HOW TO USE THIS MANUAL
is service manual describes the service procedures
the VT6O0CICD.
Follow the Maintenance Schedule (Section 3) recom-
mendations to ensure that the vehicle is in peak
operating condition and the emission levels are
within the standards set by the U.S. Environmental
Protection Agency and California Air Resources
Board,
Performing the first scheduled maintenance is very
important. It compensates for the initial wear that
occurs during the break-in period.
Sections 1 and 3 apply to the whole motorcycle.
Section 2 illustrates procedures for removal/
installation of components that may be required to
perform service described in the following sections.
Sections 4 through 19 describe parts of the
motorcycle, grouped according to location.
Find the section you want on this page, then turn to
the table of contents on the first page of the section,
Most sections start with an assembly or system
illustration, service information and troubleshooting
for the section
The subsequent pages give detailed procedures.
you don't know the source of the trouble, go to
section 21, Troubleshooting.
ENGINE AND DRIVE TRAIN
CONTENTS
GENERAL INFORMATION En
FRAME/BODY PANELS/EXHAUST Ea
SYSTEM
MAINTENANCE Ea
SS EEE
| LUBRICATION sySTEM |
FUEL SYSTEM El
| coouina system
ENGINE REMOVAL/INSTALLATION Ea
CLUTCH/GEARSHIFT LINKAGE
—
a
ALTERNATOR/STARTER CLUTCH Ea
CYLINDER HEAD/VALVES E rH
CYLINDER/PISTON E E EH
CRANKSHAFT/TRANSMISSION Ea
FRONT WHEEL/SUSPENSION/
STEERING
ALL INFORMATION, ILLUSTRATIONS, DIREC-
TIONS AND SPECIFICATIONS INCLUDED IN
THIS PUBLICATION ARE BASED ON THE LATEST
PRODUCT INFORMATION AVAILABLE AT THE
TIME OF APPROVAL FOR PRINTING. HONDA
MOTOR CO., LTD. RESERVES THE RIGHT TO
MAKE CHANGES AT ANY TIME WITHOUT
NOTICE AND WITHOUT INCURRING ANY
OBLIGATION WHATEVER. NO PART OF THIS
PUBLICATION MAY BE REPRODUCED WITHOUT
| WRITTEN PERMISSION. THIS MANUAL IS
WRITTEN FOR PERSONS WHO HAVE ACQUIRED |
BASIC KNOWLEDGE OF MAINTENANCE ON
HONDA MOTORCYCLES, MOTOR SCOOTERS
| or arvs.
HONDA MOTOR CO. LTD.
‘SERVICE PUBLICATION OFFICE
ELECTRICAL
a
QD
@ | REAR WHEEL/BRAKE/SUSPENSION Ea
2. =
© | HYDRAULIC BRAKE Fa
=
BATTERY/CHARGING systems
IGNITION SYSTEM i }17 |
ELECTRIC STARTER = Ea
LIGHTS/METERS/SWITCHES Ea
WIRING DIAGRAM El
TROUBLESHOOTING EB HW
| INDEX
Date of issuer June, 1998,
(HONDA MOTOR CO., LTD. SYMBOLS
The symbols used throughout this manual show specific service procedures, If supplementary information is required
pertaining to these symbols, it would be explained specifically in the text without the use of the symbols.
Replace the partis) with new onels) before assembly.
Use recommended engine oil, unless otherwise specified.
Use molybdenum oil solution (mixture of the engine oll and molybdenum grease in a ratio of 1: 1)
Use multi-purpose grease (Lithium based multi-purpose grease NLGI # 2 or equivalent
Use molybdenum disulfide grease (containing more than 3 % molybdenum disulfide, NLGI #2 or
equivalent
Example: Molykote® BR-2 plus manufactured by Dow Corning, U. S. A.
‘Multipurpose M-2 manufactured by Mitsubishi Oil, Japan |
equivalent)
Example: Molykote® A.n paste, manufactured by Dow Corning, U, S. A.
Honda Moly 60 (U. S.A. only)
Rocol ASP manufactured by Rocol Limited, U.K.
ocol Paste manufactured by Sumico Lubricant, Japan
Use molybdenum disulfide paste (containing more than 40 % molybdenum disulfide, NLGI #2 or
a
Use silicone grease.
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
Apply sealant |
Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise spectied
Use Fork or Suspension Fluid
ee
‘Revises October 1000 1037 7000 VTBDOOCE
(©1999 American Honda Motor Co, ne Al Regn Reserved
MSV 817 910) 1. GENERAL INFORMATION
| GENERAL SAFETY WW
LUBRICATION & SEAL POINTS 119
SERVICE RULES 1-2 CABLE & HARNESS ROUTING
MODEL IDENTIFICATION 1-3. EMISSION CONTROL SYSTEMS 133
| specirications 15 _ EMISSION CONTROL INFORMATION
‘TORQUE VALUES fom vs
TooLs 17
GENERAL SAFETY
CARBON MONOXIDE USED ENGINE OIL
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.
ga
The exhaust contains poisonous carbon monoxide gas
that can cause loss of consciousness and may lead to
death,
—_—————
Used engine oil may cause skin cancer if repeatedly left in
contact with the skin for prolonged periods. Although this
is unlikely unless you handle used oil on a daily basis, it is
still advisable to thoroughly wash your hands with soap
‘and water as soon as possible after handling used oil. KEEP
(OUT OF REACH OF CHILDREN.
Run the engine in an open area or with an exhaust
evacuation system in an enclosed area,
GASOLINE
Work in a well ventilated area. Keep cigarettes, flames or
‘sparks away from the work area or where gasoline is
stored.
rs
Gasoline is extremely flammable and is explosi
under
ccertain conditions. KEEP OUT OF REACH OF CHILDREN.
HOT COMPONENTS
Engine and exhaust system parts become very hot
and remain hot for some time after the engine is run.
Wear insulated gloves or wait until the engine and
‘exhaust system have cooled before handling these
parts.
BRAKE FLUID
CAUTION:
Spilling fluid on painted, plastic or rubber parts will
‘damage them. Place a clean shop towel over these parts
whenever the system is serviced. KEEP OUT OF REACH OF
CHILDREN.
1-1
= GENERAL INFORMATION
COOLANT
Under some conditions, the ethylene glycol in engine
coolant is combustible and its flame is not visible. If the
ethylene glycol does ignite, you will not see any flame, but
you can be burned.
Big —s_—
* Avoid spilling engine coolant on the exhaust system or
‘engine parts. They may be hot enough to cause the
‘coolant to ignite and burn without a visible flame.
* Coolant (ethylene glycol) can cause some skin irritation
and is poisonous if swallowed. KEEP OUT OF REACH OF
(CHILDREN.
* Keep out of reach of pets and some pets are attracted to
the smell and taste of coolant and can die if they drink it.
* Do not remove the radiator cap when the engine is hot.
The coolant is under pressure and could scald you.
If coolant contacts your skin, wash the affected areas
immediately with soap and water. If coolant contacts your
eyes, flush them thoroughly with fresh water and get
immediate medical attention. If swallowed, the victim must
be forced to vomit then rinse mouth and throat with fresh
‘water before obtaining medical attention. Because of these
dangers, keep out of the reach of children. Recycle used
coolant in an ecologically correct manner.
SERVICE RULES
BATTERY HYDROGEN GAS & ELECTROLYTE
ro
© The battery gives off explosive gases; keep sparks,
flames and cigarettes away. Provide adequate ventilation
when charging.
* The battery contains sulfuric acid (electrolyte). Contact
with skin or eyes may cause severe burns. Wear
protective clothing and a face shield.
~ifelectrolyte gets on your skin, flush with water.
— if electrolyte gets in your eyes, flush with water for at
least 15 minutes and call a physician immediately.
+ Electrolyte is poisonous.
—if swallowed, drink large quantities of water or milk
and follow with milk of magnesia or vegetable oll and
call a physician. KEEP OUT OF REACH OF CHILDREN.
