS -930
NOTE
The EVAP PU R G E CONTROL VALVE is located u nder the
fuel tan k.
4- 1 6
F U E L SYSTEM
I
SPECIFIED VACUU M : 250 mm (9.8 in) Hg
The specified vacu u m should be maintained.
Replace the EVAP PU R G E CO NTRO L VALVE if vacuu m is not
maintained.
TOOL:
Vacuum/Pressure pump A937X - 041 - XXXXX or
Vacuum pump ST - AH - 260- MC7
( U . S.A. only)
Con nect a p ressu re p u m p to the 8 m m (0.3 1 in. ) I . D .hose N o.4
that goes to the evaporative emission canister.While a pplying
the specified vacu u m to the EVAP PU R G E CONTROL VALVE
hose that goes to the 3-way joint p u m p air through the
evaporative emission canister hose.Air shoud flow through the
EVAP PU R G E CONTR O L VALVE and out the hose that goes to
the 3-way joint.
R eplace the EVAP P U R G E CONTROL VALVE if air does not
flow out.
CAUTION
To preven t damage to the evaporative emission purge con trol valve,
do not use high air pressure sources. Use a hand operated air pump
only.
TOOL:
Vacuum/Pressure pump A937X - 041 - XXXXX or ( 2 ) VACUUM PU MP
Vacuum pump ST -AH - 260- MC7
Pressure pump ST -AH - 255 - MC7
( U . S.A. only)
R emove the p u m ps, i n stal l the EVAP P U R G E CONTR O L
VALVE on its mount, route and reconnect the house accord
ing to the routing label.
4- 1 7
F U EL SYSTEM
CAUTION
To prevent damage to the evaporative emission carburetor air vent
con trol valve, do not use high air pressure sources. Use a hand
operated air pump only.
Connect the vacuum pump to the air vent port of the EVAP
CAV CONTROL VALVE.
Apply vacuum to the EVAP CAV CONTROL VALVE.The
vacuum should hold steady.
R eplace the EVAP CAV CONTRO L VALVE if vacuum leaks.
TOOL:
Vacuum/Pressure pump A937X - 04 1 - XXXXX or
Vacuum pump ST - AH - 260 - MC7
( U .S.A. only)
Connect the vacuum pump to the No. 1 0 hose that goes to the
right carb u retor body.
Connect the pressu re pump to the air vent port of the EVAP
CAV CONTROL VALVE.
While a pplying the vacuu m to the EVAP CAV CONTR O L
VALVE N o . 1 0 hose that goes t o t h e rig ht carburetor body,
pump air through the air vent port.
Air should flow through the EVAP CAV CONTROL VALVE and c..,_,'
out the hose that goes to the carb u retor air joint pipe.
TOOL:
Vacuum/Pressure pump A937X - 04 1 - XXXXX or
Vacuum pump ST - AH - 260 - MC7
Pressure pump ST - AH - 25 5 - MC7
( U .S.A. only)
Plug the hose that goes to the carburetor air joint pipe.
While applying vacuu m to the EVAP CAV CONTROL VALVE
No. 1 0 hose that goes to the rig ht carburetor body,apply air
pressure.
It should hold steady.
R eplace the EVAP CAV CONTR O L VALVE if pressure is not
retained.
Remove the p u m ps,install the EVAP CAV CONTROL VALVE
o n its mou nt,route and reconnect the hoses according to the
routing label.
TOOL:
Vacuum/Pressure pump A937 X - 04 1 - XXXXX or
Vacuum pump ST - AH - 260- MC7
Pressure pump ST - AH - 25 5 - MC7
( U .S.A. only)
4- 1 8
M EMO
COO L I N G SYSTEM
5-0
5. COOLI NG SYSTEM
S ER V IC E I N FO RMAT I O N 5- 1 THERMOSTAT 5-3
SERVICE I N FORMATION
G E N ERAL
Do not remove the radiator cap when the engine is hot. The coolant is under pressure and severe scalding could result. The engine
m ust be cool before servicing the cooling system.
If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.
Use only distil led water and ethylene glycol in the cooling system. A 50 - 50 mixture is recommended for maximum corro
sion protection. Do not use alcohol-based antifreeze .
Add coolant at the reserve tank. Do not remove the radiator cap except to refi l l , coolant mixture testing or drain the sys-
tem, or to test the coolant mixture.
Avoid spilling coolant on painted surfaces .
After servicing the system , check for leaks with a cooling system tester.
For thermosensor and thermostatic switch removal and inspection, refer to section 1 8 .
To service the water pump, the engine must be removed from the frame.
S P E C I F I CAT I O N S
TROUBLESHOOTI NG
Engine temperature too high Engine temperature too low
Faulty thermosensor bulb or sensor
Faulty thermosensor bulb or sensor
Thermostat stuck closed
Thermostat stuck open
Faulty radiator cap
I nsufficient coolant or coolant l evel too low Coolant leaks
Passages blocked in radiator, h oses or water jacket
Faulty pump mechanical seal
Cooling fan motor does not turn Deteriorated 0-rings
- Burned or loose sub fuse
- Faulty fan motor
- Faulty thermostatic switch
- Poor connector contact or open circuit in harness
Faulty water pump
5- 1
COO LING SYSTEM
SYSTEM TESTI NG
C O O LANT M I XT U R E
Be sure the engine is cool before removing the cap or you may
be severely scalded.
i
Wet the radiator cap sealing surface, install the cap on the
tester, and apply pressure.
Replace the radiator cap if it does not hold pressure, or if it ' s
I
t
-
( 1 I RAD IATO R
CAP
CAUTION
Excessive pressure can damage the radiator. Do not exceed 125
kPa (1 . 25 kg!cm2, 18 psi)
5-2
COOLING SYSTEM
Drain the coolant from the system by removing the drain bolt
on the water pump cover.
Remove the rea r cylinder coolant drain bolt and drain the
collant using a vinyl as shown .
Reinstal l the drain bolt. ( 1 ) DRAIN BOLT (3) VINYL
Lower the side stand and shift the transmission into neutra l .
Check the level of coolant in the reserve tank and fill to the
correct level if the level is low.
THERMOSTAT
R E M O VAL
5-3
COOLI N G SYSTEM
I N S P E CT I O N
( 1 ) THERMOSTAT
I nspect t h e thermostat visually for damage .
Suspend the thermostat in heated water to check its opera
tion.
NOTE
Data :
Start to open 80 to 84 C ( 1 7 6 - 1 8 3 F)
Valve lift 8 mm (0.3 in) minimum when
heated to 9 5 C (203 F) for five
minutes .
I N STALLAT I O N
I nstall a new 0-ring on the housing cover and i nstall the hous
ing cover onto the housing.
5-4
COOLING SYSTEM
NOTE
Be sure to secure the thermostat ground wire with the
cover mounting bolt shown.
RADIATOR/COOLI NG FAN
REM OVAL
NOTE
For fan motor i nspection, refer to section 1 8 .
Remove the steering cover and disconnect the fan motor con
nector ( 2 P BLACK)
Remove the horn mounting bolt and horn, then disconnect the
horn wires.
5- 5
COOLI N G SYSTE M
D I SAS S E M B LY ( 1 ) G R O U N D "-..
TERM INAL /""'
Disconnect the thermostatic switch wire connector from the
switch and remove the wire from the clamp.
Remove the ground wire terminal bolt.
Remove the fan motor shroud mounting bolts, and remove the
fan motor shroud and fan motor as an assembly.
Remove the nut to separate the fan from the shroud . ( 1 ) NUT
( 2 ) FAN
Remove the fan motor mounting nuts and fan motor from the
shroud.
5-6
COOLING SYSTEM
A S S EM B LY
Blow dirt out from between core fins with compressed air. If
insects, etc . , are clogging the radiator, wash them off with
low pressure water.
Install the fan to the fan motor shaft, aligning the boss of the
shaft with the groove of the fan .
NOTE
Do not overtighten the thermostatic switch, when reinstall
it.
TORQU E : 1 8 N m ( 1 . 8 kg-m , 1 3 ft-lb) .
WATE R P U M P
ME C H A N I CA L S E A L I N S P E C T I O N
NOTE
The w ater pump cover and 0-ring can be removed with
engine i n the frame .
REMOVAL
Remove the 0-ring and dowel pins from the water pump as
sembly and disconnect the water hose .
( 3 ) WATER HOSE
5- 7
COOLING SYSTEM
(4) 0-RING
I N STA L LAT I O N
Align the water pump shaft g roove with the oil pump shaft and
insert the water pump into the crankcase.
I nstall the water pump cover and tighten the cover mounting
bolts .
Connect the water hose with the clamp.
5-8
COOLI N G SYSTEM
REMOVAL/INSTALLATION
Hold the overflow tube u pright and remove the reserve tank
from the frame.
Empty the tank, if necessary.
I nstall the reserve tank i n the reverse order of removal .
Fill the tank with coolant, i f necessary.
CAUTION
The tab of the reserve tank should be aligned with the grommet
in the frame.
5-9
EN G I N E REM OVAL/INSTALLAT I O N
2 5 Nm, ( 2 . 5 kg-m, 1 8 ft-lb)
6-0
6. ENG INE REMOVAL/ I NSTALLATION
S ERVI C E I N F O RMAT I O N 6-2 EN G I N E I N STALLATION 6- 5
E N G I N E R E M OVAL 6-3
Ill
5 5 N m ( 5 . 5 kg-m,
40 ft-lb)
27 Nm (2. 7 kg-m,
20ft-lb)
6- 1
E N G I N E REM OVAL/ I N STALLATION
SERVICE I N FO RMATION
G E N E RAL
Support the motorcycle using a hoist, a floor jack or other adjustable support.
The following parts can be serviced with the engine i nstalled in the frame:
Clutch Alternator
Gearshift linkage Starter motor
Camshafts Carburetors
Front cylinder head/cylinder
To service the water pump body, oil pump, and rear cylinder head/cylinder the engine m ust be removed from the frame.
S P E C I F I CATI O N S
TO R Q U E VALU E S
6-2
E N G I N E REM OVAL/ I N STALLATION
ENG I N E REMOVAL
Support the motorcycle using a hoist or a jack.
CAUTION
Do not jack up the engine at the oil filter.
Drain the engine oil (page 2-4) and the radiator coolant (page
5-3 ) .
Disconnect the battery negative cable from the battery termi
nal .
Disconnect the oil pressu re and neutral switch wires from the
switch terminals and free the switch wire harness from the
engine and frame.
Remove the gearshift arm from the gearshift spindle.
Disconnect the starter motor cable and ground cable from the
starter motor.
Remove the right foot peg and rear brake pedal by removing
the two bracket mounting bolts.
6-3
EN G I N E REMOVAL/ I N STALLATIO N
Place a floor jack o r other adjustable support under the engi ne.
NOTE
The jack height must be continually adjusted to relieve
stress for ease of bolt removal .
41
- rear wheel (page 1 3-3)
- swingarm (page 1 3- 1 4)
- front upper engine bracket (two 8 mm bolts, 1 0 mm bolt
and collar)
., , ( 3 ) FRONT LOWER BOLT
- front lower engine bracket ( 8 mm bolts and 1 0 mm bolt) SWI N ARM PIVOT
- rear engine bracket (two 8 mm bolts and 1 0 mm bolt) BOLT
N OTE
Do not damage the radiator fin .
6-4
E N G I N E R E MO VAL/IN STALLATIO N
ENG I N E I N STALLATION
Engine insta l l ation is essentially the reverse order o f removal .
Use a floor jack or other adjustable support t o carefu lly
manuever the engine into place.
CAUTION
NOTE
NOTE
Fill the cran kcase to the proper level with the recommended
oil (page 2 - 4 ) .
6-5
CLUTCH/GEARS H I FT L I N KAGE
1 2 N m ( 1 . 2 kg-m ,
9ft-lb)
- - - - - - - - - - - - - - - - - - - - - ,
'
After' 8 9 : ,
,
'
'
'
'
'
'
2 3 N m (2 . 3 kg-m , 1 7ft-lb)
'
'
'
'
'
'
'
'
'
'
After' 9 5 :
'
'
'I
'
7 -0
7. CLUTCH/G EARSH I FT LI N KAG E
S ER V I C E I N FO RMAT I O N 7-1 P RI MARY DRIVE G EAR 7- 1 1
G EA RS H I FT L I N KA G E 7-8
S E RV I CE I N FORMATION
G E N ERAL
This section covers the removal and installation of the clutch, oil pump drive chain, gearshift linkage and primary drive
gear. All these operations can be done with the engine installed in the frame.
If the shift fork, drum and transmission require servicing, remove the engine and separate the crankcase (section 1 1 ).
C oat the new clutch discs w ith clean engine oil before reassembly.
S P E C I F I CAT I O N S
U nit: mm (in)
ITEM STANDARD SERVICE LIMIT
C l utch Spring free length 88; 39.0 ( 1 . 54) 3 7 . 4 ( 1 .47)
After 88; 43 . 2 ( 1 . 70) 4 1 . 6 ( 1 . 64)
Spring preload/length 25. 2 5 - 27 . 2 5/2 6 . 2 kg/mm --
T O R Q U E VALU ES
T O O LS
Special
Clutch center holder 07923 - KE 1 0000 o r 07 H G B -00 1 000A( U . S . A . only)
Gear holder 07724 - 00 1 0 1 00
Common
Luck nut wrench, 1 7 x 27 mm 077 1 6 - 0020300 Equ ivalent com mercially available i n U . S . A .
7- 1
CLUTCH/GEARS H I FT LI N KAGE
TROU BLESHOOTI NG
Faulty clutch operation can usually b e corrected b y adjusting the clutch lever free play .
7-2
CLUTCH/GEARS H I FT L I N KAGE
After '89:
Drain the engine oil ( page 2 - 4 ) .
Remove the clutch cable holder and disconnect the clutch
cable from the clutch l ifter arm .
Remove the right crankcase cover bolts and cover.
'88, '89 :
Remove the oil orifice.
C L U T C H L I FT E R S H A FT
Remove the clutch lifter piece, and remove the snap ring and
return spring from the right crankcase cover.
Check the clutch lifter piece and shaft for damage or excessive
scratching .
Check the return spring for fatigue or damage.
7 -3
CLUTCH/GEARS H I FT L I N KAGE
(1 l D U ST SEAL
I nstall the clutch lifter shaft, snap ring and return spring.
Hook the spring end in the cover tab securely, and turn the
shaft.
Install the clutch lifter piece, aligning the piece end with the
groove i n the clutch lifter shaft.
CLUTCH REMOVAL
Remove the following:
- clutch bolts
- clutch lifter plate
- springs
NOTE
Be careful not to damage the shaft threads .
7 -4
CLUTCH/G EARS H I FT L I N KAGE
Hold the clutch center with the special tool and loosen the
clutch lock nut. Remove the tools and the lock nut.
TOOLS :
Clutch center holder 07923- K E 1 0 0 00 or
07 H G B-00 1 000A
( U . S.A. only)
Lock nut wrench, 1 7 x 27 mm 077 1 6-0020300
Equivalent com mercially
avai lable in U . S .A.
- -
Remove the oil pump d riven sprocket mounting bolt, driven (1 l O I L PU MP DRIVEN
sprocket and oil pump drive cha i n . SPROCKET
7-5
CLUTCH/GEA R S H I FT L I N KAGE
Remove the drive sprocket and clutch outer guide from the
mainshaft.
I N SPECT I O N (1 1 BEARI N G
coloration.
-
N OTE
7 -6
CLUTCH/GEARS H I FT L I N KAGE
Check the cl utch center for nicks or indentations made by the 111 CLUTCH
clutch plates. C ENTER
,!
(1 I J U DDER SPRING
. _......... ..
Check the spring seat and judder spring for distortion, wear or
damage.
Replace them it necessary .
SERVICE LIMITS:
Clutch outer I . D. 32. 1 0 mm ( 1 . 264 in)
Clutch outer guide O.D. 3 1 .98 mm ( 1 . 259 in)
7- 7
CLUTCH/GEARS H I FT LI N KAGE
SERVICE LIMITS:
Oil pump drive sprocket 1.0. 32. 1 0 mm ( 1 .264 in)
Clutch outer guide 0 . 0 . 3 1 .98 mm ( 1 .259 in)
GEARSH I FT LI N KAGE
R E M OVAL
Loosen the two oil pipe stay mounting bolts and remove the oil
pipe mounting bolt.
Pull the oil pipe out of the stay and oil pump.
7 -8
CLUTCH/GEARS H I FT L I N KAGE
I N S PECTI O N
r
(2) RETU RN SPRING
I nspect the gearshift pedal shaft for damage or loose lock ( 1 ) GEARSH PEDAL SHAFT
nuts.
Replace the shaft if necessary.
,_
l
_ ,_
I nspect the dust seals and pivot collar for wear or damage.
Replace if necessary .
Apply grease to the dust seal lips and pivot collar and install
them into the pedal shaft.
7-9
CLUTCH/GEARS H I FT L I N KA G E
I N STA L LATI O N
I nstall the dowel pins into the holes of the gearshift dru m .
., "
I nstall the gearshift spindle, aligning the return spring ends (1 l G EARSH I FT SPI N O
with the pin in the case. !
Install the oil pipe with a new 0-ring onto the oil pipe stay and
oil pump.
7- 1 0
C LUTCH/G EARS H I FT L I N KA G E
I nstal l the gearshift pedal mounting bolt and tighten the bolt
securely.
I nstal l the d rive sprocket cover (page 1 3- 1 7 ) .
