Home

VLX VT600 88-89 91-96 Service Manual

1. FREQUENCY ODOMETER READING NOTE1 1 000 0 6 4 8 12 16 20 24 REFER ITEM NOTE 100 10 64 128 192 256 FUEL LINE THROTTLE OPERATION CARBURETOR CHOKE a AIR CLEANER NOTE2 R R CRANKCASE BREATHER gx re e C A SPARK PLUG R E VALVE CLEARANCE ENGINE OIL R R R R T ENGINE OIL FILTER R R R CARBURETOR SYNCHRONIZATION CARBURETOR IDLE SPEED amp RADIATOR COOLANT NOTES R COOLING SYSTEM 3 12 EVAPORATIVE EMISSION DRIVE CHAIN EVERY 500mi 800km 3 13 BRAKE FLUID 3 15 BRAKE SHOES PADS WEAR 3 16 BRAKE SYSTEM lt BRAKE LIGHT SWITCH 3 17 HEADLIGHT AIM 3 18 gt CLUTCH SYSTEM 3 18 2 SIDE STAND 3 19 SUSPENSION 3 19 NUTS BOLTS FASTENERS 3 20 5 WHEELS TIRES In 2820 STEERING HEAD BEARING 3 21 SHOULD BE SERVICED BY YOUR AUTHORIZED HONDA DEALER UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE DATA AND IS MECHANICALLY QUALIFIED IN THE INTEREST OF SAFETY WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY YOUR AUTHORIZED HONDA DEALER NOT
2. 1 TUBE 1 TUBE 7 EVAPORATIVE EMISSION PURGE CONTROL VALVE 5 TUBE 2 9TUBE 7 EVAPORATIVE EMISSION PURGE CONTROL VALVE TO AIR CLEANER HOUSING 1 TURE 2 STUBE 15 ENGINE BREATHER TUBE 29 FROM REAR 4 TUBE CYLINDER HEAD 6 EVAPORATIVE EMISSION CARBURETOR 3 TUBE AIR VENT CONTROL VALVE 5 TUBE EVAPORATIVE EMISSION CARBURETOR AIR VENT 15 TO AIR CLEANER HOUSING CONTROL VALVE 14 COOLANT RESERVE TANK DRAIN TUBE 10 TO EVAPORATIVE EMISSION CANISTER 9 AIR CHAMBER DUCT ZL 12 EVAPORATIVE EMISSION 11 EVAPORATIVE EMISSION CANISTER AIR TUBE 13 REAR SHOCK ABSORBER TUBE 1 20 GENERAL INFORMATION 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 emis sion 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 System is necessary in order to keep the emissions system warranty in effect
3. a REGULATOR RECTIRA gt x i T j i 5 man id 18 9 ALTERNATOR 3 9 3 BA z 8 ao HI 9 eec a E lue 506 STAND SWITCH EA i d 5 8 STARTER STTH YN32 3CP RIGHT FRONT TURN LEFT FRONT TURN 12 32 3CP 8 3 3 39 gz sff 3 d P P pd 5 8 E 8 E 19 3 WIRING DIAGRAM After 93 0000 82 Z0 00 3389 nho ame 9 umts oD m NAONS m Ss gt IN HOJIAS MOIS NEAL HOJAS 831815 4015 3NIONA HOLIAS NYOH HOLIAS HAIRS MOLVNH3LTV 51102 NOILINDI TIVA 8 13 WOT vL 038 Save Man was 4 CL C045 HOUT ____ X 0 0 SO HOLIAS USWHIO NYOH TYNDIS Nen 831311238 801v 10938 wwa wOLYM3N3O 35104 NOUINDI ANTIO wet A f ya j a NNJN 194 1081409 NOMINSI HOUAS 1HOfl 3yyae GJ FJ AES RA i ge se gg 2 gps 9 x lt 5 gees 58 7 emn imam ar a a po NYAL 1331 T9 S gt 8 LE 9 0 1 KI Wo 9
4. COMES ODOMETER READING NOTE 1 FIRST 1 000 mi 0 6 4 8 12 16 20 24 REFERTO EVERY 100 10 64 128 192 256 320 384 PAGE FUEL LINE 3 6 THROTTLE OPERATION 3 6 CARBURETOR CHOKE 3 7 AIR CLEANER NOTE 2 R R 37 CRANKCASE BREATHER NOTE 3 3 8 2 SPARK PLUG 3 8 VALVE CLEARANCE 3 8 E ENGINE OIL R R R R 2 4 ENGINE OIL FILTER R R R R 2 5 ar t CARBURETOR RW SYNCHRONIZATION Mu MSN E 2 CARBURETOR IDLE SPEED 3 11 RADIATOR COOLANT 2 YEARS R R 3 11 COOLING SYSTEM 3 12 4 1 3 13 DRIVE CHAIN EVERY 600 mi 1 000 km I L 3 13 o BRAKE FLUID 2 YEARS R EL afer or R BRAKE SHOE PAD WEAR BRAKE SYSTEM gt BRAKE LIGHT SWITCH li HEADLIGHT AIM CLUTCH SYSTEM 3 18 2 SIDE STAND SUSPENSION 2 NUTS BOLTS FASTENERS 2 WHEELS TIRES arji STEERING HEAD BEARINGS 3 21 Should be serviced an authorized Honda dealer unless the owner has proper tools service data and is mechanically qualified In 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 i
5. 15 7 Clutch Gearshift Linkage 7 1 Diode ione nanni a E a r TE 17 7 Install tion ssn E 7 12 Removal aaa 7 4 STI 18 11 System iti e eter rr Haa tea 3 18 Control Cable Lubrication 2 12 Coolant Replacement 5 3 Temperature Indicator 18 8 Coolant Reserve Tank 5 9 Cooling System 3 12 5 1 11 13 Assembly 11 19 Breathe 2 3 8 Separation ev v us 11 4 Crankshaft Transmission 11 1 Crankshaft Connecting Rod 11 5 Cylinder Head Valve 9 1 Cylinder Piston eneinio aiaia andin aia 10 1 CY npa 10 2 Compression 2 2 2 3 12 e dai cete 9 8 Assembly 9 15 Cylinder Head Cover Installation 9 21 Removal ere eds ry e Tn 9 3 Cylinder Head Installation 9 16 Installation 10 6 Drive Chain 2 eripe RR 3 13 Electric Starter 17 1 Emission Control Information Labels
6. BRAKE SHOES PADS WEAR BRAKE SYSTEM BRAKE LIGHT SWITCH IHEADLIGHT AIM o SE 4 CLUTCH SYSTEM SIDE STAND SUSPENSION INUTS BOLTS FASTENERS WHEELS TIRES STEERING HEAD BEARING SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER UNLESS THE OWNER HAS PROPER TOOLS AND SER VICE DATA AND IS MECHANICALLY QUALIFIED IN 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 Service more frequently when riding in unusually wet or dusty areas Service more frequently when riding in rain or at full throttle California type only Replace every 2 years or at indicated odometer interval whichever comes first Replacement requires me chanical skill NON EMISSION RELATED ITEMS ah WN MAINTENANCE MAINTENANCE SCHEDULE After 93 Perform the PRE RIDE INSPECTION in the Owneranual at each scheduled maintenance period 5 AND CLENA ADJUST LUBRICATE OR REPLACE IF NECESSARY C CLEAN R REPLACE L LUBRICATE los The following items require mechanical knowledge Certain items particularly those marked may require more technical information and tools Consult their authorized Honda dealer
7. TROUBLESHOOTING No Lights Come On When Ignition Switch 15 Turned Bulb at fault or burned out Faulty switch Wiring to that component has open circuit Fuse blown Wiring loose broken or at fault Battery dead or disconnected All Lights Come On but Dimly when Ignition Switch Is Turned ON Battery voltage low Faulty bulb Headlight Beam Does Not Shift When HI LO Switch Is Op erated Beam filament burned out Faulty dimmer switch Wiring loose broken or at fault 18 2 HEADLIGHT REMOVAL INSTALLATION Remove the two screws and headlight Disconnect the headlight connector and remove the rubber protector Remove the headlight retainer clip and replace the headlight bulb CAUTION This motorcycle is equipped with a halogen headlight bulb Do not put finger prints on the headlight bulb they may create hot spots on the hulb f 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 Install the rubber protector with the top mark facing up Install the headlight in the reverse order of removal LIGHTS METER SWITCHES 1 SCREWS RAS 2 RUBBER PROTECTOR 1 RETAINER CLIP 2 HALOGEN BULB 2 RUBBER
8. be severely scalded Test the coolant mixture with an antifreeze tester For maximum corrosion protection 50 50 solution of ethylene glycol and distilled water is recommended RADIATOR CAP 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 relief pressure is too high or too low It must hold specified pressure for at least six seconds RADIATOR CAP RELIEF PRESSURE 88 127 kPa 0 9 1 3 kg cm 13 18 psi 1 RADIATOR CAP SYSTEM PRESSURE TEST Remove the steering covers and radiator cap Attach the tester to the radiator and apply enough pressure to test the radiator engine and hoses Check for leaks CAUTION Excessive pressure can damage the radiator Do not exceed 125 kPa 1 25 kg cm 18 psi Repair or replace components if the system will not hold speci fied pressure for at least six seconds 5 2 COOLING SYSTEM COOLANT REPLACEMENT i 2 REAR CYLINDER m DRAIN BOLT The engine must be cool before replacing the coolant or severe scalding may result Remove the radiator cap page 5 2 Drain the coolant from the system by removing the drain bolt on the water pump cover Remove the rear cylinder coolant drain bolt and drain the collant using a vinyl as shown Reinstall the drain bolt 1 DRAIN BOLT 3 VINYL Fill the system with 50
9. 3 AIR CLEANER HOUSING 5 HOUSING COVER FUEL SYSTEM CARBURETOR REMOVAL Sis 1 AIR CLEANER CHAMBER 2 THROTTE CABLES 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 Loosen the drain screws and drain the fuel into a container Remove the sub air cleaner chamber page 4 4 Remove the throttle cable cover and disconnect the throttle cables from the carburetor Remove the left choke valve from the carburetor and loosen 1 INSULATOR BANDS the carburetor insulator bands Disconnect the evaporative emission purge control valve No 5 tubes and evaporative emission carburetor air vent control valve No 6 and 10 tubes from the carburetor California model only Pull the carburetors the upward and out of the engine 2 CHOKE VALVE CARBURETOR DISASSEMBLY ag T CHOKE NOTE 7 The carburetors can be disassembled without being sepa rated Remove the air tubes carburetors to sub air cleaner and fuel tube from the carburetor Remove the choke cable and right choke valve from the carbu retor by loosening each lock nut VACUUM CHAMBER Remove the four screws and vacuum chamber cover FUEL SYSTEM Remove the spring and diaphragm vacumm piston Inspect the vacuum piston for wear nic
10. 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 2 WIRE CONNECTOR Remove the nut to separate the fan from the shroud 1 NUT Remove the fan motor mounting nuts and fan motor from the shroud 2 SHROUD COOLING SYSTEM ASSEMBLY 1 ALIGN Inspect the radiator soldered joints and seams for leaks Blow dirt out from between core fins with compressed air If insects etc are clogging the radiator wash them off with low pressure water Carefully straighten any bent fins Install the motor on the shroud and tighten the nuts Install the fan to the fan motor shaft aligning the boss of the shaft with the groove of the fan Assemble the remained components in the reverse order of the disassembly If removed the thermostatic switch from the radiator refer to page 18 8 NOTE Do not overtighten the thermostatic switch when reinstall it TORQUE 18 Nem 1 8 kg m 13 ft lb WATER PUMP MECHANICAL SEAL INSPECTION NOTE The water pump cover and O ring be removed with engine in the frame Inspect the telltale hole for signs of mechanical seal coolant leakage Replace the water pump as an assembly if the mechanical seal is leaking REMOVAL Remove the engine
11. BRAKE SHOE PAD WEAR BRAKE PAD WEAR 88 89 91 93 Check the brake pads for wear by looking through the slot indi cated by the arrow cast on the caliper assembly Replace the brake pads if the wear grooves in the pads are visi ble page 14 5 CAUTION Always replace the brake pads as a set to assure even disc pres sure After 93 Inspect the pads visually from under the caliper to determine the pad wear Replace the brake pads if the wear grooves in the pads are visi ble page 14 5 CAUTION Always replace the brake pads as a set to assure even disc pres sure BRAKE SHOE INSPECTION Replace the brake shoes if the arrow on the brake arm aligns with the reference mark A on full application of the rear brake pedal BRAKE SYSTEM Inspect the brake hoses and fittings for deterioration cracks and signs of leakage Tighten any loose fittings Replace hoses and fittings as required BRAKE PEDAL HEIGHT Adjust the brake pedal so that the pedal height is 43 mm 1 7 in above the top of the footpeg 143 mm 1 7 in 3 16 MAINTENANCE To Adjust Loosen the stopper bolt lock nut and turn the stopper bolt Retighten the lock nut NOTE After adjusting the brake pedal height check the rear brake light switch and brake pedal free play and adjust if neces sary BRAKE PEDAL FREE PLAY NOTE Perform brake pedal free play adjustment aft
12. BTDC at 1 mm lift Closes 30 ABDC Exhaust valve Opens 30 BBDC ENGINE Closes 10 ATDC Valve clearance cold intake 0 15 0 02mm 0 006 0 0008 in exhaust 0 20 0 02 0 008 0 0008 Engine dry weight 88 89 91 93 61kg 134 Ib After 93 62kg 136 7 Ib After 94 standard type 61kg 134 Ib After 94 Deluxe type 64kg 141 Ib CARBURETOR Type Piston valve dual carburetor D number See page 4 1 Main jet FRONT 115 REAR 115 Pilot screw opening See page 4 15 Float level 7 0 mm 0 28 in Idle speed 1 200 100 rpm DRIVE TRAIN Clutch Wet multi plate Transmission 4 speed constant mesh Primary reduction 1 888 68 36 Final reduction 2 750 44 16 Gear ratio 2 571 36 14 Gear ratio 1 700 34 20 Gear ratio 1 227 27 22 Gear ratio V 0 931 27 29 Gear shift pattern Left foot operated return system 1 N 2 3 4 ELECTRICAL Ignition Battery ignition Full transistor Ignition timing Initial Full advance 88 89 91 93 After 93 6 27 BTDC at idle 6 5 BTDC at idle 30 BTDC at 6 000 rpm Alternator 345W 5 000 rpm Battery capacity 12V 8AH Spark plug NGK NIPPONDENSO Standard DPR8EA 9 X24EPR U9 502 DPR7EA 9 X22EPR U9 e ee od DPR9EA 9 X27EPR U9 riding Spark plug gap Fuse Starting system Headlight Turn signal light Brake amp taillight Meter light Indicator light Licence light Firing order Main Sub Front Rear Neutral High
13. ENGINE SPEED DOES NOT INCREASE INCORRECT INCORRECT TOO LOW CLOGGED FOULED OR DISCOLORED INCORRECT m POSSIBLE CAUSE Brake dragging Worn or damaged wheel bearings Wheel bearing needs lubrication Drive chain too tight Axle nut excessively tight Punctured tire Faulty tire valve Faulty clutch lifter system Worn clutch disc plate Warped clutch disc plate Weak clutch spring Carburetor choke closed Clogged air cleaner Restricted fuel flow Clogged muffler Clogged fuel cap vent hole Faulty fuel pump Faulty fuel pump relay Loose broken or shorted wire or connection of pump relay Faulty ignition control module Faulty ignition pulse generator Improper valve adjustment Worn valve seat Valve stuck open Worn cylinder and piston rings Leaking head gasket Improper valve timing Seized valve Improper valve and seat contact Carburetor not serviced frequently enough Plugs not serviced frequently enough Wrong heat range Oil level too high Oil level too low Contaminated oil 20 2 TROUBLESHOOTING 11 Remove cylinder head cover and inspect lubrication VALVE TRAIN LUBRICATED PROPERLY 12 Check for engine overheating NOT OVERHEATING Y 13 Accelerate
14. SOURCE OF EMISSIONS The combustion process produces carbon monoxide and hydrocarbons Control of hydrocarbons is very important because under certain conditions they react to form photochemical smog when subjected to sunlight Carbon monoxide does not react in the same way but it is toxic Honda Motor Co Ltd utilizes lean carburetor settings as well as other systems to reduce carbon monoxide and hydro carbons EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of 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 which routes crankcase emissions through the air cleaner into the combustion chamber 1 CRANKCASE BREATHER 2 AIR CLEANER HOUSING SEPARATOR FRESH AIR BLOW BY GAS 1 21 GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM California model only This model complies with California Air Resources Board evaporative emission requirements Fuel vapor from the fuel tank and carburetor is directed into the evaporative emission canister where it is adsorbed and stored while the engine is stopped When the engine is running and the evaporative emission purge control diaphragm valve is open fuel vapor in the evaporative emissi
15. 2 DRUM STOPPER gearshift spindle mn drum stopper arm bolt stopper arm collar and spring drum stopper plate bolt and stopper plate drum INSPECTION Check the gearshift spindle for bending or damage Check the return spring for fatigue or damage Na RETURN SPRING Inspect the gearshift pedal shaft for damage or loose lock 1 GEARSHIFT PEDAL SHAFT nuts Replace the shaft if necessary Lal ee ZZ Inspect 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 11 DUST SEALS 7 9 CLUTCH GEARSHIFT LINKAGE INSTALLATION Install the collar spring stopper arm washer and stopper arm bolt and tighten the bolt Install the dowel pins into the holes of the gearshift drum Lift up the drum stopper arm and install the drum stopper plate Apply locking agent to the threads of the stopper plate bolt VT p and tighten the bolt 3 T ax 4 HOLEy4 3 STOPPER PLATE BOLT TORQUE 12 N m 1 2 kg m 9 ft lb Install the gearshift spindle aligning the return spring ends 1 GEARSHIFT SPINDLE ae with the pin in the case 2 j o d Mua Install the oil pipe with a new O ring onto the oil pipe stay and oil pump Tighten the bolts securely Install the removed parts in the reverse order of removal Install the gearshift arm to the gearshift spin
16. 4 SIDE PAS STAND 5 ON Lg Light green SWITCH MODULE DOWN 12 STARTER RELAY UP SWITCH G 3 TO METER 8 CLUTCH SWITCH 13 STARTER 6 NEUTRAL MOTOR SWITCH o G 11 IGNITION 10 SUB FUSE 9 STARTER SWITCH 10A SWITCH Y R 17 0 17 ELECTRIC STARTER SERVICE INFORMATION TROUBLESHOOTING STARTER MOTOR SERVICE INFORMATION GENERAL 17 1 STARTER RELAY SWITCH 17 6 17 1 CLUTCH DIODE 17 7 17 3 The starter motor and ignition pulse generator be removed with the engine in the frame To inspect the ignition pulse generator refer to Section 16 Refer to section 8 for starter clutch removal and installation SPECIFICATION ITEM STANDARD Unit mm in SERVICE LIMIT Starter motor brush length TROUBLESHOOTING NOTE 12 5 0 49 6 5 0 26 The starter motor should turn when the transmission is in neutral and the clutch disengaged Check for the following before troubleshooting the system Blown main 30A or sub 10A fuse Loose battery and starter motor cables Discharged battery Starter motor does not turn tion You should hear the relay CLICK when the starter switch button is de pressed page 17 6 1 1 Check the starter relay switch for opera CLICK NOT HEARD CLICK HEARD _ 1 2 Apply battery voltage to the starter motor directly and check the operat
17. TK 1 324397 P LE 0 Li 9 LE EES EH L LHI I1 3 LI EE 8 gt L 11 ILI D SEH L LI T 1 Ni ANY 3HVUG IRA WNOIS AHO T YOLOW NVA 1 prr e Bik wm 30010 HOLIAS 4015 3NI N3 H31HY1S HOLAS IHJ JAVY 1NOH3 c 5 a a T HOLIMS ONYLS 3015 HOLIMS NOLLINSI HOLIAS 38055384 10 r3 WEL SN in dW3l HILHS OWUSHL WNOIS NYNA LNOHA 1331 MO EZATL AHOMOV3H MCRL wert D MOLVOION AYIB W01V2IONI ALNIN 2 2 MO1VOIQNt TWADIS NENI 38055384 10 MOLV2IONI AWAL MOLYSIONI ONYLS 3015 u313W WNOIS NANI 18043 1 9 5 2 19 4 20 TROUBLESHOOTING ENGINE DOES NOT START 1 HARD TO START ENGINE LACKS POWER POOR PERFORMANCE AT LOW AND IDLE SPEEDS 20 1 SPEED 20 2 POOR HANDLING 20 3 ENGINE DOES NOT START OR IS HARD TO START Check fuel flow to carburetor REACHING CARBURETOR Perform spark test SPARK Test cylinder compression COMPRESSION NORMAL Start by following normal procedure ENGINE DOES NOT FIRE Start with choke applied NOT REACHING CARBURETOR WEAK OR NO SPARK WET PLUG LOW COMPR
18. VTO6OOC CD Shadow VLX IMPORTANT SAFETY NOTICE Indicates a strong possibility of severe personal injury or death if instructions are not followed CAUTION Indicates a possibility of egiupment 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 ways in which service whether or not recommended by Honda might be done or of the possibly hazardous consequences of each conceivable way nor could Honda investigate all such ways Anyone using service procedures or tools whether or not recommended by Honda must satisfy himself thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected HOW TO USE THIS MANUAL Follow the Maintenance Schedule Section 3 recommendations 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 Califor nia Air Resources Board Performing the first scheduled maintenance is very important It compensates for the initial wear that occurs
19. occae ves vere Evers T eve 3 19 Swingaltri z 13 14 System Testing 5 2 Thermostat ke iecur Fokus vases eu one 5 3 Thermostatic Switch cene 18 8 Throttle Operation 3 6 M 1 8 Torque Values a 1 5 gt 52 52 eene ooo Cen 11 11 Assembly Installation 11 17 Troubleshooting Battery Charging System 15 3 Clutch Gearshift Linkage 7 2 Cooling System 5 1 Crankshaft Transmission 11 3 Cylinder Head Valve 9 2 Cylinder Piston eR 10 1 Electric Starter eee 17 1 Front Wheel Suspension Steering 12 3 Fuel System id 4 3 Hydraulic Disc Brake 14 2 Ignition System 16 2 Lights Meter Switches 18 2 ec eter 2 2 Rear Wheel Brake Suspension 13 2 Turn Signal Relay 18 12 Valve Clearance gindire esos rE d edere e E TR Vo seks 3 8 Guide Replacement 9 11 Seat Inspection Refacing 9 12
20. 18 05 mm 0 711 Measure each piston pin O D SERVICE LIMIT 17 98 mm 0 708 in Calculate the piston pin to piston clearance SERVICE LIMIT 0 40 mm 0 0016 in 10 4 Measure the 1 0 of the connecting rod small end SERVICE LIMIT 18 07 mm 0 711 in Calculate the piston pin to connecting rod clearance SERVICE LIMIT 0 060 mm 0 0024 in Refer to section 11 for connecting rod replacement PISTON RING INSTALLATION NOTE nsert the outside surface of the ring into the proper ring groove and roll around in the groove to make sure that the ring has a free fit around the piston s circumference Carefully install the piston rings onto the piston with the mark ings facing up NOTE Becareful not to damage the piston and piston rings during assembly Stagger the ring end gaps 120 apart from each other as shown NOTE To install the oil ring install the spacer first then install the side rails After installing the rings check that they rotate freely without sticking PISTON INSTALLATION Place a shop towel into the crankcase 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 Install the pistons with the mark facing towards the intake side After installing the piston pin clips make sure that they are seated properly and the end gaps are not aligned wit
21. Flange bolt Oil filter 1 20 10 1 0 7 2 Drive sprocket bolt 2 6 10 1 0 7 2 Timing hole cap 1 22 3 5 0 35 2 5 Apply grease to the threads Crankshaft hole cap 1 30 15 1 5 11 Apply grease to the threads Cylinder stud bolt 88 89 91 95 8 10 30 50 3 0 5 0 22 36 2 8 20 30 2 0 3 0 14 22 Drum stopper plate bolt 1 12 1 2 9 Apply locking agent Stator bolt 4 6 12 1 2 9 Apply locking agent Stator wire clamp bolt 2 6 12 1 2 9 Apply locking agent Right crankcase cover bolt 13 6 12 1 2 9 Left crankcase cover bolt 10 6 12 1 2 9 1 5 GENERAL INFORMATION FRAME ITEM Q ty Steering stem nut Steering bearing adjustment nut Fork top pinch bolt Fork bottom pinch bolt Front axle Front axle pinch bolt Rear axle nut Brake torque rod nut 88 89 91 93 After 94 94 Middle brake arm Middle rod joint nut After 94 Caliper mounting bolt 88 89 91 93 After 93 Brake hose oil bolt 88 89 91 93 After 93 Bleed valve Brake master cylinder holder bolt Brake master cylinder cover screw Brake lever pivot bolt nut Brake disc mounting bolt Caliper pin bolt Caliper bracket pin bolt Pad pin Pad pin plug Shock absorber upper mounting bolt Shock absorber lower mounting bolt Gearshift arm bolt Foot peg bracket bolt Swingarm pivot bolt Front upper engine mounting bolt Front upper engine bracket bolt Front lower engine mounting bolt Rear upper engine mounting bolt Rear upper engine bracket bolt
22. LUBRICATION ENGINE OIL LEVEL Support the motorcycle in an upright and level position using a hoist or a jack under the engine Start the engine and let it idle for a few minutes Stop the engine remove the oil filler cap dipstick and wipe it clean Check the oil level with the oil filler cap dipstick by inserting it without screwing it in NOTE Do not screw the in when making this check If the oil level is below the lower level mark on the dipstick fill to the upper level mark with the recommended oil Check the O ring for damage ENGINE OIL CHANGE NOTE Change the engine oil with the engine warm and the motor cycle on its side stand to assure complete and rapid drain ing Remove the oil filler cap dipstick and drain bolt With the engine stop switch OFF push the starter button for a few seconds to drain any oil which may be left in the engine 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 install the bolt TORQUE 35 N m 3 5 kg m 25 ft Ib Fill the crankcase with the correct quantity of the recommend ed oil OIL CAPACITY 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 qt after draining RECOMMENDED OIL Honda GN4 4 stroke oil or equivalent API service classifica
23. Loose connecotor STANDARD Loose 3P connector ABNORMAL Faulty stator coil Faulty regulator rectifier Faulty battery 15 3 BATTERY CHARGING SYSTEM BATTERY REMOVAL CAUTION Do not remove the battery while exhaust pipe is hot Remove the right side cover Unhook the fuse box from the battery case cover Remove the battery case cover by removing the bolts Remove the left side cover Disconnect the battery negative terminal lead from the battery first then disconnect the positive terminal lead Pull the battery out of the battery case INSTALLATION Place the battery into the case and connect the battery posi tive cable to the battery first from the right side then connect the negative cable from the left side Coat the battery terminal with clean grease Install the battery case cover by hooking the tab on the cover to the hook on the case Install and tighten the cover mounting bolts Install the fuse box onto the battery case cover Install the rubber covers in the sequence as shown Install the right and left side covers Route the battery cables as shown on the battery caution label 1 7 i UA 2 POSITIVE TERMINAL CAUTION WIRING AS SHOWN BELOW 1 BATTERY CASE NEGATIVE TERMINAL 15 4 BATTERY CHARGING SYSTEM VOLTAGE INSPECTION Remove the right and left
24. STOP RING 12 14 FRONT WHEEL SUSPENSION STEERING In 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 lock piece from the fork slider Remove the piston and rebound spring from the fork tube 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 12 15 INSPECTION Fork spring Measure the fork spring free length SERVICE LIMIT 88 89 91 93 299 mm 11 8 in After 93 333 9 mm 13 1 in Replace the spring if itis shorter than the service limit Fork tube slider piston 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 _ 1 OIL SEAL 2 SLIDER BUSHING 4 BACK UP RING 3 TUBE BUSHING 1 FORK SPRING E Hi d x i 7 i i H i 2 FORK TUBE 1 FORK SLIDER 5 REBOUND SPRING 4 PISTON 3 OIL LOCK PIECE 12 15 FRONT WHEEL SUSPENSION STEERING Set the fork tube in V blocks and read the runout Actual runout is 1 2 the total indicator reading SERVICE LIMIT 0 20 mm 0 008 in Bushings Visually inspect the slider and fo
25. Set a dial indicator on the main journals Rotate the crankshaft two revolutions and read the runout Actual runont is 1 2 the total indicator reading SERVICE LIMIT 0 05 mm 0 002 in NOTE The crankshaft connot be repaired Replace it if the journals or crankpins are burnt cracked or if the runout is beyond limits CONNECTING ROD BEARING INSPECTION Inspect the bearing inserts for damage or separation Clean all oil from the bearing inserts and crankpins 2 SEPARATION 1 DAMAGE 1 PLASTIGAUGE a OIL CLEARANCE INSPECTION 1 d Put piece of plastigauge on each crankpin avoiding the hole Install the bearing caps and rods on the correct crankpins and tighten them evenly TORQUE 34 N m 3 4 kg m 25 ft lb NOTE Do not rotate the crankshaft during inspection 11 6 CRANKSHAFT TRANSMISSION Remove the caps and measure the compressed plastigauge at its widest point on each crankpin to determine the oil clear ance SERVICE LIMIT 0 07 mm 0 003 in If the rod bearing clearance is beyond tolerance select re placement bearings CONNECTING ROD BEARING SELECTION Determine the connecting 1 0 code number The code will be either a number 1 or 2 located on the rod in the area shown Determine the corresponding crankpin O D code or measure the crankpin O D The code will be either a letter A or B on the cra
26. TROUBLESHOOTING 15 5 REGULATOR RECTIFIER BATTERY 15 4 ALTERNATOR SERVICE INFORMATION GENERAL AWARNING The battery generates hydorogen gas which 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 an enclosed 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 Black Gr Gray O 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 non maintenance free battery as a replacement All charging system components be checked on the motorcycle When inspecting 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 SPECIFICATIONS ITEM STANDARD Battery Capacity 12 V 8 AH Voltage at 20 C 6