1.Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents, Parts that don’t meet HONDA’s
design specifications may cause damage to the motorcycle,
2. Use the special tools designed for this product to avoid damage and incorrect assembly,
3, Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English
fasteners.
4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling
5.When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque
diagonally in incremental steps unless a particular sequence is specified
6.Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7.After reassembly, check all parts for proper installation and operation,
8. Route all cable and harness routing as shown on pages 1-21 through 1-29, Cable and Harness Routing, MODEL IDENTIFICATION
'97—"98:
GENERAL INFORMATION
(1) The frame serial number is stamped on the right
side of the steering head.
ENGINE SERIAL NUMBER
VEHICLE IDENTIFICATION NUMBER
(2) The engine serial number is stamped on the right
side of the crankcase below the rear cylinder.
(3) The Vehicle Identification Number (VIN) is located
on the right side of the frame below the exhaust
Pipe.
‘CARBURETOR IDENTIFICATION NUMBER
COLOR LABEL
(4) The carburetor identification numbers are stamped
Cn the intake side of the carburetor body as shown.
(6) The color label is attached on the frame under the
seat. When ordering color-coded parts, always
specify the designated color code.
1-3 GENERAL INFORMATION
MODEL IDENTIFICATION
After '98:
FRAME SERIAL NUMBER.
(1) The frame serial number is stamped on the right
side of the steering head.
ENGINE SERIAL NUMBER,
— VEHICLE IDENTIFICATION NUMBER
(2) The engine serial number is stamped on the right
side of the crankcase below the rear cylinder.
(3) The Vehicle Identification Number (VIN) is located
on the right side of the frame below the exhaust
pipe.
|
|
|
|
|
|
CARBURETOR IDENTIFICATION NUMBER
\ COLOR LABEL.
(4) The carburetor identification numbers are stamped
fon the fuel tube joint side of the carburetor body as
shown,
(5) The color label is attached on the frame under the
seat. When ordering color-coded parts, always
‘specify the designated color code.
4 GENERAL INFORMATION
SPECIFICATIONS
;- GENERAL ]
orem ‘SPECIFICATIONS
[DIMENSIONS | Overalllenath 2,310 mm (90.3 in)
| Overall width '97-'98: | 890 mm (35.0 in)
| ‘After'98: | 880. mm (34.6 in)
Overall height '97-"98: | 1,125 mm (64.3 in)
‘After'98: | 1,120 mm (44.1 in)
| Wheelbase '97~'98: | 1,605 mm (63.2 in)
‘After'98: | 1,600 mm (63.0 in)
Seat height ‘37~'98: | 690mm (27.2 in)
after'98: | 650 mm (25.6 in)
Footneg height "97='98: | 285mm (11.2 in)
asfter'98: | 283mm (11.1 in)
Ground clearance ‘97—"98: | 140mm (55 in)
After'98: | 135 mm (5.3 in)
Dry weight
‘VT600C |
49 state/Canada type '97—'98: | 199 kg (439 Ibs)
49 state/Canada type After’98: | 205 kg (452 Ibs)
Californiatype —'97—'98: | 199 kg (439 Ibs)
California type After’98: | 206 kg (454 Ibs)
vT600cD
Fuel tank capacity
Fuel tank reserve capacity
49 state/Canada type '97~'98: | 202 kg (445 Ibs)
49 state/Caneda type After'98: | 208 kg (459 Ibs)
California type '97—'98: | 203 kg (448 Ibs)
California type ——After'88: | 209 kg (461 Ibs)
| Curb weight |
\vTe00c |
| 49 state/Canada type '97—'98: | 213 kg (470 Ibs)
49 stato/Canada type After'98: | 214 kg (472 Ibs)
California type "97—"98: | 214 kg (472 Ibs)
California type After ‘98: | 215 kg (474 Ibs)
\vT600cD
49 state/Canada type '97~'98: | 216 kg (476 lbs}
49 state/Canada type After’98: | 217 kg (478 lbs)
California type '97~"98; | 217 kg (478 lbs)
California type __After’98:_| 218 kg (481 Ibs) cas
FRAME Frame type Double cradle
Front suspension Telescopic fork
| Front whoo! travel 120 mm (4.7 in}
Rear suspension ‘Swingarm
Rear whee! travel 90 mm (3.5 in}
Fronttire size 100/90-19 57S
Rear tire size 170/80-15 MIC 7S
Tire brand — Front '97~'98: | BRIDGESTONE L309 / DUNLOP F24
| After'98: | DUNLOP F24
| Rear "97~'98: | BRIDGESTONE G546 / DUNLOP 555:
After'98: | DUNLOP D404
Front brake Hydraulic single disc brake
|| Rear brake Internal expanding shoe
Caster angle 35°
Trail length '97~"98; | 164mm (6.5 in)
After’98: | 181mm (6.3in)
11.00 (2.91 US gal , 2.42 imp gall
3.4.8 (0.90 US gal , 0.75 Imp gall
Revised: August, 2000, ‘97 “01 VTBO0CICD
{©2000 American Honda Moto Co, Inc. ~All Rights Reserved
MSV 8963 (0008),
1-5 GENERAL INFORMATION
p> GENERAL (Cont'd) $$ AA ri
ITEM.
‘SPECIFICATIONS
ENGINE Bore and stroke
Displacement
Compression ratio
Valve train
Intake valve opens at mm itt
Intake valve opens at 1 mm lift
Intake valve closes at 1 mm lift '97—98:
Intake valve closes at 1 mm lift After’98:
Exhaust valve opens at 1mm lift 9788:
Exhaust valve opens at 1mm lift After ‘8:
Exhaust valve closes at 1 mm lit ‘9738:
Exhaust valve closes at 1 mm lit After ‘8:
Lubrication system
il pump type
Cooling system
Air fitration
Crankshaft type
Engine dry weight
vT600c
ae
After ‘98:
‘97:
After 98:
vTe00cD
Firing order
| Cylinder arrangement
| Cylinder number
"75.0 * 66.0 mm (2.95 * 2.60 in)
583 em? (35.6 cu-in)
92:1 |
Silent, multi-link chain drive and OHC with rocker arm
10° BTDC
or BTDC
30° ABDC.
20° ABDC
30° BBDC.
30° BBDC.
40° ATDC
o* ATO
Forced pressure and wet sump
Trochoid
Liquid cooled
Paper filter
Unit type, two main journals
61.0 kg (134.5 Ibs)
62.0 kg (136.7 Ibs)
64.0 kg (141.1 Ibs)
Front—308"—Rear—412°—Front
Two cylinders, 52° V transverse
Front: #2, Rear: #1
| CARBURETOR | Carburetor type
‘CV {Constant Velocity) dual carburetor with fuel pump
Starting system
Charging system
Regulator/rectifier
|_ Lighting system.