(1 ) 1 FT PEDAL
MOUNTING BOLT
TOOL:
Gear holder 07724 - 00 1 0 1 00
_,
I N STALLAT I O N ( 1 ) PRIMARY
- DRIVE
Instal l the primary drive gear with the " O UT" mark facing out. ,_, GEAR
NOTE
7- 1 1
CLUTCH/GEARS H I FT LI N KAGE
Temporarily install the clutch outer and install the gear holder
as shown .
TOOL:
Gear holder 07724 - 00 1 0 1 00
NOTE
If removed the ignition pulse generator wire grommets were
removed from the case g roove,reinstall them securely.
CLUTCH I NSTALLATION
Apply MoS2 paste grease t o t h e outside o f the clutch outer
guide and install the oil pump d rive sprocket over the outer
guide.
I nstall the oil pump d rive chain on the drive sprocket. 'iiToiL PU MP D R I VEN
SPROCKET
I nstall the oil pump driven sprocket with the " I N " mark facing
inside.
Guide the drive chain over the sprocket.
Apply locking agent to the threads of the driven sprocket
mounting bolt and tighten it with the washer to the specified
torque.
7- 1 2
CLUTCH/G EARS H I FT L I N KAGE
Align the grooves in the clutch outer with the bosses on the oil
pump drive sprocket while turning the sprocket with the chain
and pushing the clutch outer onto the shaft.
I nstall the spring seat, judder sprin g and clutch disc 8 on the
c l utch center.
N OTE
N ote the positions of the seat, spring and disc B.
Align the tabs in the disc 8 w ith the slots on the clutch outer. (2) J U DDER SPRING
(3) DISC B
( 1 ) SPR I N G SEAT
N OTE
Stack the discs and plates alternately as shown.
7- 1 3
CLUTCH/G EARS H I FT LI N KA G E
Hold the clutch center with the clutch center holder, and tight
en the lock nut to the specified torque .
TOOLS :
Clutch center holder 07923 - K E 1 0000 or
07 H G B-001 000A
( U . S .A. only)
Lock nut wrench, 1 7 x 27 mm 077 1 6-0020300
Equivalent com mercially
available in U .S .A.
NOTE
Make sure the pressure plate firmly pushes the discs and
plates.
7- 1 4
CLUTCH/G EARS H I FT LI N KA G E
'88, '89 :
Tighten t h e right c r a n kcase cover mounting bolts in a
crisscross pattern in 2 or 3 steps and install the clutch cable
holder and oil pipe holder at the same time.
Connect the clutch cable to the clutch lifter arm.
After '89:
Tighten t h e right c r a n kcase cover m o u nti n g bolts i n a
crisscross pattern in 2 or 3 steps and i nstall the clutch cable
holder and oil pipe holder at the same time.
Connect the clutch cable to the clutch lifter arm .
7- 1 5
ALTERNATO R/STARTER CLUTCH
8-0
8. ALTERNATOR/STARTE R CLUTCH
S E R V I C E I N FORMATI O N 8- 1 F LYW H E E L I N STALLATION 8- 5
S TA R T E R CLUTCH 8-4
SERV I CE I N FORMATION
GENERAL
This section covers the removal and i nstallation of the alternator, starter clutch and starter gears.
These o pe ration can be done with the engine installed in the frame.
Refer to section 1 5 for troubleshooti ng and inspection of the alternator.
S P EC I F I CATI O N S
mm (in) .
ITEM STANDARD SERVICE L I M IT
Starter d riven gear O . D . 5 7 . 749 - 5 7 . 768 ( 2 . 2 7 36 - 2 . 2743) 5 7 . 60 ( 2 . 268)
TORQU E VALUES
TOOLS
Common
Rotor puller 07733- 002000 1 or 0 7 9 3 3 - 3 2 9000 1 ( U . S . A . only)
Flywheel holder 0 7 7 2 5 - 0040000 Equivalent commercially available in U . S . A .
Torx bit 07 703 - 00 1 0 1 00 Equivalent commercially available in U . S . A .
8- 1
ALTE RNATO R/S TARTER CLUTCH
Remove the eleven left crankcase cover bolts and the cover.
STATOR R E P LAC E M E N T
( 1 ) BOLTS
8-2
ALTERNATO R/STARTER CLUTCH
TOOL:
Flyw heel holder 0 7 7 2 5 - 0040000
Equivalent commerc i a l l y
ava i lable i n U . S . A .
NOTE
TOO L :
Rotor puller 07733 - 002000 1 or
07933-329000 1
( U . S . A . only)
8-3
ALTERNATOR/STARTER CLUTCH
D I SA S S E M B LY
Hold the flywheel with the flywheel holder and remove the
torx bolts using a torx bit.
TOOLS :
Flywheel holder 07725-0040000
Equivalent commercia l ly
ava i l a ble in U .S.A.
Torx bit 07703-001 0 1 00
Equivalent commercially
available in U .S.A.
I nspect the oneway clutch for wear or damage and replace if ( 1 l ON EWAY CLUTCH
necessary .
8-4
ALTERNATOR/STARTER CLUTCH
ASS E M B LY
Install the oneway clutch i nto the clutch outer with the flange
side facing inside.
TOOLS :
Flywheel holder 07725-0040000
Equivalent commercially
available i n U . S.A.
Torx bit 07703-00 1 0 1 0 0
Equivalent commercially
avai lable i n U . S.A.
FLYWHEEL I NSTALLATION
Clean the crankshaft and install the woodruff key.
Instal l the starter d riven gear and washer onto the crankshaft .
8- 5
ALTERNATO R/STARTER CLUTCH
Hold the flywheel with the flywheel holder, install the washer
and flywheel bolt and tighten the bolt.
TOOL:
Flywheel holder 07725-0040000
Equivalent comm ercially
available i n U . S.A.
NOTE
The flywheel bolt has left hand threads.
Install the starter d rive gear with the " O UT" mark facing out
and the shorter shaft .
Install the drive sprocket cover and the left side cover.
8-6
M E MO
CYLI NDER H EAD/VALV E
After '89 :
' '
I
e
'
1 7 ft- l b )
2 3 N m ( 2 . 3 kg-m '
-
I
- "0
48 N m ( 4 . 8 k g - m, " 2 3 Nm ( 2 . 3 k g - m,
35 ft- l b ) 23 Nm ( 2 . 3 kg-m '
() 1 7 ft- l b )
1 0 Nm ( 1 .0 kg-m,
7 . 2 ft- l b )
/ @
10 Nm ( 1
ft-l b )
.0 kg-m '
'88, '89 :
1 0 Nm ( 1 .0 kg-m,
2 3 Nm ( 2 . 3 k g - m ,
7 . 2 ft- l b )
1 7 ft- l b )
9-0
9. CYLI N DE R H EAD/VALVE
SERVICE I N FORMATI O N 9-1 VALVE SEAT I N S PECT I O N / REFAC I N G 9- 1 2
SERVICE I N FORMATION
G E N ERAL
The front cylinder head can be removed without removing the engine.
To service the rear cylinder head, the engine must be removed from the frame. (See section 6 for engine removal and in
stal lation . ) However, the rear cylinder head cover can be removed to service the camshaft, rocker arms, cam chain and
cam chain tensioner.
Camshaft l ubricating oil is fed through an oil pass pipe. Be sure the holes in the oil pass bolts are not clogged .
D u ring assembly a p ply molybd e n u m disu lfide oil (a 50/50 m ixtu re of engine oil a nd molybde n u m disulfide g rease) to
the camshaft h olders , camshaft journals of the cylinder head , rocker a rm shafts, rocker a rm slipper faces and valve
g
stems to p rovide initial l u b rication .
S P E C I F I CATI O N S
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Compression pressure 1 , 324 kPa --
9- 1
CYL I N D E R H EAD/VALVE
TORQU E VALU E S
TO O L S
Special
Valve guide reamer ( I N ) 07984 - 200000 1 o r 0 7 9 8 4 - 2 00000D
Valve guide reamer ( E X ) 07984 -ZE2000 1 o r 0 7 9 8 4-ZE2000D
Valve guide driver attachment ( I N ) 07943 - M F50 1 00
Valve guide driver attachment (EX) 07943 - MF50200
Common
Valve guide driver, 5 . 5 mm ( I N ) 07742 - 00 1 0 1 00
Valve guide driver, 6 . 6 mm (EX) 07742 - 00 1 0200 N ot available i n U . S . A . 07942 - 6 5 7 0 1 00
Valve spring compressor 0 7 7 5 7 - 00 1 0000 or 07957 - 329000 1
TROUBLESHOOTI NG
Engine top-end problems are usually performance-related and can usually be diagonosed by a compressio n test.
Engine noises can usually be traced to the top-end with a sounding rod or stethoscope .
Valves
Incorrect valve adjustment
- Incorrect valve adjustment
Sticking valve or broken valve spring
- Burned or bent valves
Damaged or worn rocker arm or camshaft
- I ncorrect valve timing
Loose or worn cam chain
- Broken valve spring
Worn or damaged cam chain tensioner
Cylinder head
Worn cam sprocket teeth
- Leaking or damaged head gasket
- Warped or cracked cylinder head Poor idling
High compression
9-2
CYL I N D E R H EAD/VALVE
Front:
NOTE
If coolant drips on the engine, wipe it off immediately .
Rear:
After '94 :
D iscon nect the spark plug caps, c ra nkcase b reather tube and
water hose .
Remove the water p i pe mounting bolt, rea r water pipe and
0-ri n g .
9-3
C Y L I N D E R H EA D IV ALVE
(3) RUBBER
Alig n the wire harness with the valve adjusting hole, then re
move the rear cylinder head cover forward . ( 1 ) R EA R CYLI N D E R H EA D COVER
CAUTI O N
B e careful not t o damage the the wire harness .
CAMSHAFT R EMOVAL
Remove the cylinder head covers.
Remove the timing hole cap and crankshaft hole cap from the
left crankcase cover.
Align the FT mark ( rear: RT mark) on the flywheel with the
index mark on the left crankcase cover timing hole by turning
the crankshaft counterclockwise . Make sure the piston is at
TDC (TOP DEAD CENTER) on the compression stroke .
If the piston is not at TDC, turn the crankshaft 360 counter
clockwise, and re-align the mark and index mark.
9-4
CYLI N D E R H EAD IVALVE
NOTE
Be careful not to let the cam sprocket bolts fall into the
crankcase .
'88, '89:
Remove the three camshaft holder mounting bolts and the nut,
the oil plate and the holder.
After '89:
Remove the three camshaft ho ld er mou nting bo lts, nuts,
o i l p late and the ho lder.
9-5
CYLI N D E R H EAD IVALVE
I N S PE CT I O N
Cylinder head
Inspect the camshaft holder and cylinder head journal surfaces
for scoring or evidence of i nsufficient lubrication.
Camshaft runout
Support both ends of the camshaft with V-blocks and check
the camshaft runout with a dial indicator.
SERVICE LIMIT:
IN: 37. 730 mm ( 1 .4854 in)
EX: 3 7 . 7 50 mm ( 1 .4862 in)
NOTE
9-6
CYLI N D E R H EAD/VALVE
2
I nstall the camshaft holders and tighten the mounting bolts in ' 88 '89 :
,
NOTE
Do not rotate the camshaft when using plastigauge.
TORQUE:
6 mm flange bolt: 1 2 Nm ( 1 . 2 kg-m, 9 ft-lb)
8 mm flange bolt: 23 Nm ( 2 . 3 kg-m, 1 7 ft-lb)
/(2) 6 mm FLANGE
8 mm flange nut: 23 Nm (2.3 kg-m, 1 7 ft-lb) i
BOLTS
After '89 :
9- 7
CYLI N D E R H EAD/VALVE
Remove the rocker arms and wave washers from the shafts .
(2)
WAVE WASHERS
Inspect the rocker arm shafts and rocker arms for wear or
damage.
SERVICE LIMIT:
IN/EX : 1 1 .83 mm (0.466 in)
CYLI N DE R H EAD
REMOVAL
NOTE
The front cylinder head can be removed with the engine
installed . The engine must be removed to service the rear
cylinder head .
NOTE
9-8
CYLI N D ER H EAD/VALVE
Remove the gasket, dowel pins and cam chain guide from the
cylinder.
NOTE
Make sure the piston is at TDC on the rear cylinder com
pression stroke .
- o i l pass pipe ( '88, ' 89) , cy linder head cover, and cam chain
tensio ner
- head bolts and nuts, as described for front cylinder head re
moval
- cylinder head , head gasket, dowel pins, and cam chain
guide
D I SAS S E M BLY/ I N S P E CT I O N
Cylinder head
Clean the cylinder head surfaces of any gasket materia l .
CAUTION
A void damaging the gasket surfaces.
Check the spark plug hole and valve areas for cracks .
Check the cylinder head for warpage with the straight edge
and thickness gauge.
TOOL:
Valve spring compressor 07757 -001 0000 or
07957 - 329000 1
CAUTION
To prevent loss of tension, do not compress the valve springs
more than necessary to remove the cotters.
NOTE
Mark all parts during disassembly so they can be placed
back in their original locations.
9-9
CYLI N D ER H EAD/VALVE
Valve springs
Measure the free length of the inner and outer valve springs.
SERVICE LIMITS :
INNER (IN) : 36.47 mm ( 1 .436 in)
(EX) : 37 . 5 1 mm ( 1 .477 in)
OUTER (IN ) : 40 . 58 mm ( 1 . 598 in)
(EX) : 41 . 2 5 mm ( 1 .624 in)
NOTE
Ream the guides to remove any carbon deposits before
checking clearances.
9- 1 0
CYLI N D ER H EAD/VALVE
NOTE
Reface the valve seats whenever the valve guides are re
placed .
CAUTION
Do not use a torch to heat the cylinder head; it may cause
warping.
Support the cylinder head and drive out the old guides from the
combustion chamber side of the cylinder head .
TOOL:
Valve guide driver ( I N ) : 07742-00 1 0 1 00
(EX) : 07742-00 1 0200 N ot
ava i l a ble i n U .S.A.
07942-65701 00
NOTE
( 1 ) VALVE G U I D E
Avoid damaging the cylinder head . DRIVER
MENT
Make note of the valve guide projection specifications (follow
ing ) , then drive i n new guides from camshaft side of the cylin
der head .
TOOLS:
Valve guide driver
5 . 5 mm (IN) : 07742 - 00 1 0 1 00
6 . 6 mm (EX) : 07742 - 00 1 0200
Attachment
5 . 5 mm (IN): 07943 - MF50 1 00
6 . 6 mm (EX) : 07943 - MF50200
9- 1 1
CYLI NDER H EAD/VALVE
NOTE
CAUTION
The valve cannot be ground. I/ the valve face is burned or badly
worn or if it contacts the seat unevenly, replace the valve.
If the seat is too wide, too narrow or has low spots, the seat
must be ground .
9- 1 2
CYLI N D E R H EAD/VALVE
\--- 16
l'--- l }\
VALV E S EAT C U TT E R S
60
Honda Valve Seat Cutters, grinder or equivalent valve seat ------ 32 '
refacing equipment are reco m m ended to correct a worn valve ___._ _
I N : 07780 - 00 1 4000 I N : 07780 - 00 1 2 1 00 (28 c/>)
seat. EX: 07780 - 00 1 2300 (35 c/>)
(30 c/>)
EX: 07780 - 00 1 4 1 00
NOTE
(37 . 5 c/>)
Follow the refacer manufacturer's operating instructions.
NOTE
Reface the seat with a 45 degree cutter when a valve guide
is replaced .
9- 1 3
CYLI N DER H EAD IVALVE
Install a 45 degree finish cutter and cut the seat to the proper
width . Make sure that all pitting and irregularities are removed .
Refinish if necessary .
NOTE
If the contact area is too high on the valve, the seat must be
lowered using a 32 degree flat cutter.
If the contact area is too low on the valve, the seat must be
raised using a 60 degree inner cutter. ( 1 ) CONTACT T O O LOW
NOTE
9- 1 4
CYLINDER H EAD/VALVE
j/_ 11(.
while i nserting to avoid damaging the seals .
1"
( 5 ) COTTERS ?
171 SPR I N G ( 6 ) I N N E R
S EAT SPR I N G
Install the valve springs with the tightly wound coils facing the
combustion chamber.
CAUTION
TOOL:
Valve spring compressor 07757 - 00 1 0000 or
07957 - 329000 1
9- 1 5
CYLI N D E R H EAD/VALVE
Tap the valve stems gently with a soft hammer to firmly seat
the cotters .
NOTE
Make sure that the cam chain guide bosses are i n the grooves
of cylinder.
9- 1 6
CYLI N D E R H EA D IV ALVE
TORQUE :
1 0 mm nut: 48 Nm (4.8 kg-m, 35 ft-lb)
8 mm bolt: 23 Nm (2.3 kg-m, 1 7 ft-lbl
8 mm nut: 23 Nm (2.3 kg-m, 1 7 ft-lbl
6 mm bolt: 10 Nm ( 1 .0 kg-m, 7.2 ft-lbl
41
RS!
. ..
( 3 ) 8 m m BOLTS/WASHE
I nstall the oil pass pipe, new sealing washers, oil pass pipe
bolts and the pipe holder bolt.
Tighten the bolts .
r
TORQU E :
O i l pass pipe bolt:
7 mm: 1 0 Nm ( 1 .0 kg-m, 7 . 2 ft-lb)
8 mm: 23 N m (2.3 kg-m, 1 7 ft-lb)
( 3 ) O I L PIPE (2) HOLDER
9- 1 7
CYLI N D ER H EAD/VALVE
- camshaft ( page 9- 1 8 )
- camshaft holders ( page 9 - 1 9 )
- cylinder head cover (page 9-2 1 )
NOTE
F R O N T CYLI N D E R ( 1 ) G ROOVES
NOTE
If the rear cylinder head has not been serviced, remove the
rear cylinder head cover and check the camshaft position as
follows:
Turn the crankshaft counterclockwise and align the " RT"
mark on the flywheel with the index mark on the timing
hole, then look for the identification mark on the camshaft
flange .