27. VIN is attached on the left side of the steering head 2 The frame serial number is stamped on the right side of the The engine serial number is stamped on the right crank steering head case below the rear cylinder 5 COLOR LABEL 4 CARBURETOR IDENTIFICATION NUMBER The carburetor identification numbers are on the carbure The color label is attached on the frame under the seat tor body intake side When ordering a color coded part always specify its desig nated color code 1 2 SPECIFICATIONS GENERAL INFORMATION ITEM SPECIFICATIONS DIMENSIONS Overall length 2 310mm 90 9 in Overall width 88 89 791 794 760mm 29 9 After 94 890mm 35 0 in Overall height 1 125 44 3 in Wheelbase 1 605mm 63 2 in Seat height 690mm 27 2 in Footpeg height 285mm 11 2 in Ground clearance 140mm 5 5 in Dry weight 88 89 91 93 196kg 432 Ib 94 199kg 439 Ib After 94 Standard type 199kg 439 Ib After 94 Delux type 202kg 445 Ib Curb weight 88 89 91 93 207kg 456 Ib 94 213kg 470 Ib After 94 Standard type 213kg 470 Ib After 94 Deluxe type 216kg 476 Ib After 94 Standard California type 214kg 472 Ib After 94 Deluxe California type 217kg 478 Ib FRAME Type Double cradle Front suspension travel Telescopic fork 146 5mm 5 77 in Rear suspension travel Swingarm 90mm 3 5 in Front tire size 100 90 19 57S Rear tire size 170 80 15 M C
28. o lt 7 ELECTRICAL LIGHTS METER SWITCHES 15 21 Date of Issue June 1994 HONDA MOTOR LTD 1 GENERAL INFORMATION GENERAL SAFETY 1 1 SERVICE RULES 1 1 MODEL IDENTIFICATION 1 2 SPECIFICATIONS 1 3 TORQUE VALUES 1 5 GENERAL SAFETY AWARNING 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 posisonous carbon monoxide gas that may cause loss of consciousness and lead to death AWARNING The battery generates hydrogen gas which can be highly explo sive Do not smoke or allow flames or sparks near the battery especially while charging it A WARNING Inhaled asbestos fibers have been found to cause respirator y 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 SERVICE RULES TOOLS 1 8 CABLE amp HARNESS ROUTING 1 10 EMISSION CONTROL SYSTEMS 1 21 EMISSION CONTROL INFORMATION LABELS 1 22 WARNING 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 A WARNING The battery electrolyte contains sulfuric acid Prot
29. page 3 13 Tighten the axle nut TORQUE 90 N m 9 0 kg m 65 ft lb Connect the brake torque rod to the brake panel with bolt seat washer washer and nut page 13 8 Tighten the nut TORQUE 27 N m 2 7 kg m 20 ft lb Install the cotter pin and bend back it securely Connect the brake rod to the brake arm and adjust the rear brake pedal free play page 3 16 REAR BRAKE INSPECTION R th heel 13 3 emove the rear wheel page 1 BRAKE Remove the brake panel and measure the rear brake drum 1 0 AWNINGS SERVICE LIMIT 161 mm 6 3 in Measure the rear brake lining thickness SERVICE LIMIT 2 mm 0 08 in Replace the brake shoes if either one is thinner than the service limit 13 7 REAR WHEEL BRAKE SUSPENSION DISASSEMBLY Remove the cotter pins and set plate 2 COTTER PINS Remove the brake shoes and springs from the brake panel NOTE Mark the shoes to indicate their original positions before re moving them Remove the following parts form the brake panel bolt and brake arm indicator plate brake cam felt seal ASSEMBLY 1 BOLT 2 INDICATOR PLATE 3 FELT SEAL 4 BRAKE SHOES 5 BRAKE CAM 10 BRAKE ARM 9 BRAKE 8 SPRINGS PANEL 0 6 5 0 7 SET PLATE 13 8 REAR WHEEL BRAKE SUSPENSION 2 ANCHOR Apply grease to the brake anchor pins and brake cam Install 1 BRAKE CAM c the
30. then check that the timing marks on the cam sprocket align with the top of the cylinder head 9 19 CYLINDER HEAD VALVE 88 89 Install the dowel pins into the cylinder head Install the holders oil plate 8 mm boits 8 mm nut and 6 mm bolts After 89 Install the dowel pins into the cylinder head Install the holders oil pipe 8 mm bolts 8 mm nuts and 6 mm bolts TORQUE 8 mm bolt 23 N m 2 3 kg m 17 ft lb 8 mm nut 23 N m 2 3 kg m 17 ft lb 6 mm bolt 10 1 0 kg m 7 2 ft lb CAUTION Note the direction of the camshaft end holder install the flat surface on the holder facing in After installing the front cylinder camshaft turn the crank shaft counterclockwise approximately 7 8 turn 308 and align the RT mark with the index on the timing hole then install the rear cylinder camshaft Lubricate the cam lobes with fresh engine oil If the cylinder head was removed from the engine in the frame install the following radiator with upper radiator hose exhaust pipe REAR CYLINDER NOTE e f 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 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 counterclockwise approxi
31. 16 6 connector page 16 4 NORMAL Open or short circuit Faulty pulse gener in wire harness ator Loose connectors No spark at either spark group Front or Rear CHECK WRONG SPARK GROUP 1 Check the ignition secondary coil resistance ABNORMAL Faulty ignition coil page 16 4 Faulty spark plug wire NORMAL 2 1 Check the ignition primary coil resistance at ABNORMAL the ignition control module 6P connector 2 2 Check the ignition coil page 16 4 page 16 4 NORMAL ABNORMAL Loose connectors Faulty ignition coil NORMAL Open or short circuit Open circuit in wire in wire harness harness 3 1 Check the ignition pulse generator resist ABNORMAL He piss the ignition pulse generator page ances at the ignition control module 4P con e nector page 16 4 NORMAL ABNORMAL Open or short circuit Faulty ignition pulse in wire harness generator Loose connectors NORMAL 4 Exchange the ignition coil and try the spark GOOD JUMP test gt Faulty ignition coil 16 3 IGNITION SYSTEM IGNITION CONTROL MODULE INSPECTION Remove the left side cover and connector plate NOTE Check the system components and lines step by step ac cording to the troubleshooting chart on page 16 3 Disconnect the ignition control module connectors and check them for loose or corroded terminals Measure th
32. 50 mixture of distilled water and eth ylene glycol Bleed air from the cooling system Lowerthe side stand and shift the transmission into neutral Start the engine and snap the throttle grip 3 4 times at 4 000 5 000 rpm Then add coolant up to the radiator filler neck Reinstall the radiator cap Check the level of coolant in the reserve tank and fill to the correct level if the level is low THERMOSTAT 2 REMOVAL Remove the following fuel tank page 4 3 air cleaner housing page 4 4 steering covers page 5 2 radiator cap Drain the coolant Remove the thermostat housing and radiator filler mounting bolts Disconnect the siphon tube from the radiator filler Disconnect the upper radiator hose at the radiator and remove filler and the radiator hose from the frame Remove the thermostat housing cover 1 HOUSING COVER COOLING SYSTEM Remove the thermostat from the housing INSPECTION Inspect the thermostat visually for damage Suspend the thermostat in heated water to check its opera tion NOTE f the thermostat or thermometer touches the pan you ll get a false reading Replace thermostat if valve stays open at room temperature or if it responds at temperatures other than those specified Data 80 to 84 C 176 183 F Valve lift 8 mm 0 3 in minimum when heated to 95 C 203 F for five minutes INSTALLATION Install
33. 77S Cold tire Up to maximum Front 200 kPa 2 00 kg cm 29 psi pressure vehicle capacity Rear 250 kPa 2 50 kg cm 36 psi Up to 90 kg Front 200 2 00 kg cm 29 psi 200 Ibs load Rear 200 kPa 2 00 kg cm 29 psi Front brake Hydraulic single disc Swept area 88 89 91 93 448cm 69 4 sq After 93 482 3cm 74 8 sq Rear brake Mechanical leading amp trailing Swept area 201cm 31 2 sq in Fuel capacity 88 89 91 93 9 0 liters 2 4 US gal 2 0 Imp gal After 93 11 0 liters 2 9 US gal 2 4 Imp gal Fuel reserve capacity 88 89 91 93 1 9 liters O 5 US gal O 42 Imp gal After 93 3 4 liters O 9 US gal O 74 Imp gal Caster angle 35 Trail 164mm 6 5 Fork leg oil capacity 88 89 463cc 15 7 US 13 0 Imp oz 91 93 468cc 15 8 US oz 13 2 Imp oz After 93 449cc 16 9 US 2 15 8 Imp oz ENGINE Type Water cooled 4 stroke SOHC Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Oil capacity Lubrication system Air filtration Cylinder compression 52 V2 cylinders 75 0x66 0mm 2 95x2 60 583 35 5 cu in 9 2 1 Silent multi link chain drive and OHC with rocker arms 2 8 lit 2 94 US qt 2 46 Imp qt after disassembly 2 1 lit 2 21 US qt 1 85 Imp qt after draining Forced pressure and wet sump Paper filter 1 324 kPa 13 5kg cm 192 psi GENERAL INFORMATION ITEM SPECIFICATIONS Intake valve Opens 10
34. COOLANT Check the coolant level of the reserve tank with the engine running at normal operating temperature The level should be between the and level lines 2 LOWER LEVEL If necessary remove the right side cover and then remove the 1 RESERVE TANK CAP reserve tank cap DUE Fill to the upper level line with 50 50 mixture of distilled E water and antifreeze Reinstall the reserve tank cap and right sider cover MAINTENANCE COOLING SYSTEM Remove the radiator shroud and check the radiator air pas sages for clogging or damage 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 Make sure the hoses are in good condition Replace any hose that shows any sign of deterioration Check that all hose clamps are tight CYLINDER COMPRESSION Warm up the engine Stop the engine and remove the spark plug Connect a compression gauge Turn the engine stop switch OFF Open the throttle grip fully Crank the engine with the starter motor until the gauge stops rising Check the gauge reading NOTE Check that there is no leakage at the gauge connection The maximum reading is usually reached within 4 7
35. Exhaust pipe joint nut Fuel tank mounting bolt Ignition switch mounting bolt Exhaust pipe cover bolt Exhaust muffler bracket bolt nut 88 89 91 93 After 93 Helmet holder mounting bolt Side stand pivot bolt nut Driven sprocket nut Fork tube cap Front socket bolt Damper rod lock nut Spokes Handlebar mounting nut Handlebar upper holder bolt After 94 Handlebar lower holder nut After 94 Fuel valve body Throttle link cover stay screw Rear ignition coil stay bolt Battery cover mounting bolt Fuel pump stay mounting nut 88 89 91 92 MC NOHNNO HNHFA gt PNNN _N Thread dia mm 24 26 7 10 18 Torque N m Kg m ft Ib 105 10 5 76 25 2 5 18 11 1 1 8 50 5 0 36 75 7 5 54 22 2 2 16 90 9 0 65 27 2 7 20 22 2 2 16 27 2 7 20 27 2 7 20 9 0 9 6 5 27 2 7 20 31 3 1 22 30 3 0 22 35 3 5 25 5 5 0 55 4 12 1 2 9 1 5 0 15 1 1 1 0 1 0 7 6 0 6 43 40 4 0 29 22 2 2 16 12 1 2 9 18 1 8 13 2 5 0 25 1 8 45 4 5 33 45 4 5 33 12 1 2 9 40 4 0 29 90 9 0 65 55 5 5 40 27 2 7 20 55 5 5 40 55 5 5 40 27 2 7 20 25 2 5 18 19 1 9 13 7 11 1 1 8 12 1 2 9 27 2 7 20 20 2 0 14 13 1 3 9 10 1 0 7 2 30 3 0 22 65 6 5 47 22 2 2 16 30 3 0 22 70 7 0 51 4 0 4 2 9 25 2 5 18 30 3 0 22 23 2 3 16 23 2 3 16 2 1 0 21 1 5 9 0 9 6 5 9 0 9 6 5 9
36. Measure the shock absorber spring free length SERVICE LIMIT 135 0 mm 5 31 in Mark the damper rod at 10 mm below the case as shown Place the damper rod on a scale and measure the force re quired to compress the damper to the 10 mm 0 4 in mark COMPRESSION FORCE 13 4 17 4 kg 29 54 38 36 Ib If the force required is less than 13 3 kg 29 32 Ib gas is leak ing Examine the damper rod and replace the damper unit if it is bent or scored 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 SHOCK ABSORBER DISPOSAL PROCEDURE Center punch the damper case to mark a drilling point approxi mately 45 mm 1 8 in from the mount top surface Wrap the damper unit inside a plastic bag and support the damper unit upright in a vise as shown 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 WARNING Donotuse a dull drill bit which could cause a build up of exces sive heat and pressure inside the damper leading to explosion and severe personal injury The shock absorber contains nitrogen gas and oil under high pressure Do not drill any 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
37. PETAK 3 REAR IGNITION COIL 11 FUEL PUMP re ET FAM EA A LA 9 COOLANT RESERVE 25 REAR SUSPENSION TANK OVERFLOW TUBE DRAIN TUBE 8 REAR BRAKE LIGHT SWITCH 10 BRAKE TAILLIGHT 23 SIDE STAND 1 TURN SIGNAL RELAY FUEL PUMP REAR RIGHT 2P GREEN CONNECTOR TURN SIGNAL CONNECTORS 11 FUEL 24 IGNITION SWITCH Uu P BLACK CONNECTOR S 6 SS i 2 12 FUEL CUT RELAY p 13 REAR LEFT MF TURN SIGNAL N LICENCE LIGHT CONNECTORS 14 IGNITION COTROL MODULE 22 NEUTRAL SWITCH 15 REGULATOR RECTIFIER 6 BLACK CONNECTOR Zu e 16 NEUTRAL SWITCH 2P BLACK CONNECTOR a jane be 17 REGULATOR RECTIFIER 1 ae Y 18 ALTERNATOR WHITE CONNECTOR Pics 19 IGNITION SWITCH WHITE CONNECTOR gt 20 OIL PRESSURE C 2 SWITCH 21 SIDE STAND SWITCH 1 17 GENERAL INFORMATION 9 GROUND 1 STATOR COIL 2 CLAMPS POINT D n 7 8 CLAMPS 7 5 SWITCH WIRE 6 RIGHT CRANKCASE WIRE 13 LICENCE LIGHT WIRE GENERAL INFORMATION 1 ALTERNATOR WIRE After 93 x n lt cc 2 2 S 4 SIDE STAND SWITCH 3 OIL PRESSURE SWITCH 1 19 GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM California model only NOTE The hoses shown below are numbered as they appear on the Vacuum Hose Routing Diagram Label
38. PUMP Vacuum pump ST AH 260 MC7 TOBE Pressure pump ST AH 255 MC7 CC U S A only L 4 18 MEMO COOLING SYSTEM 5 0 5 COOLING SYSTEM SERVICE INFORMATION THERMOSTAT TROUBLESHOOTING RADIATOR COOLING FAN SYSTEM TESTING WATER PUMP COOLANT REPLACEMENT COOLANT RESERVE TANK SERVICE INFORMATION GENERAL KJ Do not remove the radiator cap when the engine is hot The coolant is under pressure and severe scalding could result The engine must be cool before servicing the cooling systern 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 distilled water and ethylene glycol in the cooling system 50 50 mixture is recommended for maximum sion protection Do not use alcohol based antifreeze Add coolant at the reserve tank Do not remove the radiator cap except to refill 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 18 To service the water pump the engine must be removed from the frame SPECIFICATIONS ITEM SPECIFICATIONS Radiator cap relief pressur
39. Remove the dowel pins and gasket 88 89 Remove the oil orifice CLUTCH LIFTER SHAFT Remove the clutch lifter piece and remove the snap ring and return spring from the right crankcase cover Remove the clutch lifter shaft Check the clutch lifter piece and shaft for damage or excessive scratching Check the return spring for fatigue or damage _ 2 LIFTER SHAFT 7 3 CLUTCH GEARSHIFT LINKAGE Check the needle bearing for wear or damage or a loose fit in the cover Check the dust seal for fatigue or damage Apply grease to the dust seal and needle bearing Install 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 in the clutch lifter shaft CLUTCH REMOVAL Remove the following clutch bolts clutch lifter plate springs Unstake the clutch lock nut with a drill or grinder NOTE Be careful not to damage the shaft threads 2 NEEDLE a 1 DUST SEAL BEARINGS bic 3 LIFTER PIECE 1 UNSTAKE CLUTCH GEARSHIFT LINKAGE ww 3 WM ay 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 KE10000 or 07HGB 001000A U S A only Lock nut wrench 17 x 27 mm 07
40. Ta Qn 7 Sap N an 4 SUB AIR Y CLEANER Nig d 42 7 5 AIR CLEANER HOUSING GENERATOR WIRE 1 14 GENERAL INFORMATION 1 THROTTLE CABLES 2 FRONT IGNITION COIL 3 FUEL TANK BREATHER TUBE California model only 4 FUEL TUBE INLET LINE D 2 m LO NS CX ES Ae 5 ALTERNATOR AU Y unma 25 7 WIRE 5 6 NEUTRAL SWITCH WIRE 7 RIGHT CHOKE CABLE 10 SPEEDOMETER 9 AIR CLEANER HOUSING 8 THERMOSTATIC SWITCH CABLE HOLDER BREATHER TUBE 88 89 91 93 17 FRONT BRAKE HOSE 11 IGNITION PULSE GENERATOR 18 CLAMP 4P WHITE CONNECTOR 12 HORN FAN MOTOR 2P BLACK CONNECTOR A TURN SIGNAL oe WHITE CONNECTOR 14 INDICATOR PANEL 6P GREEN CONNECTOR 15 SPEEDOMETER 6P BLACK CONNECTOR 16 RIGHT HANDLEBAR SWITCH 9P RED CONNECTOR 1 15 GENERAL INFORMATION 94 2 FRONT BRAKE HOSE 3 IGNITION PULSE GENERATOR 4P WHITE CONNECTOR 4 HORN FAN MOTOR n 2P BLACK CONNECTOR 1 CLAMP 5 TURN SIGNAL 9P WHITE CONNECTOR 6 INDICATOR PANEL 6P GREEN CONNECTOR 7 SPEEDOMETER 6P BLACK CONNECTOR 8 RIGHT HANDLEBAR SWITCH 9P RED CONNECTOR After 94 9 CRANKCASE BREATHER DRAIN TUBE 10 MAIN WIRE HARNESS 11 FAN MOTOR WIRE 12 EVAPORATIVE EMISSION PURGE CONTROL VALVE California model only 1 16 GENERAL INFORMATION 1 TURN SINAL
41. XXXXX or Vacuum pump ST AH 260 MC7 Pressure pump ST AH 255 MC7 U S A only Remove the pumps install the EVAP PURGE CONTROL VALVE on its mount route and reconnect the house accord ing to the routing label EVAPORATIVE EMISSION CARBURETOR AIR VENT CONTROL VALVE INSPECTION California model only Disconnect the Evaporative Emission Carburetor Air Vent Control Valve EVAP CAV CONTROL VALVE hoses from their connections and remove the EVAP CAV CONTROL VALVE from its mount Refer to the routing label on left side cover for hose connections 1 EVAPORATIVE EMISSION PURGE CONTROL VALVE 3 TO 3 WAY 5 TO EVAPORATIVE EMISSION CANISTER 4 TO CARBURETOR 2 VACUUM PUMP BODY 4 17 FUEL SYSTEM Connect a vacuum pump to the No 10 hose that goes to the right carburetor body 1 TO AIR 2 TO OPEN AIR Apply the specified vacuum to the EVAP CAV CONTROL JOINT PIPE 3 EVAPORATIVE EMISSION VALVE No 6 HOSE CARBURETOR AIR VENT CONTROL VALVE SPECIFIED VACUUM 250 mm 9 8 in Hg TOOL 4 TO Vacuum Pressure pump A937X 041 XXXXX or EVAPORATIVE Vacuum pump 5 260 7 ANDERE U S A only No 4 HOSE The specified vacuum should be maintained 5 TO RIGHT y Replace the EVAP CAV CONTROL VALVE if vacuum is not intai CARBURETOR 6 VACUUM PUMP maintained BODY No 10 HOSE CAUTION To prevent damage to the evaporative emission carburetor air vent control
42. as shown SERVICE LIMIT 0 10 mm 0 004 in PISTON REMOVAL Place a shop towel into the crankcase and remove the piston pin clips NOTE e Do let the clips fall into the crankcase Push the piston pin out and remove the piston 1 PIN CLIP INSPECTION Clean the piston domes ring lands and skirts Measure the piston ring to groove clearance SERVICE LIMIT Top 0 10 mm 0 004 in Second 0 10 mm 0 004 in If clearance is excessive replace the piston ring Remove the piston rings and mark them to indicate the correct cylinder and piston position for reassembly NOTE Do not damage the piston rings when removing them CYLINDER PISTON Insert the old piston ring into the proper ring groove and clean the groove by rolling the ring around the pistons circumference Inspect the piston for cracks or other damage Measure the piston O D NOTE Take measurements 10 mm 0 4 in from the bottom and 90 to the piston pin hole SERVICE LIMIT 74 90 mm 2 949 in Calculate the piston to cylinder clearance by subtracting the piston from the cylinder I D page 10 2 SERVICE LIMIT 0 32 mm 0 013 in Measure the top and second piston ring end gaps using a pis ton push the ring into the cylinder squarely and make the mea surement SERVICE LIMIT Top Second 0 50 mm 0 020 in Oil 0 90 mm 0 035 in Measure each piston pin bore SERVICE LIMIT
43. beam Turn signal 0 8 0 9 mm 0 031 0 035 in 30A 10 AX3 15 1 Electrical starter 12 V 60 55 W 12 V 32 3 CP 23 8 W X2 SAE No 1034 12 V 32 CP 23 W X2 SAE No 1073 12 V 32 3 CP 23 8 W X2 SAE No 1034 12 3 4 WwW 12 V1 7 12V1 7W 12V 1 7W 12V 4 CP Front 2 Rear 1 308 1 4 GENERAL INFORMATION TORQUE VALUES ENGINE j Thread dia Torque ITEM Q ty mm m ft lb Remark Cylinder head cover bolt 4 6 10 1 0 7 2 Special bolt Camshaft holder bolt 6 8 23 2 3 17 nut 2 8 23 2 3 17 bolt 4 6 10 1 0 7 2 Cylinder head nut 8 10 48 4 8 35 bolt 2 8 23 2 3 17 nut 4 8 23 2 3 17 bolt 2 6 10 1 0 7 2 Camshaft sprocket bolt 4 7 23 2 3 17 Apply locking agent Primary drive gear bolt 1 12 90 9 0 65 UBS bolt Flywheel bolt 1 12 130 13 0 94 UBS bolt left hand threads Connecting rod bearing cap nut 4 8 34 3 4 25 Apply oil to the threads Clutch lock nut 1 18 130 13 0 94 Oil pressure switch 1 12 1 2 9 Apply sealant Spark plug 4 12 14 1 5 10 Oil drain bolt 1 14 35 3 5 25 Starter clutch torx bolt 6 8 30 3 0 22 Apply locking agent Oli pump driven sprocket 1 6 15 1 5 11 Flange socket bolt Apply lock ing agent Oil pass pipe bolt 2 7 10 1 0 7 2 1 8 23 2 3 17 Valve adjusting screw lock nut 6 7 23 2 3 17 Apply oil Gearshift return spring pin 1 8 26 2 6 19 Starter motor cable nut 1 6 10 1 0 7 2 Clutch lifter plate bolt 4 6 10 1 0 7 2 Flange bolt Cam chain tensioner bolt 4 6 10 1 0 7 2
44. degree inner cutter Refinish the seat to specifications using a 45 degree finish cutter After cutting the seat apply lapping compound to the valve face and lap the valve using light pressure After lapping wash all residual compound off the cylinder head and valve NOTE Do not allow lapping compound to enter the guides 0 9 1 1 mm 0 035 0 043 in 1 CONTACT TOO HIGH 2 OLD SEAT WIDTH 29 1 CONTACT TOO LOW 2 OLD SEAT WIDTH I PB 9 14 CYLINDER HEAD VALVE vea wwe 2 STEM SEAL 1 VALVE 4 RETAINER sf CYLINDER HEAD ASSEMBLY Install the valve spring seats and new stem seals Lubricate each valve stem with molybdenum disulfide oil and insert the valve into the valve guide Turn the valve slowly while inserting to avoid damaging the seals 3 OUTER SPRING 7 SPRING 6 INNER SPRING 5 Korner Move the valves up and down to check for smooth operation Install the valve springs with the tightly wound coils facing the combustion chamber Install the spring retainers Compress the springs and install the valve cotters CAUTION To prevent loss of tension do not compress the valve springs more than necessary to install the valve cotters TOOL Valve spring compressor 07757 0010000 or 07957 3290001 9 15 CYLINDER HEAD VALVE Tap the valv
45. driven gear O D 57 749 57 768 2 2736 2 2743 57 60 2 268 TORQUE VALUES Flywheel bolt 130 Nem 13 0 kg m 94 ft Ib Left hand thread Starter clutch torx bolts Nem 3 0 kg m 22 ft lb Apply locking agent TOOLS Common Rotor puller 07733 0020001 or 07933 3290001 U S A only Flywheel holder 07725 0040000 Equivalent commercially available in U S A Torx bit 07703 0010100 Equivalent commercially available in U S A 8 1 ALTERNATOR STARTER CLUTCH LEFT CRANKCASE COVER REMOVAL Remove the left side cover and disconnect the alternator wire 3P connector WHITE Remove the drive sprocket cover page 13 14 Place a container under the left crankcase cover to catch the engine oil Remove the eleven left crankcase cover bolts and the cover Remove the dowel pins and gasket STATOR REPLACEMENT gt Remove the wire clamp bolts and the clamps Remove the stator mounting bolts and stator Position the new stator and the grommets in the cover Apply a locking agent to the threads of the stator mounting bolts and wire clamp bolts Tighten the stator mounting bolts and the clamp bolts 1 ALTERNATOR WIRE CONNECTOR V KS gt 4 7 COVER 2 GROMMETS 3 STATOR 1 BOLTS ALTERNATOR STARTER CLUTCH FLYWHEEL REMOVAL lt Remove the starter drive and idle reduction gears by removing the shafts Hold the flywheel with
46. from the frame section 6 Remove the water pump cover mounting bolts and cover Remove the O ring and dowel pins from the water pump as sembly and disconnect the water hose Remove the water pump from the crankcase 3 WATER HOSE 2 O RING COOLING SYSTEM INSPECTION 1 O RING 2 WATER PUMP ASSEMBLY Check the water pump for mechanical seal leakage and bear ing deterioration Replace the water pump as an assembly if necessary 3 WATER PUMP COVER INSTALLATION Apply a coat of clean engine oil to anew O ring and install it in the water pump shaft housing groove Align the water pump shaft groove with the oil pump shaft and insert the water pump into the crankcase 1 O RING 2 ALIGN Apply a coat of engine oil to a new O ring and install it around 1 DOWEL PINSIB 2 IMPELLER HOUSING the impeller housing 5 gt Install the two dowel pins Connect the water hose with the clamp Install the water pump cover and tighten the cover mounting bolts Connect the water hose with the clamp Install the engine in the frame section 6 Fill the system with coolant page 5 3 Fill the engine with the recommended engine oil page 2 4 Check the cooling system for leakage COOLING SYSTEM COOLANT RESERVE TANK REMOVAL INSTALLATION Raise and support the motorcycle rear frame using a hoist or jack under the engine Remove the evaporative emi
47. holder handle 07JMA MR60100 or equivalent commercially available in U S A 07930 50000 Not available in U S A 07930 KA50100 07930 KA40200 Ball race remover driver attachment driver handle Fork seal driver 39mm Steering stem socket Steering stem driver Bearing race remover Common 07953 MJ10100 07953 MJ10200 07953 MJ1000A 07953 MJ1000B 07949 37 10001 and 07746 0010100 07953 MJ10100 Not available in U S A 07947 4630100 07916 3710100 07946 00000 07946 3710500 07749 0010000 Attachment 42 x 47 mm Pilot 20 mm Bearing remover shaft Bearing remover head 20 mm Attachment 52 x 55 mm TROUBLESHOOTING Hard Steering Steering bearing adjustment nut too tight Faulty steering stem bearings nsufficient air in front tire Steers to One Side or Does Not Track Straight Bent fork legs Bent front axle wheel installed incorrectly Unequal oil quantity in each fork tube Front Wheel Wobbling Distorted rim Worn front wheel bearings Loose or broken spokes Faulty tire Axle or axle holder not tightened properly 07746 0010300 07746 0040500 07746 0050100 07746 0050600 07746 0010400 Equivalent commercially available in U S A Soft Suspension Weak fork springs Insufficient fluid in fork legs Hard Suspension Fork oil level too high Fork tube s bent or fork slider s damaged Front Suspension Noi
48. in Calculate the clearance between each bushing and shaft SERVICE LIMIT 0 06 mm 0 0024 in Check the each shaft grooves for damage Replace if necessary BEARING REPLACEMENT Turn the inner race of each bearing with your finger The bear ings should turn smoothly and quietly Also check that the bearing outer race fits tightly in the crankcase Remove and discard the bearings if the races do not turn smoothly quietly or if they fit loosely in the crankcase 1 M4 or C3 BUSHING 2 M2 or C1 BUSHING m 2 LOCK AND STOP WASHER GROOVES 3 SNAP RING 4 STOP GROOVE RING GROOVE 11 13 CRANKSHAFT TRANSMISSION Left crankcase Remove the left mainshaft bearing using the special tools TOOLS Bearing remover set 07936 3710001 Not available in U S A remover handle 07936 3710100 bearing remover set 07936 3710600 remover weight 07741 0010201 or 07936 3710200 Drive the countershaft bearing oil seal out of the crank case Install the new mainshaft bearing set plate on the left crank case NOTE Apply fresh engine oil to the new crankcase bearings before installation Install the new bearings with the following tools TOOLS Left mainshaft bearing Driver 07749 0010000 Attachment 42 x 47 mm 07746 0010300 Left countershaft bearing Driver 07749 0010000 Attachment 52 x 55 mm 07746 0010400 Pilot 25 mm 07746 004060
49. or run at high speed ENGINE DOES NOT KNOCK VALVE TRAIN NOT LUBRICATED PROPERLY ENGINE 5 POOR PERFORMANCE AT LOW AND IDLE SPEEDS 1 Check ignition timing and valve clearance CORRECT 2 Check carburetor pilot screw adjustment CORRECT 3 Check for leaking intake pipe NO LEAKAGE 4 Perform the spark test GOOD SPARK INCORRECT LEAKING WEAK OR INTERMITTENT SPARK POSSIBLE CAUSE Clogged oil passage Clogged oil control orifice Contaminated oil Faulty oil pump Coolant level low Fan motor not working thermostatic switch Thermostat stuck closed Excessive carbon build up in com bustion chamber Use of poor quality fuel Clutch slipping Lean fuel mixture Worn piston and cylinder Wrong type of fuel Excessive carbon build up in com bustion chamber Ignition timing too advanced Faulty ignition control module Lean fuel mixture POSSIBLE CAUSE Improper valve clearance Improper ignition timing Faulty ignition control module Faulty ignition pulse generator See Fuel System Section 4 Loose carburetor Damaged insulator Faulty carbon or wet fouled spark plug GO TO PAGE 16 2 20 3 TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED 1 Check ignition timing and valve clearance CORRECT 2 Disconnect fuel line at carburetor FUEL
50. peg bracket bolt Swingarm pivot bolt Front upper engine mounting bolt Front upper engine bracket bolt Front lower engine mounting bolt Rear upper engine mounting bolt Rear upper engine bracket bolt Exhaust pipe joint nut Fuel tank mounting bolt Exhaust muffler bracket bolt Alternator Starter motor Carburetors 61 kg 134 Ib 2 8 lit 2 94 US qt 2 46 Imp qt at disassembly 1 6 lit 1 51 US qt 1 41 Imp qt total 90 N m 9 0 kg m 65 ft Ib 45 Nem 4 5 kg m 33 ft lb 12 Nem 1 2 kg m 9 ft lb 40 4 0 kg m 29 ft lb 90 N m 9 0 kg m 65 ft Ib 55 Nem 5 5 kg m 40 ft lb 27 N m 2 7 kg m 20 ft Ib 55 N m 5 5 kg m 40 ft Ib 55 Nem 5 5 kg m 40 ft lb 27 Nem 2 7 kg m 20 ft lb 25 Nem 2 5 kg m 18 ft lb 19 Nem 1 9 kg m 13 7 ft lb 27 2 7 kg m 20 ft lb ENGINE REMOVAL INSTALLATION ENGINE 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 Remove the following fuel tank page 4 3 air cleaner housing page 4 4 air cleaner chamber page 4 4 carburetor page 4 6 exhaust pipe protectors exhaust pipe and mufflers Loosen the drive chain page 3 13 Remove the drive sprocket cover page 13 14 then remove the sprocket from the drive chain by r