| After'98: | CV (Constant Velocity} single carburetor with accelerator pump
Throttle bore 34mm (1.3 in) oe
DRIVETRAIN | Clutch system Multi-plate, wet
Clutch operation system Mechanical type
Transmission Constant mesh, 4-speed |
Primary reduction 1.888 (36/68) |
Final reduction 2.750 (44/16)
| Gear ratio ast | 2.571 (36/14)
| 2nd | 1.700 (34/20)
3rd | 1.227 (27/22)
4th | 0.931 (27/29)
L __|_ Gearshift pattern Left foot operated return system, 1~N~2~3~4
ELECTRICAL Ignition system Full transistor digital ignition
Electric starter motor
Triple phase output alternator
‘SCR shorteditriple phase, full wave rectification
Battery
1-6 GENERAL INFORMATION
NN <<
;- LUBRICATION oA
Unit: mm fin)
‘STANDARD SERVICE LIMIT
= At draining
Engine oll capacity
2101.2 US qt, 1.8imp at) e
2.84 (8.0 US at, 2.5 Imp qt)
2.25 0 (2.38 US at, 1.98 Imp gi)
Recommended
| HONDA GN4 or HPS 4-stroke oll or
equivalent motor oil
APL service classification SF or SG |
Viscosity: SAE 10W—40
441 kPa (8.5 kat/er’, 64 psi) at 6,000 rpm |
(80 °C/176 °F) - ea
Oil pump rotor 916 0008) [0.20 (0.008)
0.350.014) |
(0.100.004)
y FUEL SYSTEM
7 SPECIFICATIONS
| ‘Wstate/Canada type California type
Carburetor Wentification number 37-8 | VEDA [— VOFEA
_afier'98 VE5AC VESAB
Main jet |_97—"98 #15
- ‘Aker'98 #125 i)
Slow jet 8 #40
‘Aftor"88 E45 |
Pilot screw Tnitia/opening See page 5:30
[Hight altitude adjustment See page 5:37
Float level "98. 7.0 mm (0.26 in)
: __| After ‘98 18.5 mm (0.73 in)
‘ase carburetor (or synchronization, 6798 models] Rear cylinder (2 1)
(dle speed
‘Throttle grip free pla
7,200 = 100 ¢pm
26 mm (1/12— 1/4 ind
Fuel pump flow capacity (97 —"98 models)
Minimum 800 em® (27.1 US oz 28.2 Imp oz) per minute at 13V
;- COOLING SYSTEM
ITEM
——————
‘SPECIFICATIONS
Coviantcapaciy | Radiatorand engine
T60(17 US at, 7.4 imp at
Reserve tank
0.46 (0.4 US at 0.4 Imp at
Radiator cap relief pressure
‘GB— 127 kPa (0.9~ 1.3 kgHlem®, 12.818 psi)
Thermostat sgin to open =a 'a0—84 °C (176 183 °F)
Fully open. 95°C (2034
Valve lift ‘Bmm (0.3 in) minimum |
‘Siandard coolant concentration 50% mixture with soft water j
1 GENERAL INFORMATION
ee
[- CLUTCH SYSTEM Lit ram fi
Tem ‘STANDARD SERVICE LIM
‘Clutch lever fee pla 10-20 awa
Clutch spring ree length 32 i170) Hate
Clutch asc thickness A 282-3.08(0,115—0.129 26 (0.10)
B 282—2.08(0.115=0.121) 2610.10)
Clutch pate warpage 2.30100121
Cuten outer guide 1. Zi 991 —22,016 (0 BEE 0.8866) 22.08 (0.870)
___ Pes 31.950 21.978 (1.2562= 1.2509) 31.98 1.258)
Clutch outer 10 32.000= 32.025 (1.2508—1.2608) — 32.1011.268)
(il pump drive sprocket LD. z 32.000 32.025 (1.2568= 1.2608) 32.10/1.268)
MainshaftO.D. at cltch outer guide 21.967 71,980 (0,8648~0.8854) 21.92 (0.863)
nt mm fn
p- ALTERNATOR/STARTER CLUTCH ——__Unit- mm tin
TEM ‘STANDARD SERVICE LITT
Starer driven gear Lp. 31000370 HAT 1.87) “ari0 ae)
OD. 57.149=87.165 2.2736- 22743) 57.73(2273)
Stariercltch outer TAAA= 74.440 2.9297 —2.9807) 74.46 (2.931)
1-8 GENERAL INFORMATION
ES
— CYLINDER HEAD/VALVES EE ea
ITEM STANDARD | SERVICE LIMIT
Cylinder compression [32h © 98 kPa (135 = LO kgi/em", | =
| 492 2 14 si a 400 rpm
|" Cylinder head warpage z —t —
Valve, Walve clearance iN) 0.7570.008)
valve guide x 0.200.008),
Valve stem 00. IN| 8.475~5 490 (02158-02160)
ca excess 6. 57010.2561—0.2587)
Vaive guide 1 5.500 5.512 10.2165—0.2170)
6 600=6.615 0.2508-0.2606) 6.510.262)
‘Stonvio-guide clearance [_IN 0.010 0.037 (0,0004=0.0015) “0.10,0,008)
[ EX 0.030 0.060 (0.0012—0,0024) 0.11(0.008)
Valve guide projection IN| 19.4~19.6(0.76—0.77) | =
|_ above cylinder head ex 17.9 18.1(0.70—0.71) I
Valve seat width NEX | 0.90 1.10 0,035-0.063) I a]
Valve spring) Inner IN 38.11 (1-500) = [Bar (1436)
free length =x 36.81 (1.528) s7silia77)
Outer IN| aa. 859) [w0.58 (1.598) |
EX 42.83 (1.686) - 4.25 (1.624) |
Camshaft Zamiobe | IN| 97 "98 | 37.930 1.4933) Tans e851]
height | 37-188 37.248 (ABA LATO. 37.16 1.469)
hee | 37.9501.4961) “are ase
L l ‘After’98 | 37.605 —37.765 (1.4805 — 1.4868) [37.58 (1.480),
ournal 6. [21.959— 271.960 ( 3658) | 71900-8621
Runout 0.630 (0.0012), 095 (0.002)
Oil clearance 0.050-0.111 (0,0620—0,004) [0.13 0.0061
Identification marks "E Fron, "8: Rear al
Rocker arm |.D. TIN/EX 12.000 — 12.018 (0.4724—0.4731) 12.05 (0.474)
Rocker arm shaft OD. [IWEX | 4t9668=118840.4711—0.4718) | 19110.460)
Rocker err-to-rocker arm shaft Clearance 0.016 ~0.052(0,0008 ~0.0020) 007(0.003) GENERAL INFORMATION
;- CYLINDER/PISTON it mn fi
Tem STANDARD SERVICE LIMIT
Cylinder iD. 75.000 75.016 (2.9528 2.9535) 75102957)
Out of round 0.08 (0.002)
[Taper —— F006 0.002)
Warpage E 0.100.004) |
Fision, piston | Piston mark direction i
rings Piston 0.0 74.965 ~ 74.990 (2.9514 2.9524) 74.90 (2885)
Piston 0.0. measurement point
‘10 mm (0.6 in) from bottom of skirt
Fiston pin bore LD. 38.06 (0.711)
Piston pin 0.D. 17.98 (0.708)
Fiston-to-piston pin clearance (0.04 (0.002),
Fiston ring-to-ring | Top | 0.015 ~0.048 (0.0006 0.0018), (0.10 (0.004)
groove clearance | Second (0.015 0,045 (0,0006—0.0018) (0.10 (0.004)
Piston ring end gap |Top. '0.10—0.30 (0.004~0.012), 0.5 (0.02)
‘Second '0.10—0.30 (0.004—0.012), 0.5 (0.02)
[Oil side rail) |0.20—0.70 0.008 0.028) [0.9 (0.04)
[Piston ring mark | Topisecond | “N”" mark
Cylinderto-piston clearance 10.070 0.050 (0.0004—0.0020) 0.70 (0.004)
Connecting rod small end 18.016 — 18.034 (0.7033 0.7100) 18.07 (0.711
Connecting rod-to piston pin clearance 0.016 0,040 (0,0005 —0,0076) 0.06 0.002),
[- CRANKSHAFT/TRANSMISSION Lunit-rrn inh
TEM STANDARD ‘SERVICE LIMIT
Graniehatt [Side clearance 0.05—0.20 0.002—0.008) 0:30 (0.072)
Runout 0:05 (0.002)
Crank pin oll clearance 01028 —0.082 (0.0071 0.0030) 0.07 (0.003)