If the notch mark is facing up, turn the crankshaft counter
clockwise approximately 1 - 1 /8 turn (41 2 ) and begi n
instal l ation of t h e front camshaft.
If the notch mark faces down ( cannot be seen) , turn the
cra nkshaft cou nterclockwise approxi matel y 1 /8 turn
( 52 ) and beg i n insta l lation.
9- 1 8
CYLI N D ER H EAD IV ALVE
Align the " FT" mark on the flywheel with the index mark on
the timing hol e .
N OTE
I nstall the camshaft i n the cylinder h ead through the cam chain
and install the cam sprocket on the camshaft with the I N mark
facing inside .
With the notch mark on the camshaft flange facing up, align
the timing marks ( i ndex lines) on the cam sprocket with the top ( 1 ) N OTCH
of the cylinder head.
T u rn the crankshaft counterclockwise one fu l l t u rn (360 ) .
a l i gning the "FT" mark with the i ndex mark, then check that
the tim ing marks on the cam sprocket a l ign with the to p of
the cy l ind er head .
9-19
CYLI NDER H EAD/VALVE
'88, '89:
I nstal l the dowel pins into the cylinder head .
I nstal l the holders, oil plate, 8 mm bolts, 8 m m nut and 6 mm
bolts .
After '89:
I nsta l l the dowel p ins into the cy linder head .
1 11sta l l the ho lders, o i l pipe 8 m m bo lts, 8 m m nuts and 6 mm
bo lts.
TORQU E :
'8 mm bolt: 23 N m (2.3 kg-m, 1 7 ft-lb)
8 mm nut: 23 Nm (2.3 kg-m, 1 7 ft-lbl
6 mm bolt: 10 N m ( 1 .0 kg-m, 7.2 ft-lb)
CAUTION
Note the direction of the camshaft end holder, install the flat After '89 :
surface on the holder facing in.
R E A R CYLI N D E R
NOTE
If. the front cylinder head was not serviced, remove the
front cylinder head cover and check the camshaft position
as follows:
Turn the crankshaft counterclockwise and align the "FT"
mark on the flywheel with the index mark on the timing
hole, then look for the identification mark on the camshaft
flange. If the notch mark is facing up, turn the crankshaft
countercl ockwise approx i mate l y 7/8 tu rn (308 ) a n d
begin insta l lat ion of the rear camshaft.
I f the camshaff notch mark faces down (cannot be seen) ,
t u rn the crankshaft co unterclockw i se appro x i mately
1 -7 /8 t u rn (668 ) and begin insta l lation.
9-20
C Y L I N D E R H EADNA L V E
Make sure that the " RT" mak on the flywheel aligns with the
index mark on the timing hole .
Place the camshaft into the correct position with the notch
mark on the camshaft flange facing up and install the cam
sprocket and camshaft holders using the same procedu re as
for the front cylinder.
NOTE
'\\
TORQUE: 1 0 N m ( 1 .0 kg-m, 7 . 2 ft-lb)
( 1 ) R U BB ER
WASH E R
( 2 ) WASH E R
I nstall the 0-ring on the water pipe with the tapered side facing
out and install the water pipe i nto the cylinder head .
Connect the water hose to the water pipe and i nstall the spark
plug caps.
I nstall the following parts :
- carburetors (page 4- 1 5)
- air cleaner housing (page 4-4)
- fuel tank ( page 4-3)
- steering covers
' 2
9- 2
MEMO
CYLI N D ER/P IS TO N
1 0-0
10. CYLI N DE R/ P I STO N
S E RVIC E I N FO R M ATIO N 1 0- 1 P IS TO N R I N G I NS TALLATIO N 1 0- 5
C Y LI N D E R 1 0- 2 C Y L I N D E R I NS TALLATIO N 1 0- 6
PIS TO N 1 0- 3
SERVICE I N FORMATION
GEN ERAL
S P E C I F I CATI O N S Unit: mm ( i n )
ITEM STANDARD SERVICE LIMIT
Cylinder I. D . 7 5 . 000 - 7 5 . 0 1 5 ( 2 . 9 5 2 8 - 2 . 9 5 3 3 ) 75. 1 0 (2.957)
Warpage across top --
0 . 1 0 ( 0 . 004)
Taper --
0 . 06 ( 0 . 00 2 )
O ut-of-round --
0 . 0 6 ( 0 . 00 2 )
Piston, Piston ring-to-ring TOP 0 . 0 1 5 - 0 . 0 4 5 ( 0 . 0006 - 0 . 00 1 8 ) 0 . 1 0 ( 0 . 004)
piston g roove clearance SECO N D 0 . 0 1 5 - 0 . 0 4 5 ( 0 . 0006 - 0 . 00 1 8 ) 0 . 1 0 ( 0 . 004)
rings
and piston Ring end gap TOP 0 . 1 0 - 0 . 30 ( 0 . 004 - 0 . 0 1 2 ) 0 . 50 ( 0 . 020)
pin SECOND 0 . 1 0 - 0 . 30 ( 0 . 004 - 0 . 0 1 2 ) 0 . 50 ( 0 . 020)
OIL 0 . 20 - 0 . 7 0 ( 0 . 00 8 - 0 . 0 2 8 ) 0 . 90 ( 0 . 0 3 5 )
Piston O . D . 7 4 . 9 6 5 - 7 4 . 9 90 ( 2 . 9 5 1 4 - 2 . 9 5 2 4 ) 7 4 . 90 ( 2 . 94 9 )
Piston pin bore 1 8 . 0 0 2 - 1 8 . 008 ( 0 . 7 08 7 - 0 . 7 0 9 0 ) 1 8 .05 (0. 7 1 1 )
Connecting rod smal l end I . D . 1 8 . 0 1 6 - 1 8 . 034 ( 0 . 7 0 9 3 - 0 . 7 1 0 0 ) 1 8.07 (0. 7 1 1 )
Piston pin O . D . 1 7 . 9 94 - 1 8 . 000 ( 0 . 7084 - 0 . 70 8 7 ) 1 7 . 98 (0.708)
Piston-to-piston pin clearance 0 . 00 2 - 0 . 0 1 4 ( 0 . 000 1 - 0 . 00 0 6 ) 0 . 040 ( 0 . 00 1 6 )
Cylinder-to-piston clearance 0 . 0 1 0 - 0 . 0 5 0 ( 0 . 0004 - 0 . 00 2 0 ) 0 . 1 0 ( 0 . 004)
Piston pin-to-connecting rod
0 . 0 1 6 - 0 . 040 ( 0 . 0006 - 0 . 00 1 6 ) 0 . 060 ( 0 . 00 2 4 )
small end clearance
TROUBLESHOOTI NG
Low o r uneven compression Piston noise
Worn cylinder or piston rings. Worn cylinder and piston.
Leaking head gasket . Excessive carbon deposits .
Incorrect valve timing.
Excessive smoke
Worn cylinder and piston rings.
Improperly insta lled piston rings.
Damaged piston or cylinder.
Overheating
Excessive carbon deposits on piston or combustion
chamber.
Faulty water p u m p .
1 0- 1
CYLI N D E R/PI STO N
CYLI N DER
R E M OVAL
NOTE
Remove the clip and slide the cylinder joint collar toward
eigther the front or rear cylinder.
I N S PE CT I O N
1 0- 2
CYLI N D E R/PISTON
NOTE
P I STON
R E M OVAL
Place a shop towel i nto the crankcase and remove the piston
pin clips.
NOTE
Do not let the clips fall into the crankcase .
I N SPECTI O N
SERVICE LIMIT:
Top : 0 . 1 0 mm (0.004 in)
Second : 0 . 1 0 mm (0.004 in)
Remove the piston rings and mark them to indicate the correct
cylinder and piston position for reassembly.
NOTE
1 0-3
CYLI N D ER/PISTON
I nsert the old piston ring into the proper ring groove and clean
the groove by rol l i n g the ring around the pistons
circumference .
NOTE
Measure the top and second piston ring end gaps : using a pis
ton , push the ring into the cyl inder squarely and make the mea
surement.
SERVICE LIMIT:
Top/Second : 0 . 50 mm (0.020 in)
Oil: 0 . 90 mm (0.035 in)
1 0-4
CYLI N D E R/P ISTON
P I STON R I N G I NSTALLATION
NOTE
Insert the outside surface of the ring into the proper ring
groove and rol l around in the g roove to make sure that the
ring has a free fit around the p i ston ' s circumference.
Carefully install the piston rings o nto the piston with the mark
ings facing u p .
NOTE
To install the oil ring, instal l t h e spacer first, then instal l the
side rails.
After installing the rings, check that they rotate freely without
sticking.
P I STON I N STALLATION
Place a shop towel into the cra n k case .
Coat the rod small end with molybdenum disulfide grease . As
semble the piston and connecting rod with the piston and
piston pin clips as shown .
NOTE
I nstall the pistons with the m a rk " I N " facing towards the
intake side .
After installing the piston pin c l ips, make sure that they are
seated properly and the end gaps are not aligned with the
cut-out in the piston.
Do not let the piston pin clips fall into the crankcase .
1 0- 5
CYLI N D E R/PISTON
Install the piston assembly into the cylinder from the top of the
crankcase while compressing the piston rings with your fin
gers.
Be sure each assembly is returned to its original position as
noted during remova l .
N OTE
When the cylinder is halfway over the piston , route the cam
chain through the cylinder.
I nstal l a new 0-ring onto the cylinder joint and install the cylin
der joint collar by sliding the collar toward eigther cylinder.
I nstal l the clip securely.
Clean the cylinder gasket surface being careful not to drop any
gasket material .
NOTE
NOTE
Make sure that the end of the guide is inserted into place in
the crankcase .
1 0- 6
CYLI N D ER/PISTON
I nstal l a new 0-ring into the connecting pipe and install and
tighten the connecting pipe mounting bolts, if the connecting
pipe was removed .
If only the water hose was removed , connect the hose with
clamp.
I nstal l the dowel pins and a new gasket . , (1) DOWEL PINS
\
I nstal l the cylinder heads and covers (Section 9 ) .
1 0- 7
CRAN KSHAFT/TRANSM ISSION
T RA N S M I SSIO N 1 1 -1 1
SERVICE I N FORMATION
G E N ERAL
To service the connecting rods, crankshaft, transmission and oil pump, the engine must be removed from the frame ( Sec
tion 6 ) .
A l l bearing i nserts are select fitted a n d are identified b y color code. Select replacement bearings from the code tables.
After instal l ing new bearings, recheck them with plastigauge to verify clearance.
Apply molybdenum disulfide g rease to the main journals and crankpins during assembly.
Before separating the crankcase, the following parts must be removed .
Section 9 NOTE
Section 9
Cylinder head cover
. The front cylinder camshaft and cylinder head
Water pipe - Camshaft service c an be performed without removing
the engin e from the frame.
Ill
Camshaft holder
l
Cam chain and drive sproket
Section 1 0 Section 9
O i l pass pipe
Cylinder joint collar - Cylinder head
Water hose connecting pipe
Cam chain tensioner
Section 9, 10 Section 1 0
Cylinder
C a m chain guide ------
Piston
+
Crankshaft - C R A N KCASE _ Starter motor ( Section 1 7 )
Connecting rod SEPA RATIO N
R ight crankcase cover ( Section 7 )
Transmission - Clutch
O i l pump - Gearshift linkage
- Primary drive gear
- Oil pipe
Left crankcase cover ( Section 8 )
- Flywheel
- Starter gears
1 1 -1
C RA N KS HAFT/TRAN S M I S S I O N
S P E C I F I CATI O N S
mm (in)
ITEM STAN DAR D S E RV I C E LI M IT
Cra n kshaft/ Con nectin g rod big end side clearance 0 . 05-0 . 2 0 (0 . 002-0 . 008) 0 . 30(0 . 00 1 )
connecting rod Crankpin o i l clearance 0 . 02 8 -0 . 05 2 (0 . 00 1 1 -0 . 0020) 0 . 07 ( 0 . 003)
Main journal oil clearance 0 . 02 5-0 . 04 1 (0 . 00 1 0-0 . 00 1 6 ) 0 . 06 (0 . 002)
Crankshaft ru nout -
0 . 05 ( 0 . 002)
Transmission Gear I . D . C1 2 4 . 000-24 . 02 1 ( 0 . 9449-0 . 94 5 7 ) 2 3 . 94 (0 . 943)
M 4 , M 2 , C3 2 8 . 000-2 8 . 02 1 ( 1 . 1 02 4- 1 . 1 03 2 ) 2 8 . 04 (0 . 1 04)
Gear bushing O . D . C 1 2 3 . 9 59-23 . 980 ( 0 . 9433-0 . 944 1 ) 2 4 . 94 (0 . 982)
M 4 , M 2 , C3 2 7 . 9 59-2 7 . 980( 1 . 1 007- 1 . 1 0 1 6) 2 7 . 94 ( 1 . 1 00)
Gear bushing I . D . C1 2 0 . 0 1 6-2 0 . 03 7 ( 0 . 7 880-0 ._7889) 2 0 . 06 ( 0 . 790)
M2 2 5 . 000-2 5 . 02 1 ( 0 . 9843-0 . 9 8 5 1 ) 2 5 . 04 (0 . 986)
B ushing-to- C1 0 . 02 3 -0 . 05 7 (0 . 0009-0 . 02 2 ) 0. 1 0 (0 . 004)
shaft clearance M2 0 . 020-0 . 062 ( 0 . 0008-0 . 0024) 0. 1 0 (0 . 004)
Gear-to- M4, M2 0 . 002-0 . 062 ( 0 . 0008-0 . 0024) 0. 1 0 (0 . 004)
bushing clearance C 1 , C3
Cou ntershaft 0 . D . C 1 bushing 1 9 . 980- 1 9 . 99 3 ( 0 . 7 8 6 6-0 . 7 8 7 1 ) 1 9 . 9 6 (0 . 786)
Mainshaft 0 . D . M 2 bushing 2 4 . 9 59-24 . 980(0 . 98 3 5 -0 . 9 8 2 6 ) 2 4 . 94 (0 . 982)
Backlash 1 st, 2 n d , 3rd 1 . 02 1 -0 . 1 1 0 ( 0 . 0008-0 . 0043)
4th 1 . 02 3 -0 . 1 1 7 ( 0 . 0009-0 . 0046)
S hift fork/ Claw thickness 5 . 93-6 . 00(0 . 2 3 3 -0 . 2 3 6 ) 5 . 63 ( 0 . 2 2 2 )
fork-shaft Right and left shift '88 , ' 89 , ' 9 1 -' 9 5 : 1 3 . 000- 1 3 . 0 1 8 ( 0 . 5 1 1 8-0 . 5 1 2 5 ) 1 3 . 04 (0 . 5 1 3)
fork I . D . After'9 5 : 1 3 . 000- 1 3 . 02 1 ( 0 . 5 1 1 8-0 . 5 1 2 6 ) 1 3 . 04 (0 . 5 1 3)
' 88 , ' 89 , ' 9 1 -' 9 5 : 1 2 . 9 6 6 - 1 2 . 984(0 . 5 1 05-0 . 5 1 1 2 ) 1 2 . 9 0 (0 . 508)
Shaft O . D .
After'9 5 : 1 2 . 9 6 6- 1 2 . 984(0 , 5 1 05-0 . 5 1 1 2 ) 1 2 . 9 5 (0 . 509)
Shift drum 0 . D . (at the left side journal) 1 1 . 9 6 6 - 1 1 . 984 ( 0 . 47 1 1 -0 . 47 1 8) 1 1 . 94 (0 . 47 0)
T O R Q U E VALU ES
TOOLS
Special
Main bearing driver attachment 0 7 H M F - M M 90400
Bearing remover set 07936 - 3 7 1 000 1 N ot available in U . S . A .
- remover handle 07936 - 3 7 1 0 1 00
- bearing remover set 07936 - 3 7 1 0600
- remover weight 07741 - 00 1 020 1 or
07936 - 3 7 1 0200 U . S . A . Only
Common
Driver 07749 - 00 1 0000
Attachment, 42 x 4 7 mm 07 746 - 00 1 0300
Pilot, 20 mm 077 46 - 0040 500
Attachment, 52 x 55 mm 07746 - 00 1 0400
Pilot, 22 mm 07 746 - 004 1 000
Pilot, 2 5 mm 07746 - 0040600
1 1 -2
CRA N K S HA FT/TRANSMISS I O N
TROU BLESHOOTI N G
Excessive noise
Crankshaft
- Worn main bearing
- Worn crankpin bearing
connecting rod
- Worn rod small end
- Worn crankpin bearing
Hard to shift
Shift forks bent
Shift fork shaft bent
Shift spindle claw bent
Shift drum cam grooves damaged
Shift fork guide pin damaged
1 1 -3
CRANKS HAFT/TRANSMISSION
Remove the oil pipe stay and cam chain tensioner set plate by
removing the bolts .
Remove the rear cam chain and cam chain drive sprocket.
NOTE
2
Remove the bolts in a crisscross pattern in or 3 steps.
NOTE
2
Remove the bolts in a crisscross pattern in or 3 steps.
1 1 -4
CRANKS HAFT/TRA N S M I S S I O N
Place the left crankcase side down and separate the right
crankcase from the left crankcase while prying where indicat
ed at the point shown and tapping the cases at several loca
tions w ith a soft hammer.
Remove the dowel pins and clean the cran kcase halves of any
sealant materia l .
1 1 -5
CRANKSHAFT/TRA N S M I S S I O N
NOTE
Tap the side of the cap lightly if it is hard to remove .