51. seat cutter 35 mm 07780 0010400 45 EX Valve seat cutter 28 mm 07780 0012100 32 IN Valve seat cutter 35 mm 07780 0012300 32 EX Valve seat cutter 30 mm 07780 0014000 60 IN Valve seat cutter 37 5 mm 07780 0014100 60 EX Cutter holder 5 5 mm 07781 0010101 Valve guide Cutter holder 6 6 mm 07781 0010201 Valve guide EX 1 9 GENERAL INFORMATION CABLE amp HARNESS ROUTING Note the following when routing cables and wire harnesses A loose wire harness or cable can be a safety hazard After clamping check each wire to be sure it is secure Do not squeeze wires against welds or clamps Secure wires and wire harnesses to the frame with their re spective wire bands at the designated locations Tighten the bands so that only the insulated surfaces contact the wires or wire harnesses Route harnesses so they are neither pulled taut nor have ex cessive slack Protect wires and harnesses with electrical tape or a tube if they contact a sharp edge or corner Clean the attaching surface thoroughly before applying tape SS 0 Donot use a wire or harness with broken insulation Repair by wrapping them with protective tape or replace them Route wire harnesses to avoid sharp edges or corners Also avoid the projected ends of bolts and screws Keep wire harnesses away from the exhaust pipes and other hot parts Be sure grommets are seated in their grooves prop
52. sec onds COMPRESSION 1 324 98 kPa 13 5 1 0 kg cm 192 14 psi Low compression can be caused by Improper valve clearance adjustment Valve leakage Leaking cylinder head gasket Worn piston rings or cylinder High compression can be caused by Carbon deposits in the combustion chamber or on the piston head 3 12 MAINTENANCE EVAPORATIVE EMISSION CONTROL SYSTEM California model only Check the hoses between the fuel tank evaporative emission canister evaporative emission purge control valve EVAP PURGE CONTROL VALVE evaporative emission carburetor air vent control valve EVAP CAV CONTROL VALVE and carburetor for deterioration damage or loose connections 1 EVAP CANISTER Also check the tubes for clogging due to bending or twisting fF gee SES Check the evaporative emission canister for cracks deterio VACUUM HOSE ROUTING DIAGRAM ENGINE FAMILY C 3J EVAPORATIVE FAMILY CALIFORNIA VEHICLE FUEL TANK CAV CONTROL VALVE ration or other damage Refer to the vacuum hose routing diagram label for hose connections EVAP PURGE CONTROL VALVE DRIVE CHAIN CHAIN SLACK INSPECTION Never inspect or adjust the drive chain while the engine is run ning Turn the ignition switch off support the motorcycle on its side stand and shift the transmission into neutral Check slack in the drive chain lower run midway betw
53. specified in the fol lowing chart NOTE The O mark in the table indicates that the matching is possible in the crossed codes 2 CRANKSHAFT WEIGHT CODE SELECTION TABLE L or H no mark Front rod code Rear rod code 1 Apply molybdenum disulfide grease CAUTION For selecting crankshaft weight Select L crankshaft weight if the front rod and rear road have code A Select crankshaft weight if the front rod and rear rod have code Select crankshaft weight with no code other than the above two cases CONNECTING ROD ASSEMBLY Install the bearing inserts on the rods and caps NOTE Align the boss on the bearing with the groove in the rod or cap Apply molbdenum disulfide grease to the bearing Install the connecting rods and caps on the crankpin Be sure each part is installed in its original position as noted during re moval Tighten the bearing cap nuts NOTE Align the 1 0 code on the cap and rod Tighten the nuts in two or more steps After tightening check that the rods move freely without binding TORQUE 34 N m 3 4 kg m 25 ft lb CRANKSHAFT INSTALLATION Install the crankshaft in the left crankcase Install the dowel pins and assemble the crankcase 11 10 CRANKSHAFT TRANSMISSION TRANSMISSION 2 COUNTER SHAFT 1 MAIN SHAFT REMOVAL 88 89 91 95 Remove the mainsh
54. than 10 at any temperature listed Apply sealant to the threads of the thermosensor and tighten it in the thermostat housing NOTE Keep the clearnace of 3 4 mm 0 1 0 2 in between the case and the thermosensor threads ends Connect the wire to the thermosensor FUEL PUMP RELAY Gasoline is extremely flammable and is explosive under certain conditions Work in a well ventilated area Do not smoke or allow flames or sparks in the your work area or where gasoline is stored Remove the seat and right side cover Check the sub fuse 10 A Remove the relay from the rubber bracket and check the relay connector terminals for looseness and corrosion Inspect as follows Disconnect the connector and test the wires on the main har ness side ITEM STANDARD Between and body ground Battery voltage with the ignition switch should come Y Bu wire between the pump CONTINUITY relay and spark unit BI Bu wire between the pump CONTINUITY relay and fuel pump 1 THERMOMETER 2 THERMOSENSOR s i 1 FUEL PUMP RELAY ME 18 9 LIGHTS METER SWITCHES FUEL PUMP SYSTEM INSPECTION Turn the ignition switch OFF and remove the seat and discon nect the fuel pump wire connectors and temporarily connect the balck and black blue wire teminals at the main harness connector with a jumper wire Disconnect the fuel outlet tube at the fu
55. the new one if the projec 6 0 mm tion exceeds 6 0 mm 0 24 in 0 24 in To replace the cam chain drain the oil from the engine and remove the following parts FRONT CYLINDER HEAD REAR CYLINDER HEAD Left crankcase cover Right crankcase cover Front camshaft Rear camshaft Flywheel Primary drive gear 2 CAM CHAIN TENSIONER 9 4 CYLINDER HEAD VALVE 2 mm 2 WEDGE A Pull wedge A straight up while holding wedge B down Secure wedge A with a 2 mm pin as shown Remove the camshaft holder on the cam sprocket side moving the two mounting bolts Remove the cam sprocket bolt rotate the crankshaft counter clockwise one turn 360 and remove the other cam sprocket bolt p 1 OIL PLATE 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 holder mounting bolts nuts oil plate and the holder Remove the dowel pins Hang the cam chain on the camshaft behind the camshaft flange and remove the cam sprocket while lifting the camshaft out Attach a piece of wire to the cam chain to prevent it from being dropped into the crankcase CYLINDER HEAD VALVE Gi INSPECTION 1 JOURNAL SURFACE Cylinder head i 3 Inspect the camshaft h
56. thickness gauge SERVICE LIMIT 0 30 mm 0 012 in Check the clutch center for nicks or indentations made by the clutch plates Check the spring seat and judder spring for distortion wear or damage Replace them if necessary Check the slots in the clutch outer for nicks or indentations made by the clutch discs Measure the 1 0 of the clutch outer and the of the clutch outer guide SERVICE LIMITS Clutch outer I D 32 10 mm 1 264 in Clutch outer guide O D 31 98 mm 1 259 1 PLATE 1 CLUTCH CENTER nd 1 JUDDER SPRING 2 SPRING SEAT TT T 4 CLUTCH OUTER CLUTCH GEARSHIFT LINKAGE Check the oil pump drive sprocket for damage Measure 1 0 of the drive sprocket and the O D of the outer guide SERVICE LIMITS Oil pump drive sprocket 1 0 32 10 mm 1 264 Clutch outer guide O D 31 98 mm 1 259 in Measure the mainshaft O D at the clutch outer guide SERVICE LIMIT 21 92 mm 0 863 in GEARSHIFT LINKAGE REMOVAL Remove the following drive sprocket cover page 13 14 gearshift pedal arm from the gearshift spindle right crankcase cover page 7 3 clutch assembly page 7 4 oil pump drive chain page 7 5 Loosen thetwo oil pipe stay mounting bolts and remove the oil pipe mounting bolt Pull the oil pipe out of the stay and oil pump CLUTCH GEARSHIFT LINKAGE Remove the following 1 GEARSHIFT SPINDLE
57. 0 Install a new countershaft oil seal Check the gearshift spindle oil seal for wear or damage re place if necessary 1 BEARING REMOVER SET 1 BEARING SET PLATE 1 DRIVER 11 14 CRANKSHAFT TRANSMISSION Right crankcase d 7 AE 1 DRIVER Remove the mainshaft bearing set plate and drive the counter 2 shaft bearing mainshaft bearing and shift drum bearing out of the crankcase TOOLS Right mainshaft bearing Driver 07749 0010000 Attachment 52 x 55 mm 07746 0010400 Pilot 22 mm 07746 0041000 Right countershaft bearing Driver 07749 0010000 Attachment 42 x 47 mm 07746 0010300 Pilot 20 mm 07746 0040500 1 RIGHT CRANKCASE Apply a locking agent to the threads of the mainshaft bearing set plate attaching bolt Install the set plate and tighten the bolt securely 2 BEARING SET PLATE INSPECTION 1 10 mm STUD BOLT HOLES Crankcase studs 88 89 91 95 Check that the studs are tight If any are loose remove them clean their threads with contact cleaner then reinstall them using Honda Anaerobic Thread Lock or equivalent 2 8 mm STUD BOLT HOLE After installing be sure to measure the distance from the top 1 8 mm STUD BOLT 2 10 mm STUD BOLT of each stud to the crankcase surface Tighten the stud bolts to the specified torque TORQUE 8 mm stud bolt 20 30 N m 2 0 3 0 kg m 14 22 ft lb 178 180 mm 168 170 mm 10 mm stud bolt 7 008 7 0
58. 0 07936 3710600 07741 0010201 or 07936 3710200 Not available in U S A U S A Only 07749 0010000 07746 0010300 07746 0040500 07746 0010400 07746 0041000 07746 0040600 TROUBLESHOOTING 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 Transmission jumps out of gear Gear dogs worn Shift shaft bent Shift forks bent CRANKSHAFT TRANSMISSION 11 3 CRANKSHAFT TRANSMISSION CRANKCASE SEPARATION Remove the engine from the frame Section 6 Refer to the service information page 11 1 for the parts that must be removed before the separating the crankcase 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 Remove the bolt and cam chain tensioner set plate Remove the front cam chain from the crankshaft Remove the 8 mm bolts and 6 mm bolts from the left crank case NOTE Remove the bolts in a crisscross pattern in 2 or 3 steps Loosen the 6 mm bolts first then loosen the 8 mm bolts Remove the 8 mm bolts and 6 mm bolts from the right crank case NOTE Remove the bolts in a crisscross pattern in 2 or 3 steps Loosen the 6 m
59. 0 9 6 5 Remark 1 6 See page 12 23 Apply oil to the threads Apply locking agent Apply locking agent Apply locking agent Socket bolt Flange nut Flange bolt Shear bolt Shear bolt Socket bolt Apply locking agent GENERAL INFORMATION Torque specifications listed above are for specific tightening points If a specification is not listed follow the standard torque values below STANDARD TORQUE VALUES TYPE TORQUE kg m ft lb TYPE TORQUE Nem kg m ft lb 5 mm bolt nut 5 0 50 3 6 5 mm screw 4 0 40 2 9 6 mm bolt nut 10 1 0 7 2 6 mm screw 6 mm 8 mm bolt nut 22 2 2 16 bolt with 8 mm head 9 0 9 6 5 10 mm bolt nut 35 3 5 25 6 mm flange bolt nut 12 1 2 9 12 mm bolt nut 55 5 5 40 8 mm flange bolt nut 27 2 7 20 10 mm flange bolt nut 40 4 0 29 1 7 GENERAL INFORMATION TOOLS SPECIAL Description Tool number Oil pressure gauge Oil pressure gauge attachment Oil filter wrench Vacuum gauge Valve adjusting wrench Vacuum Pressure pump Snap ring pliers Steering stem socket Clutch center holder Bottom holder pipe holder attachment holder handle Bearing remover set remover handle bearing remover set remover weight Valve guide driver attachment IN Valve guide driver attachment EX Bearing race remover Steering stem driver Driver shaft Fork seal driver 39 mm Ball race remover driver attachmen
60. 0 mm 0 28 in 7 0 mm 0 28 in Main jet Front 115 Rear 115 Front 115 Rear 115 Slow jet 40 40 Idle speed 1 200 100 rpm 1 200 100 rpm Throttle grip free play 2 6 mm 1 8 1 4 in 2 6 mm 1 8 1 4 Pilot screw initial opening See page 4 15 FUEL SYSTEM TORQUE VALUE Fuel tank mounting bolt TOOLS Special Vacuum Pressure pump Pressure pump Vacuum pump Valve guide driver 7 mm Common Float level gauge TROUBLESHOOTING Engine cranks but won t start No fuel in tank No fuel to carburetor Engine flooded with fuel No spark at plug ignition system faulty Clogged air cleaner Intake air leak Improper choke operation Improper throttle operation Hard starting or stalling after starting Improper choke operation Ignition malfunction e Faulty carburetor Fuel contaminated Intake air leak ncorrect idle speed Incorrect valve clearance Section 3 ncorrect carburetor synchronization Section 3 Improper choke valve operation Rough idle Faulty ignition system ncorrect idle speed Incorrect valve clearance Section 3 ncorrect carburetor synchronization Faulty carburetor Fuel contaminated Faulty air cut off valve California model only Faulty evaporative emission purge control valve Faulty evaporative emission carburetor air vent control valve Worn damaged emission system hoses Afterburning during deceleration Faulty ignitio
61. 0000 07JME MR10100 07GME 0010100 07914 3230001 07746 0050100 or equivalent commercially available in U S A 07746 0050500 07749 0010000 07746 0010300 07746 0040400 07746 0010100 07746 0040300 07746 0041000 13 2 REAR WHEEL BRAKE SUSPENSION REAR WHEEL REMOVAL Support the motorcycle using a hoist or a jack under the en gine CAUTION Do not jack up the oil filter Loosen the drive chain adjusters on both sides of the swing arm Remove the following parts brake rod cotter pin nut seat washers and bolt from the torque rod on the brake panel Axle nut adjuster collars side collar and rear axle drive chain from the drive sprocket rear wheel brake panel from the brake drum INSPECTION AXLE Set the axle on V blocks and measure the runout SERVICE LIMIT 0 2 mm 0 01 in WHEEL Check the spokes and tighten any that are loose TORQUE 4 N m 0 4 kg m 2 9 ft lb TOOL Spoke wrench 07JMA MR60100 or equivalent commercially available in U S A Check the rim runout by placing the wheel on a truing stand Spin the wheel hand and read the runout using a dial indicator SERVICE LIMITS RADIAL 2 0 mm 0 08 in AXIAL 2 0 mm 0 08 in WHEEL BEARING Turn the inner race of each bearing with your finger The bearings should turn smoothly and quietly Also check that the bearing outer race fits tightly in the hub Remov
62. 1 SLOTS AND TANGS p EJ 121 FRONT WHEEL SUSPENSION STEERING Apply grease to the speedometer gearbox and gear 1 GEAR BOX 2 WASHER Install the speedometer gear and washers into the gearbox 3 SPEEDO METER GEAR Install the speedometer gearbox into the wheel hub aligning TT 2 SIDE COLLAR the tangs with the slots Clean the brake discs with a high quality degreasing agent Install the right side collar INSTALLATION S TAB AND TANG Place the front wheel between the front fork legs Fit the caliper over the brake disc taking care not to damage the brake pads Clean the axle and holder Install the axle through fork leg the side collar wheel hub and speedometer gear box Set the speedometer gearbox tab under the tang on the left fork slider Tighten the front axle TORQUE 75 N m 7 5 kg m 54 ft Ib Tighten the fork pinch bolts TORQUE 22 2 2 kg m 16 ft lb Install the speedometer cable and set screw securely 12 12 FRONT WHEEL SUSPENSION STEERING FORK 1 BRAKE CALIPER MOUNTING BOLTS 2 BRAKE HOSE CLAMP M WV REMOVAL Remove the front wheel page 12 7 Remove the brake caliper mounting bolts and brake caliper Unhook the brake hose from the hook on the fender Tie the caliper to the handlebar so its weight does not pull on the brake hose Pull the speedometer cable out of the cable holder on the fend er Remove the f
63. 1 22 I ITIN 1 21 Engine Removal Installation 6 1 Engine Installation 6 5 Engine Oil Change 2 4 Engine Oil Level rine tene 2 4 Engine Removal esses 6 3 EVAP Carburetor Air Vent Control Valve Inspection California model only 4 17 Evaporative Emission Control System 3 13 Evaporative Emission Purge Control Valve Inspection California model only 4 16 Flywheel Installation 8 5 Removal ERAI 8 3 Fork A AE ENSE 12 13 Front Wheel Suspension Steering 12 1 Wheel ep ETE 12 7 F el System adoret erc er e repe cineri 4 1 HL T 3 6 Fuel 18 10 Relay 18 9 Fuel Tank 4 3 Gearshift Linkage 7 8 General Information 1 1 1 1 Handlebar 12 4 SWITCHES EC 18 7 Headlight ree neret e 18 3 AV idis i ee ees see 3 18 High Altitude Adjustment U S A Only 4 16 18 12 Hydraulic Disc Brake 14 1 Ignition Control Modul
64. 2 FLANGE Install the oneway clutch into the clutch outer with the flange side facing inside 3 ONEWAY CLUTCH 1 TORX BIT Hold the flywheel with the flywheel holder Apply locking agent to the trox bolt threads and tighten the bolts TORQUE 30 N m 3 0 kg m 22 ft lb TOOLS Flywheel holder 07725 0040000 Equivalent commercially available in U S A Torx bit 07703 0010100 Equivalent commercially available in U S A FLYWHEEL INSTALLATION Clean the crankshaft and install the woodruff key Install the needle bearing onto the crankshaft Install the starter driven gear and washer onto the crankshaft i 4 2 STARTER DRIVEN GEAR 8 5 ALTERNATOR STARTER CLUTCH Install the flywheel aligning the woodruff key on the crank shaft with the flywheel keyway Hold the flywheel with the flywheel holder install the washer and flywheel bolt and tighten the bolt TORQUE 130 N m 13 0 kg m 94 ft lb TOOL Flywheel holder 07725 0040000 Equivalent commercially available in U S A NOTE The flywheel bolt has left hand threads Install the starter idle reduction gear with the longer shaft Install the starter drive gear with the mark facing out and the shorter shaft Install the dowel pins and new gasket LEFT CRANKCASE COVER INSTALLATION Install the left crankcase cover and tighten the cover bolts with the neutral and oil pressure switch wire harness cl
65. 4 DRIVE PIN 4 9 SPRING 12 SPACER 10 OIL SEAL 13 PUMP SHAFT 11 OIL STRAINER Install the outer rotor in the pump body with the punch mark 1 OUTER ROTOR 3 SPACER facing the cover then install the inner rotor 4 Install the drive pin and spacer on the shaft 2 PUNCH MARK PUMP SHAFT Install the shaft in the body aligning the drive pin with the inner rotor groove 6 5 INNER ROTOR DRIVE PIN 88 89 91 93 1 OIL PUMP BODY Install the dowel pin and a new gasket on the pump body then install the cover 3 DOWEL PIN 2 OIL PUMP COVER 2 9 LABRICATION After 93 1 0IL PUMP BODY 2 DOWEL PINS Install the dowel pins on the pump cover then install the pump body 3 OIL PUMP COVER Tighten the cover bolts securely 1 COVER BOLTS Install the O rings oil seal oil strainer and oil pipe on the oil 1 OIL STRAINER pump 2 O RING 3 O RINGS CAUTION Install the O rings on the oil pipe with the tapered side facing out as shown or the engine will be damaged 5 O RINGS 4 OIL PIPE After 93 1 OIL SEAL 2 EDGE Install the oil seal on the oil pump Align the edge of oil strainer with the groove of the pump cover then install the oil strainer as shown 4 OIL STRAINER 3 GROOVE 2 10 LUBRICATION OIL PUMP INSTALLATION 4 1 G RINGS DOWEL PINS CU ON otl Install the dowel pins and new O rings Install the oil pu
66. 6 SPEEDO 5 WASHERS GEAR 12 10 FRONT WHEEL SUSPENSION STEERING To replace the wheel Remove the tire and tube from the rim Place the rim and hub on the work bench and begin lacing with new spokes from inside the hub Install the spokes with a space of six holes in between Measure the distance B and make a calculation A 70 8 mm 2 787 in B 2 Adjust the hub position so that the distance 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 MR60100 or equivalent commercially available in U S A TORQUE 4 N m 0 4 kg m 2 9 ft lb Check the wheel runout page 12 8 Install the tube and tire Coat the speedometer gear retainer with grease and install the retainer into the wheel hub aligning the tangs with the slots in the hub Apply grease to the oil seal lip and install the oil seal over the gear retainer Install the brake disc onto the wheel hub Apply a thread locking agent to the bolt threads and install and tighten the bolts NOTE Tighten the bolts in a crisscross pattern in 2 or 3 steps TORQUE 40 N m 4 0 kg m 29 ft lb AWARNING Do not get grease on the brake disc or stopping power will be reduced Apply grease to the dust seal lips and install the seal on the right side of the hub o 70 8 mm 2 787 in
67. 7 14 CLUTCH GEARSHIFT LINKAGE Install the dowel pins and new gasket 88 89 Tighten the right crankcase 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 Tighten the oil pipe bolt with the sealing washers TORQUE 23 2 3 kg m 17 ft lb Fill the crankcase with engine oil page 2 4 Adjust the clutch lever free play page 3 18 After 89 Tighten the right crankcase 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 Fill the crankcase with engine oil page 2 4 Adjust the clutch lever free play page 3 18 7 15 ALTERNATOR STARTER CLUTCH 130 13 0 kg m 94 ft Ib 30 Nem 3 0 kg m 22 ft Ib 8 ALTERNATOR STARTER CLUTCH SERVICE INFORMATION FLYWHEEL INSTALLATION LEFT CRANKCASE COVERREMOVAL 8 2 LEFT CRANKCASE COVER FLYWHEEL REMOVAL 8 3 INSTALEATION 8 6 STARTER CLUTCH SERVICE INFORMATION GENERAL This section covers the removal and installation of the alternator starter clutch and starter gears These operation can be done with the engine installed in the frame Refer to section 15 for troubleshooting and inspection of the alternator SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Starter
68. 716 0020300 Equivalent com mercially available in U S A Remove the following spring washer After 95 only washer clutch center judder spring and spring seat discs and plates pressure plate Lire LUN 3 PRESSURE PLATE 2 CLUTCH CENTER 0 Remove the thrust washer and clutch outer 1 THRUST WASHER 2 CLUTCH OUTERP 4 Remove the oil pump driven sprocket mounting bolt driven 1 SE PUMP DRIVEN sprocket and oil pump drive chain 4 PROCKET CLUTCH GEARSHIFT LINKAGE Remove the drive sprocket and clutch outer guide from the r 1 DRIVE SPROCKET mainshaft p 4 d 2 CLUTCH OUTER GUIDE o su INSPECTION 1 BEARING Check the lifter plate bearing for damage Turn the bearing inner race with your finger The bearing should turn smoothly and quletly Also check that the bearing outer race fits tightly in the clutch lifter plate Replace the bearing if necessary Measure the spring free length SERVICE LIMIT 88 88 37 4 mm 1 47 in After 89 41 6 mm 1 65 in 4 Replace the clutch discs if they show signs of scoring or dis coloration Measure the thickness of discs A and B SERVICE LIMIT A 2 30 mm 0 090 in B 2 60 mm 0 102 in NOTE Replace the discs and plates as set if any one is beyond the service limit 7 6 CLUTCH GEARSHIFT LINKAGE Check the plate warpage on a surface plate using a
69. 7749 0010000 Attachment 52 x 55 mm 07746 0010400 2 STEM NUT 2 ATTACHMENT 12 22 FRONT WHEEL SUSPENSION STEERING INSTALLATION Pack the bearing cavities with grease Install the lower bearing onto the stem Insert the stem into the steering head pipe and install the upper bearing inner race dust seal and steering bearing adjustment nut Apply engine oil to the adjustment nut threads Tighten the steering bearing adjustment nut to the specified torque TOOL Steering stem socket 07916 3710100 TORQUE 25 N m 2 5 kg m 18 ft lb 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 Install a new lock washer and bend the two opposite tabs down into the grooves in the adjustment nut Install and finger tighten the lock nut all the way Hold the bearing adjustment nut and further tighten the lock nut within 90 degrees to align its grooves with the tabs of the lock washer Bend up the lock washer tabs into the grooves of the lock nut 3 BEARINGS NUT 1 INNERRACE WE EB gt STEERING BEARING ADJUSTMENT 1 STEERING STEM SOCKET 1 LOCK WASHER 2 LOCK NUT FRONT WHEEL SUSPENSION STEERING Install the indicator panel with two screws Install the fork bridge then temporarily install the fork legs Tighten the steering stem nut TORQUE 105
70. 8 F Fully cahrged 13 0 13 2 V Needs charging 12 3 V Charging current 0 8 amperes Charging time 10 Hr Regulator rectifier Type Three phase full wave Regulated voltage 14 15 V 4 000 rpm Alternator Charging coil resistance at 20 C 68 F 0 1 1 02 Output 0 345 kw 5 000 rpm Charging start rpm 1 000 100 rpm TOOLS Digital multitester KOWA 07411 0020000 or KS AHM 32 003 U S A only or Circuit tester SANWA 07308 0020001 or Circuit tester KOWA TH 5H 15 2 BATTERY CHARGING SYSTEM TROUBLESHOOTING ABNORMAL Measure the battery leakage page 15 7 NORMAL ABNORMAL Check for an overcharged battery page 15 8 NOT OVERCHARGED Measure the voltage between the R W andG with terminals of the regulator rectifier 4P Black connector wire harness side page 15 8 NO VOLTAGE BATTERY ir aes COMES Disconnect the 3P connector of the regulator rectifier check the alternator stator coil resitances page 15 8 NORMAL Check the regulator recrifier resistances be tween each regulator rectifier terminal page 15 8 ABNORMAL NORMAL Check the regulator rectifier resistances be tween each regulator rectifier terminals page 15 8 REGULATED Faulty battery NORMAL Short circuit in wire harness Faulty ignition switch ABNORMAL Faulty regulator rectifier Open or short circuit in wire harness
71. 87 in 6 614 6 693 in 30 50 N m 3 0 5 0 kg m 22 36 ft Ib 3 CRANKCASE 11 15 CRANKSHAFT TRANSMISSION After 95 Check that the studs are tight I f any are loose remove them clean their threads with contact cleaner then reinstall them apply engine oil to the threads 1 FLAT SIDE NOTE Install the studs with the flat side into the crankcase 2 BOSS SIDE After installing sure to measure the distance from the top of each stud to the crankcase surface as shown 1 8 mm STUD BOLT 2 10 mm STUD BOLT 168 170 mm 6 614 6 693 in OIL JET Remove the oil jets from the front cylinder bore of the right and left crankcase Check the O ring for fatique and damage 11 16 CRANKSHAFT TRANSMISSION TRANSMISSION ASSEMBLY INSTALLATION Apply molybdenum disulfide grease to the following shift fork grooves inside and outside of the bushings outside of the spline bushings 5 C1 36T 4 C2 34T 3 27 6 MAINSHAFT 7 1 14T 8 M2 20T 0 M4 M3 M2 M 1 MAINSHAFT 00 E 9 M3 22T 10 M4 29T 2 C C2 1 COUNTERSHAFT Install the stopper ring and C4 gear onto the countershasft 1 C4 GEAR 2 STOP RING 11 17 CRANKSHAFT TRANSMISSION Install the lock washer and stop washer aligning bigger tabs of the lock washer with bigger grooves
72. 91 93 h 27 2 7 kg m 20 ft lb After 93 31 3 1 kg m 22 ft lb Insert the speedometer cable through the fender holder FRONT WHEEL SUSPENSION STEERING STEERING STEM 1 SPEEDOMETER REMOVAL 2 SPEEDO METER Remove the fork legs and handlebar Disconnect the speedometer cable from the speedometer and the 6P black connector see page 1 13 Remove the following speedometer from the fork bridge headlight from the headlight case headlight stay and mounting nuts headlight stay and case al ede P C HN 4 STAY MOUNTING NUTS EMI 3 CONNECTOR Remove the steering stem nut and washer 1 STEERING STEM NUT Remove the top bridge Remove the indicator panel and lights by removing the two screws Straighten the lock washer tabs and remove the lock nut and 1 LOCK NUT 2 LOCK WASHER lock washer 12 20 FRONT WHEEL SUSPENSION STEERING 1 STEERING STEM SOCKET Loosen the steering head bearing adjustment nut TOOL Steering stem socket 07916 3710100 Hold the steering stem by hand and remove the adjustment 1 Rune RUE E nut dust seal upper bearing inner race and upper bearing Remove the steering stem from the steering head Check the bearings and outer race for wear or damage Replace if necessary BEARING REPLACEMENT SESS LOCK NUT 2 LOCK WASHER oS 3 BEARING Coy ADJUSTMEN
73. AB deu 3 SS Y 2 one JIB EVAPORATIVE EMISSION 9 ih 2 PURGE CONTROL CABLE 25 AB lt Ht VALVE California o lj SLY ZA d R7 4 SUB AIR m lt f CLEANER ps model only 8 GROUND CABLE 5 AIR CLEANER 8 IGNITION PULSE HOUSING REVISE CABLE GENERATOR WIRE 1 13 GENERAL INFORMATION 794 11 ENGINE BREATHER TUBE 10 STARTER MOTOR 9 STARTER MOTOR CABLE 8 GROUND CABLE After 94 11 ENGINE BREATHER TUBE 10 STARTER MOTOR 9 STARTER MOTOR CABLE 8 GROUND CABLE 7 CLUTCH CABLE 7 CLUTCH CABLE 6 IGNITION PULSE 13 CRANKCASE BREATHER 1 HANDLEBAR SWITCH TUBE WIRE BANDS 12 WATER HOSE Bum 2 CRANKCASE A UC BREATHER Ke x SEPARATOR i N SES Nono ert D DS zi C c LES 3 OS Bot IFA EVAPORATIVE SEAWAY dA EMISSION 2 PURGE CONTROL QTD 2 N VALVE California 222 Jame y 2 if B TEE E model only 4 SUB AIR CLEANER 5 AIR CLEANER 6 IGNITION PULSE HOUSING GENERATOR WIRE 1 HANDLEBAR SWITCH WIRE BANDS 13 CRANKCASE BREATHER TUBE 2 CRANKCASE BREATHER SEPARATOR 12 WATER HOSE AX 1 HANDLEBAR SWITCH WIRE gt BANDS SJ 4 27 4 ULP 222 Ws 3 EVAPORATIVE KS EMISSION PURGE CONTROL lt VALVE California model only