: Main journal oil clearance {01025—0.041 (0.0010-0,0016) 0,0640,002),
‘ranemission | Gear. {79.000 28.021(7.1024—1.1032) 78.08 (1.104)
[24.000 — 24.021 (0.9449— 0.9457) 24.94 (0.982)
Bushing OD. ‘77.959 27.98017.1007—1.1016) 77.96:7.100)
73,959 73.980 0.9493—0.9441) 73,96 (0.943)
Bushing ib. 25,000 25.071 (0.9843 0.9851), 25.04 (0.986)
20,016 20,037 (0.7880 0.7889) 20,05 0.790)
Gearto-bushing M2, Ma (0.020—0.062 (0.0008 0.0024) [0.10 0.008),
clearance c1,c3 (0.020— 0.062 (0.0008 0.0024) 0.10 (0.004)
[[Mainshaft 0.0. | M2 bushing 24,959 24,980 (0,9826~0.9835) | _24.94 (0.982)
Countershaft 0.0. | C1 bushing 19.980 — 19.993 (0.7866— 0.7871) [19.96 (0.786) |
Bushing-to-shaft _|_M2 120 ~ 0.062 (0.0008 0.0024) [0.10 (0.004) }
__| clearance C1 0.023 0.057 (0.0008 0.0022) {0.100.004}
[Shift fork, fork | Fork LD. 13.000 ~ 13.018 (0.5118 0.5125) 13.04 (0.513)
| shaft Claw thicxness | 6.93 ~ 6,00 (0.233 ~ 0.236) 5.6 (0.22)
__| Forkshafi OD. 12.966 — 12.984 (0.5105—0,5112) 72.90 (0.508)
Shift drum 0.D. {at the left side journal) 11.966 — 11.986 (0.4711—0.4718) 11.94 (0.470)
1-10 GENERAL INFORMATION
ee
[— FRONT WHEEL/SUSPENSION/STEERING te moh
TEM STANDARD [service unr
‘Minimum tire tread depth ~ 7510.06)
Cold tire pressur
Up to.80.kg (20016) load
‘Up to maximum weight capacity
200 KPa 2.00 kgflem®, 29 psi),
200 kPa (2.00 kgflem®, 29 psi)
Pale rnout : 37010 008)
Wheel im runout [—20(0.08 —]
: : 20,008)
ht
ErRESUIEUES
ox)
‘Spring as legih ssz9713 19) aa 8)
Spring dvecion Tight wound ce sould be tte top
‘ube runout : [a0 0.08
Recommended fork uid Pro Honda Svspension Fuld S58
Fu evel tar
Fluid capacity 5 02 ew? (62 = OO USO,
E 15.8 + 009mp on
Siering head Bearing preload O9=14 kgf(20~ 3116h
[REAR WHEEL/BRAKE/SUSPENSION
| STANDARD
[Minimum tire tread depth 2010.08) |
Cold tire pressure | Up t090kq (200 Ibi load —|200 KPa (2.00 Kafer? 29 psi)
‘Upto maximum weight capacity | 250 KPa 2.50 kat/em*, 36 psi). cee
Axle runout = 13.20 (0.008),
Wheel rim runout | Radial t —— a 2.00.08),
[Axial — [2.0 (0.08)
‘Wheel hubsto-rim distance 323 = 08127 = 0.03)
‘Wheel balance weight Max. 70g (2.502) —
Drive chain link 120
Drive chain slack 20=30 (41-114) 5020)
Drive chain size [_DiD. 5258
BRaee 525 SMB. e
Rearbrake Drum iD, 160.0 16031630-6.31) 78763)
Lining thickness 502) ~ 2 (0.11,
Brake pedal free play 20-30 (e174)
‘Shock absorber spring preload adjuster setting [2nd position —
Fevesd Ocober 1000 1987-2000 VTEDICICD 111
(S1909 Amoran Honda Mote Co, ne - Al Rights Reserved
MSV A817 (810), GENERAL INFORMATION
— HYDRAULIC BRAKE - nit
TEM ] STANDARD SERVICE LIMIT
Specified brake fuid es Dora S
Brake pad wear indicator : = —[-“reareove
Brake disc thickness = 501020) 40'0.16) |
Brake disc runout li 0.30 (0.012)
Master cylinder 1D. F000 1.008 831088) 11.05 0.435)
Master piston 0.0. (t0ss7= tase 0 2314—0.1320 70.945 (0.4309)
Caliper cylinder LD {"27.000—27.050 (1.0630 = 1.0850), 77.06 (1.085)
Caliper piston 0. 26.835 ~26.968 (1.0604 1.0617) | 28.93 (1.060)
; BATTERY/CHARGING SYSTEM
ITEM ‘SPECIFICATIONS |
Battery | Capaciy “av8aH |
Curent leakage 1.3 mAmax
| Voltage @0°Ce8 | Fullycharged | 130-132
| Needs charging Below12.3V
t [Normal OBATION z
Ea | Touiek ZOATT hmax
Alternator [Capacity "345 W/5,000 rpm
[Charging coil resistance (20°C/68 FI 01-102 i
Regulator/recifierrequlated vohage T= 154.0000
- IGNITION SYSTEM.
TEM ‘SPECIFICATIONS
Spark plug Standard C NEE XOAEPRLUS IDENSOI
For cold climate below 5 “C/A "F) DPRTEA (NGK) — X22EPR-US (DENSO)
[For extended high speed riding ~DPREA-S NGK) | —X7EPR-U9 (DENSO)
Spark plug gap ao 080= 0.80 ram 10.051 0.035 in)
ignition coll primary peak volage E100 rnnimum
ignition pulse generator peak voltage 0.7 V minimum
ignition tming “=” mark 65° BTDC at ile
‘Advance | Start L'97—"98- 2,000 + 200 rpm.
. Caters 1800 = 2001p
fee __ [Step 000 + 200rpm
BIDE SO"
1-12 GENERAL INFORMATION
LEE E EEE
;- ELECTRIC STARTER List: men
TEM STANDARD SERVICE LIMIT
‘Starter motor brush length 12.5 (0.49) 6510.26)
;~ LIGHTS/METERS/SWITCHES —————
ITEM | SPECIFICATIONS
Bulbs | Headlight (High/low beam) 2-6 0/56
Brakeytail light _ 42V-32/3CP 2
Front turn signal/running light 1DV-21/5W x2
Rear turn signal light if 12V-21W » 2
License light tava P- —
Instrument light 1av-3.4W.
“Turn signal indicator v1.7
High beam ini Tr 72V-1.7W_
_| Neutral indicator 12V-1.7W
Fuse Mainfuse i) eeeaOAs ae
Sub fuse 0A 3, 15A* 1 -
{-Fust pump few capacity min inte) (87 "98 modes)
{800 om? (27.1 US o2, 28.2 imp oz)
Fan motor, | Start to close (ON) 98 — 102°C (208 — 216°F)
switch [Start to open (OFF) a "53 — 97°C (199 = 207°)
Thermosensor resistance (97~'00)|_60°C/2°F 130 ~ 180.0
[eo-cne*F 45-600 —_
. 120 °¢/248 *F 10-200 zl
“Thermo switch (Aftor"00) |_Starttociose (ON) 72 — 118°C (259 — 2701 |
‘Start to open (OFF) Below 108°C
Revised: August, 2000, ‘87 -01 VTBOOCICD
(©2000 American Honda Mota Co, nc. All Fights Reserved
Mv 8969 (0008)
1-13 GENERAL INFORMATION
TORQUE VALUES
Sain a
| FASTENER TYPE Nem tkgtm, tf) | FASTENER TYPE ‘Nem (kgf.m, Ibfft)
| 10 mm hex bolt and nut 35 (3.5, 25) | 6mm flange bolt (10 mm head) 12 (1.2,9)
NOTES: 1. Apply sealant to the threads.
ENGINE ‘THREAD ‘TORQUE
a OTK piActmm) | Nem (kgm, ibfft) REMARKS
ian
eae
il pump driven sprocket bolt | ile 15 (1.5, 11) NOTE2
eniere sate
CLUTCH/GEARSHIFT LINKAGE: |
Gearshift cam plate bolt dees 8 12(1.2,9) NOTE 2
1-14 GENERAL INFORMATION
;— ENGINE (Cont'd) 7
THREAD Toraue |
| ALTERNATOR/STARTER CLUTCH: |
Left crankcase cover bolt 10 6 wai2.9 |
Fiywhee! bolt 1 2 127113094) | NOTES
128 (13.1 95)
Stator mounting socket bolt 4 6 12112,9) | NOTE2
Starter one-way clutch socket bolt 8 8 | mie0.z | NOTE?