CAUTION
Do not interchange the crankpin bearings. They must be in
stalled in their original positions or the correct bearing oil clear
ance may not be obtained resulting in engine damage.
C RA N K S H A FT R U N O U T I N S P ECTI O N
NOTE
C O N N E CTI N G R O D B E A R I N G I N S P E CT I O N
( 2 1 SEPARATION ( 1 1 DAMA G E
I nstal l the bearing caps and rods on the correct crankpins, and
tighten them evenly.
NOTE
1 1 -6
CRAN KS HAFT/TRA N S M ISSION
1\ C RANKPIN O . D . CODE
A
3 9 . 982 - 39.974-
B
( 1 ) CRANKPIN BEAR I N G S
3 9 . 990 mm 39.98 1 mm
/
\
C O N N ECTI NG ( 1 . 5 741 - ( 1 . 5738-
R O D I.D. CODE 1 . 5 744 in) 1 . 5741 in)
43.000 - 43 . 007 mm c B
1
( 1 . 6 9 29 - 1 . 6932 i n ) ( BROWN ) (BLACK)
43.008 - 43 .0 1 6 m m B A
2
( 1 . 6932 - 1 .6935 i n ) ( B LACK) ( BLUE)
1 1 -7
CRANKS HAFT/TRA N S M ISSION
M A I N BEAR I N G I N S PECTI O N
Calculate the clearance between the main journal and the main
bearing .
M A I N BEAR I N G S E LECTI O N
2
Determine the crankshaft main journal O . D . code. The code
will be either a number 1 or on the crank weight.
1 1 -8
C RAN KSHAFT/TRAN S M ISSION
M A I N J O U RNAL 1 2
O . D . CODE 44. 992- 44. 984 -
4 5 . 000 mm 44 . 9 9 1 mm
\
( 1 . 7 7 1 3- ( 1 . 77 1 0-
CASE I . D . C O D E 1 . 77 1 7 i n ) 1 . 7 7 1 3 in)
48 . 9 90 - 49 . 000 mm c B
A
( 1 . 9 2 8 7 - 1 . 9 2 9 1 in) ( B ROWN ) ( BLACK)
49.000 - 49 .0 1 0 mm B A
B
( 1 . 9 2 9 1 - 1 . 92 9 5 i n ) ( B LACK) ( BLU E)
MAI N B EA R I N G R E P LA C E M E N T
NOTE
Always use a press to remove the main bearing.
TOOLS :
Driver 07749 - 0 0 1 0000
Main bearing remover attachment 07HM F - MM90400
(2) MARKS
(3) G ROOVE
Align the marks on the bearing w ith the groove in the bearing
hole, and press the main bearing i nto the crankcase .
CAUTION
Be careful not to damage the bearings.
1 1 -9
CRAN KS HAFT/TRANSMISSION
C O N N ECTI N G R O D/ C RA N K S H A FT
S E L E CT I O N
NOTE
The " 0 " mark in the table indicates that the matching is
possible in the crossed codes. ( 2 ) CRANKSHAFT
WEIGHT CODE
SELECTIO N TABLE ( " L" or "H" or no mark)
B 0 0 0
c 0 0 * *
CAUTION
For selecting crankshaft weight:
Select "L " crankshaft weight, if the front rod and rear road
have code A ( ) .
Select "H" crankshaft weight, if the front rod and rear rod
have code C ( * *) .
C O N N ECTI N G R O D A S S E M B LY
NOTE
Align the boss on the bearing with the groove in the rod or
cap.
Apply molbdenum disulfide grease to the bearing.
NOTE
Align the I . D . code on the cap and rod .
CRA N K S H A FT I N STALLAT I O N
1 1-10
C RAN KSHAFT/TRAN S M ISSION
After'9 5 :
Remove the shift fork shaft then remove the shift drum and
shift forks .
Remove the mainshaft and countershaft as a n assembly.
After'9 5 :
Separate the mainshaft and countershaft assemblies from
each other.
(3) COUNTERSHAFT
ASSEM BLY
1 1 -1 1
C RAN KSHAFT/TRA N S M I S S I O N
I
SERVICE LIMIT: 1 1 . 94 m m (0.470 in)
1 2 1 S H I FT DRUM
M easure the shift fork I. D. ( right and left) and the shift fork
claw thickness .
SERVICE LIMIT:
I.D.: 1 3 .04 m m (0 . 5 1 3 in)
CLAW THICKNESS: 5.63 mm (0. 222 in)
I nspect the shift drum and shift fork shaft journals for exessive
wear or damage .
1 1 -1 2
CRANKSHAFT/TRANSMISSION
SERVICE LIMITS :
M4 gear bushing : 27 . 94 mm ( 1 . 1 00 in)
C3 gear bushing : 2 7 . 94 mm ( 1 . 1 00 in)
M 2 gear bushing : 2 7 . 94 mm ( 1 . 1 00 in)
C1 gear bushing : 24. 94 mm ( 0 .982 in)
SERVICE LIMITS :
Mainshaft (at M2 gear bushing) (1) 2
24. 90 mm (0.980 in)
Countershaft (at C 1 gear bushing)
1 9 .92 mm (0. 784 in)
Replace if necessary .
( 2 ) LOCK A N D STOP
WASHER G ROOVES
+ +
t t
( 3 ) SNAP RING (4) STOP
G ROOVE R I N G GROOVE
CRAN KCASE
BEA R I N G R E P LA C E M E N T
Turn the inner race of each bearin g with your finger. The bear
ings should turn smoothly and q uietly . Also check that the
bearing outer race fits tightly i n the crankcase.
1 1 -1 3
CRAN KSHAFT/TRAN S M I S S I O N
Left crankcase
Remove the left mainshaft bearing using the special tools.
TOOLS:
Bearing remover set 07936 - 37 1 000 1 N ot
ava i lable i n U . S . A .
- remover handle 07936 - 37 1 0 1 00
- bearing remover set 07936 - 37 1 0600
- remover weight 0774 1 - 00 1 020 1 or
07936-37 1 0200
Drive the countershaft bearing and oil seal out of the crank
case .
I nstal l the new mainshaft bearing set plate on the left crank (1 ) BEARING
case. S ET
PLATE
NOTE
TOOLS :
Left mainshaft bearing
Driver 07749 - 00 1 0000
Attachment, 42 x 47 mm 07746 - 00 1 0300
Left countershaft bearing
Driver 07749 - 00 1 0000
Attachment, 52 x 55 mm 07746 - 00 1 0400
Pilot, 25 mm 07746 - 0040600
1 1-14
CRANKSHAFT/TRANSMISSION
Right crankcase
Remove the mainshaft bearing set plate and drive the counter
shaft bearing, mainshaft bearing and shift drum bearing out of
the crankcase .
TOOLS :
Right mainshaft bearing
Driver 07749 - 00 1 0000
Attachment, 52 x 55 mm 07746 - 00 1 0400
Pilot, 22 mm 07746 - 0041 000
Right countershaft bearing
Driver 07749 - 00 1 0000
Attachment, 42 x 47 mm 07746 - 00 1 0300
Pilot, 20 mm 07746 - 0040500
Crankcase studs
'88 ' ' 8 9 ' ' 9 1 -'9 5 :
Check that the studs a re tight. I f any are loose, remove them ,
clean their threads with c ontact cleaner, then reinstall them
using Honda Anaerobic Thread Lock , o r equivalent.
After i nstalling, be sure to measure the distance from the top ( 1 ) 8 mm STU D BOLT ( 2 ) 1 0 mm STUD BOLT
of each stud to the crankcase surface .
1 1 -1 5
C RAN KS H A FT /TRAN S M ISSI O N
After'9 5 :
Check that the studs a re tight, I f any a re loose, remove them ,
clean their threads with contact cleaner, then reinstall them
apply engine oil to the threads . (1 ) FLAT SI DE
NOTE
Install the studs with the flat side into the crankcase .
\I=-=;1..1 %,...
.--- .. 1 11,
(2 ) B OSS S I DE
1 8 5- 1 8 7 mm 1 68 - 1 70 mm
( 7 . 2 83-7 . 3 62 in) (6.6 1 4 - 6.693 in)
O I L J ET
Remove the oil jets from the front cylinder bore of the right and
left crankcase .
1 1 -1 6
CRAN KSHAFT/TRA N S M ISSION
(4) C2 (34T)
( 3 ) C3 ( 2 7TI
(6) MAINSHAFT
( 1 I COUNTERSHAFT
M4
( 1 0) M4 (29TI
(2) C4 C3 C 2 C1
C O U NTERSHAFT
1 1 -1 7
C RAN KSHAFT/TRANSMISSION
I nstall the lock washer and stop washer, aligning bigger tabs of
the lock washer with bigger grooves of the stop washer in the
countershaft groove .
I nstall the stop washer first, and then the lock washer for the ( 1 ) STOP
C3 gear. WASHER
I
Align and lock the washers using the procedure above.
I
their end gaps with the lands of the splines.
( 2 ) LOCK WASHER
( 2 ) G ROOVE
' 8 8 , ' 89 , ' 9 1 -' 9 5 :
Tighten the bolt with the lock washer a n d bend up the tabs of ( 1 ) BOLT
the lock washer.
( 2 ) TABS
1 1 -1 8
CRANKSHAFT/TRANSMISSION
After'9 5 :
Assemble the mainshaft a n d countershaft .
STE P P E D
I nstall them into the left cankcase as an assembly . EN D
I nstall the shift forks into the shifter gear g rooves with the
markings facing up ( right crankcase side) .
I nstall the shift drum by aligning the shift fork guide pins wiht
the shift drum guide g rooves .
I nsert the shift fork shaft throug h the shift forks into the left
crankcase with the stepped end facing u p .
( 1 I DOW EL PINS
,
CAUTION
Do not force the crankcase halves together; if there is exessive
force required, something is wrong. Remove the right crank
case and check for misaligned parts.
1 1 -1 9
C RAN KSHAFT/TRANSMISSION
2
Instal l and tighten the right crankcase bolts i n a crisscross pat
tern in or 3 steps.
NOTE
2
I nstall and tighten the left crankcase bolts in a crisscross pat
tern in or 3 steps.
NOTE
I nstall the rear cam chain drive sprocket over the crankshaft,
aligning the extra-wide splines i n the sprocket and crankshaft.
Install the oil pipe stay and cam chain tensioner set plate .
Tighten the bolt sercurely.
1 1 - 20
C RAN KS HAFT/TRA N S M ISSION
I nstal l the front cam chain over the front cam chain d rive
sprocket.
I nstall the cam chain tensioner set p l ate and tighten the bolt
securely.
1 1 -2 1
F R O NT W H E E L/ S U S P E N S I O N / STE E R I N G
3 0 N m (3 . 0 K g-m , 2 2 ft-lb )
After g4 .
1 05 N m ( 1 0 . 5 Kg -m, 76 ft-lb)
2 3 N m (2 . 3 K g-m , 1 7 ft-lb)
2 2 N m (2 . 2 K g-m , 1 6 ft-lb)
12-0
1 2. FRONT WH EEL/SUSP ENSION/STEER I NG
SERVICE I N F O RMATION 1 2- 1 FRONT W H EEL 1 2-6
TROU BLES H O O T I N G 1 2-2 FORK 1 2- 1 2
HAN D LEBAR 1 2-3 STEERING STEM 1 2- 1 9
SERV I CE I N FORMATION
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high
quality brake degreasing agent.
Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to clean brake
assemblies. Use an OSHA -approved vacuum cleaner or alternate method approved by OSHA, designed to minimize the hazard
caused by air borne asbestos fibers.
This section covers maintenance of the front wheel, fork and steering ste m . Refer to section 1 4 for front (hydraulic) brake
service .
Support the motorcycle using a hoist or a jack under the engine.
The VT600C uses leaf valve to the left .
S P E C I F I CATI O N S
Fork flu id capacity ' 9 1 -' 9 3 : 468 cc( 1 5.8 US oz, 1 3.2 Imp oz) -
'88.'89
Left 93.0 mm(3.66 i n ) -
' 9 1 -'93
Left 87.0 m m ( 3 .43 i n ) -
T O R Q U E VALU E S
1 2- 1
FRONT WHEEL/S U S P E N S I O N/STE E R I N G
T O O LS
Special
Spoke wrench
Bottom holder pipe
- holder attachment
07930- KA50000
07930- KA50 1 00
j
07JMA - M R60 1 00 o r equivalent commercially available in U . S . A .
N ot available i n U . S . A .
07953 - MJ 1 0 1 00 T
Ball race remover 07953 - MJ 1 0000 N ot available in U . S . A .
07953 - MJ 1 0200 J
- driver attachment 0 7 9 5 3- MJ 1 000A . 0 7 9 5 3- M J 1 000B o r
- driver handle 0 7 949 -37 1 000 1 a n d 0 7 7 4 6-00 1 0 1 00
Common
Driver 07 749 - 00 1 0000
Attachment, 42 x 47 mm 07 746 - 00 1 0300
Pilot, 20 mm 07 746 - 0040500
Bearing remover shaft 07 746 - 0050 1 00 -r-- Equivalent commercially available i n U . S . A .
Bearing remover head , 20 m m 07 746 - 0050600 _j
Attachment, 52 x 55 m m 07 746 - 00 1 0400
TROUBLESHOOTI N G
Hard Steering Soft Suspension
Faulty tire
1 2- 2
FRONT WH EEL/SUSPENSION/STEERING
HAN DLEBAR
G R I P R E PLAC E M E N T
Remove the grip end cap and right handlebar grip. ( 1 ) CEMMENT
Remove the grip from the throttle pipe.
Connect the throttle cables to the throttle pipe and i nstall the
"()
right handlebar switch.
Remove the grip end cap and pull the grip off of the left handle ( 1 ) C E M M ENT
bar.
NOTE
REMOVAL
1 2-3
FRONT W H EEL/S USPENSION/STEERING
Disconnect the front brake light switch wires from the switch. ( 1 l BARKE LIGHT SWITCH
Remove the following : WIRE
- rear view mirror from the master cylinder
- master cylinder holder mounting bolts and holder
- right handlebar switch wire bands
- right handlebar switch screws and switch
After '94 :
Remove the ha ndlebar upper holder bolts caps .
Remove the socket bolts , upper holders and handleba r .
1 2-4
F R O N T WHEEL/SUSPENSIO N/STEERING
I N STA LLAT I O N
After '94 :
I nstall the handlebar lower holders a n d tem porarily tighten
the n uts .
I nstal l the handlebar and upper holders with their pu nch marks
facing forward .
Tem porarily tighten the socket bolts .
( 1 ) LOWER H O L D E R N UTS
T O R QU E : 3 0 N m ( 3 . 0 kg-m , 22 ft-lb)
Install the left handlebar switch set collar on the upper switch
housing . Align the locating pin in the lower switch housing
w ith the hole in the handlebar.
1 2- 5
FRONT WH EEL/S U S PE N S I O N/STE E R I N G
Install the clutch holder/lever and with the " U P" mark facing
up.
Align the end of the holder with the punch mark on the handle
. bar and tighten the upper bolt first then tighten the lower bolt.
Apply grease to the throttle cable ends and connect the cables
to the throttle pipe.
I nstal l the right handlebar switch onto the handlebar, aligning
the locating pin with the hole in the handlebar.
I nstall the right handlebar switch screws and tighten the for
ward screw first, then tighten the rear screw.
I nstall the front brake master cylinder/holder with the " U P"
mark facing up.
Align the end of the holder with the punch mark on the handle
bar and tighten the upper bolt first, then tighten the lower bolt.
1 2-6
FRONT WHEEL/S U S PE N S I O N /STEERING
FRONT WHEEL
R E M OVA L
( 2 ) SET SCREW
Remove the axle pinch bolt caps, a n d bolts from the right front
fork leg .
NOTE
Do not operate the front brake lever after removing the
front wheel. To do so will cause difficulty in fitting the
brake disc between the brake pads.
1 2- 7
FRONT W H E E L/SUSPEN S I O N/STEE R I N G
I N S P E CT I O N (1 ) FRONT AXLE
e AXLE
Set the axle in V blocks and measure the runout .
Actual ru nout is 1 /2 the tota l i n dicator reading .
e WHEEL
Check the spokes and tighten any that are loose .
SERVICE LIMITS :
RADIAL: 2 . 0 mm (0.08 in)
AXIAL: 2.0 mm (0.08 in)
\
all safety of the motorcycle. A lways check balance when the
tire has been removed from the rim .
\a
NOTE
1 2- 8
F R O N T W H EEL/S USPENSION/STEERING
( 1 ) WHEEL BEARING
B EA R I N G R E P LA C E M E N T
-
( 1 ) DUST SEALS
1 2-9
FRONT WH E E L/S USPENSION/STE E R I N G
CAUTION
TOOLS :
Bearing remover shaft 07746-005 0 1 0 0
Equivalent commercially
available in U .S.A.
Bearing remover head, 20 mm 07746-0050600
Equivalent commercially
available i n U .S.A.
N OTE
TOOLS :
Driver 07749 - 00 1 0000
Attachment, 42 x 47 mm 07746 - 00 1 0300
Pilot, 20 mm 07746 - 0040500
A S S E M B LY
Do not get get grease on the brake disc or stopping power will
be reduced.
- (1 l DISTAN C E COLLAR
(1 1 l
'__:::..c:o .
SIDE .
CO LLAR
(9) BEARI NG
(4) SPEEDOMETER
GEARBOX
(6) SPEEDO f?
M ETER (5) WASHERS
G EAR
1 2- 1 0
FRONT WH EEL/S U S PEN S I O N /STEERING
Adjust the hub position so that the d ista n ce from the hub sur
face where the brake disc mounts to the side of rim is (A) .