74. CRANKCASE BREATHER 88 89 91 94 Disconnect the spark plug caps crankcase breather tube and water hose Remove the water pipe mounting bolt rear water pipe and O ring Remove the cylinder head cover bolts and cover Unclamp the wire harness from the frame 3 REAR CYLINDER HEA WATER PIPE After 94 Disconnect the spark plug caps crankcase breather tube and water hose 1 SOCKET BOLTS Remove the water pipe mounting bolt rear water pipe and O ring Remove the socket bolt and valve adjusting cover 2 VALVE ADJUSTING COVER 9 3 CYLINDER HEAD VALVE Remove the cylinder head cover bolts washers and rubber Align the wire harness with the valve adjusting hole then re move the rear cylinder head cover forward CAUTION careful not to damage the the wire harness CAMSHAFT REMOVAL 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 2 RT MARK Measure the amount of the cam chain tensioner projection as 1 WEDGE B shown Replace the cam chain with
75. Check the spokes and tighten any that are loose TORQUE 4 0 4 kg m 2 9 ft lb Check the rim runout by placing the wheel on a truing stand Then spin the wheel with hand and read the runout using a dial indicator SERVICE LIMITS RADIAL 2 0 mm 0 08 in AXIAL 2 0 mm 0 08 in CAUTION Wheel balance directly affects the stability handling and over all safety of the motorcycle Always check balance when the tire has been removed from the rim NOTE For optimum balance the tire balance mark a paint dot on the sidewall must be located next to the valve stem Remount the tire if necessary Mount the front wheel in a inspection stand Spin the wheel allow it to stop and mark the lowest heaviest part of the wheel with chalk Do this two or three times to verify the heaviest area If the wheel is balanced it will not stop consistently in the same position 1 FRONT AXLE 1 VALVE 2 BALANCE MARK 12 8 FRONT WHEEL SUSPENSION STEERING To balance the wheel install wheel weights on the highest side of the rim the side opposite to the chalk marks Add just enough weight so the wheel will no longer stop in the same po sition when it is spun Do not add more than 70 grams 1 WHEEL WEIGHT WHEEL BEARING Turn the inner race of each bearing with your finger The bearings should turn smoothly and quietly Also ch
76. DLEBAR SWITCH Disconnect the left handlebar switch connector 9P White And check for continuity between the terminals Continuity should exsit between the color coded wires in each chart Dimmer Switch 1 RIGHT HANDLEBAR SWITCH Color code Turn Signal Switch 88 89 91 RIGHT N LEFT Color code Horn Button Turn Signal Switch 88 89 91 After 91 After 91 Hoz 221 Ho Hoz W R L Th PR PL Released Released RIGHT E 2 Depressed O O Depressed a Color code Color code Lg LEFT EE STS Coler code Gr Lb Br BI Lb W O W RIGHT HANDLEBAR SWITCH Disconnect the right handlebar switch connector 9P Red and check for continuity between the terminals Continuity should exist between the color coded wires as indi cated in each chart 88 89 91 93 After 93 So IG Released Released Pushed Pushed Color code Color code BI W Y R BI R Bu W Engine Stop Switch 88 89 91 93 After 93 IG 1G2 RUN RUN OFF OFF Color code Color code BI G BI W 18 7 LIGHTS METER SWITCHES THERMOSTATIC SWITCH Bc THERMOSTATIC SWITCH INSPECTION The thermostatic switch senses the temperature
77. E 3 ADJUSTER NOTE Choke knob operating friction be adjusted by turning the adjuster Check for smooth operation of the choke knob Lubricate the choke cable and or adjust the choke knob operat ing friction if operation is not smooth To adjust the friction pull the rubber cover away and turn the adjuster 4 RUBBER COVER 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 AIR CLEANER Remove the air cleaner housing cover bolt and cover N Remove the holder bolts and the air cleaner element Replace the element in accordance with the maintenance schedule Also replace the element any time it is excessively dirty or damaged MAINTENANCE CRANKCASE BREATHER The crankcase breather drain tube is behind the left frame pipe and front cylinder head Pull the drain tube out of the frame clamp Remove the drain plug from the tube to empty any deposits Reinstall the drain plug NOTE Service more frequently when ridden in rain at full throttle or after the motorcycle is washed or overturned Service if the deposit level can be see
78. ES 1 At higher odometer readings repeat at the frequency interval established here Service more frequently when riding in unusually wet or dusty areas Service more frequently when riding in rain or at full throttle California type only Replace every 2 years or at indicated odometer interval whichever comes first Replacement requires me chanical skill apwhd 3 5 MAINTENANCE FUEL LINE Remove the seat Check the fuel lines for deterioration damage or leakage Replace the fuel lines if necessary FUEL FILTER Pull 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 THROTTLE OPERATION Check for smooth throttle grip full opening and automatic full closing in all steering positions Check the throttle cables and replace them if they are deterio rated kinked or damaged Lubricate the throttle cables if throttle operation is not smooth Measure the free play at the throttle grip flange FREE PLAY 2 6 mm 1 16 1 4 in Throttle grip free play can be adjusted at either end of the throttle cable Minor adjustments are made with the upper ad juster Major adjustments are mode with the lower adjuster Adjust the free play by loosening the lock nut and turning the adjusting nut Tighten the lock nuts Recheck throttle operation Replace any damaged parts if necessary 3 6 MAINTENANCE CARBURETOR CHOK
79. ESSION m ENGINE STARTS BUT STOPS 9 POOR PERFORMANCE AT HIGH 20 4 20 4 POSSIBLE CAUSE Fuel tank empty Clogged fuel line or fuel filter Sticking float valve Faulty fuel pump Faulty fuel pump relay Clogged fuel tank vent hole Loose or disconnected fuel pump relay wire GO TO PAGE 16 2 Mixture too rich Carburetor flooded Carburetor choke on or partially closed Cylinder flooded Air cleaner dirty Improper valve clearance too small Valve stuck open Worn cylinder and piston rings Damaged cylinder head gasket Seized valve Improper valve timing Improper valve and seat contact Improper choke operation Carburetor incorrectly adjusted Intake pipe leaking Improper ignition timing Faulty spark unit or pulse gener ator Fuel contaminated 20 1 TROUBLESHOOTING ENGINE LACKS POWER 1 Raise wheels off ground and spin by hand WHEELS SPIN FREELY 2 Check tire pressure PRESSURE NORMAL 3 Check for clutch slippage CLUTCH ENGAGED PROPERLY 4 Accelerate lightly ENGINE SPEED INCREASES 5 Check ignition timing CORRECT 6 Check valve clearance CORRECT 7 Test cylinder compression NORMAL 8 Check carburetor for clogging NOT CLOGGED 9 Check spark plug condition NOT FOULED OR DISCOLORED 10 Check oil level and condition CORRECT WHEELS DO SPIN FREELY gt PRESSURE LOW P CLUTCH SLIPS
80. FLOWS FREELY 3 Remove carburetors and check for clogged jets NO CLOGGED JETS 4 Check valve timing CORRECT 5 Check valve spring tension POOR HANDLING INCORRECT FUEL FLOW RESTRICTED _ gt CLOGGED gt INCORRECT e WEAK gt Check tire pressure 1 If steering is heavy 2 If either wheel is wobbling 3 If the motorcycle pulls to one side POSSIBLE CAUSE Improper valve clearance Improper ignition timing Faulty ignition control module Faulty ignition pulse generator Clogged fuel line Clogged fuel cap vent hole Clogged fuel valve Faulty fuel pump or relay Clogged fuel filter Clogged jets Camshaft not installed properly Faulty valve spring POSSIBLE CAUSE Bearing adjustment nut too tight Damaged steering head bearings Bent steering stem Excessive wheel bearing play Bent rim s Improperly installed wheel hub s Swingarm pivot bearings excessively worn Bent frame or swingarm Loose swingarm pivot bolt Incorrect drive chain adjustment Front and rear wheels not aligned Bent fork legs Bent swingarm Bent
81. H MR1010B 13 1 8 GENERAL INFORMATION COMMON Description Tool number Alternate tool Tool number Refer to section Float level gauge 07401 0010000 4 Lock nut wrench 17 x 27 mm 07716 0020300 Equivalent 7 Gear holder 07724 0010100 commercially 7 Flywheel holder 07725 0040000 available 8 Torx bit 07703 0010100 in U S A 8 Rotor puller 07733 0020001 07933 3290001 8 Valve guide remover 5 5 mm 07742 0010100 9 Valve guide remover 6 6 07742 0010200 Not available 07942 6570100 9 in U S A Attachment 32 x 35 mm 07746 0010100 13 Attachment 42 x 47 mm 07746 0010300 11 12 13 Attachment 52 x 55 mm 07746 0010400 11 12 Pilot 15 mm 07746 0040300 13 Pilot 17 mm 07746 0040400 13 Pilot 20 mm 07746 0040500 11 12 Pilot 22 mm 07746 0041000 11 13 Pilot 25 mm 07746 0040600 11 Bearing remover head 17 mm 07746 0050500 Equivalent 13 Bearing remover shaft 07746 0050100 commercially 13 Bearing remover head 20 mm 07746 0050600 available 12 in U S A Driver 07749 0010000 11 12 13 Valve spring compressor 07757 0010000 Valve spring 07957 3290001 9 Shock absorber compressor compressor screw Spoke wrench compressor 07GME 001 0000 07GME 0010100 07JMA MR601 00 VALVE SEAT CUTTERS NOT AVAILABLE IN U S A 13 Not available in U S A Description Tool number Remarks Valve seat cutter 27 5 mm 07780 0010200 45 IN Valve
82. H SYSTEM VALVE CLEARANCE 3 8 SIDE STAND CARBURETOR SYNCHRONIZATION 3 10 SUSPENSION CARBURETOR IDLE SPEED 3 11 NUTS BOLTS FASTENERS RADIATOR COOLANT 3 11 WHEELS TIRES COOLING SYSTEM 3 12 STEERING HEAD BEARINGS SERVICE INFORMATION If the engine must be running to do some work make sure the area is well ventilated Never run the engine 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 GENERAL Engine oil See page 2 4 Engine oil filter change See page 2 5 SPECIFICATIONS ENGINE Ignition timing Initial 88 89 91 93 6 2 BTDC at idle After 93 6 5 BTDC at idle Full advance 30 BTDC at 6 000 rpm For cold climate below 5 C 41 F DPR7EA 9 X22EPR U9 For extended high speed driving DPR9EA 9 X27EPR U9 Spark plug gap 0 8 0 9 mm 0 031 0 035 Valve clearance IN 0 15 0 02 mm 0 006 0 0008 in COLD EX 0 20 0 02 mm 0 008 0 0008 in Idle speed 1 200 100 rpm Cylinder compression 1 324 98 kPa 13 5 1 0 kg cm 192 14 psi Throttle grip free play 2 6 mm 1 16 1 4 in MAINTENANCE lt CHASSIS gt Rear brake free play Brake pedal height Clutch lever free play Drive chain sla
83. INNER IN 38 11 1 500 36 47 1 436 38 81 1 765 37 51 1 477 Cylinder head warpage 0 10 0 004 9 1 CYLINDER HEAD VALVE TORQUE VALUES Cylinder head cover bolt Camshaft holder 8 mm bolt 8 mm nut 6 mm bolt Cylinder head 10 mm nut 8 mm bolt 8 mm nut 6 mm bolt Camshaft sprocket bolt Cam chain tensioner bolt 10 Nem 1 0 kg m 7 2 ft lb 23 Nem 2 3 kg m 17 ft lb 23 Nem 2 3 kg m 17 ft lb 10 Nem 1 0 kg m 7 2 ft lb 48 N m 4 8 kg m 35 ft lb 23 Nem 2 3 kg m 17 ft lb 23 Nem 2 3 kg m 17 ft lb 10 1 0 kg m 7 2 ft lb 23 Nem 2 3 kg m 17 ft lb 10 Nem 1 0 kg m 7 2 ft lb Oil pass pipe 7 mm bolt 10 Nem 1 0 kg m 7 2 ft lb 8 mm bolt 23 Nem 2 3 kg m 17 ft lb TOOLS Special 07984 2000001 07984 200000D 07984 2E20001 or 07984 ZE2000D 07943 MF50100 07943 MF50200 Valve guide reamer IN Valve guide reamer EX Valve guide driver attachment IN Valve guide driver attachment EX Common Valve guide driver 5 5 mm IN Valve guide driver 6 6 mm EX Valve spring compressor 07742 0010100 07742 0010200 Not available in U S A 07942 6570100 07757 0010000 or 07957 3290001 Valve seat cutter Not available in U S A Cutter holder IN 5 5 mm EX 6 6 mm IN 28 mm 32 EX 35 mm 32 Interior cutter IN 30 mm 60 EX 37 5 mm 60 IN 27 5 mm 459 EX 35 mm 459 TROUBLESHOOTING Engine top end problems are usually perf
84. Install a new O ring into the connecting pipe and install and 1 O RING tighten the connecting pipe mounting bolts if the connecting ee pipe was removed If only the water hose was removed connect the hose with clamp Install the dowel pins and a new gasket Install the cylinder heads and covers Section 9 GASKET inane 10 7 CRANKSHAFT TRANSMISSION 88 89 91 95 20 30 Nem 2 0 3 0 kg m 14 22 ft lb 88 89 791 9 30 50 N m 3 0 5 0 kg m 22 36 ft lb 20 30 Nem 2 0 3 0 kg m Pj 88 89 91 95 14 22 ft lb DER gt 09 lt 0 a gt D ix 4 p 4 9 i e EN 2 x NE D 88 89 91 95 30 50N m 3 0 5 Okg m 22 36ft Ib 11 0 11 CRANKSHAFT TRANSMISSION SERVICE INFORMATION CRANKCASE TROUBLESHOOTING TRANSMISSION ASSEMBLY CRANKCASE SEPARATION INSTALLATION CRANKSHAFT CONNECTING ROD CRANKCASE ASSEMBLY TRANSMISSION SERVICE INFORMATION GENERAL To service the connecting rods crankshaft transmission oil pump the engine must be removed from the frame Sec tion 6 All bearing inserts are select fitted and are identified by color code Select replacement bearings from the code tables After installing new bearings recheck them with plastigauge to verify clearance Apply molybdenum disulfide grease to the main journals and crankpins during assembly Before separating the crankcase the foll
85. LULSLC LCLLLLLELLLLLLLILIUUL ILLLLULULN L CAUALEALEEELELCBQALOOGLCECDSRNRUMEZZEEOUEZZ SERVICE INFORMATION 2 2 PRESSURE CHECK 2 5 TROUBLESHOOTING 23 OIL PUMP 2 6 ENGINE OIL LEVEL 2 4 CONTROL CABLE LUBRICATION 2 12 ENGINE OIL CHANGE 2 4 LUBRICATION POINTS 2 12 OIL FILTER CHANGE 2 5 SERVICE INFORMATION 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 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 possi ble after handling used oil GENERAL The oil pump can be serviced after removing the engine from the frame SPECIFICATIONS Engine oil Oil capacity 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 qt after draining HONDA GN4 4 stroke oil or equivalent API service classification SF or SG VISCOSITY SAE 10W 40 Oil recommendation OIL VISCOSITIES a SAE 20W 50 ae SAE 20W 40 10W 40 Other viscosities shown in the chart may be used when the average t
86. Measure the resistance between the yellow wire terminals and check for no continuity between each terminal and ground STANDARD 0 1 1 0 Q Replace the stator if the resistance is out of specification or if there is continuity between each yellow wire terminal and ground page 15 8 15 9 IGNITION SYSTEM 1 ENGINE STOP SWITCH 52 4 MAIN FUSE Y 2 SUB FUSE adv 5 IGNITION 3 BATTERY SWITCH y 2 Ae 6 NAE 7 FRONT IGNITION COIL 13 SIDE STAND 11 NEUTRAL 6 REAR IGNITION SWITCH SWITCH COIL 12 IGNITION CONTROL MODULE 88 89 89 16 IGNITION SYSTEM 1 ENGINE Bl o 2 SUB 5 IGNITION 4 MAIN STOF USE SWITCH FUSE 13 SIDE STAND SWITCH 8 TO UP 3 BATTERY METER G W 12 V 8AH G BI Black Cant Y Yellow G 11 NEUTRAL Bu Blue SWITCH 12 TO See FUEL CUT 4 RELAY W White Lg Light Green BIW Bu Y 12 IGNITION CONTROL MODULE 9 FRONT 10 REAR 1 1 1 9 FRONT 10 REAR 7 IGNITION COIL AW Seg R BI 9 11 NEUTRAL SWITCH BI W Bu Y 12 IGNITION CONTROL MODULE 1 7 IGNITION COIL 14 IGNITION PULSE GENERATOR FUSE 30 A e 3 BATTERY 12 V 8AH 1 ENGINE 2 SUB 5 IGNITION 4 MAIN STOP FUSE SWITCH DOWN SWITCH 10A 13 SIDE STAND SWITCH 8 TO
87. N m 10 5 kg m 76 ft lb Install the following parts fork legs page 12 18 front wheel page 12 12 Check the steering head bearing preload STEERING HEAD BEARING PRELOAD Place a stand under the engine and raise the front wheel off the ground Position the steering stem to the straight ahead position Hook a spring balance to the fork tube and measure the steer ing head bearing preload NOTE Make sure that there is no cable and wire harness interfer ence The preload should be within 1 0 1 5 kg 2 20 3 31 Ib for right and left turns If the readings do not fall within the limits lower the front wheel on the ground and adjust the bearing adjustment nut After making sure the bearing preload install the removed parts in the reverse order of removal 12 24 MEMO REAR WHEEL BRAKE SUSPENSION TAS 45 4 5 kg m 33 ft lb 13 0 13 REAR WHEEL BRAKE SUSPENSION SERVICE INFORMATION 13 1 BRAKE PEDAL 13 10 TROUBLESHOOTING 13 2 SHOCK ABSORBER 13 11 REAR WHEEL 13 3 SWINGARM 13 14 REAR BRAKE 13 7 SEAT REAR FENDER SUB FRAME 13 18 SERVICE INFORMATION GENERAL Support the motorcycle using a hoist or a jack under the engine CAUTION Do not jack up the motorcycle using the oil filter Use only genuine Honda replacement fasteners for the rear suspension Note the installation direction of the bolts AWARNING Any attempt to mount au
88. NDER HEAD 1 FEELER p di GAUGE Rotate the flywheel counterclockwise to align the FT mark with the index notch the left crankcase cover Make sure the piston is at TDC Top Dead Center on the compression stroke Inspect the clearance of all three valves by inserting a feeler gauge between the adjusting screw and the valve VALVE CLEARANCES Intake 0 15 0 02 mm 0 006 0 0008 in Exhaust 0 20 0 02 mm 0 008 0 0008 in Adjust by loosening the lock nut and turning the adjusting screw until there is a slight drag on the feeler gauge Hold the adjusting screw and tighten the lock nut TOOL Valve adjusting wrench 07908 KE90000 Not available in U S A 07908 KE90100 TORQUE 23 N m 2 3 kg m 17 ft lb 1 CRANKSHAFT HOLE 2 1 VALVE ADJUSTING Apply oil to the nut and bolt threads 4 WRENCH MAINTENANCE REAR CYLINDER HEAD Rotate the flywheel counterclockwise to align the mark with the index notch on the left crankcase cover Make sure the piston is at TDC on the compression stroke Check the O rings of the valve adjusting covers IN EX for damage and replace if necessary Install the front and rear valve adjusting covers Apply grease to the timing and crankcase hole caps then install and tighten them TORQUE Timing hole cap 3 5 0 35 kg m 2 5 ft lb Crankshaft hole cap 15 1 5 kg m 11 ft lb CARBURETOR SYNCHR
89. NER YA SPRING Install the retainer spring as shown Apply silicone grease to the inside of the boot and install it Install the following pads and pad pins to the caliper bracket to the caliper Install the caliper assembly over the brake disc so that the disc is positioned between the pads CAUTION careful not to damage the pads 2 BOOT fes Install and tighten the caliper mounting bolts TORQUE 88 89 91 93 27 2 7 Kg m 20 ft lb After 93 31 3 1 Kg m 22 ft Ib Tighten the pad pins and install and tighten the pad pin plugs Connect the brake hose to the caliper with the hose bolt and two new sealing washers TORQUE 30 N m 3 0 kg m 22 ft Ib VL 2 Bleed the air from the brake system page 14 4 3 e 2 o BOLT 5 3 SEALING WASHERS 14 12 MEMO BATTERY CHARGING SYSTEM 5 0 1 REGULATOR RECTIFIER P ANN S 7 f aN X 4 ALTERNATOR 3 STARTER RELAY 2 BATTERY SWITCH MAIN FUSE 30A 15 BATTERY CHARGING SYSTEM 88 89 91 Y Y 3 MAIN FUSE 30A Y G BI G BI 4 ALTERNATOR 1 REGULATOR RECTIFIER Yellow BI Black G Green R Red White After 91 3 MAIN FUSE 30A Y Yellow G Green R Red W white 4 ALTERNATOR 1 REGULATOR RECTIFIER 15 1 BATTERY CHARGING SYSTEM SERVICE INFORMATION 15 2 CHARGING SYSTEM
90. NG 92 5 SNAP RING LUBRICATION Remove the oil strainer and oil pipe from the oil pump 1 OIL STRAINER Check the O rings and oil seal for fatigue or damage 1 OIL SEAL Clean the oil strainer and oil pipe with non flammable or high flash point solvent Remove the three cover bolts 1 COVER BOLTS Disassembled parts and clean them with non flammable or high flash point solvent OIL PUMP INSPECTION 2 INNER ROTOR Install the outer and inner rotors to the pump body Measure the outer rotor to pump body clearance SERVICE LIMIT 0 35 mm 0 014 in 3 OUTER ROTOR 2 7 LUBRICATION Remove the oil pump shaft from the oil pump and measure the pump end clearance SERVICE LIMIT 0 10 mm 0 004 in Temporarily install the shaft in the pump body Measure the inner rotor tip clearance SERVICE LIMIT 0 20 mm 0 008 in 1 SHAFT Replace the oil pump if necessary as an assembly 2 INNER ROTOR BB OIL PUMP ASSEMBLY 88 89 91 93 1 PUMP BODY 4 PRESSURE RELIEF VALVE BODY 2 OUTER ROTOR 3 INNER ROTOR 5 VALVE 7 RELIEF VALVE lt COVER Q 1 14 DRIVE 13 PUMP SHAFT 10 O RING 11 OIL STRAINER 2 8 LUBRICATION After 93 1 BODY 4 PRESSURE RELIEF VALVE BODY 6 SNAP RING 2 OUTER ROTOR B VALVE 7 RELIEF VALVE COVER 3 INNER ROTOR dio nd lt Q 8 WASHER ye 1
91. NG 9 4 BOLTS g 5 SUB FRAME Beh MOUNTING 9 REAR BOLTS FENDER RH gr y 2 S ANO 25 6 TAILLIGHT CASE MOUNTING NUTS 8 LEFT SIDE 7 SUB FRAME COVER MOUNTING NUTS 13 18 MEMO HYDRAULIC DISC BRAKE 88 89 91 93 N m 0 15 kg m 1 1 ft Ib 12 Nem 1 2 kg m 9 ft lb 27 Nem 2 7 kg m 20 ft lb 27 N m 2 7 kg m 20 ft lb 14 0 14 HYDRAULIC DISC BRAKE After 93 1 5 N m 0 15 Kg m 1 1 ft lb 12 N m 1 2 Kg m 9 ft lb 31 3 1 Kg m 22 ft Ib 2 5 0 25 Kg m 1 8 ft Ib 14 1 HYDRAULIC DISK BRAKE SERVICE INFORMATION TROUBLESHOOTING BRAKE FLUID REPLACEMENT AIR BLEEDING SERVICE INFORMATION GENERAL E 14 2 BRAKE PAD DISC 14 5 14 3 MASTER CYLINDER 14 8 BRAKE CALIPER 14 11 14 4 Acontaminated brake disc or pad reduces stopping power Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent Useonly DOT 4 brake fluid 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 flui
92. OND 0 10 0 30 0 004 0 012 0 50 0 020 OIL 0 20 0 70 0 008 0 028 0 90 0 035 Piston O D 74 965 74 990 2 9514 2 9524 74 90 2 949 Piston pin bore 18 002 18 008 0 7087 0 7090 18 05 0 711 Connecting rod small end 1 0 18 016 18 034 0 7093 0 7100 18 07 0 711 Piston O D 17 994 18 000 0 7084 0 7087 17 98 0 708 Piston to piston pin clearance 0 002 0 014 0 0001 0 0006 0 040 0 0016 Cylinder to piston clearance 0 010 0 050 0 0004 0 0020 0 10 0 004 Piston rod 0 016 0 040 0 0006 0 0016 0 060 0 0024 small end clearance TROUBLESHOOTING Low or uneven compression Worn cylinder or piston rings Leaking head gasket Incorrect valve timing Excessive smoke Worn cylinder and piston rings Improperly installed piston rings Damaged piston or cylinder Overheating Excessive carbon deposits on piston or combustion chamber Faulty water pump Piston noise Worn cylinder and piston Excessive carbon deposits 10 1 CYLINDER PISTON CYLINDER REMOVAL NOTE To service the rear cylinder piston first remove the engine and then proceed with the common removal steps below Remove the following cylinder head cover page 9 3 cylinder head page 9 8 gaskets dowel pins and cam chain guides Disconnect the water hose from the coolant connector Remove
93. ONIZATION NOTE Perform this maintenance with the engine at normal operat ing temperature 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 Connect the vacuum gauge TOOL Vacuum gauge 07404 0030000 Not available in U S A 07LMJ 001000A Warm up the engine and adjust the idle speed with the throttle Stop screw IDLE SPEED 1 200 100 rpm 3 10 MAINTENANCE Check that the difference in vacuum readings is 40 mm 1 6 in Hg or less NOTE The rear cylinder carburetor is the base carburetor If necessary synchronize to the specification by turning the synchronization adjusting screw Recheck the idle speed and synchronization Disconnect the gauge and adaptors and install the removed parts 1 SYNCHRONIZATION ADJUSTING SCREW CARBURETOR IDLE SPEED NOTE nspect and adjust idle speed after all other engine adjust ments are within specifications The engine must be warm for accurate adjustment Ten minutes of stop and go riding is sufficient Warm up the engine shift to NEUTRAL and place the motor cycle on its side stand Turn the throttle stop screw as required to obtain the specified idle speed IDLE SPEED 1 200 100 rpm RADIATOR
94. PROTECTOR eee LIGHTS METER SWITCHES BULB REPLACEMENT NOTE See page 18 5 for speedometer bulb replacement TURN SIGNAL LIGHT Remove the turn signal lens attaching screws While pushing in turn the bulb counterclockwise to remove Replace the bulb if desired Instal in the reverse order of removal NOTE Seat the rubber packing properly BRAKE TAILLIGHT Remove the taillight lens attaching screws While pushing in turn the bulb counterclockwise to remove Replace the bulb if desired Install in the reverse order of removal NOTE Seat the rubber packing properly LICENSE LIGHT Remove the bolts and license light case mounting nuts Replace the bulb with a new one SPEEDOMETER REMOVAL Disconnect the speedometer cable from the meter Remove the steering covers and disconnect the speedometer connector 6P Black Remove the speedometer stay mounting bolts and meter from the fork bridge 1 TURN SIGNAL LIGHT 1 SPEEDOMETER CABLE 18 4 BULB REPLACEMENT Remove the trip meter knob by removing the attaching screw Romove the speedomater cover mounting screws and cover Replace the meter bulb with new one 4 METER 3 STAY 2 MOUNTING SCREWS 1 O RING 10 SPEEDOMETER CABLE COVER Assemble the removed parts in the reverse order of disassem bly Route the speedometer wire as shown and install and tighten the mounting sc
95. RING REPLACEMENT 1 SNAP RING Remove the dust seals from the right and left swingarm pivots Remove the snap ring from the right pivot TOOL Snap ring pliers 07914 3230001 Drive the right pivot ball bearing out of the swingarm using a 1 DRIVER SHAFT hydraulic press and driver shaft TOOL Driver shaft 07946 MJ00100 REAR WHEEL BRAKE SUSPENSION 1 DRIVER SHAFT Drive the left needle bearing out of the swingarm TOOL Driver shaft 07946 MJ00100 Carefully press new bearings into the swingarm pivots NOTE Install the bearings with the marks facing out Right side ball bearing TOOLS Driver 07749 0010000 Attachment 32 x 35 mm 07746 0010100 Pilot 15 mm 07746 0040300 4 1 2 ATTACHMENTS AND PILOTS Left side needle bearing 1 SNAP RING TOOLS Driver 07749 0010000 Attachment 28 x 30 mm 07746 1870100 Pilot 22 07746 0041000 Snap ring pliers 07914 3230001 Install the snap ring into the right pivot Apply grease to the new dust seal lips and install them and the collars in the correct positions 2 PIVOT COLLARS 13 16 REAR WHEEL BRAKE SUSPENSION ASSEMBLY INSTALLATION 1 CHAIN COVER Install the chain slider and chain cover with protector Install the swingarm in the frame Install the swingarm pivot bolt and nut and tighten the nut to the specified torque TORQUE 90 N m 9 0 kg m 65 ft lb Instal
96. ROTTLE 1 CEMMENT 2 GRIP END CAP 1 REAR VIEW 2 CLUTCH SWITCH MIRROR un WIRES 4 LEFT HANDLEBAR SWITCH 3 HOLDER FRONT WHEEL SUSPENSION STEERING Disconnect the front brake light switch wires from the switch 1 BARKE LIGHT SWITCH 2 REARVIEW Remove the following WIRE MIRROR 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 Loosen the throttle cable lower adjusting nuts at the carbure tors and disconnect the throttle cables from the throttle pipe 3 HOLDER Remove the handlebar mounting nuts handlebar and rubber i HANDREBAR MOUNTING NUTS A seat from the fork bridge After 94 1 5 Remove the handlebar upper holder bolts caps Remove the socket bolts upper holders and handlebar 2 SOCKET BOLTS Remove the nuts and handlebar lower holders 2 LOWER HOLDERS 12 4 FRONT WHEEL SUSPENSION STEERING INSTALLATION 88 89 91 94 Install the rubber seat into the fork bridge Install the washers and handlebar mounting nuts Tighten the nuts TORQUE 23 N m 2 3 kg m 17 ft lb After 94 Install the handlebar lower holders and temporarily tighten the nuts Install the handlebar and upper holders with their punch marks facing forward Temporarily tighten the socket bolts Tigh
97. T CRANKCASE COVER CLUTCH REMOVAL INSTALLATION GEARSHIFT LINKAGE SERVICE INFORMATION GENERAL 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 f the shift fork drum and transmission require servicing remove the engine and separate the crankcase section 11 Coat the new clutch discs with clean engine oil before reassembly SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Spring free length 39 0 1 54 37 4 1 47 After 88 43 2 1 70 41 6 1 64 Spring preload length 25 25 27 25 26 2 kg mm Disc thickness 2 62 2 78 0 103 0 107 2 30 0 090 2 92 3 08 0 115 0 121 2 60 0 102 Plate warpage 0 30 0 012 Outer guide 21 991 22 016 0 8658 0 8668 22 09 0 870 31 959 31 025 1 2582 1 2589 31 98 1 259 Outer 1 0 32 000 32 025 1 2598 1 2608 32 10 1 264 Oil pump drive sprocket 1 0 32 000 32 025 1 2598 1 2608 32 10 1 264 Mainshaft O D at clutch outer guide 21 967 21 980 0 8648 0 8654 21 92 0 863 TORQUE VALUES Drum stopper plate bolt 12 Nem 1 2 kg m 9 ft lb Apply locking agent Primary drive gear bolt 90 9 0 kg m 65 ft lb Oil pump driven sprocket bolt 15 Nem 1 5 kg m 11 ft lb Apply locking agent Clutch lock nut 130 N m 13 0 kg m 94 ft Ib Oil pas