; 3018.1,22) |
‘Attornator cord clamper fe 6 12(12,9) | NOTE2
Ignition pulse generator bolt 4 6 12(12,8) NoTE2
CYLINDER HEAD:
Cylinder head cover bolt 4 6 1011.9,7)
Camsheft holder 8 mm bolt 6 6 ees |
8 mmnut 4 8 223,17 — |
Camshaft end holder bolt ‘7-98 | a 6 908,65) |
Aer 98: 10(1.0,7)
Cam chain tensioner mounting bot ‘ 6 | 101017 | Novez
Cylinder head 8 mm bolt oe 8 23123,17) | NOTES
Smmbolt 2 6 12112,9) | NOTES
10mm nut 8 10 47148,35) | NOTES
CRANKSHAFT/TRANSMISSION.
Mainshaft bearing set plate bolt 97 ~"96) 1 6 12(1.2,8) Note2
Countershaft bearing set plate bolt ’97~'88) 3 6 9(08,65) | NOTE2
Bearing set plate bolt (After '38) 4 6 12(12,9) | NOTE2
Cam chain tensioner set plate bolt ag 12112,9) NoTE2
Crankcase & mm bolt ee a
Smmboit ‘o—98: | 7 6 9(08,65)
After 98 12(1.2,9)
Connecting rod bearing nut oe | sia) | Nore
Neutral switch la 10 1211.2,9), NOTE 1
ELECTRIC STARTER:
Starter motor cable nut gig 1011.0,7)
(- FRAME 7
| THREAD Torque — |
ran om | cae | wate | mame
FRAME/BODY PANELS/EXHAUST SYSTEM: |
Exhaust pipe joint nut 4 e | 205,10
Exhaust cover bolt 3 Caza)
Muffler bracket mounting bolt 1 | 8 | 200,
nut a] 8 | 2002.0, 14)
Sub-frame mounting bolt 2 Core ||
nut oe | rei)
MAINTENANCE:
Side stand pivot bolt 10 | 10(1.0,7)
nut ‘e7-"98: | 41 10 | 2913.0,22)
After 98: | 3018.1/22)
FUEL SYSTEM: |
Air cleaner housing cover bolt [a Cio
Air cleaner housing mounting bolt | 6 12(12/9)
after 98 35 (36,26) |
Fuel valve lever screw 1 5 410.4,28) |
Fuel tank mounting bolt a 19119, 14)
Throttle link cover screw 1 * | watts |
1-15 GENERAL INFORMATION
—_——
FRAME (Cont'd)
| THREAD TORQUE REMARKS
ire oa [DIA (mm) | Nem tkgf-m, IbFft)
COOLING SYSTEM: ei 6 9 (09,65)
Radiator mounting bot 1 : 9109.68)
Radiator gril mounting screw 1 ‘ nan
‘Thermostat bracket bolt ie é waaln
‘Thermostat housing cover bolt ‘0 | 1 |opTae 10 (1.0.7) NOTE1
Thermosensor a eos.) | ‘NOTET
Thermo switch TAA | | oe 7107/50
Water hose band screw i 16 18 (1.8, 13) NOTE 1
Fan motor switch |
ENGINE MOUNTING: 54(55, 40)
Front engine mounting bott (upper) aa 1 a 5515.6. 41)
ee 0 5455.40)
oe 55(56.41)
‘iter 5455.40)
Rear engine mounting bol ae * 55 (56,41)
| 8 26(27 20)
Engine bracket bot front aT a2. 20)
Afer'9e: | 8 26(27,20)
(rear aoe 2128.20)
: . 12(12,9)
Gearshift peda pinch bolt i i ouoen
Footpeg bracket bolt |
FRONT WHEE! /SUSPENSION/STEERING: : . 103 (10.5, 76) —r} Seepage 1240
Steering stem nut ja x a
Toptnread A ; a —
Toptread @ ] : noa.9
Fork top bridge pinch bolt 13 10 49 (5.0, 36)
Fork bottom bridge pinch bolt je : 29 (3.0, 22)
Handlebar upper holder : a 23023,
Handlebar lower holder 7 : river
Handlebar site sorow 4 ia 74075, 54)
Front axle | 3 7 2212.2,16)
Front axle pinch bolt : Ea 8 39 (4.0, 29) NOTES
Front brake disc mounting bolt aes | 42(4.3.31)
le 36 23(2.3,17)
Fork cap, a 10 2913.0, 22) NOTE 2
Fork socket bolt = a 404,28)
Spoke
REAR WHEEL /BRAKE/SUSPENSION: i: 88(90,65) | NOTES
Rear axle nut : 0 6416.5, 47) NOTE 8
Driven sprocket nut : ; i" us 33)
Rear shockabsorber mounting ni upper 1 HH a
on - a | 3 1 8819.0, 65
ingarm pvt — 2222.16)
Rear brake stopper arm bolt ‘97 —"98: 2 e | e138)
| 26(27 20)
Rear brake arm pinch bolt }? Beran
90.9, 6.5) |
Rear brake middle rod joint bolt ce ‘ iver
Spoke |
vod qi 20005701 viso06eD
ae ‘American Honda Motor Co., Inc, - All Rights Reserved
: cate ‘MSV 8969 (0008) GENERAL INFORMATION
r- FRAME (Cont'd)
THREAD TORQUE
eM | ot DIA. (mm) N-m (kgf-m, Ibf-ft) Lisette
HYDRAULIC BRAKE:
Brake caliper mounting bolt 2 8 20(81,2) | NOTES
Caliper pin bolt 1 a | ass
Bracket pin bolt fea 8 1313,9)
Pad pin 1 10 1818.13)
Pad pin plug 1 0 2025.18)
Brake caliper bleeder 1 8 6i0es.47) | |
Brake lever pivot bott 1 6 110.1,07)
Brake lever pivot nut 1 6 6106, 43)
Master eylinder holder bolt 2 8 12(12,8)
Master eylinder cover screw 2 4 110.18,
Front brake light switch screw 1 4 4012,08),
Brake hose ol bolt 2 10 34185, 25)
UGHTS/METERS SWITCH
Side stand switch mounting bolt 1 6 909,65 | NOTE
OTHER FASTENERS:
Fuel pump stay mounting nut '87—'88)/ |
Turn signal relay stay mounting nut (After '96) 1 6 909,65)
TOOLS
NOTES: 1.quivalent commercially avalable in U.S.A
2’ Not avellable in USA.
2. Alternative tool
4. Newiy provided too
DESCRIPTION | to01 numaen REMARKS REF. SEC.