Tighten the spokes in 2 or 3 progreassive steps.
TOOLS :
Spoke wrench : 07JMA - MR60 1 00 or
equivalent commercially
available in U . S .A.
Coat the speedometer gear retainer with grease and install the
retainer i nto the wheel hub, aligning the tangs with the slots in
the hub.
Apply grease to the oil seal lip and instal l the oil seal over the
gear retainer.
N OTE
Apply grease to the dust seal lips and install the seal on the ( 1 ) DUST SEAL
right side of the hub.
1 2- 1 1
FRONT WHEEL/SUSPENSIO N/STEERING
INSTALLATION
Set the speedometer gearbox tab under the tang on the left
fork slider.
t2 1 ST SCREW
1 2- 1 2
FRONT W H EEL/S U S PENSION/STEERING
FORK
R E MOVAL
Pull the speedometer cable out of the cable holder on the fend
er.
Remove the front fender mounting bolts from the fork legs.
If the fork legs will be disassembled, loosen the fork cap bolts,
but do not remove them yet.
Pull the fork tubes out of the top bridge and steering stem.
1 2- 1 3
FRONT W H E E L/S U SPENSION/STE E R I N G
The cap bolts are under spring pressure. Take care when re
moving, and wear eye and face protection.
'\
al times .
Hold the fork slider in a vise with soft jaws or a shop towe l . ( 1 ) HOLDER HANDLE
CAUTION
I nstall the special tool i nto the fork tube and hold the piston,
then remove the socket bolt.
TOOLS :
Bottom holder pipe 07930-KA50000
N ot available i n U . S .A.
- holder attachment 07930- KA5 0 1 00
N ot available i n U . S .A.
- bottom holder handle 07930- KA40200
N ot available i n U . S .A.
Remove the dust seal and stop ring . ( 1 ) D U ST SEAL
CAUTION
1 2- 1 4
FRONT W H E EL/S USPENS I O N/ST E E R I N G
I n quick successive motions, pull the fork tube out of the slid
er.
NOTE
The slider bushing that is pressed into the slider, and the
fork tube bushing on the end of the fork tube, must be
forced out.
Remove the oil seal, back-up ring and slider bushing from the
fork tube.
Do not remove the fork tube bushing until inspection
determines it is necessary ( page 1 2- 1 5 ) .
\
(4) BACK-U P RING (3) TUBE BUS H I NG
I N S PE CT I O N ( 1 ) FO SPRI NG
Fork spring
Measure the fork spring free lengt h .
.
Fork tube/slider/piston ( 1 I FORK S L I D E R ( 2 ) FORK TUBE
\
Check the fork tube, fork slider and piston for score marks, ex
cessive or abnormal wear.
Replace any components which are worn or damaged .
Check the rebound spring for fatigue or damage. . ,
(5)
REBO U N D
SPRING ! '\(3) OIL LOCK PIECE
(4) PISTON
1 2- 1 5
FRONT W H E E L/SUSPEN S I O N/STEERING
Bushings
Visually inspect the slider and fork tube bushings. (11 BUSH I N G (21 BACK-UP RING
Replace the bushings if there is excessive scoring or scratch
ing, or if the teflon is worn so that the copper surface a ppears
on more than 3/4 of the entire surface.
~
Check the back-up ring; replace it if there is any distortion at
the points shown.
.. ... ... (31 CHECK
PO INTS
(41 COPPER
SU RFACES
A S S E M BLY
(1 I FORK TUBE CAP
'88 . '89 . ' 9 1 -'93 O N LY
0-RING LEFT FORK TUBE (21 RIGHT FO RK TUBE
--_JJ
( 1 91 (1 I
;:!
( 1 51 PISTON RING ( 9 1 DRAIN BOLT
( 1 41 PISTO N
J.-- ( 1 01
@>
( Except after'9 5)
SOCKET BOLT
FORK TUBE
(1 1 I
( 1 31 REBOU N D BUSH I N G CAUTION
SPRING
( 1 21 O I L LOCK PIECE
The fork tube cannot be disassembled.
Do not interchange the right and left fork tube when in
stalling the fork tu be in th e fork slider.
1 2- 1 6
FRONT WHEEL/S U S P E N S I O N /STEERING
I nstall the rebound spring i nto the fork tube. ( 1 I OIL SEAL
(21 BACK-U P R I N G
/
I nstall a new postion ring i nto the piston groove .
Place the oil lock piece on the end of the piston and insert the
fork tube i nto the slider. PISTON
(61 SLIDER I
BUSH I N G ( 5 ) TUBE BUSH I N G ( 4 ) LOCK PIECE
I nstal l the special tools i nto the fork tube to hold the pis (1 I HOLDER ATTACH MENT ( 2 1 BOTTO M HOLDER
HANDLE
ton,and i nstall and tighten the socket bolt.
TOOLS :
Bottom holder pipe 07930- KA50000
N ot ava i l a ble i n U . S.A.
- holder attachment 07930- KA50 1 00
N ot ava i lable i n U . S.A.
- bottom holder handle 07930- KA40200
N ot ava i l able i n U . S.A.
Place the fork slider i n a vise with soft jaws or use a shop ( 1 l SOCKET
-
BOLT
,
towel. Apply a locking agent to the socket bolt and thread it .....
'
i nto the piston . Tighten w ith a 6 mm hex wrench . .....
'
'
NOTE
Temporarily install the fork sprin g and fork cap bolt to tight
en the socket bolt.
Place the sl ider bushing over the fork tube until it rests on the
slider.
N OTE
Tape the upper edge of the fork tube to avoid damaging the
( 2 ) D U ST SEAL
oil seal lip, while i nstalling the o i l sea l . V
d Iv ( 3 ) STOP
(4) O I L SEAL
RING
U s i n g a fork seal driver , drive t h e bushing into place .
-
I nstal l the back-up ring with the c hamfered side facing the
slider bushing.
Coat the oil seal lip with the recom mended fork oil.
D rive the oil seal i nto place using a fork seal driver.
l ( 5 ) BACK-U P
RING
I nstall the oil seal stop ring and the dust sea l .
TOOL:
Fork seal driver, 39mm 07947 - 4630 1 00
1 2- 1 7
FRONT WHEEL/S U S P E N S I O N/STEERING
Com press the fork leg and pour Honda Su spensio n F luid
SS-8 o r equ iva lent i nto the fork tube.
SPECI F I E D L E V E L :
'88, 89:
'
' 9 1 -'93 : 468 cc ( 1 5.8 U S oz, 1 3. 2 Imp oz )
After '93: 449 cc( 1 6 . 9 U S oz , 1 5.8 1 m p oz)
I nstal l the fork spring, washer and spacer into the fork tube. ( 1 )TI G HTLY WO U N D
C O I LS
'88 . '89 . ' 9 1 - '93 :
r t'
NOTE
tom .
A Fter '93 :
N OT E
Loosely install the fork tube cap with a new 0-ring. ( 1 l 0-RING (2) FORK TUBE CAP
I N STA LLAT I O N
I nstall t h e fork tube, aligining its top e n d with the upper sur
face of the top bridge as show n .
1 2- 1 8
FRONT WHEE L/S U S P E N S I O N/STEERING
I nstall the front fender and tighten the mounting bolts secure
ly.
,1
"
(2) M O U N T I N G BOLTS
1 2- 1 9
FRONT W H EEL/S U S P E N S I O N /STEER I N G
(4) STAY
Straighten the lock washer tabs and remove the lock nut and (1 ) LOCK NUT (2) LOCK WAS H E R
lock washer. TABS
1 2-20
FRONT WHEEL/S U S P E N S I O N/STEERING
B EA R I N G R E PLAC E M E N T
( 9 ) LOWER B E A R I N G
( 1 0 ) L O W E R B EA R I N G I N N E R RACE
( 1 1 ) D U ST S E A L
1 2- 2 1
FRONT WH EEL/S U S P E N S I O N /STEERING
NOTE ( 2 ) STEM
NUT
I nstal l the steering stem nut o n the top end of the steering
stem to protect the threads from damage.
Remove the lower i n ner race and dust seal using a punch or
d river.
Replace the dust seal with a new one whenever it is removed .
(3) LOWER I N N E R R A C E
Remove the lower outer race using the special tools and a suit
able shaft.
Remove the upper bearing outer race using the special tools.
TOOLS :
Ball race remover 07953 - MJ 1 0000 N ot ava i l a b l e
- attachment
- driver handle
07953 - MJ 1 0 1 00
07953 - MJ 1 0200 J in U . S . A .
or
Attachment 0 7 9 5 3 - MJ 1 OOOA ,
07953 - MJ 1 0008 or
D river 0 7 949-3 7 1 000 1 and
Attachment, 32 X 35 m m 0 7746-00 1 0 1 00
Drive new upper and lower bearing outer races into the steer
ing head pipe .
TOOLS :
U pper bearing outer race :
Drive 07749 - 00 1 0000
Attachment, 42 x 47 mm 07746 - 00 1 0300
1 2-22
FRONT WH EEL/S USPEN S I O N /STE E R I N G
,,
I N STALLAT I O N
E R I N G B EA R I N G A DJ U ST M E N T t
... .
NUT
( 1 ) 1NNER RACE
Turn the steering stem back and forth five times to seat the
bearings.
Retighten the adjustment nut to the same torque.
Turn the steering stem to seat the bearings.
I nstall a new lock washer and bend the two opposite tabs ( 1 I LOCK WA S H E R (2) LOCK NUT
down into the grooves i n the adjustment nut.
1 2-23
FRONT WH EEL/S U S PENS I O N /ST E E R I N G
I nstall the fork bridge then temporarily i nstal l the fork legs.
Tighten the steering stem nut.
ST E E R I N G H EA D B EA R I N G P R E L O A D
Place a stand under the engine and raise the front wheel off
the groun d .
Position t h e steering stem t o the straight ahead position.
Hook a spring balance to the fork tube and measure the steer
ing head bearing preload .
NOTE
1 2 - 24
MEMO
REAR WHEEL/BRAKE/S U S PENSION
1 3-0
1 3. REAR WH EEL/ B RAK E/SUSP E NSION
SERVICE I N FO R M AT I O N 1 3- 1 BRAKE PEDAL 1 3- 1 0
SERVICE I N FORMATION
G E N ERAL
CAUTION
Do not jack up the motorcycle using the oil filter.
Use only genuine Honda replacement fasteners for the rear suspension.
Note the i nstallation direction of the bolts.
A ny attempt to mount automobile tires on a motorcycle rim may cause the tire bead to separate from the rim with
enough explosive force to cause serious injury or death.
The rear shock absorber contains nitrogen under high pressure. Do not allow fire or heat near the shock absorber. Use only nitro
gen to pressurize the shock absorber. The use of an unstable gas can cause a tire or explosion resulting in serious energy.
Before disposal of the shock absorber, release the nitrogen by pressing the valve core. Then remove the valve from the shock ab
sorber.
IIEI:f:l
Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to clean brake
assemblies. Use an OSHA -approved vacuum cleaner or alternate mothod approved by OSHA, designed to minimize the hazard
coused by airborne asbestos fibers. ..:I
S P E C I F I C AT I O N
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Rear wheel runout Radial --
2 . 0 mm (0.08 in)
Axial --
2 . 0 mm (0.08 in)
Rear axle runout --
0 . 2 mm (0.01 in)
Rear brake drum I . D . 1 60 mm ( 6 . 3 in) 1 6 1 mm ( 6 . 3 in)
Rear brake lining thickness 5 mm (0. 2 in) 2 mm (0.08 in)
Shock absorber spring free length 1 37 . 5 m m ( 5 . 4 1 in) 1 3 5 . 0 mm ( 5 . 3 1 in)
Rear suspension damper compression 1 3 . 4 - 1 7 . 4 kg ( 2 9 . 5 4 - 3 8 . 36 lb) 1 3 . 3 kg ( 2 9 . 3 2 lb)
T O R Q U E VALU E S
1 3- 1
REAR WHEEL/BRAKE/S USPEN S I O N
T O O LS
Special
Driver shaft 07 946 - MJ00 1 00
Attachment, 28 x 30 mm 07746 - 1 870 1 00
Spoke wrench 07JMA - M R60 1 00 or equivalent commercially
available i n U . S .A.
Shock absorber compressor 07G M E - 00 1 0000
Attachment 07 J ME - M R 1 0 1 00
Compressor screw 07G M E - 00 1 0 1 00
Snap ring pliers 079 1 4 - 323000 1
Common
Bearing remover shaft 07 746 - 0050 1 OO or equivalent commercially
TROUBLESHOOTI NG
Wobble o r vibration i n motorcycle
Bent rim
Loose wheel bearing(s)
Loose or bent spokes
Damaged tire
Axle not tightened properly
Swingarm pivot bearing worn
Chain adjusters not adjusted equally
Bent frame or swingarm
Soft suspension
Weak spring
Hard suspension
Suspension noise
Loose fasteners
:,,1 3-2
R E A R W H EEL/BRAKE/S U S P E N S I O N
REAR WHEEL
REM OVAL
Support the motorcycle using a hoist or a jack under the en
gine.
CAUTION
Do not jack up the oil filter.
I N S PE CT I O N
e AXLE
Set the axle on V blocks and measure the runout.
e WHEEL
Check the spokes and tighten any that are loose .
SERVICE LIMITS:
RADIAL: 2.0 m m (0.08 in)
AXIAL: 2.0 mm (0.08 in)
e WHEEL BEARING
Turn the i n ner race of each bearing with your finger.
The bearings should turn smoothly and quietly .
Also c h e c k that t h e bearing outer race fits tightly in t h e hub.
Remove a n d discard the bearings if the races do not turn
smoothly, q uietly, or if they fit loosely i n the hub.
NOTE
Replace wheel bearings i n pairs .
e WHEEL BALANCING
Refer to page 1 2- 7 .
NOTE
Do not add more than 70 grams of balancing weight to the
11 l WHEEL BEA RING
rear wheel
1 3- 3
REAR W H EEL/BRAKE/S USPENSION
S P R O C K ET/D R I V E N FLAN G E
D I SA S S E M B LY / I N S PECTI O N
( 1 1 GOOD ( 2 1 REPLACE
NOTE
The d rive chain and d rive sprocket must also be inspected if
the driven sprocket is worn or damaged . Never instal l a new
drive chain on worn sprockets or a worn chain on new
sprockets . Both chain and sprocket must be i n good condi
tion or the new replacement chain or sprockets will wear
rapidly.
BEA R I N G R E PLAC E M E N T
Wheel bearing
Drive out the wheel bearings and the distance collar.
NOTE
If the bearings are removed , they must replaced .
TOOLS :
Bearing remover shaft 07746 - 0050 1 00
Bearing remover head, 1 7 mm 07746 - 0050500
or equivalent commercially
available in U . S . A .
1 3-4
REAR WH EEL/BRAK E/S U S PENSION
TOOLS :
Driver 07749 - 00 1 0000
Attachment, 42 x 47 mm 07746 - 00 1 0300
Pilot, 1 7 mm 07746 - 0040400
NOTE
Flange bearing
Drive out the bearing using a suitable tool.
Drive the new bearing in with its vendor mark facing out.
TOOLS :
Driver 07749 - 00 1 0000
Attachment, 42 x 47 mm 07746 - 00 1 0300
Pilot, 1 7 mm 07746 - 0040400
( 3 ) ATTACHM ENT
A S S E M B LY
- -
(3) 0-RING
j
A
/1
( 1 1 1 BEARING (4) DRIVEN SPROCKET
1 1 01 DAMPER RUBBER
( 9 ) COLLAR
(8) FLANGE
( 7 ) NOISE ARRESTER
1 3- 5
REAR WH EEL/BRAKE/S U S P E N S I O N
Place the rim and hub on the work bench and begin lacing with
a new spoke from the hole of inside i n the hub.
Install the spoke with a space of two holes in between .
Measure the distance ( B ) , a n d make a calculation.
(A) = 79 mm ( 3 . 1 1 0 in) ( B ) + 2
-
Adjust the hub position so that the distance from the hub right
end surface to the side of rim is (A) .
Tighten the spokes i n 2 or 3 progressive steps.
TOOL:
Spoke wrench 07JMA - MR60 1 00
or equivalent commercially
available in U . S .A.
I nstall the damper rubbers on the flange and place flange i n the
hub.
Apply grease to a new 0-ring and i nstall it onto the flange
groove .
(2) 0-RING
1 3-6
REAR WH EEL/BRAKE/S USPENSION
--=
I N STALLAT I O N
Install the left side adjuster collar onto the rear axle and insert
the axle (from the left side) through the swingarm, wheel hub
and right side collar.
I nstall the adjuster collar and axle nut.
Tighten the axle nut lightly.
Adjust the drive chain ( page 3 - 1 3 ) .
Tighten the axle nut.
Connect the brake torque rod to the brake panel with bolt, seat
washer, washer and nut. (page 1 3-8 ) .
Tighten the nut.
R EAR BRAK E
I N S PECT I O N
Remove the brake panel and measure the rear brake drum I . D.
Replace the brake shoes if either one is thinner than the service
limit.
1 3- 7
REAR WHEEL/BRAKE/S USPENSION
D I SASS E M B LY
Remove the brake shoes and springs from the brake panel .
NOTE
A S S E M BLY
( 1 ) BOLT
(2) I N D I CATOR
PLATE
(3) FELT SEAL
(4) BRAKE SHOES
( 1 0) BRAKE
ARM
1 3-8
REAR W H E E L/BRAKE/S USPENSION
Apply grease to the brake anchor pins and brake cam. I nstall ( 1 ) BRAKE CAM
the brake cam into the brake panel .
Install the indicator plate on the brake cam aligning its tab with
cut-out on the brake cam .