98. T NUT d S 4 DUST SEAL SS 5 UPPER BEARING INNER RACE 6 UPPER BEARING 7 UPPER BEARING OUTER RACE 8 LOWER BEARING OUTER RACE 9 LOWER BEARING 10 LOWER BEARING INNER RACE D 11 DUST SEAL 12 21 FRONT WHEEL SUSPENSION STEERING NOTE 1 DUST Always replace the bearing and race as a set Install the steering stem nut on the top end of the steering stem to protect the threads from damage Remove the lower inner race and dust seal using a punch or driver Replace the dust seal with a new one whenever it is removed 3 LOWER INNER RACE Remove the lower outer race using the special tools and a suit 1 BEARING RACE able shaft REMOVER TOOLS Bearing race remover 07946 3710500 Remove the upper bearing outer race using the special tools TOOLS Ball race remover 07953 MJ10000 Not available attachment 07953 Mu10100 im U S A driver handle 07953 MJ10200 or Attachment 07953 MJ1000A 07953 MJ1000B or Driver 07949 3710001 and Attachment 32x 35 mm 07746 0010100 1 1 STEERING d Install a new dust seal over the steering stem STEM Press a new lower bearing inner race onto the stem DRIVER TOOL Steering stem driver 07946 MBOO000 Drive new upper and lower bearing outer races into the steer ing head pipe TOOLS Upper bearing outer race Drive 07749 0010000 Attachment 42 x 47 mm 07746 0010300 Lower bearing outer race Driver 0
99. TE Mark all parts during disassembly so they can be placed back in their original locations 1 VALVE SPRING COMPRESSOR 2 apr e se CYLINDER HEAD VALVE Remove the valve stem seals and valve spring seats Remove carbon deposits from the combustion chamber 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 51 mm 1 477 in OUTER IN 40 58 mm 1 598 in EX 41 25 mm 1 624 in Replace the springs as a set if they are shorter than the service limit Valve stem to guide clearance 1 VALVE STEM Inspect each valve for bending burning scratches abnormal stem wear Check valve movement in the guide and measure and record each valve stem O D SERVICE LIMITS IN 5 45 mm 0 215 in EX 6 55 mm 0 258 in Measure and record each valve guide 1 0 NOTE Ream the guides to remove any carbon deposits before checking clearances SERVICE LIMIT IN 5 56 mm 0 219 in EX 6 65 mm 0 262 in Subtract each valve stem O D from the corresponding guide 1 0 to obtain the stem to guide clearance SERVICE LIMIT IN 0 10 mm 0 004 in EX 0 11 mm 0 004 in 9 10 CYLINDER HEAD VALVE If the stem to guide clearance exceeds the service limits de 1 VALVE GUIDE REAMER termine if a new guide with standard dimensions would bring the clearance within tolerance If so re
100. UP METER Black Y Yellow Bu Blue G Green R Red W White 9 FRONT 10 REAR 14 IGNITION PULSE GENERATOR Lg Light Green 16 1 IGNITION SYSTEM SERVICE INFORMATION 16 2 IGNITION PULSE GENERATOR 16 6 TROUBLESHOOTING 16 3 SIDE STAND SWITCH 16 7 IGNITION CONTROL MODULE INSPECTION 16 4 IGNITION TIMING 16 8 IGNITION COIL 16 5 SERVICE INFORMATION If the engine must be running to do some work make sure the area is well ventilated Never run the engine on enclosed area The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death GENERAL e Ignition timing cannot be adjusted since the ignition control module is non adjustable If ignition timing is incorrect check the system inspection and replace any faulty parts For spark plug gap inspection and adjustment procedure see page 3 8 For alternator removal and installation see section 8 For ignition pulse generator removal and installation see page 7 11 When inspecting the ignition system check the system components and lines step by step according to the trouble shooting on next page Each pair of the spark plugs Front and Rear has its own ignition circuit To test the neutral switch refer to section 18 SPECIFICATIONS STANDARDS 20 C 68 F Spark plug NGK NIPPONDENSO DPR8EA 9 X24EPR U9 0 8 0 9 mm 0 03 0 04 in Spark p
101. Water Pump eee Tr eR RE o RET os 5 7 Wheels Tir s 3 20 Wiring Diagram 19 1 21 2 278 HONDA MOTOR CO LTD TOKYO JAPAN 61MR107 G MADE FROM 50 RECYCLED PAPER MINIMUM 10 POST CONSUMER CONTENT IPC SM A20009506J T PRINTED IN U S A
102. a n sonora FH 95 UYA 1891 83138 3VM8 1NOH3 WHOIS 110 WYLNIN v 2 YOL vo 351 2 1 2214 g nena 9 IWNI NUMA 1331 KILNS LON 9 On a ISNIN T OF E 9 MOEZ 9 L1 it MS PCI AS Sanma YR 9 pc 1 9 2 THOS NADL BY A HOM 2 2 103100 miro TOS VOLYOKNI 70 MOLYOXNI WYLS 305 25 amp g 6 5 18083 1498 RUE Ld 55 5 19713 1 ai avez dE ZCAZI HLAS NOLIN MOLIAS 4015 NAG 1319715 L vina 1 T S 5 5 HOLS HOLS DON NUE 14043 gwas 305 Mre 7 19 2 WIRING DIAGRAM 792 93 i 3 5 48 3 i E TH i i 3 5 TEF 0030Z MYO 7700 1 15 FRONT REAR BRAKE TURN SIGHAL NEUTRAL OIL TALL METER LIGHT Iuj e alel 284258 8 3oao zs H ane FUSE MAU PRESSURE SWITCH EA L H 9 oe 5 m 77 i hae 234 STARTER MOTOR NEUTRAL e HH E o BI ESS cap 1
103. aft countershaft shift fork shaft and shift drum as an assembly After 95 Remove the shift fork shaft then remove the shift drum and shift forks Remove the mainshaft and countershaft as an assembly m at 3 SHIFT 5 88 89 91 95 1 MAINSHAFT 2 SHIFT FORK Separate the shift fork shaft mainshaft and countershaft ASSEMBLY SHAFT assemblies from each other AN After 95 Separate the mainshaft and countershaft assemblies from each other umi 3 COUNTERSHAFT ASSEMBLY DISASSEMBLY INSPECTION Temporarily install the mainshaft and countershaft to the left crankcase Measure the backlash of each gear STANDARD 1st 2nd 3rd 1 021 0 110 mm 0 0008 0 0043 in 4th 1 023 0 117 mm 0 0009 0 0046 88 89 91 95 Bend down the lock washer tabs and remove the bolt and lock washer from the left shift fork Remove the shift fork shaft 1 LOCK WASHER 2 BOLT 3 C4 GEAR Disassemble the mainshaft and countershaft Remove the C4 gear by removing the stop ring CRANKSHAFT TRANSMISSION Inspect the shift drum end for scoring scratches or evidence of insufficient lubrication Check the shift drum grooves for damage Measure the shift drum shaft O D at the left side journal SERVICE LIMIT 11 94 mm 0 470 in Check the bearing inner and outer races for damage The bearing should turn smoothly and quietly Check the shift fork shaft for scratc
104. amps as shown Route the alternator wire and connect the alternator 3P con nector Install the drive sprocket cover and the left side cover Check the oil level and add oil if necessary 8 6 MEMO CYLINDER HEAD VALVE 10 Nem 1 0 kg m 7 2 ft lb 23 N m 2 3 kg m 17 ft lb 10 Nem 1 0 kg m 7 2 ft lb 200 23 Nem 2 3 kg m 710 Nem 1 0 kg m 7 2 ft lb Qu E cae of gt 2 oN e E x Ze x On e Ne N 2 N _ VE E RT x l g d E zu oN 9 0 9 CYLINDER HEAD VALVE VALVE SEAT INSPECTION REFACING CYLINDER HEAD ASSEMBLY CYLINDER HEAD INSTALLATION CAMSHAFT INSTALLATION CYLINDER HEAD COVER INSTALLATION SERVICE INFORMATION TROUBLESHOOTING CYLINDER HEAD COVER REMOVAL CAMSHAFT REMOVAL CYLINDER HEAD VALVE GUIDE REPLACEMENT SERVICE INFORMATION GENERAL The front cylinder head 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 stallation However the rear cylinder head cover can be removed to service the camshaft rocker arms cam chain and cam chain tensioner Camshaft lubricating oil is fed through oil pass pipe Be sure the holes in the oil pass bolts are not clogged During assembly apply molybdenum disulfide oil 50 50 mixture of engine o
105. available in U S A bottom holder handle 07930 KA40200 Not available in U S A Place the fork slider in a vise with soft jaws or use a shop towel Apply a locking agent to the socket bolt and thread it into the piston Tighten with a 6 mm hex wrench NOTE Temporarily install the fork spring and fork cap bolt to tight en the socket bolt TORQUE 30 N m 3 0 kg m 22 ft lb Place the slider bushing over the fork tubeuntilit rests on the slider NOTE Tape the upper edge of the fork tube to avoid damaging the oil seal lip while installing the oil seal Using a fork seal driver drive the bushing into place Install the back up ring with the chamfered side facing the slider bushing Coat the oil seal lip with the recommended fork oil Drive the oil seal into place using a fork seal driver Install the oil seal stop ring and the dust seal TOOL Fork seal driver 39mm 07947 4630100 6 SLIDER 1 OIL SEAL 2 BACK UP RING 3 PISTON BUSHING 5 TUBE BUSHING 4 LOCK PIECE 1 HOLDER ATTACHMENT 2 BOTTOM HOLDER 1 SOCKET BOLT M 1 FORK SEAL DRIVER HANDLE 2 DUST SEAL 3 STOP RING 4 OIL SEAL 5 BACK UP RING 12 17 FRONT WHEEL SUSPENSION STEERING Compress the fork leg and pour Honda Suspension Fluid SS 8 or equivalent into the fork tube SPECIFIED LEVEL 88 89 Right fork 95 0 mm 3 74 in Left fork 93 0 m
106. bom CAN S NS EM ED MX 4 a li ES J 6 HORN SS 7 HORN WIRE After 94 1 THROTTLE CABLES 2 CLUTCH CABLE 3 LEFT HANDLEBAR SWITCH WIRE j lt 3 LEFT HANDLEBAR gt E SWITCH WIRE Weg 5 FRONT BRAKE HOSE 4 SPEEDOMETER CABLE BF 1 THROTTLE D d A CABLES y 9 RIGHT HANDLEBAR SWITCH WIRE 2 CLUTCH CABLE b FRONT BRAKE HOSE 9 RIGHT HANDLEBAR SWITCH WIRE 6 HEADLIGHT CONNECTOR 7 HORN 8 HORN WIRE 1 12 GENERAL INFORMATION 88 89 791 2 HANDLEBAR SWITCH WIRE BANDS 13 CRANKCASE BREATHER TUBE A h 12 WATER HOSE il 11 ENGINE BREATHER C O 1 EVAPORATIVE E XN EMISSION 14 PURGE CONTROL os model only AR A Sip NET NC NS we 4 10 STARTER um c NN AP e m VALVE California pee 3 CRANKCASE MOTOR ME SS BREATHER LR e SEPARATOR A 90 9 STARTERZ MOTOR Ew CABLE S pos 1 8 9 SUB AIR CABLE CLEANER NONE M 5 AIR CLEANER 6 IGNITION puLse HOUSING GENERATOR 7 CLUTCH CABLE WIRE eres 1 HANDLEBAR SWITCH WIRE BANDS 13 CRANKCASE BREATHER TUBE pus 11 ENGINE BREATHER d le T A 2 CRANKCASE TUBE yy BREATHER gt 12 WATER EM M SEPARATOR HOSE N se 9 10 STARTER i SN S
107. brake cam into the brake panel Install the felt seal 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 2 ae and cam Install and tighten the bolt 4 1 PUNCH MARKS 3 BRAKE ARM Position the brake shoes in their original locations and install 1 BRAKE the springs WSS Grease on the brake linings will reduce stopping power Keep grease off of the brake linings Wipe excess grease off the cam and anchor pin Install the set plate and cotter pins then bend back the pins Install the brake panel onto the wheel hub and install the rear wheel page 13 7 4 SET PLATE 3 COTTER PINS 2 SPRINGS 13 9 REAR WHEEL BRAKE SUSPENSION BRAKE PEDAL REMOVAL Remove the foot peg bracket mounting bolts and washers Remove the brake pedal by removing the cotter pin washer and bolt 1 FOOT PEG BRACKET 80115 INSTALLATION Install the brake pedal in the reverse order of removal NOTE 1 WASHER As e Note the locations of the washers Sc L LL o 4 BRAKE SHAFT ARM 5 PUNCH MARK 1 BRAKE PEDAL ADJUSTER BOLT 1 3 MIDDLE BRAKE ROD 2 DUST SEALS 6 BRAKE ROD 9 BRAKE PEDAL 5 PUNCH MARK 8 PIVOT COLLAR 7 MIDDLE BRAKE ARM NOTE Align the punch mark the brake shaft arm end with th
108. ccordance with the table below MAIN JOURNAL 1 2 0 0 CODE 44 992 44 984 45 000 44 991 1 7713 1 7710 CASE 1 0 CODE 1 7717 in 1 7713 in 48 990 49 000 mm C B 1 9287 1 9291 in BROWN BLACK 49 000 49 010 mm B A 1 9291 1 9295 in BLACK BLUE A BEARING INSERT THICKNESS BLUE 2 003 2 013 mm 0 0789 0 0793 B BLACK 1 998 2 008 mm 0 0787 0 0791 in BROWN 1 993 2 003 mm 0 0785 0 0789 1 DRIVER MAIN BEARING REPLACEMENT Press the main bearing out of the crankcase using a hydraulic press and special tools NOTE Always use a press to remove the main bearing TOOLS Driver 07749 0010000 Main bearing remover attachment 07HMF MM90400 Mark a vertical line below each side of the bearing tab Apply molybdenum disulfide grease to the outer surface of the main bearing Align the marks on the bearing with the groove in the bearing hole and press the main bearing into the crankcase CAUTION Becareful not to damage the bearings TOOLS Driver 07749 0010000 Main bearing driver attachment O7HMF MM90400 11 9 CRANKSHAFT TRANSMISSION CONNECTING ROD CRANKSHAFT 1 CONNECTING ROD SELECTION WEIGHT CODE If a connecting rod requires replacement you should select rod with the same weight code as the original But if that is unavailable you may use one of the others
109. ch outer and install the gear holder as shown TOOL Gear holder 07724 0010100 Install the washer and bolt and tighten the bolt TORQUE 90 N m 9 0 kg m 65 ft Ib Remove the gear holder and clutch outer AR HOLDER 1 GE eso Install the following ot Lr we 1 BOLT ignition pulse generators clutch page 7 12 NOTE If removed the ignition pulse generator wire grommets were removed from the case groove reinstall them securely 2 IGNITION PULSE G CLUTCH INSTALLATION Apply MoSz paste grease to the outside of the clutch outer guide and install the oil pump drive sprocket over the outer guide Install the oil pump drive chain on the drive sprocket OIL PUMP DRIVEN SPROCKET Install the oil pump driven sprocket with the 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 TORQUE 15 N m 1 5 kg m 11 ft lb 3 IN MARK 7 12 CLUTCH GEARSHIFT LINKAGE 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 Install the thrust washer onto the mainshaft Install the spring seat judder spring and clutch disc B on the clutch center 6 TAB 3 7 SLOT 4 PLATE 6
110. ck Tires 20 30 mm 3 4 1 3 16 43 mm 1 7 in 10 20 mm 3 8 3 4 20 30 mm 3 4 1 3 16 we qme ecc refs call Front Rear Tire size 100 90 19 57S 170 80 15 77S Cold tire pressures Up to vehicle capacity load 200 2 00 29 250 2 50 36 kPa kg cm psi Up to 90 kg 200 Ibs load 200 2 00 29 200 2 00 29 Maximum weight capacity 161 kg 355 Ibs Tire brand Bridgestone L309 G 546 Dunlop F24 K555 TORQUE VALUES Rear axle nut Valve adjusting screw lock nut Spokes front rear Timing hole cap Crankshasft hole cap TOOLS Special Valve adjusting wrench Vacuum gauge Drive chain cutter Spoke wrench 90 9 0 kg m 65 ft lb 23 Nem 2 3 kg m 17 ft lb 4 0 4 kg m 2 9 ft lb 3 5 Nem 0 35 kg m 2 5 ft Ib 15 Nem 1 5 kg m 11 ft lb 07908 90000 Not available in U S A 07908 90100 U S A Only 07404 0030000 Not available in U S A 07LMJ 001000A U S A Only 07HMH MR10100 or 07HMH MR1010B U S A Only 07JMA MR60100 Not available in U S A 3 2 MAINTENANCE MAINTENANCE SCHEDULE 88 Perform the PRE RIDE INSPECTION in the Owner s Manual at each scheduled maintenance period INSPECT AND CLEAN ADJUST LUBRICATE OR REPLACE IF NECESSARY CLEAN REPLACE L LUBRICATE
111. d does get on these parts wipe it off immediately with a clean cloth Always check brake operation before riding the motorcycle 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 SPECIFICATIONS Unit mm in ITEM STANDARD ERVICE LIMIT Disc thickness 5 0 0 2 4 0 0 16 Disc runout 0 30 0 012 g8 89 10 12 700 12 743 0 5000 0 5017 12 76 0 502 Master 91 93 piston O D 12 657 12 684 0 4983 0 4994 12 65 0 498 cylinder Arenga 10 11 0 11 043 0 4331 0 4348 11 05 0 435 piston O D 10 957 10 984 0 4314 0 4324 10 945 0 4309 88 89 cylinder 1 0 30 230 30 280 1 1902 1 1921 30 29 1 193 Brake 91 93 piston O D 30 165 30 198 1 1876 1 1889 30 16 1 187 caliper T cylinder 1 0 27 000 27 050 1 0630 1 0650 27 06 1 065 piston O D 26 935 26 968 1 604 1 0617 26 93 1 060 TORQUE VALUES Caliper mounting bolt Brake hose oil bolt Bleed valve Master cylinder holder bolt Master cylinder cover screw TOOL Special Snap ring pliers 27 Nem 2 7 kg m 20 ft lb 30 3 0 kg m 22 ft lb 5 5 Nem 0 55 kg m 4 ft lb 12 Nem 1 2 kg m 9 ft lb 1 5 Nem 0 15 kg m 1 1 ft lb 07914 3230001 or equivalent commercially ava
112. dle Align the punch mark on the arm with the punch mark on the spindle Tighten the gearshift arm mounting bolt 4 GEARSHIFT SPINDLE 3 GEARSHIFT ARM 7 10 CLUTCH GEARSHIFT LINKAGE Install the gearshift pedal mounting bolt and tighten the bolt securely Install the drive sprocket cover page 13 17 1 GEARSHIFT PEDAL MOUNTING BOLT PRIMARY DRIVE GEAR 3 2 p ATON BUE GENERATOR ROTOR 47 REMOVAL Remove the following right crankcase cover page 7 3 clutch assembly page 7 4 Remove the ignition pulse generator mounting bolts and ignition pulse generators d PA 3 CLUTCH 2 PRIMARY DRIVE GEAR i oo Temporarily install the clutch outer 7 13 then install 1 IGNITION GENERATOR MOUNTING BOLTI the gear holder as shown m TOOL Gear holder 07724 0010100 Remove the following ignition pulse generator rotor bolt and rotor clutch outer and gear holder primary drive gear INSTALLATION 1 PRIMARY DRIVE SGAM NOTE 4 Install the primary drive gear with the OUT mark facing out The primary drive gear and ignition pulse generator rotor will only go on in one position because of the extra wide aligning spline Install the ignition pulse generator rotor 4 IGNITION PULSE cx at ABA GENERATOR ROTOR _ CLUTCH GEARSHIFT LINKAGE Temporarily install the clut
113. during the break in period Sections 1 through 3 apply to the whole motorcycle while sections 4 through 19 describe parts of the motorcycle grouped ac cording to location Find the section you want on this page then turn to the table of contents on the first page of that section Most sections start with an assembly or system illustration service information and troubleshooting for the section The subse quent pages give detailed procedures If you don t know the source of the trouble go to section 20 TROUBLESHOOTING ALL INFORMATION ILLUSTRATIONS DI RECTIONS 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 OBLI GATION WHATEVER NO PART OF THIS PUBLI CATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION HONDA MOTOR CO LTD SERVICE PUBLICATIONS OFFICE CONTENTS GENERAL INFORMATION LUBRICATION MAINTENANCE 3 FUEL SYSTEM COOLING SYSTEM ENGINE REMOVAL INSTALLATION CLUTCH GEARSHIFT LINKAGE amp ALTERNATOR STARTER CLUTCH CYLINDER HEAD VALVE CYLINDER PISTON CRANKSHAFT TRANSMISSION 11 FRONT WHEEL SUSPENSION STEERING REAR WHEEL BRAKE SUSPENSION E HYDRAULIC DISC BRAKE 14 BATTERY CHARGING SYSTEM IGNITION SYSTEM e
114. e 88 127 kPa 0 9 1 3 kg cm 13 18 psi Freezing point Hydrometer test 55 Distilled water 4596 ethylene glycol 329 25 F 50 Distilled water 5096 ethylene glycol 37 C 349 F 45 Distilled water 5596 ethylene glycol 44 59 48 F Coolant capacity Coolant change 1 45 lit 1 37 US qt 1 28 Imp qt Total system 1 6 lit 1 51 US qt 1 41 Imp qt Thermostat Begins to open 80 to 84 C 176 to 183 F Valve lift Minimum of 8 mm at 95 C 0 3 in at 203 F Boiling point with 50 50 mixture Unpressurized 107 7 C 226 F on pressurized 125 6 C 258 F TROUBLESHOOTING 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 Insufficient coolant or coolant level too low Coolant leaks Passages blocked in radiator hoses or water jacket Faulty pump mechanical seal Cooling fan motor does not turn Deteriorated O rings Burned or loose sub fuse Faulty fan motor Faulty thermostatic switch Poor connector contact or open circuit in harness Faulty water pump COOLING SYSTEM SYSTEM TESTING COOLANT MIXTURE Remove the fuel tank page 4 3 Remove the steering covers by removing the bolt Remove the radiator cap AWARNING Be sure the engine is cool before removing the cap or you
115. e Inspection 16 4 Ignition Pulse 16 6 Ignition System sess 16 2 sp 16 4 SI D 18 6 16 6 Left Crankcase Cover Installation 8 6 Removal Lights Meter Switches E brication Des POINTS t oct Mie debis Maintenance e RR Wee Master Cylinder occ ret Model Identifiction 2 Ne tral SWItCly ecc reir rena rd m Een Nuts Bolts Fasteners Oil Filter Change fess ceive c eot eet ner etx Oil Pressure Check nere rr eere uer SWItCh 15 Oil Pump ERG eS Pilot Screw Adjustment PISTON eA eee n E E E UA greca eu Ring Installation Primary Drive Gear Radiator Coolant Radiator Cooling Fan Rear Wheel Brake Suspension 13 1 Brake pe 13 7 Wheel 13 3 Regulator Rectifier 15 8 INDEX Right Crankcase Cover Installation 7 14 Removal 7 3 Seat Rear Fender Sub frame 13 18 Service Informa
116. e and discard the bearings if the races do not turn smoothly quietly or if they fit loosely in the hub NOTE 1 CHAIN ADJUSTER Replace wheel bearings in pairs For bearing replacement see page 13 4 WHEEL BALANCING Refer to page 12 7 NOTE Do not add more than 70 grams of balancing weight to the rear wheel 1 WHEEL BEARING 13 3 REAR WHEEL BRAKE SUSPENSION SPROCKET DRIVEN FLANGE DISASSEMBLY INSPECTION 1 GOOD 2 REPLACE Remove the wheel page 13 3 Remove the mounting nuts and separate the sprocket from the flange Check the condition of the sprocket teeth Replace a worn or damaged sprocket ee ae NOTE The drive chain and drive sprocket must also be inspected if the driven sprocket is worn damaged Never install new drive chain on worn sprockets or a worn chain on new sprockets Both chain and sprocket must be in good condi tion or the new replacement chain or sprockets will wear QW If driven flange the hub drive it out by tapping it at several lo cations with wood block Remove the dampers from the flange in the hub Remove the collar and dust seal from the flange Drive out the driven flange bearing if necessary Inspect the dampers for deterioration Turn the inner race of the bearing with your finger The bearing should turn smoothly and quietly Also check that the outer race fi
117. e punch mark on the middle brake arm 13 10 REAR WHEEL BRAKE SUSPENSION REAR SHOCK ABSORBER 2 FUEL PUMP REMOVAL 1 STAY The rear shock absorber contains nitrogen under high pressure Do not allow fire or heat near the shock absorber Support the motorcycle using a hoist or a jack under the en gine Remove the following seat right and left side cover rear ignition coil mounting bolts page 16 5 rear ignition coil stay mounting bolt OLT Disconnect the fuel pump fuel pump relay and turn signal 2 LOWER MOUNTING BOLT relay from the fuel pump stay Remove the fuel pump stay mounting bolt nut and fuel pump stay Remove the upper and lower shock absorber mounting bolts and nuts then remove the shock absorber DISASSEMBLY a 2 ATTACHMENT Set the spring preload adjuster to No 1 position Compress the shock absorber with the compressor and attach ment CAUTION 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 0010000 3 SHOCK ABSORBER Attachment 07JME MR10100 COMPRESSOR Compressor screw 07GME 0010100 1 LOWER JOINT Loosen the lock nut and remove the lower joint and nut Remove the compressor and disassemble the shock absorber 2 LOCK NUT 13 11 REAR WHEEL BRAKE SUSPENSION SPRING FREE LENGTH
118. e resistance between connector terminals using 1 IGNITION CONTROL MODULEMES the following chart 6P CONNECTOR ITEM TERMINALS STANDARD 20 C 68 F Ignition primary coil Y and BI Rear Bu Y and BI Front 1 89 2 32 9 DC power supply circuit line BI G Bu Y and Y and G Battery voltage should come with the ignition switch ON and engine stop switch RUN lt 4P CONNECTOR gt TERMINALS STANDARD 20 C 68 F Ignition pulse generator coil W Y and Y Front W Bu and Bu Rear 450 550 2 Each terminal and body ground NO CONTINUITY IGNITION COIL INSPECTION Remove the fuel tank page 4 3 and crankcase breather tank Measure the primary coil resistance of the front ignition coil in the frame Remove the right side cover and rear ignition coil and measure the primary coil resistance Checking for continuity between the primary terminals STANDARD 1 89 2 32 Q 20 C 68 F Disconnect the spark plug caps from the plugs and measure the secondary coil resistance with the spark plug caps in place STANDARD 23 55 30 45 20 C 68 F 16 4 n IGNITION SYSTEM If the resistance is out of range remove the spark plug wires and measure the resistance between the secondary coil termi nals STANDARD 19 8 24 2 20 C 68 F REPLACEMENT Rear ignition coil Remove the right side cover Disconnect the fuse connectors a
119. e stems gently with a soft hammer to firmly seat the cotters NOTE Support the cylinder head above the work bench surface to prevent possible valve damage Apply locking agent to the threads of the sealing bolts and tighten them if removed CYLINDER HEAD INSTALLATION Install the cam chain guide into the cylinder Make sure that the cam chain guide bosses are in the grooves of cylinder Clean the cylinder head surface of any gasket material 1 Install the dowel pins and a new head gasket 9 16 CYLINDER HEAD VALVE 4i 1 BOSS 2 SLOT Install the carburetor insulator on the cylinder head aligning the boss on the cylinder head with the slot in the insulator After 91 California model only Install the insulator bands aligning the pins on the insulator bands with the slots on the insulators as shown Tighten the band screws securely Install the cylinder head Install the 10 mm nut washer 8 mm nut washer 8 mm bolt washer and 6 mm bolt and tighten them in a crisscross pattern in 2 or 3 steps TORQUE 10 mm nut 48 N m 4 8 kg m 35 ft Ib 8 mm bolt 23 2 3 kg m 17 ft lb 8 mm nut 23 2 3 kg m 17 ft lb 6 mm bolt 10 N m 1 0 kg m 7 2 ft lb 2 ud A 4 6 mm BOLT 3 8 mm BOLTS WASHERS 88 89 1 SEALING WASHERS Check the oil pass pipe bolts and oil pass pipe for clogging or bending Install the pass pipe new sealing washers oil pas
120. e switch is suddenly turned on during a test the tester fuse may blow LEAKAGE INSPECTION Check the battery ampere leakage before making the regulat ed ampere inspection Turn the ignition switch off and disconnect the battery nega tive cable from the battery Connect the tester between the negative cable and the nega tive battery terminal The voltage should indicate less than O 1 mA with the ignition switch off LEAKAGE AMPERES 0 1mA max TIMER Trickle NEW BATT EN loo RED d 2 YELLOW gt 1 NEGATIVE TERMINAL NEGATIVE CABLE 15 7 BATTERY CHARGING SYSTEM REGULATED VOLTAGE INSPECTION NOTE Be sure the battery is in good condition before performing this test Warm up the engine to normal operating temperature Stop the engine and connect the voltmeter as shown Start the engine and allow it to idle then increase the engine speed gradually The voltage should be controlled to 14 3 15 1 V at 5 000 rpm CAUTION Becareful not to let the battery positive cable contact the frame while testing INSPECTION Remove the left side cover Disconnect the 3P WHITE and 4P BLACK regulator rectifier connectors Check the connectors for loose or corroded terminals If the regulated voltage reading was out of specification check the circuits between the connector terminals wire harness side and alternator side following
121. eck that the bearing outer race fits tightly in the hub Remove and discard the bearings if the races do not turn smoothly quietly or if they loosely in the hub BEARING REPLACEMENT Remove the front wheel page 12 7 Remove the dust seal and retainer from the left side of the wheel hub Remove the dust seal from the right side of the hub Remove the brake disc mounting bolts and disc FRONT WHEEL SUSPENSION STEERING Drive out the wheel bearings and distance collar 1 BEARING REMOVER SHAFT CAUTION Never reuse old bearings TOOLS Bearing remover shaft 07746 0050100 Equivalent commercially available in U S A Bearing remover head 20 mm 07746 0050600 Equivalent commercially available in U S A 2 BE BEARING REN REMOVER HEAD Drive in the new left bearing first until it seats 1 DRIVER Install the distance collar and drive in the right bearing jenes NOTE Install the bearings with the vendor markings facing the outside Be sure to drive the bearings in squarely Always replace wheel bearings in pairs TOOLS Driver 07749 0010000 Attachment 42 x 47 mm 07746 0010300 Pilot 20 mm 07746 0040500 ASSEMBLY EM 0o 0690 oo Do not get get grease on the brake disc or stopping power will be reduced E 1 DISTANCE COLLAR 11 SIDE D COLLAR wr 2 BEARING 10 DUST 3 DUST SEAL SEAL 9 BEARING 4 SPEEDOMETER GEARBOX 0
122. ect your eyes Skin and clothing In case of contact flush thoroughly with water and call a doctor if electrolyte gets in your eyes CAUTION Used engine oil may cause skin cancer if repeatedly left in con tact with the skin for prolonged periods Although this is unlikely unless you handle used oil on a daily basis it is still adviseable to thoroughly wash your hands with soap and water as soon as possible after handling used oil 1 Use genuine HONDA or HONDA recommended parts and lubricants or their equivalents Parts that don t meet HONDA 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 interchangeable with English fas teners aft Install new gaskets O rings cotter pins and lock plates when reassembling When tightening bolts or nuts begin with the larger diameter or inner bolts first Then tighten to the specified torque diag Onally in 1 5 steps unless a particular sequence is specified 6 Clean parts in non flammable or high flash point solvent upon disassembly Lubricate any sliding surfaces before reassembly 8 After reassembly check all parts for proper installation and operation 1 1 GENERAL INFORMATION MODEL IDENTIFICATION 1 VEHICLE IDENTIFICATION NUMBER The vehicle identification number