Carburetor float level gauge | 07401—0070000 a
Pilot screw wrench | o7LMA-MTBO10A
with
o7PMA™-MZ20118
Vacuum gauge ‘07404~0030000 | NoTEs:o7Lms—o010008 |
Oil pressure gauge 07506-30000 | NOTE? 4
Oil pressure gauge atachment | o7st0-azz0100 | NOTE la
Lock nut wrench 17 27 mm | orre-oozesto | NoTE1 8
Gear holder | 0772«—cox0100 8
Rotor puller 07733-0020001 | NOTEa:07933~2290001 | 8
Valve guide driver, 6. mm o7742-o010100 | | 10
Valve guide driver, 66 mm | 07742-o010200 | NOTE2:07942~6570100 | 10
Attachment, 32 % 35 mm 07746-0010100 [ie
Attachment, 42 % 47 mm 07748-0010300 12,13,14
Attachment, §2 % 65 mm 07746~0010400 | ta3
Pilot, 15 mm 07746-0040300 | ts
Pilot, 17 mim 07746-0040400 is
| Pilot, 20 mm 077460040500 12,13
Pilot 22 mm 07746~0041000 m1
Pilot 25 mm | 07748-0040600 he
Beating remover shaft | 07746—c080100 Bu
Bearing remover head, 17 mm 977480050500 u
Bearing remover head, 29 mm | 07748~o050600 8
Attachment, 28 % 30mm 07948~ 1870100 4
Driver 97749~0010000 12,13,14
Main bearing driver attachment oTHME—MM90400 | a2
Valve spring compressor 07757—0010000__|_ NOTE 3: 07957 ~ 3290001 | 10
1-17 GENERAL INFORMATION
DESCRIPTION TOOL NUMBER | REMARKS, [ sersec |
Valve seat cutter NOTET | |
Seat cutter, 27.5 mm (45° IN} 07780—0010200
Seat cutter, 35 mm (45° EX) (07780—0010400
Flat cutter, 28 mm (32° IN) (077800012100
Flat cutter, 35 mm (32° EX) 07780—0012300 |
Interior cutter, 30 mm (60° IN} (07780~0014000 |
Interior cutter, 37.5 mm (60° EX) (07780~0014100
Cutter holder, 5.5 mm 07781~0010101 |
Cutter holder, 6.6mm 07781~0010201
Valve adjusting wrench 07908—KE90000 | NOTE 2:07908—KES0100 5
Snap ring pliers 07914~3230001 | NOTE1 2,14, 15
Steering stem socket 07916~3710101 13 |
Clutch center holder 07JMB—MN5O301_ | NOTE 3: 07HGB—001010A or 8
O7HGB—0010108 and |
O7HGB—0010208
o7HGB—0010208,
Bottom holder pipe 97930—KAs0000 | NOTE2 | 13 |
— Holder attachment (97930—KA50100 |
= Holder handle 07930—KA¢o200 | NOTE2
Bearing remover set 07936—3710001 | NOTE2 |e
Remover handle 07936-3710100 |
~ Bearing remover set 07936-3710600
~ Remover weight 07741-0010201 | NOTE3:07936~3710200 |
Flywheel holder 07725~-0040000 | NOTE 1 i
Valve guide driver attachment {IN) 07943~MF50100 | 10 |
my Ova43—MFS0200 (bo
Bearing race remover (07946~3710500 fatal
Driver shaft set 07946~KA50000 | 4
Steering stem driver 07946~MB00000 | 18
Driver shaft 07946~-MJ00100 | 14
Fork seal driver, 38 mm (07947 ~ 4630100 fata
| Ball race remover 07953~MJ10000 | NOTE 2: 07953~M1000A or 8
(07953—MJ10008 and
(07949~3710001 or
| 07748-0010100
— Driver attachment 07953—MJ10100 i
~ Driver handle 07953—MJ10200 i
Valve guide reamer, 5.5 mm (IN) 07984~2000001 | NOTES:07984~200000D | 10
Valve guide reamer, 6.6 mm (EX) 07984—ZE20001 | NOTE3:07986~ZE2000D | 10
Oil filter wrench O7HAA—PI70100 2
Peak voltage adapter 07HGJ—0020100 7
Main bearing driver attachment o7HMF—MMg0400 a:
Drive chain cutter O7HMH—MR10103 | NOTE3:07HMH—MR1010B | 3
‘Spoke wrench o7JMA~MR6O100 | NOTE 2 ny
Vacuum/Pressure pump, A93TX—041-XXXXX | NOTES: ST—AH-255—MC7 | 5
‘ST—AH~260—MC7
1-18 GENERAL INFORMATION
EEE
LUBRICATION & SEAL POINTS
[— ENGINE T T
LocATION [arena REMARKS
| Camshaft lobes/journals | enum disul
Valve stem (valve guide sliding surface) fide oil (a mixture of
Rocker arm slipper surface 1/2 engine oil and 1/2
Rocker arm shaft sliding surface molybdenum disul- |
Connecting rod bearing surface fide grease
| Crankshaft journals
Clutch outer guide outer surface
Crankshaft hole cap threads
‘Timing hole cap threads
2, M3 shifter gear (shift fork grooves)
| Transmission collars inner and outer surface
Transmission spline collars outer surface
Connecting rod small end inner surface
ton outer surface | rain
‘on ring outer surface
Piston pin outer surface
Primary drive gear bolt threads and seating surface |
Flywheel bolt threads and seating surface |
Starter reduction gear shaft outer surface
Clutch dise outer surface |
Clutch center lock nut |
Cylinder stud bolt threads | |
Cylinder head 8 x 187mm mounting bolt threads |
Valve adjusting screw threads and seating surface |
Connecting rod boltnut threads and seating surface,
Cylinder head mounting bolt seating surface
Each bearing raling area
Each oil seal lip Multi-purpose grease |
|
T
Oil pressure switch threads | Sealant
34mm
(0.12-0.16in) | |
|
Fan motor switch theses
Thomasonsr treads (9700) |
Thermo ewizh ate
Revised: August, 2000, 97 -01 VTOOCICD 4-19
{60000 american Honda Molar Co, Ine.~ Al Fights Reserved
‘MSV 8969 (0008) GENERAL INFORMATION
ENGINE (Cont'd)
Starter one-way clutch bolt threads
Oil pomp driven sprocket bolt threads
Alternator cord clamper bolt threads
Gearshift cam plate bolt threads
Transmission bearing set plate bolt threads
Countershaft oil seal set plate bolt threads
Cam chain tensioner set plate bolt threads
Stator mounting bolt threads
Oil filter boss crankcase inside threads
Ignition pulse generator bolt threads,
Left crankcase cover bolt threads (marked “A")
LOCATION MATERIAL REMARKS
R. crankcase cover mating surface (After 98) Sealant
+ See page (8-21, 9-10)
| L- crankcase cover mating surface (After ‘98)
Fan motor switch threads |
Thermo sensor threads
Cam sprocket bolt threads Locking agent
Coating width: 6.5 ++ 1 mm
1-20 GENERAL INFORMATION
r~ FRAME
LOCATION
MATERIAL,
REMARKS.
‘Steering head bearing sliding surface
Steering head dust seal lips
‘Swingarm pivot bearing and dust seal lips
Whee dust seal lips
Rear wheel axle sliding surface
Side stand pivot sliding area
Main and pillion footpeg sliding area
Throttle pipe inner sliding surface
Throttle pipe rolled up portion
Clutch lever pivot bolt sliding surface
Rear brake middle arm sliding area
Rear brake pivot collar sliding area
Brake pedal dust seal rubber
Gearshift pedal dust seal rubber
Multi-purpose grease
Spreading 1.09
Spreading 1.0 ~ 2.09
Spreading 0.2 ~ 0.3.9
Wheel axle distance collar
‘Swingarm pivot distance collar
Steering top threads
‘Steering bottom bridge threads and seating surface
Crankcase breather tube entry end
Engine oil
Brake master cylinder cups
Brake master piston
Brake caliper piston seals
Brake caliper dust seals
Brake lover pivot and piston tips
Brake caliper slide pin surface
DOT 4 brake fluid
Silicone grease
Final driven flange bolt threads
Fork socket bolt threads
Locking agent
Handle grip rubber inside
Front fork cap O-ring
Front fork oil seal lips
Front fork spring
Front fork rebound spring
Honda Bond A or
Honda Hand Grip
Cement (U.S.A. only}
Pro-Honda Suspen-
sion Fluid $S-8
Each cable inside
Cable lubricant
Drive chain
Pro Honda Chain
Lube or equivalent
1-21 GENERAL INFORMATION
CABLE & HARNESS ROUTING
'97—'98:
‘THROTTLE CABLES CLUTCH CABLE
LEFT HANDLEBAR
SWITCH WIRE
RIGHT HANDLEBAR SWITCH WIRE SPEEDOMETER CABLE
FRONT BRAKE HOSE
HEADLIGHT CONNECTOR
HORN
HORN WIRE
After '98:
‘THROTTLE CABLES: CLUTCH CABLE
RIGHT HANDLEBAR SWITCH WIRE
LEFT HANDLEBAR,
SWITCH WIRE
HORN WIRE ‘SPEEDOMETER CABLE
FRONT BRAKE HOSE
1-22 GENERAL INFORMATION
‘97—"B8: HANDLEBAR SWITCH WIRE BANDS.