Install the brake arm by aligning the punch marks on the arm
and cam.
I nstall and tighten the bolt.
(3)
I nstall the set plate and cotter pins, then bend back the pins.
I nstall the brake panel onto the wheel hub and install the rear
wheel (page 1 3-7 ) .
( 3 ) COTTER PI N ( 2 ) SPRINGS
....
(4) SET PLATE
1 3-9
REAR WHE EL/BRAKE/S U S PE N S I O N
BRAKE PEDAL
R E M OVAL
I N STA LLAT I O N
NOTE
Note the locations of the washers .
( 2 ) DUST SEALS
-
(5) PUNCH M A R K
1 3- 1 0
R EAR W H EEL/BRAK E/S USPEN S I O N
Disconnect the fuel pump, fuel pump relay and turn signal
relay from the fuel pump stay .
Remove the fuel pump stay mounting bolt, nut and fuel pump
stay .
.;:f;:.':
ment.
CAUTION 'I
,
Be sure the base is adjusted correctly for the shock spring seat
and the clevis pin is all the way in.
:::
TOOLS :
Shock absorber compressor 07GME - 00 1 0000
Attachment 07J ME - MR 1 0 1 00
(1 ) No. 1 POSITION
Compressor screw 07GME - 00 1 0 1 00
11 1 INT
J
Loosen the lock nut and remove the lower joint and nut.
. -
LOCK NUT
1 3- 1 1
REAR WHEEL/BRA K E/S U S PENSION
Check the damper unit for oil leaks or other damage and the
damper rod for trueness .
Check the upper mount bushing for wear or damage .
S H O C K A B S O R B E R D I S POSAL PR O C E D U R E
Through the open end of the bag, insert a power drill with a
sharp 2 or 3 mm ( 5/64 - 1 /8 in) drill bit.
Do not use a dull drill bit which could cause a build-up of exces
sive heat and pressure inside the damper, leading to explosion (3) D A M P E R U N I T
and severe personal injury.
The shock absorber contains nitrogen gas and oil under high
pressure. Do not drill any farther down the damper case than
the measurement given above, or you may drill into the oil
chamber; oil escaping under high pressure may cause serious
personal injury.
Always wear eye protection to avoid getting metal shavings in
your eyes when the gas pressure is released. The plastic bag is
only intended to shield you from the escaping gas.
Hold the bag around the drill motor and briefly run the drill
motor inside the bag; this will inflate the bag with air from the
motor and help keep the bag from getting caught in the bit
when you start.
1 3- 1 2
R EAR W H EEL/BRAKE/S U S PENSION
A S S E M B LY
( 1 ) DAMPER
( 2 ) SPRING
( 1 2 ) ADJU STER ADJUSTER
SEAT (4) SPRING
( 5 1 LOWER
SPRING
SEAT
p
(3) U PPER SPRING
SEAT
lQ
( 9 ) LOCK N UT
:\'
(7) LOWER JO I NT ( S) DRAI TU BE
N
- stop rubber onto the damper rod
- spring a djuster seat and spring a djuster onto the damper so
that it rests in the softest position LOCK NUT
- upper spring seat, spring (with the tightly wound end
upward and lower spring seat ) ,
- lock nut
Screw the lower joint onto the d a m per rod fully, hold it, and
tighten the lock nut.
I N STA L LAT I O N
( 1 ) UPPER MOUNTING BOLT
Install the rear shock absorber w ith the drain tube pointing
dow n .
Install a n d tighten the upper and lower mounting bolts and
nuts.
Route the drain tube into the tube guide in the swingarm .
Install the removed parts in the reverse order of removal .
Adjust t h e shock absorber spring preload b y turning the spring
adjuster, if necessary .
1 3- 1 3
REAR WH EEL/BRAKE/S U S P E N S I O N
SWI NGARM
R E M OVAL
( 1 I PEDAL
BOLT
(i') DRIVE S 2 )
Remove the drive sprocket cover. BO LTS
Remove the drive sprocket bolts, set plate and drive sprocket. COVER
Disconnect the gearshift arm from the gearshift spindle.
!?W, .
D I SA S S E M B LY ( 1 I CHAIN COVER
1 3- 1 4
REAR W H E E L/BRAKE/S U S PE N S I O N
I N S PECT I O N
\
'
\
'
Disassemble the drive chain cover and inspect the chain pro ( 1 ) CHAIN COVER
tector for wear or damage, Replace if necessary .
(2) PROTECTOR
P I VOT B E A R I N G R E PLAC E M E N T
Drive the right pivot ball bearing out of the swingarm using a
hydraulic press and driver shaft.
1 3- 1 5
REAR WHEEL/ BRAKE/SUSPENSION
NOTE
TOOLS :
Driver 07749 - 00 1 0000
Attachment, 32 x 35 mm 07746 - 00 1 0 1 00
Pilot, 1 5 mm 07746 - 0040300
TOOLS :
Driver 07749 - 00 1 0000
Attachment, 28 x 30 mm 07746 - 1 870 1 00
Pilot, 22 mm 07746 - 0041 000
Snap ring pliers 079 1 4 - 323000 1
Apply grease to the new dust seal lips and install them , and
the collars i n the correct positions .
( 2 ) PIVOT COLLARS
1 3- 1 6
REAR WH EEL/BRAKE/S USPENSION
I nstall the lih ock absorber lower mounting bolt and nut.
I nstall the drive sprocket cover and tighten the mounting bolt.
Adjust the drive chain (page 3 - 1 3 ) and rear brake pedal free
play ( page 3 - 1 6 )
1 3- 1 7
REAR W H E E L/BRAKE/S U S P E N S I O N
Remove the right and left side covers, pull out the prongs then
pull the cover down slowly to the release tabs .
Remove the fuel tank (page 4-3) and the rear fender mounting
bolts and Remove the tallight case mounting nuts .
Disconnect the right and left turn signal wire connectors, and
the rear brake light and licence light connectors.
Remove the rear fender from the main frame and sub-frame.
Remove the two sub-frame mounting bolts and two nuts, then
remove the sub-frame.
- - - . .
( 2 ) SEAT
(3) RIGHT
SIDE
COVER
( 9 ) REAR
FENDER -----
( 7 ) SUB-FRA M E
MOUNTING
N UTS
1 3- 1 8
M E MO
HYDRA U LI C D I S C BRAKE
1 . 5 N m (0 . 1 5 kg-m , 1 . 1 ft-lb)
12 Nm ( 1 .2 kg-m , 9 ft- l b )
2 7 N m ( 2 . 7 kg-m, 20 ft-lb)
1 4-0
14. HYDRAU LIC DISC BRAK E
After '93 :
1 2 N m ( 1 .2 Kg-m,9 ft-lb )
7
3 5 N m ( 3 . 5 Kg-m,2 5 ft-l b )
0 /:0
2 2 N m (2 . 2 Kg-m, 1 6 ft-lb)
co go
5 . 5 N m(0.5 4 ft-lb )
1 2 N m ( 1 .2 Kg-m,9 ft-lb)()
3 1 N m ( 3 . 1 Kg-m,22 ft-lb)
1 4- 1
H Y D RA U LI C D I S K B R A K E
SERVICE I N FORMATION
G E N E RAL
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high
quality brake degreasing agent.
The brake caliper can be removed without disconnecting the hydraulic system.
Once the hydraulic system has been disassembled, or if the brakes feel spongy, the system must be bled.
Do not allow foreign material to enter the system when filling the reservoir.
Brake fluid will damage painted, plastic, and rubber parts. Whenever handling brake fluid, protect the painted, plastic and rubber
parts by covering them with a shop towel. If fluid does get on these parts, wipe it off immediately with a clean cloth.
Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to clean brake
assemblies. Use an OSHA -approved vacuum cleaner or alternate method approved by OSHA, designed to minimize the hazard
caused by airborne asbestos fibers.
S P E C I F I CAT I O N S
U n it: m m ( i n )
ITEM STAN DA R D E R V I C E LI M IT
Disc thickness 5.0(0.2 ) 4.0(0. 1 6)
Disc runout -
0.30(0.0 1 2 )
' 8 8,'89, I. D. 1 2. 7 00- 1 2 .743 (0.5000-0. 50 1 7 ) 1 2 . 7 6 (0.502 )
Master '9 1 -'93: piston O.D. 1 2 . 6 5 7 - 1 2 .684(0.4983-0.4994) 1 2 . 6 5 (0.498 )
cylinder I . D. 1 1 .0- 1 1 .043 (0.433 1 -0.4348) 1 1 .05(0.43 5 )
After ' 9 3:
piston O.D. 1 0.9 5 7-1 0.984(0.43 1 4-0.4324) 1 0.94 5 ( 0.4309)
' 88,'89, cylinder I . D . 30.2 3 0-30.280( 1 . 1 902 - 1 . 1 92 1 ) 30.2 9 ( 1 . 1 93 )
B rake ' 9 1 -'93 : piston O.D. 30. 1 6 5-30. 1 9 8 ( 1 . 1 8 7 6- 1 . 1 8 8 9 ) 3 0. 1 6 ( 1 . 1 87 )
caliper cylinder I . D. 2 7 .000-2 7 .050( 1 .0630- 1 .06 50) 2 7 .06 ( 1 .065 )
After ' 9 3:
piston O.D. 2 6.93 5-2 6 . 9 6 8 ( 1 .604- 1 .06 1 7 ) 2 6.93 ( 1 .060)
T O R Q U E VA L U E S
TOOL
Special
Snap ring pliers 07 9 1 4 - 32 3000 1 or equivalent commercia lly
available in U . S . A .
1 4- 2
H Y D RA U L I C D I S C BRAKE
TROUBLESHOOTI N G
Brake lever soft o r spongy
Low f l u i d leve l .
H y d r a u l i c system l e a k i n g .
Sticking pisto n ( s ) .
Pads g l a zed or w o r n e x c e s s i ve l y .
Brake drag
H y d r a u l i c system stic k i n g .
Sti c k i n g piston ( s ) .
D i s c or wheel m i sa l ig n e d .
C a l i p e r insta l l e d i n correct l y .
D i s c or w h e e l m i s a l i g n e d .
1 4-3
HYDRAULIC DISC BRAKE
Check the fluid level with the fluid reservoir parallel to the
ground.
Remove the reservoir cover, set plate and diaphragm.
BRAKE F LU I D D RA I N I N G
Loosen the caliper bleed valve and pump the brake lever. Stop
operating the lever when fluid stops flowing out of the bleed
valve.
BRAKE FLU I D F I L L I N G /A I R B L E E D I N G
Close the bleed valve, fill the master cylinder with DOT 4 brake
fluid to the casting ledge level ( brake fluid upper level ) .
CAUTION
Do not mix different types of fluid since they are not
compatible.
NOTE
If air is entering the bleeder from around the bleed valve
threads, seal the threads with teflon tape .
1 4-4
H Y D RAU LIC D I SC BRAKE
1 ) Squeeze the brake lever, then open the bleed valve 1 /2 turn
and close the valve.
NOTE
Do not release the brake lever (or pedal) u ntil the bleed
valve has been closed .
Close the bleed valve, fill the reservoir with the specified brake
fluid to the casting ledge leve l .
BRAKE PAD/DISC
F R O N T B RA K E PAD R E PLAC E M E N T
NOTE
Pry one old pad agai nst the caliper with a screwdriver to push
the pistons i nto the caliper.
1 4- 5
HYDRA U L I C D IS C BRAKE
Pull the pad pins out of the caliper and remove the brake pads.
NOTE
I nstall the pad pins, first one pin, then the other, by pushing
the pads against the caliper to depress the pad spring .
1 4- 6
H Y D R A U LI C D I S C B RA K E
I nstal l the brake caliper over the disc, being careful not to
( 1 ) CALIPER MOUTING
- '
damage the pads, then tighten the caliper mounting bolt. BOLTS
Tighten the pad pins and tighten the pad pin plugs securely.
NOTE
-
After '93 :
Remove the pad pin plug and loosen the pad pin.
(
.
. " -l
f .
f /, ( 1 ) PAD PI N
I nsert new outsid e pad and push the caliper piston in allow
clearance for installation of the new inside pad .
Install the pad pin by pushing the pads against the caliper to
depress the pad spring.
1 4- 7
HYDRAULIC DISC BRAKE
D I S C TH I C K N E S S
BRA K E D I S C WA R PA G E
CAUTION
A void-spilling brake fluid on painted surfaces. Place a rag over
the fuel tank whenever the brake system is serviced.
N OTE
When removing the oil hose bolt, cover the end of the hose
to prevent contamination . Secure the hose to prevent fluid
from leaking out.
D I SA S S E M B LY (1 ) BRAKE LEVER
1 4-8
H Y D RA U LIC DISC BRAKE
TOOL:
Snap ring pliers 079 1 4 - 323000 1
or equivalent commercially ( 2 ) BOOT
available in U . S . A.
Clean the inside of the master cylinder, reservoir, spring and ( 1 )SPRING
piston with clean brake fluid .
, .,.._ ( 2 ) PISTON
I N SPECT I O N
AS S E M B LY
CAUTION
When installing the piston, do not allo w the cup lips to turn
iside out.
1 4-9
HYDRA U L I C DISC BRAKE
CAUTION
Be certain that the snap ring is seated firmly in the groove.
TOOL:
Snap ring pliers 079 1 4 - 323000 1
or equivalent commercially
available in U . S A .
.
( 2 ) BOOT
I N STALLAT I O N
Set the master cylinder onto the handlebar with the holder
" U P" mark facing up.
Temporarily install the holder bolts. Align the slit of the master
cylinder with the punch mark on the handlebar.
Tighten the upper bolt first, then the lower bolt.
Connect the brake light switch wires to the switch terminals.
I nstall the rear view mirror.
Connect the brake hose with the oil bolt and two sealing wash
ers and tighten the oil bolt.
Fill the reservoir with DOT 4 brake fluid to the casting ledge
and bleed the brake system (page 1 4- 4) .
1 4- 1 0
HYDRAULIC DISC BRAKE
BRAKE CALl P E R
R E M OVAL
CAUTION
A void spilling brake fluid on painted surfaces.
D I SA S S E M BLY
CAUTION
Do not bring the nozzle too close to th inlet.
Push the dust seals and piston seals in, lift them out and dis ( 1 ) PISTON SEAL
card the m .
NOTE
The seals must be replaced whenever they are removed.
CAUTION
Be careful not to damage the piston sliding surfaces.
I N S P ECTI O N
1 4- 1 1
HYDRAULIC D I S C BRAKE
A S S E M BLY
Coat new piston seals and dust seals with clean brake fluid
and install them in the caliper.
I nstall the pistons anrJ i nstall them with the open ends toward
the pads.
( 2 ) D U ST SEALS
(3) SILICONE
-
I nstall the caliper assembly over the brake disc so that the disc
is positioned between the pads.
CAUTION
(2) SILICONE
-
Be careful not to damage the pads.
( 2 ) BOOT
Connect the brake hose to the caliper with the hose bolt and
two new sealing washers.
1 4- 1 2
MEMO
BATTERY CHARG I N G SYSTEM
( 3 ) ST
SWITCH
MAIN FUSE
30A
1 5-0
1 5. BATTERY /CHARG I NG SYSTEM
y
y
( 3 ) MAIN F U S E 30A
y
R/W
G
8 1 /G
81 81 81
Y : Yellow
(4) ALTER NATO R ( 1 ) R E G U LATO R/R E CTI F I E R
8 1 : Black
G : G reen
R : Red
W : White
After '9 1 :
y
y
( 3 ) M A I N F U S E 3 0A
y
G R/W
Y : Yellow
(4) ALTER NATO R ( 1 ) R E G U LATO R/R ECTI F I E R G : G reen
R : Red
W : white
1 5- 1
B ATTERY/ C H A R GING SYSTEM
SERVICE I N FORMATION
G E N E RA L
The battery generates hydorogen gas which can be highly explosive. Do not smoke or allow flames or sparks near the battery,
expecially while charging it.
If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed. The ex
haust contains posisonous carbon monoxide gas that may cause loss of consciousness and, lead to death.
The following color codes are used throughout the electrical sections .
Bu = Blue G = Green Lg = Light Green R = Red
Bl Black Gr = Gray 0 = Orange W = White
Br = Brown Lb = Light Blue P = Pink Y = Yellow
Slow charge the battery whenever possible, quick charging should be an emergency procedure only.
Remove the battery from the motorcycle for charging.
The battery on this motorcycle is a sealed type . Do not remove the filler hole caps even during charging. Do not use a non
maintenance free battery as a replacement.
All charging system components can be checked on the motorcycle.
When i nspecting the charging system , check the system components and circuits step-by-step according to the trouble
shooting chart on the next page.
Alternator removal is described in Section 8.
S P E C I F I CATI O N S
ITEM STANDARD
Battery Capacity 1 2 V - 8 AH
Voltage at 20 C ( 68 F) Fully cahrged 1 3.0- 1 3.2 v
Needs charging 1 2.3 v
Charging current 0.8 amperes
Charging time 1 0 Hr
Regulator/rectifier Type Three-phase/ful l-wave
Regulated voltage 1 4 - 1 5 V/4, 000 rpm
Alternator Charging coil resistance at 20 C (68 F) 0. 1 - 1 . 0 0
Output 0 . 345 kw/5,000 rpm
Charging start rpm 1 ,000 1 00 rpm
TO O LS
1 5-2
BATTERYI CHARG I N G SYSTEM
TROU BLESHOOTI NG
I
ABNORMAL
Measure the battery leakage (page 1 5- 7 ) . Check the regulator/rectifier resistances be-
tween each regulator/rectifier terminals (page
1 5- 8 )
NORMAL
NORMAL . Short circuit in wire
harness
ABNORMAL ----+ Faulty ignition
L.
switch
I
ABNORMAL
Check for an overcharged battery (page 1 5-8 ) . I Faulty regulator/
J I
rectifier
NOT OVE CHARG E D REG U LATED . Fault y battery
ABNORMAL
...___________.,. Faulty stator coil
NORMAL
'"------- Faulty battery
1 5-3
BATTE RY/CHARG I N G SYSTEM
BATTERY
R E M OVAL
CAUTIO N
D o not remove the battery while exhaust pipe is hot.