123. een the sprockets SLACK 20 30 mm 3 4 1 3 16 in 1 SCALE CHAIN ADJUSTMENT Loosen the axle nut Loosen both lock nuts and turn both adjusting bolts as neces sary Make sure the index marks on both the adjuster collars are aligned with the corresponding scale graduations on both sides of the swingarm Tighten both lock nuts then tighten the rear axle nut 3 LOCK NUT TORQUE 90 N m 9 0 kg m 65 ft Ib 4 ADJUSTER BOLT 3 13 MAINTENANCE Recheck chain slack and free wheel rotation Lubricate the drive chain with Pro Honda Chain Lube or equiv alent chain lubricant designed specifically for use on O ring chains 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 REPLACEMENT CHAIN RK525 SM5 DID525 8 LUBRICATION AND CLEANING When the drive chain becomes extremely dirty it should be cleaned prior to lubrication Clean the drive chain with a non flammable or high flash point and wipe dry The drive chain on this motorcycle is equipped with small O rings between the link plates The O rings can be damaged by steam cleaners high pressure washers and certain solvents Lubricate the drive chain with Pro Honda Chain Lube or equiv alent chain lubricant designed specifically for use on O ring chains CHAIN REPLACEMENT The VT6OOC uses a drive chain 120 pins with a staked mast
124. el pump and connect a fuel tabe or equivalent to the pump outlet line Hold a graduated beaker under the pump outlet line AWARNING Gasoline is extremely flammable and is explosive under certain conditions Work in a well ventilated area Do not smoke or allow flammes or sparks in your work area or where gasoline is stored Turn the ignition switch on and let fuel flow into the beaker for 5 seconds then turn the ignition switch off Multiply the amount in the beaker by 12 to determine the fuel pump flow capacity per minute FUEL PUMP FLOW CAPACITY 800 cc 0 76 US qt 0 70 Imp qt min minute OIL PRESSURE SWITCH Make sure that the oil pressure warning light comes on with the ignition switch If the light does not come on inspect as follows Remove the drive sprocket cover Page 13 14 Disconnect the oil pressure switch wire from the switch by re moving the terminal screw Short it to ground using a jumper wire Turn the ignition switch The oil pressure warning light should come If the light does not come on check the bulb sub fuse 10 A and wires for a loose connection or an open circuit Start the engine and make sure that the light goes out If the light does not go out check the oil pressure page 2 5 If the oil pressure is normal replace the oil pressure switch 4 992 1 page 2 5 pe mand 1 OIL PRESSURE SWITCH 18 10 LIGHTS METER SWITCHES NEUTRAL SWITCH
125. emoving the two sprock et bolts Disconnect the oil pressure 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 Disconnect the clutch cable from the clutch lifter arm by re moving the holder bolt Remove the right foot peg and rear brake pedal by removing the two bracket mounting bolts PROTECTORS 2 EXHAUST PIPE AND MUFFLERS s 2 DRIVE SPROCKET BOLTS amp 1 NEUTRAL SWITCH m 3 BRACKET MOUNTING BOLTS 6 3 ENGINE REMOVAL INSTALLATION Disconncet the ignition pulse generator wire connector 4P 1 IGNITION PULSE GENERATOR WIRE CONNECTOR WHITE Remove the lower radiator hose radiator to water pump Disconnect the water hoses thermostat housing to cylinder heads from the cylinder heads page 9 3 1 LOWER RADIATOR HOSE FRONT UPPER vane LL OTD ae Place a floor jack or other adjustable support under the engine 1 REAR UPPER BOLT 2 NOTE The jack height must be continually adjusted to relieve stress for ease of bolt removal Remove the following rear wheel page 13 3 swingarm page 13 14 front upper engine bracket two 8 mm bolts 10 mm bolt 2 and collar E front lower en
126. emperature in your riding area is within the indicated range Oil pump ITEM STANDARD SERVICE LIMIT Rotor tip clearance 0 15 mm 0 006 in 0 20 mm 0 008 in Pump body clearance 0 15 0 22 mm 0 006 0 009 in 0 35 mm 0 014 in Pump end clearance 0 02 0 07 mm 0 001 0 003 in 0 10 mm 0 004 in Oil pressure TORQUE VALUES Oil pressure switch Engine oil drain bolt Oil filter 2 2 441 kPa 4 5 kg cm 64 psi at 6 000 rpm 12 N m 1 2 kg m 9 ft Ib 35 N m 3 5 kg m 25 ft Ib 10 Nem 1 0 kg m 7 2 ft lb LUBRICATION TOOLS Special Oil filter wrench O7HAA PJ70100 Oil pressure gauge 07506 3000000 equivalent commercially available in U S A Oil pressure gauge attachment 07510 4220100 Snap ring pliers 07914 3230001 or equivalent commercially available in U S A TROUBLESHOOTING Oil level too low Normal oil consumption External oil leaks Worn piston rings Oil contamination Oil not changed often enough Faulty head gasket Worn piston rings Low oil pressure Faulty oil pump e Clogged oil strainer Low oil level Faulty pressure relief valve Oil leaks High oil pressure Faulty pressure relief valve Clogged oil filter or oil orifice No oil pressure Oil level too low Broken oil pump drive or driven sprockets Broken oil pump drive chain Faulty oil pump Oil leaks
127. ended to correct a worn valve seat NOTE Follow the refacer manufacturer s operating instructions VALVE SEAT REFACING Use a 45 degree cutter to remove any roughness or irregulari ties from the seat NOTE Reface the seat with a 45 degree cutter when a valve guide is replaced Use a 32 degree cutter to remove the top 1 4 of the existing valve seat material Use a 60 degree cutter to remove the bottom 1 4 of the old seat Remove the cutter and inspect the area you have refaced o 60 32 IN 07780 0014000 IN 07780 0012100 28 30 EX 07780 0012300 35 EX 07780 0014100 37 5 459 07780 0010200 27 5 07780 0010400 35 9 1 ROUGHNESS IRREGULARITIES 2 VALVE SEAT 1 OLD SEAT WIDTH 1 OLD SEAT WIDTH 9 13 CYLINDER HEAD VALVE 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 Apply a thin coating of Prussian Blue to the valve seat Press the valve through the valve guide and onto the seat to make a clear pattern NOTE The location of the valve seat in relation to the valve face is very important for good sealing 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
128. er adjusting brake pedal height Check the brake pedal free play 3 4 1 1 4 in 1 in FREE PLAY 20 30 mm 3 4 1 1 4 in If adjustment is necessary use the rear brake adjusting nut NOTE After adjusting the brake pedal free play check the rear brake light switch operation and adjust if necessary BRAKE LIGHT SWITCH NOTE Perform rear brake light switch adjustment after adjusting the brake pedal play and height The front brake light switch does not require adjustment 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 _ 1 BRAKE LIGHT SWITCH MAINTENANCE HEADLIGHT AIM Adjust vertically by turning the vertical adjustment screw Adjust horizontally by turning the horizontal adjusting screw 1 HORIZONTAL ADJUSTING SCREW NOTE e Adjust the headlight beam as specified by local laws and regulations A WARNING An improperly adjusted headlight may blind oncoming drivers or it may fail to light the road for a safe distance 2 VERTICAL ADJUSTING SCREW CANO v CLUTCH SYSTEM Measure the clutch lever free play at the lever end FREE PLAY 10 20 mm 3 8 3 4 in 1 10 20 mm 3 8 3 4 in Minor adjustments are made with the uppe
129. er link Loosen the drive chain page 3 13 Locate the crimped pin ends of the master link from the out side of the chain and remove the link with the chain cutter TOOL Drive chain cutter 07HMH MR10103 Not available in U S A 07HMH MR1010B NOTE When using the special tool follow the manufacturer s op erating instructions CAUTION Never reuse the old drive chain master link master link plate and O rings REPLACEMENT CHAIN RK525 SM5 DID525 V8 Install the new drive chain through the swingarm as shown 1 WEAR LABEL 3 INDEX M 1 WIPE DRY 3 MASTER LINK 2 DRIVE CHAIN CUTTER 1 SWINGARM 2 DRIVE CHAIN 3 14 MAINTENANCE Assemble the new master link O rings and plate 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 Measuring the master link pin length projected from the plate Standard length RK 1 2 1 4 mm 0 05 0 06 in DID 1 15 1 55 mm 0 05 0 06 in Stake the master link pins using the special tool Make sure that the pins are staked properly by measuring the diameter of the staked area using a slide calipers DIAMETER OF THE STAKED AREA 5 50 5 80 mm 0 217 0 228 in After staking check the staked area of the master link for cracks If there is an
130. erly 5 After clamping check each harness to be certain that it does not interfere with any moving or sliding parts After routing check that the wire harnesses are not twisted or kinked Wire harnesses routed along the handlebars should not be pulled taut have excessive slack be pinched by or interfere with adjacent or surrounding parts in all steering positions Do not bend or twist the control cables Damaged control cables will not operate smoothly and may stick or bind O CORRECT X INCORRECT 1 10 GENERAL INFORMATION 88 89 91 1 THROTTLE CABLES 2 CEUTCIECABLE SWITCH WIRE z 23 571 PN 6 3 LEFT HANDLEBAR yi gt 9 FRONT BRAKE HOSE 5 HEADLIGHT CONNECT 8 RIGHT HANDLEBAR CTOR SWITCH WIRE A lt lt 6 HORN M 7 HORN WIRE 2 CLUTCH CABLE 1 THROTTLE CABLES 3 LEFT HANDLEBAR 25 P y f SWITCH WIRE fo 4 SPEEDOMETER 225 9 FRONT BRAKE HOSE 5 HEADLIGHT 8 RIGHT HANDLEBAR SWITCH WIRE jf 7 HORN WIRE ey 6 HORN 1 11 GENERAL INFORMATION 94 1 THROTTLE CABLES 2 CLUTCH CABLE 3 LEFT HANDLEBAR SWITCH WIRE o 4 SPEEDOMETER CABLE D Ne D N 54 9 FRONT BRAKE HOSE 8 RIGHT HANDLEBAR SWITCH WIRE Fa 5 HEADLIGHT CONNECTOR
131. es Insert the shift fork shaft through the shift forks into the left crankcase with the stepped end facing up STEPPED END CRANKCASE ASSEMBLY Apply sealant to the crankcase mating surfaces Install the dowel pins Assemble the right and left crankcases being careful to align the dowel pins and shafts 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 11 19 CRANKSHAFT TRANSMISSION Apply oil to all crankcase bolts Install and tighten the right crankcase bolts in a crisscross pat tern in 2 or 3 steps NOTE Tighten the 8 mm bolts first then tighten the 6 mm bolts Install and tighten the left crankcase bolts in a crisscross pat tern in 2 or 3 steps NOTE e Tighten the 8 mm bolts first then tighten the 6 mm bolts Install the rear cam chain drive sprocket over the crankshaft aligning the extra wide splines in the sprocket and crankshaft Install the rear cam chain over the drive sprocket Install the oil pipe stay and cam chain tensioner set plate Tighten the bolt sercurely 11 20 R CAM CHAIN CRANKSHAFT TRANSMISSION Install the front cam chain over the front cam chain drive sprocket Install the cam chain tensioner set plate and tighten the bolt securely iU FRONT CAM CHAIN PO Install the remaining parts in the r
132. everse order of removal page 11 1 11 21 FRONT WHEEL SUSPENSION STEERING 30 N m 3 0 Kg m 22 ft Ib After 94 105 N m 10 5 Kg m 76 ft lb After 93 50 N m 5 0 Kg m 75 N m 7 5 Kg m 54 ft Ib 36 ft Ib 22 N m 2 2 Kg m 16 ft lb 88 89 91 93 27 N m 2 7 Kg m 20 ft lb After 93 31 N m 3 1 Kg m 22 ft lb 12 0 12 FRONT WHEEL SUSPENSION STEERING SERVICE INFORMATION TROUBLESHOOTING HANDLEBAR SERVICE INFORMATION WARNING 12 1 FRONT WHEEL 12 2 12 3 FORK STEERING STEM 12 6 12 12 12 19 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 OSH A 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 stem Refer to section 14 for front hydraulic brake service Support the motorcycle using a hoist or a jack under the engine The VT60OC uses leaf valve to the left SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Axle runout 0 2 mm 0 008 Front w
133. f the hose to prevent contamination Secure the hose to prevent fluid from leaking out 3 HOLDER DISASSEMBLY 1 BRAKE LEVER Remove the master cylinder holder bolts and holder then remove the master cylinder from the handlebar hc Remove the brake lever and brake light switch 2 BRAKE LIGHT SWITCH naan 14 8 HYDRAULIC DISC BRAKE Remove the boot 1 SNAP RING Remove the piston and spring by removing the snap ring TOOL Snap ring pliers 07914 3230001 or equivalent commercially available in U S A 2 BOOT Clean the inside of the master cylinder reservoir spring and piston with clean brake fluid 2 PISTON INSPECTION Measure the master cylinder I D SERVICE LIMIT 88 89 91 93 12 76 mm 0 502 After 93 11 05 mm 0 435 in Check the master cylinder for scores scratches or nicks Measure the master piston O D at the shown position SERVICE LIMIT 88 89 91 93 12 65 mm 0 498 in After 93 10 945 mm 0 4309 in Check the primary and secondary cups for damage before as sembly ASSEMBLY CAUTION Handle the master cylinder piston cylinder and spring as a set Coat all parts with clean brake fluid before assembly If the spring and seat were disassembled assemble the wide end of the spring on the seat Install the spring in the master cylinder with its seat facing in side Install the piston CAUTION When installing the piston do not a
134. facing Yu 1 WATER PIPE out and install the water pipe into the cylinder head 1 Connect the water hose to the water pipe and install the spark plug caps Install the following parts carburetors page 4 15 air cleaner housing page 4 4 fuel tank page 4 3 steering covers Fill the cooling system page 5 3 9 22 MEMO CYLINDER PISTON a gt e 3 D E Wo 10 0 10 CYLINDER PISTON SERVICE INFORMATION TROUBLESHOOTING CYLINDER PISTON SERVICE INFORMATION GENERAL This section covers service of the cylinder and piston 10 2 The front cylinder piston can be serviced with the engine installed in the frame The engine must be removed to service to rear cylinder piston To service the crankcase stud bolts refer to 11 15 SPECIFICATIONS PISTON RING INSTALLATION 10 1 PISTON INSTALLATION CYLINDER INSTALLATION 10 5 10 6 Unit mm in ITEM STANDARD SERVICE LIMIT Cylinder 75 000 75 015 2 9528 2 9533 75 10 2 957 Warpage across top 0 10 0 004 Taper 0 06 0 002 Out of round 0 06 0 002 Piston Piston ring to ring TOP 0 015 0 045 0 0006 0 0018 0 10 0 004 piston gioove clearance SECOND 0 015 0 045 0 0006 0 0018 0 10 0 004 Ring end gap TOP 0 10 0 30 0 004 0 012 0 50 0 020 SEC
135. ff valve cover is under spring pressure Do not loose the spring and screws 1 O RING 2 SPRING 4 WASHER 3 PILOT SCREW 1 AIR CUT OFF VALVE COVER FUEL SYSTEM Visually check the following diaphragm for deterioration pin hole or other damage spring for deterioration or other damage diaphragm needle for excessive wear at the tip or other damage orifice of air vent for clogging O ring for damage 2 O RING 3 DIAPHRAGM Replace the air cut off valve as an assembly if necessary o 4 SPRING 8 T amp Separate the carburetors page 4 13 Blow open all passages with compressed air before installing jets and valves CARBURETOR ASSEMBLY 7 VACUUM CHAMBER COVER 5 HOLDER SS QP 4 SPRING z 3 JET ic y Sue 2 WASHER OSS PS 1 DIAPHRAGM UR 18 SYNCHRONIZATION STS ADJUSTING SCREW n UR 14 PISTON Ove 17 NEEDLE JET 3 M HOLDER A d 8 O RING 16 MAIN JET a C gt 7 i 96 Rey O 15 FLOAT 7 4 e q 9 AIR CUT LN PU VALVE 13 FLOAT COVER CHAMBER 11 PILOT SCREW i 39 2 12 VALVE 10 SLOW JET SEAT 4 10 FUEL SYSTEM PILOT SCREW Install the pilot screws and return them to their original posi tion as noted during removal Perform pilot screw adjustment if new pilot
136. frame 20 4 21 INDEX Ait reus 3 7 HOUSING 4 4 Alternator Starter Clutch 8 1 Alternator terre ea 15 9 Battery Charging System 15 2 Battery x ende ette epa E Dra ea 15 4 x disserere eire i dra ce vu 14 11 Brake re reser vd 3 15 Replacement Air Bleeding 14 4 Brake Light Switch 1222 18 11 SWITCH a E Ve EINE 3 17 Brake Pad DisG 14 5 Pedal wrist a von reat Tavs 13 10 Shoe Pad Wear 3 16 3 16 Bulb Replacement 18 4 Cable amp Harness Routing 1 10 Camshaft Installation 9 18 Removal eee eemper Rhe 9 4 Carburetor Assembly 4 10 CHOKG heaves 3 7 Disassembly cete e 4 6 idle Speed nenna 3 11 Installation iera airea RR Da a 4 15 Removal aE E SESS 4 6 Separation Assembly 4 13 Synchronization 3 10 Charging System
137. g ledge level brake fluid upper level CAUTION Do not mix different types of fluid since they are not compatible Connect the commercially available brake bleeder to the bleeder valve Pump the brake bleeder and loosen the bleed valve Add fluid when the fluid level in the reservoir is low Repeat above procedures until no air bubbles appear in the plastic hose NOTE f air is entering the bleeder from around the bleed valve threads seal the threads with teflon tape If a brake bleeder is not available fill the system as follows Pump up the system pressure with the lever or pedal until there are no air bubbles in the fluid flowing out of the reservoir hole and lever or pedal resistance is felt 14 4 1 RESERVOIR COVER HYDRAULIC DISC 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 until the bleed valve has been closed 2 Release the brake lever slowly and wait several seconds after it reaches the end of its travel Repeat steps 1 and 2 until bubbles cease to appear in the fluid at the end of the hose Tighten the bleed valve TORQUE 5 5 N m 0 55 kg m 4 ft Ib Close the bleed valve fill the reservoir with the specified brake fluid to the casting ledge level Reinstall the diaphragm set plate and cover AWARNING A contaminated brake disc or pad reduces stopping power Di
138. g m 2 9 ft lb 65 N m 6 5 kg m 47 ft Ib 45 Nem 4 5 kg m 33 ft Ib 90 Nem 9 0 kg m 65 ft Ib 90 Nem 9 0 kg m 65 ft Ib 70 Nem 7 0 kg m 51 ft Ib 27 Nem 2 7 kg m 20 ft lb 13 3 kg 29 32 Ib 13 1 REAR WHEEL BRAKE SUSPENSION TOOLS Special Driver shaft Attachment 28 x 30 mm Spoke wrench Shock absorber compressor Attachment Compressor screw Snap ring pliers Common Bearing remover shaft Bearing remover head 17 mm Driver Attachment 42 x 47 mm Pilot 17 mm Attachment 32 x 35 mm Pilot 15 mm Pilot 22 mm TROUBLESHOOTING Wobble or vibration in 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 Improper shock absorber spring preload Hard suspension Improper shock absorber spring preload Bent shock absorber rod Swingarm pivot bearings damaged Bent frame or swingarm Suspension noise Faulty rear damper Loose fasteners Poor brake performance Improper brake adjustment e Worn brake shoes Brake linings oily greasy or dirty Worn brake cam Worn brake drum Brake arm serrations improperly engaged Brake shoes worn at cam contact area 07946 MJOO 100 07746 1870100 07JMA MR60100 or equivalent commercially available in U S A 07GME 001
139. gine bracket 8 mm bolts and 10 mm bolt 4 PIVOT FRON LOW R BOL rear engine bracket two 8 mm bolts and 10 mm bolt BOLT _ Ritil 3 FRC T ER BOLT NOTE Do not damage the radiator fin ENGINE REMOVAL INSTALLATION ENGINE INSTALLATION Engine installation is essentially the reverse order of removal Use a floor jack or other adjustable support to carefully manuever the engine into place CAUTION Carefully align mounting points with the jack to prevent damage to mounting bolt threads and wire harness and cables NOTE Be sure to install the mounting collars and swingarm dust seals in their correct positions Tighten all the fasteners to the specified torque given on page 5 O 1 and 2 NOTE Route the wires and cables properly section 1 Fill the crankcase to the proper level with the recommended oil page 2 4 Fill the cooling system page 5 3 Perform the following inspection and adjustments Throttle operation page 3 6 Clutch page 3 18 1 COLLAR 1 SWINGARM LEFT SIDE COLLAR PEEL i 2 SWINGARM RIGHT SIDE COLLARS 6 5 CLUTCH GEARSHIFT LINKAGE 12N m 1 2kg m 9ft Ib 430N m 13 Okg m 94ft Ib 15N m 1 5kg m 11ft Ib e 9O0N m 9 Okg m 6bft Ib 7 CLUTCH GEARSHIFT LINKAGE SERVICE INFORMATION PRIMARY DRIVE GEAR TROUBLESHOOTING CLUTCH INSTALLATION RIGHT CRANKCASE COVER REMOVAL RIGH
140. h the cut out in the piston Do not let the piston pin clips fall into the crankcase CYLINDER PISTON 5 SPACER 3 OIL RING 6 SIDE RAIL 7 7 20 mm OR 20 mm OR MORE MORE SSAA 4 END GAP 3 CUT OUT CYLINDER PISTON CYLINDER INSTALLATION Clean the cylinder gasket surface being careful not to drop any gasket material into the crankcase Install the dowel pins and new gasket Coat the cylinders piston rings grooves and piston with oil 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 removal NOTE Be careful not to damage the piston rings during assembly When the cylinder is halfway over the piston route the cam chain through the cylinder Install a new O ring onto the cylinder joint and install the cylin der joint collar by sliding the collar toward eigther cylinder Install the clip securely Clean the cylinder gasket surface being careful notto drop gasket material NOTE Avoid damaging the gasket surface Install the cam chain guide NOTE Align the guide boss with the groove in the cylinder Make sure that the end of the guide is inserted into place in the crankcase 1 GASKET 9 3 CYLINDER JOINT COLLAR 1 CAM CHAIN GUIDE V 10 6 CYLINDER PISTON
141. he rocker arm shafts by tapping the holder with a soft hammer CYLINDER HEAD VALVE 88 89 1 8 mm FLANGE BOLTS 3 8 mm FLANGE NUT 2 6 mm FLANGE BOLTS After 89 1 8mm FLANGE BOLTS 3 8 mm FLANGE NUTS 2 6 mm FLANGE BOLTS 9 7 CYLINDER HEAD VALVE Remove the rocker arms and wave washers from the shafts Inspect the rocker arm shafts and rocker arms for wear or damage Check the rocker arms for clogged oil holes Measure the O D of each rocker arm shaft SERVICE LIMIT IN EX 11 83 mm 0 466 in Measure the 1 0 of each rocker arm SERVICE LIMIT 12 05 mm 0 474 in CYLINDER HEAD REMOVAL NOTE The front cylinder head can be removed with the engine installed The engine must be removed to service the rear cylinder head Drain the coolant page 5 3 and remove the following front camshaft page 9 3 the cam chain tensioner mounting bolts and washers from the cylinder head and cylinder cam chain tensioner Remove the exhaust pipes as an assembly Section 6 by re moving the heat protector and exhaust pipe joint nuts Disconnect the clutch cable from the clutch lifter arm by re moving the clutch cable holder bolt Remove the oil pipe from the engine NOTE Do not bend the oil pipe during removal Loosen the 6 mm bolt 8 mm bolts 8 mm nut and 10 mm nuts washers in a criss cross pattern in 2 or 3 steps Remove the bolts and
142. he shock absorber spring preload by turning the spring adjuster if necessary REAR WHEEL BRAKE SUSPENSION SWINGARM REMOVAL Remove the rear wheel page 13 3 Remove the gearshift pedal mounting bolt from the foot peg 1 PEDAL MOUNTING BOLT Remove the drive sprocket cover 1 DRIVE SPROCKET Remove the drive sprocket bolts set plate and drive sprocket COVER Disconnect the gearshift arm from the gearshift spindle i 7 26 4 GEARSHIFT Remove the reserve tank from the frame 5 9 1 SHOCK ABSORBER 2 PIVOT NUT y Remove the shock absorber lower mounting bolt and nut LOWER M Remove the swingarm pivot bolt caps pivot bolt and nut then remove the swingarm from the frame DISASSEMBLY Inspect the drive chain slider for wear or damage Replace it if necessary Inspect the drive chain for dirt or damage Clean or replace it if necessary page 3 14 Remove the following drive chain slider and chain cover dust seals and pivot collars 13 14 REAR WHEEL BRAKE SUSPENSION INSPECTION 1 COLLARS 2 BEARING 3 DUST SEALS Inspect the swingarm for deformation or cracks Check the pivot bearings collars and dust seals for wear or damage 0 3 DUST SEALS 5 COLLAR 4 BEARINGS Disassemble the drive chain cover and inspect the chain pro 1 CHAIN COVER tector for wear or damage Replace if necessary 2 PROTECTOR PIVOT BEA
143. heel rim runout Radial 2 0 mm 0 08 Axial 2 0 mm 0 08 in i 88 89 91 93 305 mm 12 0 in 299 mm 11 8 in 93 333 9 mm 13 1 in 327 2 mm 12 9 in Fork tube runout 0 2 mm 0 008 in 88 89 463 15 7 US 2 13 0 Imp oz Fork fluid capacity 91 93 468 cc 15 8 US 2 13 2 Imp oz After 93 449 cc 16 9 US 2 15 8 Imp oz Right 95 0 mm 3 74 in 88 89 Left 93 0 mm 3 66 in Fork fluid level 91 93 Right 89 0 mm 3 50 in Left 87 0 mm 3 43 in After 93 111 mm 4 4 in TORQUE VALUES Handlebar mounting bolt 23 N m 2 3 kg m 17 ft Ib Handlebar upper holder bolt After 94 30 N m 3 0 kg m 22 ft Ib Clutch lever holder bolt 12 Nem 1 2 kg m 9 ft Ib Brake mastercylinder holder bolt 12 Nem 1 2 kg m 9 ft Ib Spokes 4 N m 0 4 kg m 2 9 ft lb Brake disc mounting bolt 40 N m 4 0 kg m 29 ft lb Front axle 75 N m 7 5 kg m 54 ft Ib Fork axle pinch bolt 22 Nem 2 2 kg m 16 ft lb Fork socket bolt 30 N m 3 0 kg m 22 ft Ib Fork top pinch bolt 11 Nem 1 1 kg m 8 ft lb Fork bottom pinch bolt 50 N m 5 0 kg m 36 ft Ib Brake caliper mounting bolt 88 89 91 93 27 Nem 2 7 kg m 20 ft lb After 93 Steering bearing adjustment nut Steering stem nut 12 1 31 Nem 3 1 kg m 22 ft lb 25 Nem 2 5 kg m 18 ft lb 105 Nem 10 5 kg m 76 ft lb FRONT WHEEL SUSPENSION STEERING TOOLS Special Spoke wrench Bottom holder pipe holder attachment
144. hes scoring or evidence of insufficient lubrication Measure the shift fork shaft O D SERVICE LIMIT 88 89 91 95 12 90 0 508 in After 95 12 95mm 0 509 Measure the shift fork D right and left and the shift fork claw thickness SERVICE LIMIT 1 0 13 04 mm 0 513 in CLAW THICKNESS 5 63 mm 0 222 in Inspect the shift drum and shift fork shaft journals for exessive wear or damage Check the gear dogs holes and teeth for excessive or abnormal wear or evidence of insufficient lubrication Measure the 1 0 of the following mainshaft countershaft at C3 C1 gears SERVICE LIMITS C1 gear 24 04 mm 0 947 in M2 M4 C3 gear 28 04 mm 1 104 in 1 BEARING 2 SHIFT DRUM SHIFT DRUM HOLE 11 12 CRANKSHAFT TRANSMISSION Measure the O D of the mainshaft following bushings SERVICE LIMITS M4 gear bushing 27 94 mm 1 100 in C3 gear bushing 27 94 mm 1 100 in M2 gear bushing 27 94 mm 1 100 in C1 gear bushing 24 94 mm 0 982 in Calculate the clearance between each bushing and gear SERVICE LIMIT 0 10 mm 0 004 in Measure the 1 0 of the M2 and C1 bushings SERVICE LIMITS M2 gear bushing 1 0 25 04 mm 0 986 C1 gear bushing 1 0 24 06 mm 0 790 in Measure the O D of the mainshaft and countershaft at the M2 and C1 bushings SERVICE LIMITS Mainshaft at M2 gear bushing 24 90 mm 0 980 in Countershaft at C1 gear bushing 19 92 mm 0 784
145. ibed below Open the throttle slightly by rotating the throttle valve then release the throttle Make sure that there is no drag when opening and closing the throttle A if u 1 SYNCHRONIZATION S Turn the throttle stop screw to align the rear cylinder carbure tor throttle valve with the edge of the by pass hole Align the front cylinder carburetor throttle valve with the by pass hole edge by turning the synchronization adjusting screw Make sure the throttle returns smoothly 4 14 FUEL SYSTEM CARBURETOR INSTALLATION Install the carburetors onto the cylinder heads and tighten the insulator bands securely Install the following parts air cleaner chamber air cleaner housing fuel tank throttle cables Adjust as follows pilot screw page 4 15 P carburetor synchronization page 3 10 d 1 URET BAND throttle grip free play page 3 6 carburetor idle speed page 3 11 carburetor choke page 3 7 PILOT SCREW ADJUSTMENT IDLE DROP PROCEDURE U S A ONLY NOTE The pilot screws are factory pre set and no adjustment is necessary unless the pilot screws are replaced Use a tachometer with graduations of rpm or smaller that will accurately indicate a 50 rpm change 1 Remove the pilot screw plugs page 4 8 2 Turn each pilot screw clockwise until it seats lightly and back it out to the specification gi