ENGINE BREATHER TUBE WATER HOSE
STARTER MOTOR
‘STARTER MOTOR
CABLE
CRANKCASE
BREATHER
SEPARATOR
EVAPORATIVE
EMISSION
PURGE CONTROL
VAL
(California type only)
SUB-AIR CLEANER
GROUND CABLE
CLUTCH CABLE IGNITION PULSE ‘AIR CLEANER HOUSING
GENERATOR WIRE
After '98:
HANDLEBAR SWITCH WIRE BANDS.
ENGINE BREATHER TUBE WATER HOSE
‘STARTER MOTOR
‘STARTER MOTOR
CABLE
CRANKCASE
BREATHER
SEPARATOR
‘THROTTLE CABLES
GROUND CABLE
CLUTCH CABLE IGNITION PULSE AIR CLEANER HOUSING
GENERATOR WIRE
1-23 GENERAL INFORMATION
‘97 —'98: THROTTLE CABLES: FRONT IGNITION COIL. FUEL TANK BREATHER TUBE
(California type only}
FUEL TUBE INLET LINE
ALTERNATOR
wine
RIGHT SE VALVE CABLE
‘SPEEDOMETER AIR CLEANER HOUSING
CABLE HOLDER BREATHER TUBE
After '98:
FAN MOTOR SWITCH
WATER HOSE
MAIN WIRE HARNESS
FUEL TUBE (To carburetor)
SIPHON TUBE
FUEL TUBE
(To fuel tank)
BRAKE HOSE
ALTERNATOR,
WIRE.
‘SPEEDOMETER CABLE
|
AIRCLEANER CHAMBER — FANMOTORSWITCHWIRE SPARK PLUG WIRE
BREATHER TUBE
1-24 GENERAL INFORMATION
eee TURN SIGNAL RELAY REAR IGNITION COIL.
FUEL FILTER
REAR BRAKE LIGHT SWITCH
COOLANT RESERVE TANK
SUB FUSE BOX OveRALOW TUBE
After 98: REAR AJL. TURN SIGNAL, TAILBRAKE LIGHT,
LICENSE LIGHT CONNECTORS
TURN SIGNAL RELAY
IGNITION COIL,
CONNECTORS MAIN FUSE
BATTERY
EVAPORATIVE EMISSION COOLANT RESERVE TANK
REAR BRAKE LIGHT SWITCH WIRE CANISTER TUBE ‘OVERFLOW TUBE
Fuel tank to Canister
(California type only) ‘SUB FUSE BOX
1-25 GENERAL INFORMATION
'97—'98: TURN SIGNAL RELAY BRAKE/TAILLIGHT, FUEL PUMP,
REAR RIGHT TURN SIGNAL
CONNECTORS:
REAR LEFT
TURN SIGNAL,
LICENSE LIGHT
CONNECTORS
SIDESTAND y a i —ENITION CONTROL MODULE
2P GREEN CONNECTOR ~~ : is oe
REGULATOR/RECTIFIER
4P BLACK CONNECTOR
RECULATOARECTIIER
"ALTERNATOR 99 WHITE CONNECTOR
IGNITION SWITGH"AP WHITE CONNECTOR
NEUTRAL SWITCH lL. PRESSURE SWITCH
SIDE STAND SWITCH
After ‘98:
TURN SIGNAL RELAY BRAKE/TAILLIGHT, LICENSE LIGHT
REAR R/L. TURN SIGNAL CONNECTORS.
IGNITION SWITCH 4 ALTERNATOR 3P REGULATOR/RECTIFIER
WHITE CONNECTOR WHITE CONNECTOR 4P BLACK CONNECTOR GENERAL INFORMATION
'97—'98:
IGNITION PULSE GENERATOR HORN/FAN MOTOR.
4P WHITE CONNECTOR 2P BLACK CONNECTOR
FRONT BRAKE HOSE TURN SIGNAL
9P WHITE CONNECTOR,
|
CLAMP
INDICATOR PANEL
6P GREEN CONNECTOR
‘SPEEDOMETER
6P BLACK CONNECTOR
RIGHT HANDLEBAR SWITCH
‘9P RED CONNECTOR
'97—'98: After ‘98:
CRANKCASE BREATHER DRAIN TUBE — MAIN WIRE WATER HOSE
HARNESS,
EVAPORATIVE EMISSION PURGE EVAPORATIVE EMISSION PURGE
CONTROL VALVE TUBE (California type only) CONTROL VALVE TUBE (California type only)
1-27 GENERAL INFORMATION
ALTERNATOR WIRE —
'97—'98:
SIDE STAND SWITCH OIL PRESSURE SWITCH
After ‘98:
ALTERNATOR WIRE
NEUTRAL SWITCH
SIDE STAND SWITCH
OIL PRESSURE SWITCH
1-28 GENERAL INFORMATION
'97—'98: GROUND POINT After ‘98: GROUND POINT
CLAMPS THERMOSTATIC CLAMPS THERMOSTATIC
SWITCH WIRE ‘SWITCH WIRE
‘97 —'98/After '98:
STATOR COIL CLAMPS:
IGNITION PULSE | ~
RIGHT
GENERATOR. CRANKCASE
1-29 GENERAL INFORMATION
'97—"98:
BRAKE/TAILLIGHT
CASE
LICENSE LIGHT
WIRE
TAILLIGHT WIRE
TURN SIGNAL,
LIGHT WIRE
After '98:
BRAKE/TAILLIGHT WIRE
REAR RIGHT
TURN SIGNAL LIGHT WIRE
TURN SIGNAL RELAY LICENSE LIGHT WIRE
1-30 GENERAL INFORMATION
EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE ONLY)
NOTE:
‘The hoses shown below are numbered as they appear on the Vacuum Hose Routing Diagram Label.
@TUBE
EVAPORATWE EMissioN
Hace eNTaeL valor SYAPORATIE EMISSION
(DTUBE
@TUBE
BREATHER
TUBE
(FROM REAR
CYLINDER
HEAD)
(TUBE EVAPORATIVE EMISSION CARBURETOR
@TUBE AIR VENT CONTROL VAL\
TUBE
TO EVAPORATIVE
EMISSION CANISTER
AIR CHAMBER DUCT
COOLANT RESERVE TANK
DRAIN TUBE
EVAPORATIVE
EMISSION.
CANISTER
PE
AIR TUBE EVAPORATIVE EMISSION CANISTER
REAR SHOCK ABSORBER TUBE
1-31 GENERAL INFORMATION
After '98:
RETURN TUBE
(TO AIR CLEANER CASE)
EVAPORATIVE EMISSION CARBURETOR
AIR VENT CONTROL VALVE
ENGINE BREATHER
TUBE
(TO SEPARATOR)
@TuBe @TuBE
-DTUBE (FROM FUEL TANK)
COOLANT RESERVE TANK
DRAIN TUBE
EVAPORATIVE
EMISSION
CANISTER
OPEN
AIR TUBE
EVAPORATIVE EMISSION CANISTER
@TuBe EVAPORATIVE
EMISSION.
CANISTER,
1-32 GENERAL INFORMATION
_ TION
EMISSION CONTROL SYSTEMS
The U.S. Environmental Protection Agency and California Air Resources Board (CARB) require manufacturers to certify that
their motorcycles comply with applicable exhaust emissions standards during their useful life, when operated and
maintained according to the instructions provided, and that motorcycles built after January 1,1983 comply with applicable
noise emission standards for one year or 6,000 km (3,730 miles) after the time of sale to the ultimate purchaser, when
operated and maintained according to the instructions provided. Compliance with the terms of the Distributor’s Limited
Warranty for Honda Motorcycle Emission Control Systems is necessary in order to keep the emissions system warranty in
effect.
SOURCE OF EMISSIONS
The combustion process produces carbon monoxide and hydrocarbons control of hydrocarbons is very important because,
under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not
react in the same way, but itis toxic,
Honda Motor Co., Lid. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and
hydrocarbons,
EXHAUST EMISSION CONTROL SYSTEM.
‘The exhaust emission control system is composed of a lean carburetor setting, and no adjustments should be made except
Idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcase
‘emission control system,
CRANKCASE EMISSION CONTROL SYSTEM
The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere.