--- \ ',
2:,L.) - - "
v v< r\\ -- -
\ \\
(2) POSITIVE "'-
_.._ _ TER M I NAL \
I N STALLATION
P l a c e the battery i nto the case and connect the battery posi
tive cable to the battery fi rst from the rig ht side, then connect
the negative cable from the left side .
Coat the battery term i n a l with clean g rease .
I nsta ll the battery case cover by hooking the tab on the cover
to the hook on the case .
I nsta ll and tighten the cover m o u nting bolts .
I nstall the fuse box onto the battery case cover .
CAUTI O N
WIRING AS SHOWN BELOW
1 5-4
BAlTERY/CHARG I N G SYSTEM
VO LTAGE I N S PECTI O N
TOO L :
Digital multimeter 0741 1 -0020000 ( KOWA)
(1\ BATTERY
KS-A H M -32-003 ( U . S. A. only)
BATTERY TESTI N G
N OTE
Secu rely con nect the tester's p ositive ( + ) cable first, then
connect the negative ( - ) cable .
N OTE
Set the tem pe ratu re switch to " H I G H" o r " LOW" depending
o n the ambient tem pe ratu re .
~
HIGH:
6 0 F ( 1 5 C ) o r higher
LOW:
00@ @ 0
M-
6 0 F ( 1 5. C ) or lower
LIM
LJ LJ
Push in the appropriate test b utton for th ree secon d and read
the condition of the battery on the mete r .
N OTE
Be sure you 've selected the test butto n of 5 . 5 Ah-9Ah .
For the first check, DO N OT charge the battery before
testing-test it is an "as is" condition .
Test B utton s
lQoOOOO@ @ O
1 5- 5
BATTERY/CHARG I N G SYSTEM
CAUTIO N
To avoid damaging the tester, only test betteries with an
amperage rating of less than 30A .
YELLOW
Tester damage can result from overheating when : RED (- 1 ) G RE E N
- The test button in pushed in for more than three seconds. (-3, -2) (+ 1 ' +2, +3)
- The tester is used without being allowed to cool for at
least one minute when testing more than one battery.
- Move than ten consecutive tests are performed without
allowing at least a 30- minute cool-down period.
N OTE
BATTERY C H AR G I N G
N OTE
. ... .
5.5 10 1.0
4 . Attach the clam ps to the battery terminals-R E D to Posi
tive, B LACK to N egative .
\11)
3 . .. .
1 5- 6
BATTE RY/CHARG I N G SYSTEM
N OTE
N OTE
For accurate test results, let the battery cool for at least ten
m i nutes o r u ntil gassing subsid es after charging .
CHARG I NG SYSTEM
N OTE
LEAKAG E AM P E R ES : 0 . 1 mA max.
1 5- 7
BATTERY/ C HA R GING SYSTEM
R E G U LATED V O LTAG E I N S P E CT I O N
N OTE
CAUTION
Be careful not to let the battery positive cable contact the frame
while testing.
REGULATOR/ RECTI Fl ER
I N S PECT I O N
Check the resistances between the leads with an ohmmeter. If '88-'89 , '9 1 U n it : KO
the resistance is out of the specifications, replace the regulator
rectifier.
NOTE
Red/White
e
Red/White
G reen
00
Yellow
00
Yellow
00
Yellow
00
Use a SANWA [SP- 1 0Dl or [TH-5Hl tester or KOWA D I G I G reen 5 "' 30 ------ 1 "' 20 1 "' 20 1 "' 20
You ' ll get a false reading if your finger touches the tester
probe . After '9 1 : U n it: KO
If the pointer of the tester fails to swing to zero when the
adjusting knob is turned fully clockwise or counter Red/White Yellow Yellow Yellow G reen
e
clockwise, replace the battery in the tester.
Red/White ------ 00 00 00 00
Yellow 0.5- 1 0 00 00 00
15- 8
B ATT E R Y/ C HA R GIN G SYST E M
ALTERNATOR
I N S P ECTI O N
NOTE
STANDARD: 0 . 1 - 1 . 0 0
1 5- 9
I G N I T I O N SYST E M
(4) MAIN
FUSE
( 5 ) IGN ITION
SWITCH
A FTE R '93 ;
( 1 4) S I D E STAN D SWITCH
1 6-0
1 6 . I G N I T I O N SYST EM
'88 , '89
B l : Black
Y : Yellow
B u : Blue
G : G reen
( 1 2 ) TO
R : Red
FUEL CUT
R E LAY W : White
Lg : Light G re e n
>-
( 9 ) FRONT
11 - -
( 1 0) REAR
11 - -
( 1 2 ) I G N ITION
CONTRO L
M O D U LE
( 9 ) FRONT ( 1 0) REAR
( 1 4 ) I G N ITION P U L S E G E N E R A T O R
( 7 ) I G N IT I O N C O I L
AFTER '89 :
B l : Black
Y : Yellow
Bu : B l u e
G -:: G : G reen
( 1 2 ) TO R : Red
FUEL C U T W : White
R E LAY Lg : Light G reen
Bl
a:
Bu
aJ -
>: G/W G Y
( 9 ) FRONT
11
- -
( 1 0) REAR
11- -
( 1 2 ) I G N ITI ON
CONTROL
M O D U LE
( 7 ) I G N ITION COIL
1 6- 1
I G N I TIO N S Y ST E M
SERVICE I N FORMATION
If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in on enclosed area.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.
G E N ERAL
Ignition timing cannot be adjusted since the ignition control module is non-adjustable.lf ignition timing is incorrect.check
the system inspectio n and replace any faulty parts.
For spark plug gap inspectio n and adjustment procedu re,see page 3-8.
For alternator removal and i nstallation,see sectio n 8.
For ignition pulse generator removal and installation,see page 7 - 1 1 .
When i nspecti n g the i g n ition system,check the system components a n d li nes step-by-step according to the tro u ble
shooting on next page.
Each pair of the spark plugs( Front and Rear) has its own ignition circu it.
To test the neutral switch,refer to section 1 8.
S P E C I F I CAT I O N S
DPR8EA-9 X24EPR-U9
S p a r k plug 0.8-0.9 mm (0.03 - 0.04 in)
I g nition t i m i n g I n it i a l ( F m a r k ) 6.2 BTDC/i d l e
I g n ition c o i l Pri m a ry 1 .89- 2.32 n
resistance 2 3 . 5 5 - 30 . 4 5 kO
Secondary With p l u g w i re
Without p l u g w i re 1 9 . 8 - 24 . 2 kO
Ignition pulse g e n e rator C o i l resistance 4 50 - 550 n
TOOLS
Tester
D i g it a l m u ltitester ( KOWAl 074 1 1 - 0020000 or KS-AH M-32-003 ( U . S . A . only)
or
C i rc u i t tester (SANWA) 07 308 - 0020000 N ot available in U .S.A.
or
C i rc u it tester (KOWAl TH-5H J
1 6-2
I G N ITI O N SYSTEM
TROU BLESHOOTI N G
When performing a spark test, keep open flames or sparks away from the work area.
3- 1 . C h e c k the i g n it i o n p u lse g e n e rato r resist- ABNORMAL 3-2. Check the ignition pulse generator( page
l
ances at the ignition control module 4P 1 6- 6 ) .
connector( page 1 6-4). NORMAL ABNORMAL
No spark at either spark group ( Front or Rear) - (CHECK WRONG SPARK GROUP)
NORMAL
r
\
O_R_M_A_L
2- 1 . Check the ignition primary coil resistance at 1---A_B_N_
l
__
1
loose connectors Faulty ignition coil
NORMAL Open or short circuit Open circuit in wire
in wire harness harness
}
I
3- 1 . C h e c k the i g n it i o n p u lse g e n erator resist- I -ABNORMAL 3-2. Check the ignition pu lse generator( page
l
- -.! 6 -_6)
1_
ances at the ignition control module 4P con - - --- -- L____ ,.:-. ________....-________
nector(page 1 6- 4). NORMAL ABNORMAL
4. Exchange the ignition coil and try the spark GOOD JUMP
r------t ' Faulty ignition coil
test.
1 6-3
I G N ITION SYSTEM
N OTE
D C power supply circuit line 81 (+) and G (- ) , Bu/Y (+) and G ( - ) , Y (+) and G Battery voltage should come.
(-) with the ignition switch " O N " and engine stop
switch " R U N "
< 4 P C O N N ECTOR>
ITEM TERMINALS STANDARD ( 2 0 C/68 F)
I g n ition pulse generator coil W/Y and Y ( Front) W/Bu and Bu ( Rear) 450 - 550 (}
Each terminal and body ground NO CONTI N U ITY
I G N ITION COI L
I N S PECTI O N
Disconnect the spark plug caps from the plugs and measure
the secondary coil resistance with the spark plug caps in place.
1 6 -4
I G N ITION SYSTEM
R E PLAC E M E N T
Install the new ignition coil in the reverse order of the removal .
NOTE
1 6- 5
IGN ITIO N S YSTEM
I G N ITION P U LS E G E N ERATOR
I N S PECT I O N
r(i') I G N ITI O N P U LS E
G E N E RATO R C O N
"
NOTE
-ig nition circuit Y e l l o w / B l a c k to G re e n N o conti n u ity
closed
(21 TO
-. Y/BI
I II ( 2 ) TO -- Y/BI I
SPARK U N I T SPARK U N I T
--GIW .,. --- G/W
G G
1 6- 6
I G N IT I O N S Y ST E M
After '93 :
Remove the left side cover.
Disconnect the side stand 3 P g reen connector and check for
conti n u ity between each terminals as shown below.
There should be continuity between the 0-0 positions on the
conti n u ity chart.
( 1 ) B O LT
R E M OVAL/ I N STA L LATI O N
Remove t h e left side cover.
Discon nect the side stand 3 P g reen connector.
N OTE
Align the switch pin with the side stan d h ole.Aiign the
switch g ro ove with the setting plate tang and align the
setting plate solt with the side stand return spring holding
pin.
TO R Q U E :
Side stand switch mounting bolt : 9 N m (0 . 9 kg-m , 7 ft-lb)
I G N ITION TI M I NG
NOTE
r
The ignition control module system is factory pre-set and
can not be adjusted.lgnition tim i n g inspectio n procedures
a re g iven to inspect the fu nction of the ignition control
module com ponents.
Con nect the timing light to the other spark plug wire if you
see that the ignition timing is i ncorrect,and you might be
able to see the timing is correct.
1 6-7
I G N ITION SYSTEM
The timing is correct if the " F" mark aligns with the index
mark on the right crankcase cover at idle for each cylinder.
Raise the engine rpm and the " F " mark should begin to rotate
counterclockwise for each cylinder.
(2) I NDEX
MARK
1 6-8
MEMO
ELECTRIC S TARTER
( 8 ) CLUTCH
SWITCH
I
I
I
I
I
I
I
I
I
(7) D I O D E
A FT E R '93 ;
( 1 2) STARTER RELAY
SWITCH
B l : Black
( 1 4) S I D E STAN D SWITCH ( 1 l M A I N FUSE Y : Yellow
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30A G: G reen
R: Red
(4) SIDE W: White
( 5 ) I G N ITI O N Lg : Light green
STAND C O NT R O L
SWITC H M O D U LE
( 2 l BATT E R Y DOWN
I I
1 2 V 8AH
( 1 2) STARTER
RELAY Lg/R G/W
SWITCH
1 7 -0
1 7. ELECTR IC STARTER
S ERV I C E I N FO RMATIO N 1 7- 1 STARTER RELAY SWITCH 1 7-6
SERVICE I N FORMATION
G E N E RA L
SPEC I F I CATI O N
Unit: m m (in)
TRO U BLESHOOTI NG
N OT E
_I
1 -1 . C h e c k the starter relay s w it c h for opera- "CLICK"
I I
ti o n . Y o u s h o u l d h e a r the r e l a y " C LI C K " H EA R D 1 - 2 . A p p l y battery voltage t o t h e starter motor
J J
w h e n t h e starte r switch button is de- d i rectly a n d check the operati o n .
pr e s s e d . ( pa g e 1 7 - 6 )
TURNS DOES NOT TURN
Loose c a b l e s .
Fau lty sta rter motor
" C L I C K " NOT H E A R D .
Fau lty sta rter relay ( page 1 7 - 3 )
switch ( page 1 7 - 6 )
A B N O R M AL
2. Check t h e n e u t r a l i n d icator for f u n cti o n . .
F a u lty neutral s w itch ( p age 1 8 - 1 1 ) .
.
Loose neutral s w itch connectors
N O R MAL .
Fau lty i g n it i o n s w itch ( p age 1 8 - 6 )
3. C h e c k t h e starter r e l a y s w i t c h v o l t a g e N O V O LTAGE
.
Loose c l u t c h d i o d e con nector
( page 1 7-6) .
F a u lty starter relay sw itch ( page 1 7 - 6 )
BATTERY
.
Fau lty cl utch d i o d e ( page 1 7 - 7 )
V O LTA G E C O M E S
.
Open or s h o rt c i rcuit in w i re harness
1 7- 1
ELECTRIC S TARTER
The starter motor can turn i n the neutral position, but should not turn except with the gear selector i n neutral , the side stand
up and the cluth lever pulled in.
BATTERY VOLT
I
Measure the Voltage between the Green/White AGE M EASURED
(+) and Green (-) terminals of the side stand
t-------+!J Check the clutch switch ( page 1 8-1 1 ) .
connector (wire harness side ) .
There should b e battery voltage .
N O VOLTAG E
(or too l ittle voltage)
Check the side stand switch ( page 1 6- 5 )
Starter motor and engine turns, but engine does not start
Faulty ignition system
Engine problems
- Low compression
- Fouled spark plugs
1 7-2
ELECTRIC STARTER
STARTER MOTOR
R E M OVAL
With the ignition switch OFF, remove the negative cable at the
battery before servicing the starter motor.
D I S A S S E M B LY (1 l FRONT COVER
(4) REAR COVER
Remove the following components :
- motor case screws.
- front and rear covers.
- armature .
NOTE
( 2 ) CASE
I N S P ECT I O N
Check for continuity from the cable terminal to the motor case
and from the cable termina to the brush wire ( black) . (1 CONTINU ITY
1 7-3
ELECTRIC STARTER
Check the front cover oil seal for wear or fatigue. (1 ) O I L SEAL
1 7 -4
ELECTRIC STARTER
A S S E M B LY
( 2 ) CASE
(7) 0-RING
(4) SHIMS
( 1 0) 0-RI N G
( 1 3) S H I M S
,
( 1 2 ) N UTS
( 1 ) FRONT COVER
( 9 ) REAR COVER
Install the rear shims in the same location and number when
disassembled .
Install the 0-ring on the case.
Install the rear cover, aligning its slot with the brush holder pin.
(3) SLOT
1 7-5
ELECTRIC STARTER
I nstall the front shims in the same location and number when (2) FRONT
disassembled . COVER
Align i ndex marks of the front cover, case and rear cover as
shown.
Instal l and tighten the starter motor case screws and apply oil
to the 0-ring and install it on the front cover.
I N STALLATI O N
NOTE
T
STARTER RELAY SWITCH
O P E RATI O N I N S PECT I O N
OR
Depress t h e starte switch button with the ignition switch O N .
The c o i l is normal if the starter relay switch clicks.
V O LTA G E I N S PE CT I O N
1 7-6
ELECTRIC STARTER
C O N T I N U I TY I N S P E C T I O N
CLUTCH DIODE
R E M OVAL
I N S P ECTI O N
Connect the positive probe to the (+) terminal and the negative
probe to the (-) terminal of the diode.
N OTE
The test results shown above are for a positive ground ohm ( 1 ) CONTI N U ITY
meter and the opposite results will be obtained when a neg
ative ground ohmmeter is used .
1 7- 7
MEMO
1 8. LI GHTS/ M ETER/SWITCH ES
S E RVI C E I N FO R MATIO N 1 8- 1 F U E L P U MP RELAY 1 8-9
T RO U BL ES HOO T I N G 1 8-2 F U E L P U MP 1 8- 1 0
SERVICE I N FORMATION
If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.
Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area with the engine stopped.
Do not smoke or allo w flames or sparks in the work area or where gasoline is stored.
G E N E RA L
Some wires have different colored bands around them near the connector. These are connected to other wires which cor
respond to the band color.
A l l p last i c co nnecto rs have lock ing tabs that must be released befo re d isco nnect i ng, and must be a l igned and fu l ly engaged
when reco nnect i ng.
To isolate an electrical failure, check the continuity of the electrical path through the part. A continuity check can usually
be made without removing the part from the motorcycle. Simply disconnect the wires and connect a continuity tester or
volt-ohmmeter to the terminals o r connections.
A contin u ity tester is useful when checking to find out whether or not there is an electrical connection between the two
points . An ohmmeter is needed to measure the resistance of a circuit, such as when there is a specific coil resistance in
volved , o r when checking for high resistance caused by corroded connections.