146. il and molybdenum disulfide grease to EJ the camshaft holders camshaft journals of the cylinder head rocker arm shafts rocker arm slipper faces and valve stems to provide initial lubrication SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Compression pressure 1 324 kPa ue 13 5 1 0 kg cm 192 14 psi Camshaft Cam lobe height IN 37 930 1 4933 37 730 1 4854 37 950 1 4941 37 750 1 4862 Journal 21 959 21 980 0 8645 0 8654 21 90 0 862 Runout 0 030 0 0012 0 05 0 002 Oil clearance 0 050 0 111 0 0020 0 0044 0 130 0 0051 Rocker arm Rocker arm 1 0 IN EX 12 000 12 018 0 4724 0 4731 12 05 0 474 Rocker arm shaft IN EX 11 966 11 984 0 4711 0 4718 11 83 0 466 O D Valves and Valve stem O D IN 5 475 5 490 0 2156 0 2161 5 45 0 215 Valve guides EX 6 555 6 570 0 2580 0 2587 6 55 0 258 Valve guide I D IN 5 500 5 512 0 2165 0 2170 5 56 0 219 6 600 6 615 0 2598 0 2604 6 65 0 262 Stem to guide IN 0 010 0 037 0 0004 0 0015 0 10 0 004 clearance EX 0 030 0 060 0 0014 0 0024 0 11 0 004 Valve seat width 0 9 1 1 0 035 0 043 1 5 0 06 Valve guide pro IN 19 4 19 6 0 76 0 77 jection height EX 17 9 18 1 0 70 0 71 Valve springs Free length OUTER IN 42 14 1 659 40 58 1 598 42 83 1 686 41 25 1 624
147. ilable in U S A 14 2 TROUBLESHOOTING Brake lever soft or spongy Air bubbles in hydraulic system Low fluid level Hydraulic system leaking Faulty dust seal or piston seal Brake lever too hard Sticking piston s Clogged hydraulic system Pads glazed or worn excessively Brake drag Hydraulic system sticking Sticking piston s Brake grab or pull to one side Pads contaminated Disc or wheel misaligned Brake chatter or squeal Pad contaminated Excessive disc runout Caliper installed incorrectly Disc or wheel misaligned HYDRAULIC DISC BRAKE 14 3 HYDRAULIC DISC BRAKE BRAKE FLUID REPLACEMENT AIR BLEEDING CAUTION careful not to allow dust or water to enter the brake system when filling the reservoir USE ONLY DOT 4 BRAKE FLUID Do not mix different types of fluid since they are not compatible Avoid spilling fluid on painted surfaces Place a rag over the fuel tank whenever the system is serviced Check the fluid level with the fluid reservoir parallel to the ground Remove the reservoir cover set plate and diaphragm BRAKE FLUID DRAINING Connect a bleed hose to the bleed valve Loosen the caliper bleed valve and pump the brake lever Stop operating the lever when fluid stops flowing out of the bleed valve BRAKE FLUID FILLING AIR BLEEDING Close the bleed valve fill the master cylinder with DOT 4 brake fluid to the castin
148. 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 an enclosed area The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death GENERAL Refer to Section 3 for carburetor synchronization throttle cable and choke cable adjustments When disassembling fuel system parts note the locations of the O rings replace them with new ones on reassembly The carburetor float chambers have drain screws that can be loosened to drain residual gasoline For fuel pump refer to section 18 All hoses used in the evaporative emission control system are numbered for identification When connecting one of these hoses compare the hose number with the Vacuum Hose Routing Diagram Label on page 4 16 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 NOTE f vehicle is to be stored for more that one month drain the float bowls Fuel left the float blowls will cause clogged jets resulting in starting and drivability complaints SPECIFICATIONS Item 49 St model California model Type Constant Vacuum dual carburetor Throttle bore 34 mm 1 4 in 34 mm 1 4 in Identification No VDFDA VDFEA Float level 7
149. in the engine Install and tighten the motor mounting bolts securely NOTE Install the ground cable with one mounting bolt as shown Connect the motor cable to the motor terminal and install the rubber cap over the terminal Connect the battery negative cable STARTER RELAY SWITCH OPERATION INSPECTION Depress the starte switch button with the ignition switch ON The coilis normal if the starter relay switch clicks VOLTAGE INSPECTION If you don t hear the switch CLICK disconnect the switch connector Shift the transmission into neutral and turn the ignition switch ON Measure the voltage between the yellow red and green red wires of the relay connector as you press the starter The tester should show battery voltage If it does not make the following continuity inspection 17 6 ELECTRIC STARTER CONTINUITY INSPECTION Remove the starter relay switch Connect an ohmmeter to the switch large terminals Connect a fully charged 12 V battery positive wire to the start er relay switch Yellow Red wire terminal and the battery neg ative wire to the Green Red wire terminal There should be continuity while the battery is connected to the terminals and no continuity when the battery is discon nected CLUTCH DIODE REMOVAL Remove the left side cover Remove the clutch diode from the wire harness INSPECTION Check for continuity with an ohmmeter Connect the p
150. inder holder with the 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 TORQUE 12 N m 1 2 kg m 9 ft Ib Connect the front brake light switch wires Install the right rear view mirror into the master cylinder holder Secure the wire with wire bands Adjust the following throttle operation and free play page 3 6 clutch lever free play page 3 18 12 6 2 UP MARK 01 PUNCH MARK 2 THROTTLE CABLE lo SCREWS 1 PUNCH MARK 2 UP MARK FRONT WHEEL SUSPENSION STEERING FRONT WHEEL REMOVAL Raise and support the motorcycle using a hoist or a jack under the engine Remove the set screw and pull the speedometer cable out of the speedometer gearbox Remove the axle pinch bolt caps and bolts from the right front fork leg Remove the axle and the front wheel 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 20 3 AXLE PINCH BOLTS Remove the side collar 2 1 SIDE COLLAR Remove the speedometer gearbox 1 SPEEDOMETER GEARBOX FRONT WHEEL SUSPENSION STEERING INSPECTION AXLE Set the axle in V blocks and measure the runout Actual runout is 1 2 the total indicator reading SERVICE LIMIT 0 2 mm 0 01 in WHEEL
151. ing tabs that must be released before disconnecting and must be aligned and fully engaged when reconnecting 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 or connections A continuity 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 or when checking for high resistance caused by corroded connections SPECIFICATIONS headlight 12 V 60 W 55 W Brake taillight 12 V 32 3 cp 27 8 W x 2 Turn signal lights Front 12 V 32 3 cp 23 8 W x 2 Rear 12 V 32 cp 23 W License light 12V 4 cp Indicator lights turn signal 12V 1 7W neutral 12V 1 7W high beem 12V 1 7W Meter light 12V 3 4 Main fuse 30 Sub fuse 88 89 10Ax6 15A x1 After 89 10Ax3 15A x 1 800 0 76 USat 0 70 Impat Fuel pump flow capacity TORQUE VALUES Radiator thermostatic switch 18 Nem 1 8 kg m 13 ft lb Oil pressure switch 12 Nem 1 2 kg m 9 ft lb Apply sealant to the threads Ignition switch mounting bolt 11 Nem 1 1 kg m 8 ft lb Shear bolt 18 1 LIGHTS METER SWITCHES
152. ion TURNS DOES NOT TURN Loose cables Faulty starter motor Faulty starter relay page 17 3 switch page 17 6 ABNORMAL 2 Check the neutral indicator for function NORMAL 3 Check the starter relay switch voltage page 17 6 NO VOLTAGE BATTERY VOLTAGE COMES Check the starter relay switch for continuity page 17 7 ABNORMAL NORMAL Faulty neutral switch page 18 11 Loose neutral switch connectors Faulty ignition switch page 18 6 Loose clutch diode connector Faulty starter relay switch page 17 6 Faulty clutch diode page 17 7 Open or short circuit in wire harness Faulty starter relay switch Loose starter relay switch connector 17 1 ELECTRIC STARTER The starter motor can turn in the neutral position but should not turn except with the gear selector in neutral the side stand up and the cluth lever pulled in BATTERY VOLT Measure the Voltage between the Green White AGE MEASURED and Green terminals of the side stand Check the clutch switch page 18 11 connector wire harness side There should be battery voltage NO VOLTAGE or too little voltage Check the side stand switch page 16 5 Starter motor turns engine slowly Low specific gravity Excessive resistance in circuit Binding in starter motor Starter motor turns but engine does not turn Faulty starter clutch Faulty starter
153. ise approximately 1 1 8 turn 412 and begin installation of the front camshaft If the notch mark faces down cannot be seen turn the crankshaft counterclockwise approximately 1 8 turn 52 and begin installation 9 18 amp 2 MARK CYLINDER HEAD VALVE Align the FT mark on the flywheel with the index mark on 1 INDEX the timing hole f the front and rear cylinder camshafts were removed do not confuse them Check the identification mark on the neck of the camshaft flange Install the camshaft in the cylinder head through the cam chain and install the cam sprocket on the camshaft with the IN mark facing inside With the notch mark on the camshaft flange facing up align the timing marks index lines on the cam sprocket with the top 1 NOTCH of the cylinder head Place the cam chain on the sprocket Install the cam sprocket on the camshaft flange and recheck that the timing marks index lines align with the top of the cyl inder head Align the cam sprocket bolt holes in the cam sprocket and camshaft install and tighten the cam sprocket bolt 2 HOLDER 1 CAM SPROCKET BOLT o4 TORQUE 23 N m 2 3 kg m 17 ft lb Turn the crankshaft counterclockwise one full turn 360 install the other sprocket bolt Turn the crankshaft counterclockwise one full turn 360 aligning the mark with the index mark
154. justed as follows to improve driveability and decrease exhaust emissions Remove each pilot screw plug page 4 8 Warm up the engine to operating temperature Stop and go driving for 10 minutes is sufficient Turn each pilot screw to the specification below HIGH ALTITUDE SETTING 1 2 Turns Adjust the idle speed to 1 200 100 rpm with the throttle stop screw Drive new pilot screw plugs into the pilot screw bores page 4 15 NOTE This adjustment must be made at high altitude to ensure proper high altitude operation Attach a Vehicle Emission Control Information up date label onto the inside of the left side cover as shown See SL 132 for information on obtaining the label NOTE Do not attach the label to any part that can be easily re moved from the vehicle 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 specification below its original position LOW ALTITUDE SETTING 1 2 turn out Adjust the idle speed to 1 200 100 rpm with the throttle stop screw Drive new pilot screw plugs into the pilot screw bores page 4 15 Be sure to make these adjustments at low altitude Remove the Vehicle Emission Contr
155. k body Remove the fuel tank mounting bolt 3 FUEL VALVE Disconnect the fuel tube from the fuel tank and fuel breather tube to canister California model only Lan Check that fuel flows out of the fuel valve freely If flow is restricted clean the fuel strainer Remove the fuel tank from the frame INSTALLATION Install the fuel tank in the reverse order of removal Install the fuel valve knob onto the fuel valve as shown and tighten the bolt Tighten the fuel tank mounting bolt securely 5 ALIGN 4 KNOB 1 FUEL TANK 3 FUEL STRAINER SCREEN 4 O RING 5 FUEL FILTER 6 FUEL VALVE BODY NOTE The fuel filter with its narrow pointing toward the outside 8 TO FUEL PUMP 7 FUEL VALVE KNOB 7 ROSS 2 FUEL PIPE JOINT 9 TO CARBURETOR NOTE The fuel pipe joint with its nar row end toward outside FUEL SYSTEM AIR CLEANER HOUSING 1 AIR CLEANER HOUSING MOUNTING BOLTS REMOVAL 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 housing INSTALLATION Wipe clean the mating surfaces shown and apply a cemment or equivalent Install the removed parts in the reverse order of removal SUB AIR CLEANER ELEMENT Remove the following
156. ks scratches or other damage Make sure the piston moves up and down freely in the cham ber Push the needle jet holder in and turn it in 90 degrees counter clockwise Then remove the needle holder spring jet needle and washer from the piston Inspect the needle for excessive wear at the tip bending or other damge Inspect the diaphragm for damage fatigue or pin holes Inspect the vacuum piston for wear or damage FLOAT CHAMBER FLOAT AND JETS Remove the four screws and float chamber 1 DIAPHRAGM PISTON 2 SPRING 3 PISTON 1 NEEDLE JET HOLDER 1 WASHER 2 JET 3 HOLDER NEEDLE 4 SPRING 1 FLOAT CHAMBER 2 SCREW FUEL SYSTEM Remove the float pin float and float valves 1 FLOAT VALVE 2 PIN Check the float valve and valve seat for scratches clogging or damage Inspect the operation of the float valve 2 FLOAT VALVE 1 NEEDLE JET HOLDER Remove the main jet needle jet holder slow jet and valve seat filter 9 PL 2 Check each part for wear or damage JET Blow open all jets with compressed air Clean each jet with non flammable or high flash point solvent Inspect the float valve seat and filter for grooves nicks or de posits gt e Clean the filter with low pressure compressed air 5 FILTER ve 4 VALVE SEAT 3 SLOW JET PILOT SCREW NOTE The pilot screws are factory pre set and should not be re moved unless
157. l the shock absorber lower mounting bolt and nut TUnGJE 45 4 5 kg m 33 ft lb Install the following swingarm pivot caps reserve tank page 5 9 evaporative emission canister California model only drive sprocket with the drive chain gearshift arm Install the drive sprocket cover and tighten the mounting bolt Install the gearshift pedal mounting bolt Apply grease to the gearshift pedal pivot collar refer to page 7 9 Adjust the drive chain page 3 13 and rear brake pedal free play page 3 16 rear wheel page 13 7 1 DRIVE SPROCET 2 PEDAL MOUNTING COVER BOLT 13 17 REAR WHEEL BRAKE SUSPENSION SEAT REAR FENDER SUB FRAME REMOVAL INSTALLATION Remove the seat mounting socket bolts and unhook the seat hooks from the frame then remove the seat 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 Install the removed parts in the reverse order of removal 2 SEAT 1 FENDER MOUNTING 3 RIGHT SIDE 4 FENDER COVER MOUNTI
158. llow the cup lips to turn iside out HYDRAULIC DISC BRAKE Install the snap ring using a snap ring pliers Install the boot 1 SNAP RING CAUTION Becertain that the snap ring is seated firmly in the groove TOOL Snap ring pliers 07914 3230001 or equivalent commercially available in U S A dn 2 Install the brake lever and brake light switch 1 BRAKE LEVER 2 BRAKE LIGHT SWITCH INSTALLATION Set the master cylinder onto the handlebar with the holder 1 PUNCH MARK 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 Install the rear view mirror Connect the brake hose with the oil bolt and two sealing wash ers and tighten the oil bolt TORQUE 30 N m 3 0 kg m 22 ft lb Fill the reservoir with DOT 4 brake fluid to the casting ledge lt H i and bleed the brake system page 14 4 Oil 2 UP MARK 14 10 HYDRAULIC DISC BRAKE BRAKE CALIPER REMOVAL Place a clean container under the caliper and disconnect the p e brake hose from the caliper by removing the oil bolt and sealing washers CAUTION Avoid spilling brake fluid on painted surfaces Remove the brake pads page 14 5 DISASSEMBLY Remove the following
159. lt 9 N m 0 9 kg m 7 ft lb Route the side stand switch wire properly IGNITION TIMING NOTE The ignition control module system is factory pre set and cannot be adjusted lgnition timing inspection procedures are given to inspect the function of the ignition control module components Connect the timing light to the other spark plug wire if you see that the ignition timing is incorrect and you might be able to see the timing is correct Warm up the engine to operating temperature Remove the timing inspection hole cap on the right crankcase cover Connect the timing light to the front spark plug wire 1 BOLT amp lt gt 2 PLATE 3 WASHER IGNITION 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 If the ignition timing is incorrect make a system inspection page 16 3 and replace any faulty parts 16 8 1 F MARK 2 INDEX MARK MEMO ELECTRIC STARTER 8 CLUTCH SWITCH M e 10 SUB FUSE 10A 7 DIODE Em EE D OT Te Bf 11 IGNITION 6 NEUTRAL 4 SIDE STAND SWITCH 2 BATTERY SWITCH SWITCH 12 STARTER RELAY SWITCH BI Black 1 ME FUSE Y Yellow G Green R Red W White
160. lug Ignition timing Initial F mark 6 2 BTDC idle Ignition coil Primary 1 89 2 32 9 resistance Secondary With plug wire 23 55 30 45 kQ Without plug wire 19 8 24 2 kQ Ignition pulse generator Coil resistance 450 550 Q Firing order F 2 R 1 308 TOOLS Tester Digital multitester KOWA 07411 0020000 or KS AHM 32 003 U S A only or Circuit tester SANWA Not available U S A or Circuit tester KOWA TH 5H 16 2 IGNITION SYSTEM TROUBLESHOOTING When performing a spark test keep open flames or sparks away from the work area No spark at one spark plug Faulty spark plug Faulty spark plug wire No spark at all plugs 1 Check the ignition control module connec ABNORMAL L Loose connectors tors for loose contact Faulty NORMAL Fuel cut relay page 18 9 2 Measure voltage between the BI and G Fuel pump page 18 10 between the Bu Y and G between Y Open circuit in wire harness and G of the ignition control module 6P ABNORMAL NORMAL 20 1 connector Battery voltage should appear with the ignition switch ON and engine stop Faulty Switch at RUN Side stand switch page 16 6 Neutral switch page 18 11 NORMAL Short circuit in wire harness 3 1 Check the ignition pulse generator resist ABNORMAL 3 2 Check the ignition pulse ances at the ignition control module 4P
161. m 3 36 in 91 793 Right fork 89 0 mm 3 50 Left fork 87 0 mm 3 43 in After 93 Right and left forks 111mm 4 4 in CAPACITY 88 89 463cc 15 7 US oz 13 0 Imp oz 91 93 468 15 8 US oz 13 2 Imp oz After 93 449 cc 16 9 US oz 15 8l oz 1 OIL LEVEL Install the fork spring washer and spacer into the fork tube 1 TIGHTLY WOUND COILS 88 89 91 93 NOTE TAREE wap wow fd buy Note the direction the tightly wound coils should be at bot tom AFter 93 NOTE Note the direction the tightly wound coils should be at top Loosely install the fork tube cap with a new O ring 1 O RING 2 FORK TUBE CAP INSTALLATION Install the fork tube aligining its top end with the upper sur face of the top bridge as shown Temporarily install and tighten the fork top pinch bolts and turn signal mounting bolts 3 TURN SIGNAL X MOUTING BOLT 8 2 FORK TOP PINCH BOLT 12 18 FRONT WHEEL SUSPENSION STEERING Install and tighten the bottom pinch bolt TORQUE 50 5 0 kg m 36 ft lb Tighten the top pinch bolt TORQUE 11 N m 1 1 kg m 8 ft lb Install the front fender and tighten the mounting bolts secure ly Hook the brake hose onto the hose clip 1 HOSE CLAMP Install the brake caliper with the mounting bolts a LAG HOLDER Tighten the bolts to the specified torque TORQUE 88 89
162. m bolts first then loosen the 8 mm bolts 11 4 a NO que 1 OIL PIPE ead ai Ry _ CEDE 2 FRONT CAM CHAIN 2 REAR CAM CHAIN CRANKSHAFT TRANSMISSION 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 with a soft hammer Remove the dowel pins and clean the crankcase halves of any sealant material CRANKSHAFT CONNECTING ROD CRANKSHAFT REMOVAL Remove the crankshaft from the left crankcase CRANKSHAFT SIDE CLEARANCE INSPECTION 1 FEELER GAUGE Check the connecting rod side clearance with feeler gauge SERVICE LIMIT 0 30 mm 0 001 in If either side clearance exceeds the service limit replace the connecting rod and recheck If still beyond the limit replace the crankshaft Inspect the crankshaft for rough spots or damage CRANKSHAFT TRANSMISSION CONNECTING ROD DISASSEMBLY 1 BEARING CAPS Remove the connecting rod bearing caps noting their loca tions NOTE 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 CRANKSHAFT RUNOUT INSPECTION Place the crankshaft on a stand or V blocks
163. mately 7 8 turn 308 and begin installation of the rear camshaft If the camshaft notch mark faces down cannot be seen turn the crankshaft counterclockwise approximately 1 7 8 turn 668 and begin installation 9 20 9 88 8 After 89 E 8 mm a Y 2 OIL PLATE ae 4 N A 9 4 8 mm 3 6 BOLTS 1 8 BOLTS 2 OIL PLATE 3 NOTCH CYLINDER HEAD VALVE Make sure that the mark 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 procedure as for the front cylinder Remove the 2 mm pin holding cam chain tensioner wedge A NOTE Be careful not to let the 2 mm pin fall into the crankcase Do not forget to remove the 2 mm pin before installing the cylinder head cover CYLINDER HEAD COVER INSTALLATION Clean the gasket and apply contact cement to the gasket groove Apply sealant around the gasket 2 GASKET Install the cylinder head cover rubber washer washer cover and cylinder head cover bolts Tighten the cover bolts TORQUE 10 N m 1 0 kg m 7 2 ft lb 3 1 RUBBER WASHER 2 WASHER COVER 3 BOLT 9 21 CYLINDER HEAD VALVE Install the O ring on the water pipe with the tapered side
164. mm is 1 NEUTRAL SWITCH CONNECTOR INSPECTION Remove the left side cover and disconnect the 2P Black con nector Check the neutral switch for continuity between the light green red connector and body ground There should be continuity between the light green red con nector and body ground There should be continuity with the transmission in neutral and no continuity with the transmission in any gear If there is no continuity in neutral remove the drive sprocket cover page 13 14 and check the wire connection for an open circuit BRAKE LIGHT SWITCH FRONT INSPECTION Disconnect the front brake light switch connectors and check for continuity between the switch terminals There should be continuity with the front brake applied and no continuity with the brake released Replace the switch if necessary REAR INSPECTION Disconnect the rear brake light switch connector and check for continuity between the terminals There should be continuity with the rear brake applied and no continuity with the rear brake released Replace the rear brake light switch if necessary CLUTCH SWITCH INSPECTION Disconnect the clutch switch wire connectors Check for continuity between the switch terminals There should be continuity with the clutch applied and no con tinuity with the clutch released Replace the clutch switch if necessary 18 11 LIGHTS METER SWITCHES TURN SIGNAL RELAY Remove the seat
165. motor gears Starter motor and engine turns but engine does not start Faulty ignition system Engine problems Low compression Fouled spark plugs 17 2 ELECTRIC STARTER STARTER MOTOR REMOVAL EX With the ignition switch OFF remove the negative cable at the battery before servicing the starter motor Remove the rubber cap and disconnect the starter motor cable Remove the motor mounting bolts gt Remove the motor from the left side 442 42 STARTER MOUNTING n0 DISASSEMBLY 1 FRONT COVER 4 REAR COVER Remove the following components motor case screws front and rear covers armature NOTE Record the location and number of shims 3 SCREW 2 CASE INSPECTION Measure each brush length SERVICE LIMIT 6 5 mm 0 26 in Check for continuity from the cable terminal to the motor case and from the cable termina to the brush wire black 1 CONTINUITY CABLE TERMINAL MOTOR CASE NO CONTINUITY NORMAL CABLE TERMINAL BRUSH BLACK WIRE CONTINUITY NORMAL Disassemble the brush holder if necessary 2 NO CONTINUITY S 17 3 ELECTRIC STARTER Inspect the commutator bars for discoloration 1 COMMUTATOR Bars discolored in pairs indicate grounded armature coils Check for continuity between pairs of commutator bars There should be continuity Check for continuity between individual commutator bars and
166. mp as an assembly Install the pressure relief valve in the oil pump Install the pressure relief valve cover with the bolt Assemble the crankcase Section 1 1 2 BOLT 2 11 LUBRICATION CONTROL CABLE LUBRICATION Periodically disconnect the throttle and choke cable at their upper ends Thoroughly lubricate the cables and their pivot points with a commercially available cable lubricant or a light weight oil LUBRICATION POINTS Use general purpose grease when not otherwise specified here Apply oil or grease to the other sliding surfaces and cables not shown here 1 CLUTCH AND BRAKE 4 LEVER PIVOTS 2 THROTTLE GRIP 11 STEERING HEAD BEARINGS 10 FORK 3 FOOT PEG PIVOTS N 7 BRAKE PEDAL 5 SWINGARM 9 SPEEDOMETER PIVOT ON DRIVE GEAR FSH a BEARINGS 4 DRIVE CHAIN PRO HONDA CHAIN LUBE BRAKE amp CHANGE SESH CALIPER PIVOTS 6 SIDE STAND SILICON GREASE PIVOT 2 12 3 MAINTENANCE SERVICE INFORMATION 3 1 CYLINDER COMPRESSION MAINTENANCE SCHEDULE 88 3 3 EVAPORATIVE EMISSION MAINTENANCE SCHEDULE 89 91 93 3 4 CONTROL SYSTEM MAINTENANCE SCHEDULE 93 3 5 lt 5515 gt lt ENGINE gt DRIVE CHAIN FUEL LINE 3 66 BRAKEFLUID THROTTLE OPERATION 3 6 BRAKE SHOE PAD WEAR CARBURETOR CHOKE 3 7 BRAKE SYSTEM AIR CLEANER 3 7 BRAKE LIGHT SWITCH CRANKCASE BREATHER 3 8 HEADLIGHT AIM SPARK PLUGS 3 8 CLUTC
167. n in the transparent section of the drain tube SPARK PLUGS Disconnect the spark plug cap and remove the spark plugs RECOMMENDED SPARK PLUG NIPPONDENSO X24EPR U9 NGK DPR8EA 9 Standard For cold climate below 5 C 41 F For extended high speed driving DPR7EA 9 X22EPR U9 DPR9EA 9 X27EPR U9 Measure the spark plug gap with a wire type feeler gauge SPARK PLUG GAP 0 8 0 9 mm 0 031 0 035 in Adjust by bending the side electrode carefully With the plug washer attached thread each spark plug in by hand to prevent crossthreading Continue tightening by hand until the spark plug bottoms Then tighten the spark plugs another 1 2 turn with a spark plug wrench to compress the plug washer Connect the spark plug caps VALVE CLEARANCE NOTE nspect and adjust valve clearance while the engine is cold below 35 C 95 F Remove the following parts fuel tank page 4 3 air cleaner housing page 4 4 air cleaner chamber and intake duct 3 8 1 PLUG GAP 0 8 0 9 mm 0 031 0 035 in 3 CENTER ELECTRODE 2 SIDE ELECTRODE 1 INTAKE DUCT 2 CLEANER CHAMBER 2 ae ae 4 MAINTENANCE Remove the crankshaft and timing hole caps Remove the valve adjusting covers from the cylinder head cov ers NOTE Adjust the front cylinder valves first FRONT CYLI
168. n system Faulty air cut off valve Lean mixture California model only Worn damaged emission system hoses 07401 0010000 19 Nem 1 9 kg m 13 7 ft Ib A937X 041 XXXXX or ST AH 255 MC7 U S A only ST AH 260 MC7 U S A only 07942 8230000 U S A only Misfiring during acceleration Faulty ignition system Backfiring Faulty ignition system faulty carburetor Poor performance driveability and poor fuel economy Clogged fuel system Faulty ignition system Dirty air cleaner California model only Faulty evaporative emission carburetor air vent control valve Warn damaged emission system hoses Lean mixture Clogged fuel jets Stuck vacuum piston Faulty float valve Low float level Clogged fuel tank breather Clogged fuel strainer e Restricted fuel line Intake air leak Restricted or faulty fuel pump Rich mixture Clogged air jets Faulty float valve Float level too high Dirty air cleaner 4 2 FUEL SYSTEM VALVE KNOB FUEL TANK REMOVAL 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 2 FUEL TANK MOUNTING BOLT d Remove the seat and turn the fuel valve off Remove the fuel valve knob mounting bolt and fuel valve knob from the fuel tan
169. nd starter relay switch from the case Front ignition coil Remove the fuel tank page 4 3 Remove the crankcase breather tank from the frame Remove the ignition coil mounting bolts and disconnect the primary terminals from the coils Remove the spark plug caps from the spark plugs Install the new ignition coil in the reverse order of the removal NOTE Connect the primary wire terminals properly Front coil black terminal black white wire green terminal yellow blue wire Rear coil black terminal black white wire green terminal blue yellow wire 2 STARTER RELAY SWITCH 1 CRANKCASE BREATHER TANK 1 FRONT IGNITION GP COIL IGNITION SYSTEM IGNITION PULSE GENERATOR Bii icnition PULSE GENERATOR CONNECTOR Ey 704 INSPECTION It is not necessary to remove the ignition pulse generator to make this inspection Remove the left steering cover Disconnect the ignition pulse generator 4P connector WHITE Measure the resistances between the white yellow and yellow wires front ignition pulse generator and white blue and blue wires rear ignition pulse generator STANDARD 450 550 0 20 C 68 F For ignition pulse generator replacement refer to section 8 SIDE STAND SWITCH INSPECTION 88 89 91 93 Remove the seat and left side cover Disconnect the 2P Green connector and the Green White wire