Blow-by gas is returned to the combustion chamber through the air cleaner and carburetor.
'97~"98:
CRANKCASE BREATHER AIR CLEANER HOUSING
SEPARATOR
=>: FRESH AIR
+ BLOW.BY GAS.
1-33 FORMATION
After '98:
SEPARATOR
(CARBURETOR
<=: FRESH AIR,
=: BLOW-BY GAS
EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE ONLY)
This model complies with California Air Resources Board evaporative emission requirements.
Fuel vapor from the fuel tank and carburetor(s) (‘97 —'98) are routed into the evaporative emission (EVAP) canister where itis
absorbed and stored while the engine is stopped. When the engine is running and the evaporative emission (EVAP) purge
control valve is open, fuel vapor in the EVAP canister is drawn into the engine through the carburetor. At the same time,
EVAP carburetor air vent (CAV) control valve is open and air is drawn into the carburetor through the valve.
'97—'98:
CARBURETORS EVAP PURGE CONTROL VALVE (
{Cd CO
7 rain
r E EVAP CANISTER
EVAP CAV
[2 CONTROL VALVE
Ly
to
a =
“+: FUEL VAPOR,
1-34 GENERAL INFORMATION
After ‘98:
eaeeiecron EVAP PURGE CONTROL VALVE
t T Ic
DRAIN
EVAP CANISTER
= AH
Fy
EVAP CAV CONTROL VALVE
i:
TOOPEN AIR 7
Ely
elvave
=) ses an ERGRE STORY
——> > FUEL vapor
NOISE EMISSION CONTROL SYSTEM
TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Federal law prohibits the following acts or the causing
thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or
replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to
its sale or delivery to the ultimate purchaser or while itis in use; (2) the use of the vehicle after such device or element of
design has been removed or rendered inoperative by any person.
‘AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:
1.Removal of, or puncturing ofthe muffler, baffles, hesder pipes or any other component which conduct exhaust gases.
2. Rremoval of, or puncturing of any part ofthe intako system.
3.Lack of proper maintenance.
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,
1-35 GENERAL INFORMATION
EMISSION CONTROL INFORMATION
LABELS
‘An Emission Control Information Label is located
(on the inside of the left side cover as shown.
‘The left side cover must be removed to read it
Rofer to page 2-3 for left side cover removal.
It gives base tune-up specifications.
VACUUM HOSE ROUTING
DIAGRAM LABEL
EMISSION CONTROL
INFORMATION \ oy
LABEL
'97-'98:
UPDATE
EMISSION CONTROL ABEL
INFORMATION LABEL
(Canada type only)
[Afer'se: VACUUM HOSE ROUTING
DIAGRAM LABEL (California type only)
EMISSION CONTROL
INFORMATION LABEL
(Canada type only)
EMISSION CONTROL
INFORMATION LABEL
UPDATE
LABEL
VEHICLE EMISSION CONTROL
INFORMATION UPDATE LABEL
After making a high altitude carburetor adjustment,
attach an update label on the inside of the left side
‘cover as shown.
‘The left side cover must be removed to read it.
Refer to page 2-3 for left side cover removal.
Instructions for obtaining the update label are
given in Service Letter No 132.
When readjusting the carburetor(s/'97—'98) back to |
the low altitude specifications, be sure to remove
this update label
TERIGLE EWISSION CONTROL WFORMATION UPDATE
WONDA HOTOR co..TD
Tis VENICLE HAS BEEN ADJUSTED TO
IMPROVE Eussion CONTROL PERFORMANCE
ALTITUDE PERFORMANCE ADJUSTUENT INSTRUCTIONS
ARE AVAILABLE AT YOUR AUTHORIZED HONDA DEALER
WHEW OPERATED AT HIGH ALTITUDE.
1-36 VACUUM HOSE ROUTING DIAGRAM.
LABEL (CALIFORNIA TYPE ONLY)
The Vacuum Hose Routing Diagram Label is on the
inside of the let side cover as shown,
The left side cover must be removed to read it.
Refer to page 2-3 for left side cover removal.
GENERAL INFORMATION
‘97 ~'98:
VACUUM HOSE ROUTING DIAGRAM
ENGINE FAWILY
EVAPORATIVE FAMILY
CALIFORNIA VEHICLE
EVEL TANK EUW
10 OPEN AiR
After '98;
VACUUM HOSE ROUTING DIAGRAM
negate Hue)
CALIFORNIA VERICLE
FUEL TANK EVAP CAV CONTROL VALVE
=e
FF cwaneron
Ss
aes
oe
EVAP CANISTER MEMO. 2. FRAME/BODY PANELS/EXHAUST SYSTEM
—eer eT TM [EAAV OT OYOTEM
‘SERVICE INFORMATION 2-1 SIDE COVER 23
TROUBLESHOOTING 2-1 FUELTANK 24
| SEAT(’97—'98) 2-2 REAR FENDER/REAR SUB-FRAME 28 |
SEAT (After ‘98) 2-2. EXHAUST PIPE/MUFFLER 214
STEERING COVER 23
SERVICE INFORMATION
GENERAL
* Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area. Smoking or
allowing flames or sparks in the work area or where the gasoline is stored can cause a fire or explosion,
+ Engine and exhaust system parts become very hot and remain hot for some time after the engine is run. Wear
insulated gloves or wait until the engine and exhaust system have cooled before handling these parts.
* When the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an
enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to
'20 open area or with an exhaust evacuation system in an enclosed area.
* Work in a wall ventilated area, Smoking or allowing flames or sparks in the working area or where gasoline is stored can
cause a fire or explosion,
Tris section covers removal and installation of the frame body panels, fuel tank and exhaust system,
‘Always replace the exhaust pipe gaskets when removing the exhaust pipe from the engine.
‘* Always inspect the exhaust system for leaks after installation,
TORQUE VALUES
Exhaust pipe joint nut 25 Nem (2.5 kgf-m, 18 lott)
Fuel tank mounting bolt 19 Nem (1.9 kgf. 14 lott)
Fuel valve aut '97~"9823N.m (2.3 kati, 17 lf)
After'98_ 35 N.m (3.6 kgf. , 28 lft)
Fusl valve lever scraw 4 Nem (0.4 kgf-m , 2.8 loft
Exhaust pipe cover bolt T2N.m (1.2 kgm, 9 lot
Exhaust muffler bracket bolt 20Nem 2.0 kgf-m, 14 lott)
nut 20.Nem (2.0 kgm, 14 lott)
Sub-frame mounting bolt T2Nem (1.2 kgf. 9 IFA)
nut 12 Nem (1.2 kgf. 9 IBF)
TROUBLESHOOTING
Excessive exhaust noise
Broken exhaust system
Exhaust gas leak
Poor performance
Deformed exhaust system
+ Exhaust gas leak
Clogged mutfier FRAME/BODY PANELS/EXHAUST SYSTEM
SEAT ('97—'98)
REMOVAL
Remove the two mounting socket bolts.
Slide and remove the seat to the back,
INSTALLATION
Install the seat by inserting the hook of the seat,
Under the raised lip of the frame cross member.
Install the hooks on the rear fender to the tabs of
the seat and push the seat forward. Align the bolt
holes and tighten the mounting socket bolts
securely.
CAUTION:
Be careful not to pinch the wire harness between
the seat and the fram
SEAT (AFTER ‘98)
REMOVAL
Remove the two mounting socket bolts.
Slide and remove the seat toward the back.
INSTALLATION
Install the seat by aligning the holes in the back of
the seat with the bosses on the rear fender.
Inserting the hook of the seat under the raised lip of,
the frame cross menber while pushing the seat
forward.
Tighten the socket bolts securely.
CAUTION:
Be careful not to pinch the wire harness between
the seat and the frame.
‘97—'98:
HOOK
SEAT
SOCKET BOLTS
HOOKS
After ‘98:
‘SOCKET BOLT SEAT
Bosses FRAME/BODY PANELS/EXHAUST SYSTEM
———
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