S P E C I F I C ATI O N S
headlight 12 V 60 W/55 W
Brake/ta i l l ight 1 2 V 32/3 cp ( 2 7/8 W) x 2
Turn signal lights Front 1 2 V 32/3 cp ( 2 3/8 W) x 2
Rear 1 2 V 32 cp ( 2 3 W)
License light 12 V 4 cp
Indicator lights turn signal 1 2 V 1 .7 W
neutral 1 2 V 1 .7 W
high beem 1 2 V 1 .7 W
M eter light 1 2 v 3.4 w
Main fuse 30 A
Sub-fuse '88, '89 1 0 A x 6, 1 5A x 1
After '89 1 0 A x 3, 1 5A x 1
F uel pu m p f low capacity 800 cc ( 0.76 USqt, 0.70 l mpqt)
TO R Q U E V A L U E S
Radiator thermostatic switch 1 8 Nm (1 .8 kg-m, 1 3 ft-lb)
Oil pressure switch 1 2 Nm (1 .2 kg-m, 9 ft-lb) - Apply sealant to the threads
Ignition switch mounting bolt 1 1 Nm (1 .1 kg-m , 8 ft-lb) - Shear bolt
1 8- 1
LIG HTS/METER/S W I TC H ES
TROUBLESHOOTI NG
N o Lights Come O n When Ignition Switch I s Turned O N : All Lights Come O n , but Dimly, when Ignition Switch I s
Faulty switch
Battery voltage low
Fuse blown
Wiring loose, broken, or at fault Headlight Beam Does Not Shift When HI-LO Switch Is Op
1 8-2
L I G HTS/M ETER/SWITC H ES
H EADLIGHT
I
R E M OVAL/ I N STALLAT I O N I
I
I
Remove the two screws a n d headlight.
Remove the headlight retainer clip and replace the headlight (1 ) RETAINER CLIP (2) HALOGEN BULB
bulb.
CAUTION
Do not put finger prints on the headlight bulb, they may create
hot spots on the hulb.
If you touch the bulb with your bare hands, clean it with a cloth
moistened with alcohol to prevent its early failure.
Do not try to replace the bulb or clean the headlight with the
light ON.
After replacing the bulb, install the rubber boot tightly against
the unit.
NOTE
1 8-3
LIG HTS/M ETER/SWITC H ES
BULB REPLACE M E NT
NOTE
T U R N S I G NAL LIGHT
NOTE
B R A K E/TA I L L I G H T
N OTE
Seat the rubber packing properly.
LICENSE LIGHT
SPEEDOM ETER (1 l S P E E D O M ET E R
CABLE
R E M OVAL
1 8-4
LIG HTS/M ETER/SWITC H ES
B U L B R E PLAC E M E N T
( 5 ) SPEEDOMETER
(3) STAY
( 2 ) MOUNTI NG
SCREWS
(8) 6P BLACK
( 1 ) 0-RI N G CON NECTOR
( 1 0) SPEEDOMETER
CABLE ( 9 ) SPEEDOM ETER
COVER
I N STA L LAT I O N
1 8- 5
LIG HTS/M ETER/SWITC H ES
I G N ITION SWITCH
I N S PECTI O N
ON 0 -o 0 -o
OFF
p 0 -o
After '89:
(1 ) HOLDER
1 8- 6
LIGHTS / M ETER/S WITC H ES
L E FT H A N D L E B A R SWITCH
------- H L2 Hi Lo
Lo 0 -o
(N)
Hi 0 -o
------- w R L TL1 PR PL
RIGHT 0--- --o 0 -o
N
LEFT 0 -o 0 -o
LEFT 0 {) 0 -o
Color code W/G Lg Color code BI/Br Lg
Coler code Gr Lb 0 B r/ B I Lb/W 0/W
R I G H T H A N D L E B A R SWITC H
Pushed Pushed 0 {)
1 8-7
LIG HTS/ M ET ER/SWITC H ES
THERMOSTATIC SWITCH
I N S P E CT I O N
T h e the rmostati c switch senses t h e temperature o f t h e r a d i a
tor coolant a n d s i g n a l s t h e f a n moto r . The motor c o m e s i nto
action at 9 8 - 1 0 2 C ( 2 08 - 2 1 6 F ) a n d stops at b e l o w
9 3 - 9 7 C ( 1 9 9 - 2Q1 F ) .
[]]
I f there i s n o voltage, c h e c k the su b-fuse ( 1 0 A ) . o r loose ter
m i n a l s or connector, o r an o p e n c i r c u it
N OTE
o
Keep the temperature for 3 m i n utes to confirm cont i n u it y .
A s u d d e n c h a n g e of t e m p e rature w i l l c a u se error tempera
ture reading between the thermometer a n d switc h .
o
Do not let the s w itch or thermo meter touch the pan as it w i l l
g i ve a false read i n g .
o
I m merse the s w itch i n c o o l a n t u p to its thread s .
I nsta l l a n e w 0 - r i n g on t h e switc h .
A p p l y sea l a nt t o t h e switch thread a n d i n sta l l i t .
T i g hten the s w i t c h to the s p e c i f i e d torq u e .
NOTE
o
Do not over tig hten t h e sw itch .
1 8-8
L I G HTS/ M ETER/SWITC H ES
m
the d r a i n bolt i n t h e h o u s i n g .
D i sconn ect the w i re from t h e t h e rmosensor a n d remove the
thermosenso r .
Suspend t h e thermosensor i n o i l o v e r a he ater a n d measure the
resistance thro u g h t h e sensor as the o i l heats u p . Q
Temperatur ( C/ F ) 50/ 1 2 2 80/ 1 7 6 1 20/248
Resista nce ({}) 1 53 . 9 51 .9 1 6. 1
NOTE
NOTE
FU EL PUM P R E LAY
Inspect as follows :
D i s con nect t h e c o n n e ctor a n d test the w i res on the m a i n har
ness side .
ITEM STA N DA R D
Between Bl ( + ) a n d b o d y g r o u n d ( - ) Battery voltage
w ith the i g n it i o n s w itch " O N " s h o u l d come .
Y /Bu wire bet w e e n the p u m p
C O N T I N U I TY
relay a n d s p a r k u n it
BI/Bu wire betwe e n the p u m p
C O N T I N U ITY
re l a y and fuel p u m p
1 8-9
L I G H TS / M ETER/SWITC H ES
FU EL PUM P
S Y S T E M I N S P ECTI O N
Disconnect the fuel outlet tube at the fuel pump and connect a
fuel tabe or equivalent to the pump outlet line.
Hold a graduated beaker under the pump outlet line.
Turn the ignition switch on and let fuel flow into the beaker for
5 seconds, then turn the ignition switch off .
M u ltiply the amount in the beaker by 1 2 to determine the fuel
pump flow capacity per minute .
O I L P R ESSU RE SWITCH
Make sure that the oil pressure warning light comes on with
the ignition switch " O N " .
Start the engine and make sure that the light goes out. If the
light does not go out, check the oil pressure (page 2 -5) . - !I
( 1 ) O I L PRESS R E SWITC
If the oil pressure is normal, replace the oil pressure switch
( page 2 -5) .
1 8- 1 0
LIGHTS/METER/SWITC H ES
N EUTRAL SWITCH
I N S P E CT I O N
R E A R I N S P ECTI O N
Disconnect the rear brake light switch connector and check for
contin u ity between the terminals.
CLUTCH SWITCH
I N SPECTI O N
1 8- 1 1
LIG HTS/ M ET E R/SWITC H ES
HORN
Disconnect the wire connectors from the horn a n d connect a
1 2 V battery to the horn wire terminals. The horn is normal if it
sounds.
1 8- 1 2
1 9. WI R I N G DIAG RAM
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W I R ING D I AGRAM
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1 9- 2
W I RING D I A G R A M
'92 , '93 ;
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1 9- 3
W I R IN G DIAGRAM
After '93 :
1 9-4
20. TROUBLESHOOTI NG
E N G I N E DO ES NOT START O R I S POO R PERFO R MANCE AT H I G H
H A R D TO START 20- 1 SPEED 20-4
PO O R PERFO RM A N C E AT LOW A N D
IDLE SPEEDS 20-3
1 . Check fuel flow to carburetor N OT REAC H I N G CARBU RETO R --- Fuel tank empty
Clogged fuel line or fuel filter
REAC H I N G CARBURETOR Sticking float valve
Faulty fuel pump
Faulty fuel pump relay
Clogged fuel tank vent hole
Loose or disconnected fuel pump
relay wire
1
closed
Cylinder flooded
Air cleaner dirty
3 . Test cylinder compression LOW COMPRESSION ------+ Improper valve clearance (too small )
Valve stuck open
C O M PRESSION NORMAL Worn cylinder and piston rings
l
Damaged cylinder head gasket
Seized valve
Improper valve timing
I mproper valve and seat contact
4. Sta by fol lowing no,mal pmcedu" E N G I N E STARTS BUT STOPS --- Improper choke operation
Carburetor incorrectly adjusted
E N G I N E DOES NOT FIRE I ntake pipe leaking
l
Improper ignition timing
( Faulty spark u nit or pulse gener
ator)
Fuel contaminated
20- 1
TROUBLESHOOTING
E N G I N E LACKS POWER
POSSIBLE CAUSE
1. Raise wheels off ground and spin WHEELS DO NOT SPIN FREE LY --- Brake dragging
by hand Worn or damaged wheel bearings
Wheel bearing needs lubrication
WHEELS SPIN FREELY Drive chain too tight
Axle nut excessively tight
Weak clutch spring
7.
+
Test cylinder compression TOO LOW ------ Valve stuck open
Worn cylinder and piston rings
NORMAL Leaking head gasket
j
I mproper valve timing
Seized valve
I mproper valve and seat contact
8. Check carburetor for clogging CLOGGED ------ Carburetor not serviced frequently
enough
N OT CLOGGED
t
9. Check spark plug condition FOU LED OR D I SCOLORED----___, Plugs not serviced frequently
enough
NOT FOULED OR DISCOLORED Wrong heat range
t
1 0 . Check oil level and condition I N C O RRECT-------- Oil level too high
Oil level too low
CORRECT Contaminated oil
1
20-2
TROUBLESH OOTI N G
POSSIBLE CAUSE
1 1 . Remove cylinder head cover and VALVE TRAIN NOT LUBRICATED -- Clogged oil passage
inspect lubrication PROPERLY Clogged oil control orifice
Contaminated oil
VALVE TRAI N LUBRICATED Faulty oil pump
PROPERLY
1 2 . Check for engine overheating OVERHEATING --------___, . Coolant level low
Fan motor not working
NOT OVERH EATI N G (thermostatic switch)
Thermostat stuck closed
Excessive carbon build-up in com-
bustion chamber
Use of poor quality fuel
Clutch slipping
Lean fuel mixture
.
1 Check ignition timing and valve I NCORRECT _________ ___, . I mproper valve clearance
clearance Improper ignition timing
- Faulty i g n it i o n control m o d u l e
CORRECT - F a u lty i g n it i o n p u lse g e n e rator
+
2. Check carburetor pilot screw I N CO RRECT -------___, . See Fuel System, Section 4
adjustment
CORRECT
3 . Check for leaking intake pipe LEAKING ------ Loose carburetor
Damaged insulator
NO LEAKAG E
4.
+
Perform the spark test WEAK OR I NTERM ITTENT SPARK- Faulty, carbon or wet fouled spark
plug
GOOD SPARK GO TO PAG E 1 6-2
20-3
TRO U BLESH OOTI N G
1
Fau lty fuel p u m p o r relay
Clogged fuel filter
NO C L O G G E D J ETS
C O R RECT
5 . Check valve spring tension W E A K ------- Fau lty v a l v e s p r i n g
20-4
2 1 . I N DEX
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Alternator/Starter Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 1 EVAP Carburetor Air Vent Control Valve I nspectio n
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-9
. (California m o d e l o n ly) . . . . . . . . . . . ..
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1 7
Battery/Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-2 Evaporative Emission Control System . . . . . . . . . . . . . . . . . 3- 1 3
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-4
. Evaporative Emission Purge Control Valve Inspection
Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4- 1 1 (California model only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1 6
Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 5 Flywheel I nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Replacement/Air Bleeding . 1 4-4. . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Brake Light Switch . . . .
. . . .
. . . . . . . . . . . . . . 1 8- 1 1 . . . . . . . . . . . . . . . . . . . . Fork . . . . . . . . . . : . ..
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . 1 2- 1 3
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 7
. Front Wheel/Suspension/Steering . . . . . . . . . . . . . . . . . . . . . . . 1 2- 1
Brake Pad/Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4-5
. Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2-7
Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 - 1 0
. Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 4- 1
Shoe/Pad Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 6 Line . . . . . . . . . . . . . . . . . . . . .....
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 6
. Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8- 1 0
Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-4 Relay . . ... . . . . . . . . . .; . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-9
Cable & Harness Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 0 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .. . . . . . . .. . . . . . . . . . . .
.. 4-3
Camshaft Installation . . . . . . . . . . . . . s- 1 8
. . . . . . . . . . . . . . . . . . . . . . . . . . Gearshift Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 7-8
Removal . . . . . .
. . . . . . . . . . . . . . . . ..
. . . .9- 4
. . . . . . . . . . . . . . . . . . . . General I nformation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 -1
Carburetor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1 0
. Safety . . . . . . . . . ..
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -1
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 . . . . . . . . . . . . . . . . . . . . . . H andlebar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 2-4
D isassembly . . .
. . . . . . . . .. .
. . . . . . . . . . . 4-6 . . . . . . . . . . . . . . . . . . Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 8-7
Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 1
. Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 8-3
I n stallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1 5
. Aim .
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 8
Removal . ..
. . . . . . . . . . . . . . . . . . . 4-6
. . . . . . . . . . . . . . . . . . . . . . . . . . High Altitude Adjustment ( U . S . A . Only) . . . . . . . . . . . . . . 4- 1 6
Separation/ Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1 3 . Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8- 1 2
Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 0
. Hydraulic Disc Brake . . ; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 1 4- 1
Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-7
. Ignition Control Module Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6-4
Clutch/Gearshift Linkage . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 1 Ignition Pulse Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6-6
Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7-7 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 6-2
I nstallation .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1 2
. Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 . Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-6
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8- 1 1 . Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 6-6
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 8 . Left Crankcase Cover I nstallation . . . . . . . . . . . . . . . . . . . . . . . 8-6
Control Cable Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 1 2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 8-2
Coolant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 5-3 Lights/Meter/Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8- 1
Temperatu re Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-8 . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 2- 1
Coolant/Reserve Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 5-9 Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 2- 1 2
Cooling System . . . . . . .. . .
. . . . . . . . . . 3- 1 2 , 5 - 1
. . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1
Crankcase . ... .
. . . . . . . . . . . . . . . . . . . . . . 1 1 -1 3
. . . . .. . . . . . . . . . . . . . . . . . . . . . . Sched u le ' 8 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 - 1 9
. Schedule ' 8 9 , ' 9 1 -'93 : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 3-8 Sched ule After '93 : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 -4
. . Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 4-8
Crankshaft/Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 - 1 . Model ldentifiction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 -2
Crankshaft/Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 -5 . Neutral Switch . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - . . . . 1 8- 1 1
Cylinder Head/Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 9- 1 N uts, Bolts, Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 3-20
Cylinder/Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0- 1 O i l Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 2- 5
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0-2
. Oil Pressure Check . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 5
Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 2
. Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 8- 1 0
Cylinder Head . . . . . . . . ... .
. . . . . . . . . . . . 9-8
. . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 2-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 1 5
. Pilot Screw Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1 5
Cylinder Head Cover Installation . . . . . . . . . . . . . . . . . . . . . . . 9-2 1 . Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 0-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 0-5
Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 1 6 . Ring I nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 0-5
I nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0-6
. Primary Drive Gear . . . . . . . . ...
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 1
D rive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3
. Radiator Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 1
Electric Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 - 1
. Radiator/Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 5-5
Emission Control I nformation Labels . . . . . . . . . . . . . . . . . . . 1 -22 Rear Wheel/Brake/Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3- 1
Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2 1 Brake .
. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3-7
Engine Removal/Installation . . . . 6 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . - Wheel . . .
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . 1 3-3
Engine I nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Regulator/Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 5- 8
Engine Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
21 -1
I N D EX
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 1
Crankshaft/Transmission . . . . . . . . . . . . . . . . . . . . . . . 1 1 - 1 . .
Front Wheel/Suspension/Steering . . . . . 1 2- 2 . . . . . . . . .
Fuel System . .. . . . . . . . . . . . . . . .. . . . 4- 1 . . . . . . . . . . . . . . . . . . . . .
Lights/Meter/Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8- 1 . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 2- 2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 3- 1
Rear Wheel/Brake/Suspension . . . . . . . . . . . . . . . . . 1 3- 1 .
Service Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1-1
Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . 1 3- 1 1
.
Side Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 9
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6-6
.
Spark Plugs .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .
. 3- 8
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -3
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-4
Starter Clutch . . ... .... .. ..
. . . . . . . . . . .. . . . 8-4
. . . . . . . . . . . . . . . . . . . . .
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7-3
Relay Switch . .. . ..
. . . . . . . . . . . . . . . . 1 7-6 . . . . . . . . . . . . . . . . . . . .
Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 9
Swingarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3- 1 4
.
System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 5-2
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Thermostatic Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-8
.
Throttle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 3-6
Tools 1 -8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting
Battery/Charging System . . . . . . . . . . . . . . . . . . . . . . . . 1 5-3 .
Cooling System . . .. .. .. .. .. .. .. . . .. . . .. .. .. .. .. . . . . . . 5- 1
Crankshaft/Transmission . . . . . . . . . . . . . . . . . . . . . . . . 1 1 -3 .
Front Wheel/Suspension/Steering . . . . . . . . . . . . 1 2- 3 . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 4- 3
Hydraulic Disc Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4-2 . .
Lights/Meter/Switches . . . . . . . . . . . . . . . . . . . . . . . . .. . 1 8-2 ..
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.. 2-2
Rear Wheel/Brake/Suspension . . . . .. . . . . . . . . .. 1 3-2 ..
2 1 -2 (278)