170. ne up speci fications 1 VEHICLE EMISSION CONTROL INFORMATION LABEL 1 22 GENERAL INFORMATION VACUUM HOSE ROUTING DIAGRAM LABEL California model only The Vacuum Hose Routing Diagram label is on the inside of the left side cover Route the vacuum hoses as shown on this label ee e gt GE VACUUM HOSE ROUTING DIAGRAM ENGINE EVAPORATIVE FAMILY _ _ CALIFORNIA VEHICLE FUEL TANK CAV CONTROL VALVE TO OPEN AIR EVAP PURGE CONTROL VALVE 1 23 LUBRICATION 88 89 1 13 CAMSHAFT gt 2 OIL PIPE 12 PISTON 11 OIL JET o Ld i 10 CRANK SHAFT 3 MAINSHAFT J O 9 COUNTER SHAFT 8 OIL PRESSURE SWITCH ie A 4 OIL PUMP lea add 5 OIL STRAINER 6 PRESSURE 7 OIL FILTER RELIEF VALVE L LUBRICATION 12 CAMSHAFT 11 PISTON 10 OIL JET 9 CRANKSHAFT 277 2 MAINSHAFT 8 COUNTERSHAFT 7 OIL PRESSURE SWITCH 3 OIL PUMP 4 OIL STRAINER 6 OIL FILTER 5 PRESSURE RELIEF VALVE LUBRICATION EAM E 1 l 1 G l sgga E D JCLALLU
171. nections Connect a vacuum pump to the 8 mm 0 31 in I D hose No 5 that goes to the 3 way joint Apply the specified vacuum to the EVAP PURGE CONTROL VALVE SPECIFIED VACUUM 250 mm 9 8 in Hg The specified vacuum should be maintained Replace the EVAP PURGE CONTROL VALVE if vacuum is not maintained TOOL Vacuum Pressure pump A937X 041 XXXXX or Vacuum pump ST AH 260 MC7 U S A only Remove the vacuum pump and connect it to the vacuum hose No 11 that goes to the left carburetor body Apply the specified vacuum to the EVAP PURGE CONTROL VALVE SPECIFIED VACUUM 250 mm 9 8 in Hg The specified vacuum should be maintained Replace the EVAP PURGE CONTROL VALVE if vacuum is not maintained TOOL Vacuum Pressure pump A937X 041 XXXXX or Vacuum pump ST AH 260 MC7 U S A only Connect a pressure pump to the 8 mm 0 31 in I D hose No 4 that goes to the evaporative emission canister While applying the specified vacuum to the EVAP PURGE CONTROL VALVE hose that goes to the 3 way joint pump air through the evaporative emission canister hose Air shoud flow through the EVAP PURGE CONTROL VALVE and out the hose that goes to the 3 way joint Replace the EVAP PURGE CONTROL VALVE if air does not flow out CAUTION To prevent damage to the evaporative emission purge control valve do not use high air pressure sources Use a hand operated air pump only TOOL Vacuum Pressure pump A937X 041
172. nk weight Cross reference the crankpin and connecting rod codes to de termine the replacement bearing color A B CRANKPIN O D CODE 39 982 39 974 39 990 mm 39 981 mm CONNECTING 1 5741 1 5738 ROD 1 0 CODE 1 5744 in 1 5741 in 43 000 43 007 mm C B 1 6929 1 6932 in BROWN BLACK 43 008 43 016 mm B A 1 6932 1 6935 in BLACK BLUE BEARING INSERT THICKNESS BLUE 1 495 1 499 mm 0 0589 0 0590 BLACK 1 491 1 495 mm 0 0587 0 0589 in C BROWN 1 487 1 491 mm 0 0585 0 0587 in WEN 1 PLASTIGAUGE 1 1 0 CODE NUMBER 1 O D CODE LETTERS 1 CRANKPIN BEARINGS 11 7 CRANKSHAFT TRANSMISSION MAIN BEARING INSPECTION Measure the main journal O D and record it Measure the main journal bearing I D and record it Calculate the clearance between the main journal and the main bearing SERVICE LIMIT 0 06 mm 0 002 in If the oil clearance is beyond the service limit select a replace ment bearings as follows MAIN BEARING SELECTION Determine the crankshaft main journal O D code The code will be either a number 1 or 2 on the crank weight Determine the replacement main bearing Determine the corresponding main bearing I D code The code will be either a letter A or B on the crankcase 171 0 CODE LETTER 7 11 8 CRANKSHAFT TRANSMISSION Choss replacement main bearings in a
173. nterval 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 MAINTENANCE SCHEDULE 89 91 93 Perform the PRE RIDE INSPECTION in the Owner s Manual at each scheduled maintenance period INSPECT AND CLEAN ADJUST LUBRICATE OR REPLACE IF NECESSARY CLEAN REPLACE L LUBRICATE The following items require some mechanical knowledge Certain items particularly those marked and may require more technical information and tools Consult their authorized Honda dealer ODOMETER READING NOTE 1 FREQUENCY 1 000 06 4 8 12 16 20 24 to 1 000 1 6 4 12 8 119 2 25 6 32 0 FUEL LINE THROTTLE OPERATION CARBURETOR CHOKE 3 7 CLEANER NOTE 2 R R 3 7 2 CRANKCASE BREATHER NOTE 3 Pee 3 8 E SPARK PLUG 3 8 VALVE CLEARANCE 3 8 i ENGINE OIL R R R R 2 4 S ENGINE OIL FILTER R R R R 2 5 9 CARBURETOR SYNCHRONIZATION 3 10 CARBURETOR IDLE SPEED 3 11 RADIATOR COOLANT NOTE 5 R 3 11 COOLING SYSTEM 3 12 EVAPORATIVE EMISSION CON wore 4 DRIVE CHAIN EVERY 600 mi 1 000 km 3 13 BRAKE FLUID NOTE 5
174. nuts 1 ROCKER ARMS 2 WAVE WASHERS TENSIONER MOUNTING BOLTS SS L 9 8 CYLINDER HEAD VALVE Remove the upper radiator hose and the radiator mounting bolts page 5 5 Release the radiator from the frame grommets and suspend it with a piece of rope or something suitable Remove the front cylinder head Remove the gasket dowel pins and cam chain guide from the cylinder Rear cylinder head Remove the following engine section 6 NOTE Make sure the piston is at TDC on the rear cylinder com pression stroke oil pass pipe 88 89 cylinder head cover and cam chain tensioner head bolts and nuts as described for front cylinder head re moval cylinder head head gasket dowel pins and cam chain guide DISASSEMBLY INSPECTION Cylinder head Clean the cylinder head surfaces of any gasket material CAUTION Avoid damaging the gasket surfaces Gaskets will come off easier if soaked in solvent Check the spark plug hole and valve areas for cracks Check the cylinder head for warpage with the straight edge and thickness gauge SERVICE LIMIT 0 10 mm 0 004 in Remove the valve spring cotters retainers springs and valves using a Valve Spring Compressor TOOL Valve spring compressor 07757 0010000 or 07957 3290001 CAUTION To prevent loss of tension do not compress the valve springs more than necessary to remove the cotters NO
175. o operating tempera ture Check the oil pressure at 6 000 rpm STANDARD OIL PRESSURE 441 kPa 4 5 kg cm2 64 psi Stop the engine Apply sealant to the pressure switch threads and install it TORQUE 12 N m 1 2 kg m 8 7 ft Ib 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 UM Am 2 OL gt PRESSURE Route the oil pressure switch wire properly page 1 15 5 E GAUGE LUBRICATION OIL PUMP PRESSURE RELIEF VALVE REMOVAL Separate the crankcase Section 11 Remove the bolt and pressure relief valve cover Remove the pressure relief valve from the oil pump PRESSURE RELIEF VALVE DISASSEMBLY Remove the snap ring and disassemble the relief valve TOOL Snap ring pliers 07914 3230001 or equivalent commercially available in U S A INSPECTION Check the spring O ring and valve for fatigue wear or dam age Check the body for clogging or damage Replace the relief valve as an assembly Clean all the parts and assemble them in the reverse order of disassembly OIL PUMP REMOVAL DISASSEMBLY Remove the oil pump by removing two mounting bolts Remove the dowel pins and O rings 2 6 1 PRESSURE RELIEF VALVE COVER 3 PRESSURE RELIEF VALVE 2 BOLT 1 SNAP RING 1 O RING 2 BODY 00 3 VALVE 4 SPRI
176. of the radia tor coolant and signals the fan motor The motor comes into action at 989 1029 208 216 F and stops at below 93 97 C 199 207 F Before testing check the coolant level at warm up the engine to operating temperature If the fan does not turn disconnect the connectors from the thermostatic switch and jump the terminals using a jumper wire Turn the ignition switch ON If the fan turns replace the thermostatic switch If the fan does not start test the fan motor Disconnect the fan motor connector 2P Black at the left steering head connec tor holder Check for battery boltage between the blue black wire and ground with the ignition switch ON If there is no voltage check the sub fuse 10 A or loose ter minals or connector or an open circuit Suspend the thermostatic switch in a pan of coolant 50 50 mixture and check the temperatures at which the switch opens and closes Make sure that there is no continuity at room temperature and then gradually raise the coolant temperature The switch should show continuity close at 93 979 C 1999 2 THERMOSTATIC 207 SWITCH NOTE Keep the temperature for 3 minutes to confirm continuity A sudden change of temperature will cause error tempera ture reading between the thermometer and switch Do not let the switch or thermometer touch the as it will give a false reading Immerse the s
177. of the stop washer in the countershaft groove Turn the washers as shown to lock them on the nearest spline Install the stop washer first and then the lock washer for the C3 gear Align and lock the washers using the procedure above Assemble the countershaft and mainshaft Check the gears for freedom of movement or rotation on the shaft Check that the snap rings are seated in the grooves and align their end gaps with the lands of the splines 88 89 91 95 Install the left shift fork on the shaft with MR1 mark facing the groove on the shaft end and the bolt hole aligned with the shaft hole 88 89 91 95 Tighten the bolt with the lock washer and bend up the tabs of the lock washer 1 LOCK WASHER 2 STOP WASHER 1 STOP WASHER 2 LOCK WASHER 1 MR1 MARK 2 GROOVE 1 BOLT 2 TABS 11 18 CRANKSHAFT TRANSMISSION 88 89 91 95 Install the right shift fork with the mark onthe fork facing 1 RIGHT SHIFT up Assemble the mainshaft countershaft shift fork shaft and shift drum Install them into the left crankcase as an assembly After 95 1 R SHIFT FORK Assemble the mainshaft and countershaft Install them into the left cankcase as an assembly Install the shift forks into the shifter gear grooves with the markings facing up right crankcase side Install the shift drum by aligning the shift fork guide pins wiht the shift drum guide groov
178. ol Update Label that attached to the inside of the left side cover after adjusting for the low altitude EVAPORATIVE EMISSION PURGE CONTROL VALVE INSPECTION California model only NOTE The evaporative emission purge control valve should be inspected if hot restart is difficult Check all fuel tank Evaporative Emission Purge Control Valve EVAP PURGE CONTROL VALVE and evaporative emission canister hoses to be sure they are not kinked and are securely connected Replace any hose that shows signs of damage or deterioration NOTE The EVAP PURGE CONTROL VALVE is located under the fuel tank 1 VEHICLE EMISSION CONTROL INFORMATION UP DATE LABEL VEHICLE EMISSION CONTROL INFORMATION UPDATE HONDA MOTOR CO LTD THIS VEHICLE HAS BEEN ADJUSTED TO IMPROVE EMISSION CONTROL PERFORMANCE WHEN OPERATED AT HIGH ALTITUDE ALTITUDE PERFORMANCE ADJUSTMENT INSTRUCTIONS ARE AVAILABLE AT YOUR AUTHORIZED HONDA DEALER ANE TI VACUUM HOSE ROUTING DIAGRAM ENGINE FAMILY C EVAPORATIVE FAMILY CALIFORNIA VEHICLE FUEL TANK CAV CONTROL VALVE TO OPEN AIR EVAP PURGE CONTROL VALVE 4 DRAIN EVAP CANISTER 28 930 4 16 FUEL SYSTEM Disconnect the EVAP PURGE CONTROL VALVE hoses from their connections and remove the EVAP PURGE CONTROL VALVE from its mount Refer to the routing label on the inside of the left side cover for hose con
179. older and cylinder head journal surfaces i for scoring or evidence of insufficient lubrication Camshaft runout Support both ends of the camshaft with V blocks and check the camshaft runout with a dial indicator SERVICE LIMIT 0 05 mm 0 002 in Using a micrometer measure the height of each cam lobe SERVICE LIMIT IN 37 730 mm 1 4854 in EX 37 750 mm 1 4862 in Check the camshaft journals for wear or damage Measure the O D of each journal SERVICE LIMIT 21 90 mm 0 862 in 3 CAM HEIGHT Camshaft bearing oil clearance Wipe any oil from the journals Lay a strip of plastigauge lengthwise on top of each camshaft journal NOTE Avoid placing plastigauge over the oil hole Install the camshaft holders and tighten the mounting bolts in a crisscross pattern in 2 or 3 steps NOTE not rotate the camshaft when using plastigauge TORQUE 6 mm flange bolt 12 1 2 kg m 9 ft lb 8 mm flange bolt 23 2 3 kg m 17 ft lb 8 mm flange nut 23 2 3 kg m 17 ft lb Remove the camshaft holder and measure the width of each plastigauge The widest thickness determines the oil clear ance SERVICE LIMIT 0 23 mm 0 009 in When the service limit exceeded replace the camshaft and re check the oil clearance Replace the cylinder head and camshaft holder if the clearance still exceeds the service limit Camshaft holder Rocker arm shaft Rocker arm Remove t
180. on canister is drawn into the engine through the carburetor 3 DRAIN 4 EVAPORATIVE EMISSION CANISTER 5 EVAPORATIVE EMISSION CARBURETOR AIR VENT CONTROL VALVE 7 TO OPEN 6 EVAPORATIVE EMISSION AIR CARBURETOR AIR VENT CONTROL VALVE ENGINE STOP 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 replace ment 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 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 PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW 1 Removal of or puncturing the muffler baffles header pipes or any other component which conducts exhaust gases 2 Removal of or puncturing of any part of the intake system 3 Lack of proper maintenance 4 Replacing any moving parts of the vehicle or parts of the exhaust or intake system with parts other than those specified by the manufacturer EMISSION CONTROL INFORMATION LABELS An Emission Control Information Label is located on the inside of the left side cover as shown It contains basic tu
181. ormance related and can usually be diagonosed by a compression test Engine noises can usually be traced to the top end with a sounding rod or stethoscope 07781 0010101 07781 0010201 07780 0012100 07780 0012300 07780 0014000 07780 0014100 07780 0010200 07780 0010400 Flat cutter Seat cutter Uneven or low compression Excessive noise Valves ncorrect valve adjustment ncorrect valve adjustment Sticking valve or broken valve spring Burned or bent valves Damaged or worn rocker arm or camshaft 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 Cylinder and piston Refer to Section 10 Compression too low High compression Excessive carbon build up on piston crown or combus tion chamber 9 2 CYLINDER HEAD VALVE S CYLINDER HEAD COVER REMOVAL as 1 WATER HOSES Remove the following parts steering covers fuel tank page 4 3 air cleaner housing page 4 4 carburetors page 4 6 Drain the coolant page 5 3 Front Disconnect the spark plug caps and the water hose Remove the water pipe mounting bolt front water pipe and O ring NOTE f coolant drips on the engine wipe it off immediately Remove the cylinder head cover bolts and cover Rear 1
182. ositive probe to the terminal and the negative probe to the terminal of the diode There should be continuity then reverse the probes there should be no continuity NOTE The test results shown above are for a positive ground ohm 1 CONTINUITY meter and the opposite results will be obtained when neg ative ground ohmmeter is used 17 7 MEMO 18 LIGHTS METER SWITCHES SERVICE INFORMATION 18 1 FUEL PUMP RELAY 18 9 TROUBLESHOOTING 18 2 FUEL PUMP 18 10 HEADLIGHT 18 3 OIL PRESSURE SWITCH 18 10 BULB REPLACEMENT 18 4 NEUTRAL SWITCH 18 11 SPEEDOMETER 18 4 BRAKE LIGHT SWITCH 18 11 IGNITION SWITCH 18 6 CLUTCH SWITCH 18 11 HANDLEBAR SWITCHES 18 7 TURN SIGNAL RELAY 18 12 THERMOSTATIC SWITCH 18 8 HORN 18 12 COOLANT TEMPERATURE INDICATOR 18 8 SERVICE INFORMATION If the engine must be running to do some work make sure the area is well ventilated Never run the engine 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 GENERAL Some wires have different colored bands around them near the connector These are connected to other wires which cor respond to the band color All plastic connectors have lock
183. overheating when The test button in pushed in for more than three seconds 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 NOTE The result of a test on the meter scale is relative to the amp hour rating of the battery Any BATTERY READING IN THE GREEN ZONE IS OK Batteries should only be char ged if they register in the YELLOW or RED zone BATTERY CHARGING NOTE Be sure the area around the charger is well ventilated clear of flammable materials and free from heat humidity water and dust Clean the battery terminals and position the battery as far away from the charger as the leads will permit Do not place batteries below the charger gases from the battery may corrode and damage the charger Do not place batteries on top of the charger Be sure the air vents are not blocked gt Turn the Power Switch to the OFF position Set the battery Amp Hr Selector Switch for the size of the battery being charged Set the Timer to theposition indicated by the Honda Battery Tester RED 3 RED 2 or YELLOW 1 If you are charging a new battery set the switch to the NEW BATT position Attach the clamps to the battery terminals RED to Posi tive BLACK to Negative Connect the battery cables only when the Power Switch is OFF Connect the batter
184. owing parts must be removed Section 9 Section 9 NOTE Cylinder head cover The front cylinder camshaft and cylinder head Water pipe Camshaft service can be performed without removing Camshaft holder the engine from the frame Cam chain drive sproket Section 10 Section 9 Oil pass pipe Cylinder joint collar Cylinder head Water hose connecting pipe Cam chain tensioner Section 9 10 Section 10 Cam chain guide Cylinder Piston Y Crankshaft 22 Starter motor Section 17 Connecting rod Right crankcase cover Section 7 Transmission Clutch Oil pump Gearshift linkage Primary drive gear Oil pipe Left crankcase cover Section 8 Flywheel Starter gears 11 1 CRANKSHAFT TRANSMISSION SPECIFICATIONS mm in ITEM STANDARD SERVICE LIMIT Crankshaft Connecting rod big end side clearance 0 05 0 20 0 002 0 008 0 30 0 001 connecting Crankpin oil clearance 0 028 0 052 0 001 1 0 0020 0 07 0 003 Main journal oil clearance 0 025 0 041 0 0010 0 0016 0 06 0 002 Crankshaft runout E 0 05 0 002 Transmission Gear I D C1 24 000 24 021 0 9449 0 9457 23 94 0 943 M4 M2 C3 28 000 28 021 1 1024 1 1032 28 04 0 104 Gear bushing O D C1 23 959 23 980 0 9433 0 9441 24 94 0 982 M4 M2 C3 27 959 27 980 1 1007 1 1016 27 94 1 100 Gear b
185. p 2 Check the continuity between each terminal of the side stand switch gt SIDE STAND DOWN RELEASED SIDE STAND UP PUSHED Side stand 1 Tester S Terminals i position Reading Side stand up nm pushed Green White to Green No continuity ignition circuit Yellow Black to Green Continuity s 1 TO Side stand down 7 WARNING released Green White to Green Continuity LIGHT WARNING circuit Yellow Black to Green No continuity LIGHT 7 SPARK UNIT SPARK UNIT G W G W 16 6 IGNITION SYSTEM After 93 Remove the left side cover Disconnect the side stand 3P green connector and check for continuity between each terminals as shown below There should be continuity between the positions on the continuity chart Green White Yellow Black Side stand down Side stand up REMOVAL INSTALLATION Remove the left side cover Disconnect the side stand 3P green connector Remove the side stand switch mounting bolt setting plate washer and side stand switch Install the switch in the reverse order of removal NOTE Align the switch pin with the side stand hole Align the switch groove with the setting plate tang and align the setting plate solt with the side stand return spring holding pin TORQUE Side stand switch mounting bo
186. pad spring and pin bolt boot from the caliper retainer spring and pin bolt boot from the bracket If necessary apply compressed air to the caliper fluid inlet to get the piston out Place a shop rag under the caliper to cush ion the piston when it is expelled Use the air in short spurts 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 them NOTE The seals must be replaced whenever they are removed Clean the seal grooves with clean brake fluid CAUTION Be careful not to damage the piston sliding surfaces INSPECTION Check the pistons for scoring scratches or other faults Measure the piston O D SERVICE LIMIT 88 89 91 93 30 16 mm 1 187 in After 93 26 93 mm 1 060 in Check the caliper cylinder for scoring scratches or other faults Measure the caliper cylinder 1 0 SERVICE LIMIT 88 89 91 93 30 29 mm 1 193 in After 93 27 06 mm 1 065 in 14 11 HYDRAULIC DISC BRAKE ASSEMBLY 1 PISTON SEALS Coat new piston seals and dust seals with clean brake fluid and install them in the caliper Install the pistons and install them with the open ends toward the pads 2 DUST SEALS e Install the pad spring on the caliper as shown 1 BOOT Apply silicone grease to the inside of the boot and install it 3 SILICONE EE fures 2 PAD SPRING 1 RETAI
187. pcs Note the positions of the seat spring and disc B Install clutch discs clutch plates clutch disc A the plates discs and pressure plate on the clutch center and install them in the clutch outer as an assembly Align the tabs in the disc B with the slots on the clutch outer 2 JUDDER SPRING 1 SPRING SEAT NOTE Stack the discs and plates alternately as shown Coat the new clutch discs with clean engine oil Install the washer on the mainshaft After 95 Install the spring washer on the mainshaft with the OUT SIDE mark facing outside 7 13 CLUTCH GEARSHIFT LINKAGE 2 Hold the clutch center with the clutch center holder and tight 1 CLUTCH CENTER HOLDER 77 7 en the lock nut to the specified torque lt E amp M1 TORQUE 130 N m 13 0 kg m 94 ft Ib TOOLS Clutch center holder 07923 KE10000 or 07HGB 001000A U S A only Lock nut wrench 17 x 27 mm 07716 0020300 Equivalent commercially available in U S A Stake the lock nut with the center punch Install the clutch springs lifter plate and bolts Tighten the bolts in a crisscross pattern in 2 or 3 steps NOTE Make sure the pressure plate firmly pushes the discs and plates Install the bearing into the lifter plate RIGHT CRANKCASE COVER INSTALLATION 88 89 Install a new O ring on the oil orifice Install the oil orifice with its smaller hole facing in 3 INSIDE
188. per mounting bolt 4 d TORQUE 27 N m 2 7 kg m 20 ft lb NOTE Operate the brake lever to seat the caliper pistons against the pads 6 ab 3 PIN PLUGS After 93 Remove the pad pin plug and loosen the pad pin Pull the pad pin out of the caliper Remove the brake pads Insert new outside pad and push the caliper piston in allow clearance for installation of the new inside pad Install new inside pad Install the pad pin by pushing the pads against the caliper to depress the pad spring Tighten the pad pin to the specified torque TORQUE 18 1 8 Kg m 13 ft Ib Install and tighten the pad pin plug to the specified torque TORQUE 2 5 N m 0 25 Kg m 1 8 ft Ib HYDRAULIC DISC BRAKE EEE ll DISC THICKNESS Measure the thickness of the disc SERVICE LIMIT 4 0 mm 0 16 in BRAKE DISC WARPAGE Measure the brake disc for warpage with a dial indicator as shown SERVICE LIMIT 0 30 mm 0 012 in MASTER CYLINDER REMOVAL Drain brake fluid from the hydraulic system Remove the rear view mirror from the master cylinder and dis connect the brake light switch wires Disconnect the brake hose by removing the oil bolt and sealing washers 1 OIL BOLT 2 REAR VIEW CAUTION Avoid spilling brake fluid on painted surfaces Place a rag over the fuel tank whenever the brake system is serviced NOTE When removing the oil hose bolt cover the end o
189. place any guides as necessary and ream to fit TOOLS Valve guide reamer IN 07984 2000001 or 07984 200000D EX 07984 ZE20001 or 07984 ZE2000D NOTE It is important that the reamer always be rotated in the 7 gt same direction when it is inserted removed EE Ha F If the stem to guide clearance exceeds the service limits with new guides also replace the valves NOTE Reface the valve seats whenever the valve guides are re placed VALVE GUIDE REPLACEMENT Chill the valve guides in the freezer section of a refrigerator for about an hour Heat the cylinder head to 212 F 100 C with a hot plate or oven Maximum allowable temperature is 300 F 150 C AWARNING To avoid burns wear heavy gloves when handling he heated 1 VALVE GUIDE REMOVER cylinder head CAUTION Do not use a torch to heat the cylinder head it may cause warping Support the cylinder head and drive out the old guides from the combustion chamber side of the cylinder head TOOL Valve guide driver IN 07742 0010100 EX 07742 0010200 Not available in U S A 07942 6570100 NOTE 1 VALVE GUIDE 4 Avoid damaging the cylinder head DRIVER 2 ATTACHMENT Make note of the valve guide projection specifications follow ing then drive in new guides from camshaft side of the cylin der head TOOLS Valve guide driver 5 5 mm IN 07742 0010100 6 6 mm 07742 0010200 Attachmen
190. r adjuster 1 UPPER ADJUSTER Pull the lever cover back loosen the lock nut and turn the ad juster to obtain the specified free play Tighten the lock nut and install the cover Check clutch operation Major adjustments made with the lower adjuster XS CS Loosen the lock nut and turn the adjusting nut to obtain the RI SN SS specified free play EHS SE FY 2 Tighten the lock nut and check the clutch operation gt 20 N SS D pes YA N 6 D ei 1 LOWER ADJUSTER 3 18 MAINTENANCE SIDE STAND Check the spring for damage or 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 TORQUE BOLT 10 1 0 kg m 7 2 ft lb NUT 30 N m 3 0 kg m 22 ft lb 1 PIVOT BOLT Check the side stand ignition cut off system N Sit astride the motorcycle and raise the side stand i Start the engine with the transmission in neutral then shift the transmission into gear with the clutch lever squeezed J Move the side stand full down The engine should stop as the side stand is lowered 4 If there is problem with the system check the side stand switch section 16 4 SUSPENSION FRONT Check the suspension action by compressing it
191. rews INSTALLATION Install the speedometer in the reverse order of removal LIGHTS METER SWITCHES 5 SPEEDOMETER BULB 6 TRIP METER KNOB 7 ATTACHING SCREW 8 6P BLACK CONNECTOR 9 SPEEDOMETER 1 SPEEDO METER 18 5 LIGHTS METER SWITCHES INDICATOR PANEL BULB REPLACEMENT Remove the indicator bulbs from the indicator panel by first pulling out each bulb and socket together Replace the bulb if desired IGNITION SWITCH INSPECTION Remove the seat and right side cover Disconnect the ignition switch 4P White and 2P Black connec tor Check for continuity between the ignition switch connector terminals in each switch position d 4 2 Continuity should exsist between the color coded wires j eT P each chart below Wesce 1 IGNITION SWITCH 88 89 Remove the ignition switch cover by removing the bolt 3 COVER Remove the shear bolt heads using a drill then remove the switch cylinder Install the new switch and new shear bolts Tighten the shear bolts until the head twist off 1 HOLDER 4 SHEAR BOLT 18 6 LIGHTS METER SWITCHES HANDLEBAR SWITCHES 1 LEFT HANDLEBAR SWITCH The handlebar switches dimmer turn signals horn starter engine stop etc must be replaced as assemblies Remove the steering covers LEFT HAN
192. rk tube bushings 1 BUSHING 2 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 appears on more than 3 4 of the entire syrface Check the back up ring replace it if there is any distortion at the points shown 3 CHECK POINTS 4 COPPER SURFACES ASSEMBLY 1 FORK TUBE CAP 3 STOP RING 88 89 91 93 ONLY OIL SEAL 1 LEFT FORK TUBE 2 RIGHT FORK TUBE 19 O RING 18 SPACER 0c 5 BACK UP RING 17 SPRING SEAT 7 FORK SLIDER 3 LEAF 8 FORK TUBE VALVE 6 SLIDER BUSHING 16 FORK SPRING 15 PISTON RING QD 9 DRAIN BOLT Except after 95 Ga 10 SOCKET BOLT 11 FORK TUBE BUSHING CAUTION 12 OIL LOCK PIECE The fork tube cannot be disassembled Do not interchange the right left fork tube when stalling the fork tube in the fork slider 14 PISTON 13 REBOUND SPRING 12 16 FRONT WHEEL SUSPENSION STEERING Install the rebound spring into the fork tube Install a new postion ring into the piston groove Place the oil lock piece on the end of the piston and insert the fork tube into the slider Install the special tools into the fork tube to hold the pis ton and install and tighten the socket bolt TOOLS Bottom holder pipe 07930 KA50000 Not available in U S A holder attachment 07930 KA50100 Not
193. ront 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 Loosen the following bolts turn signal mounting bolt fork top pinch bolt fork bottom pinch bolt Pull the fork tubes out of the top bridge and steering stem 7 T 8 2 TURN SIGNAL LIGHT MOUNTING BOLT 12 13 3 a 3 FORK BOTTOM PINCH BO FRONT WHEEL SUSPENSION STEERING DISASSEMBLY 1 FORK CAP Remove the fork cap bolt AWARNING bolts are under spring pressure Take care when re moving and wear eye and face protection Remove the fork spring seat washer and spacer 1 WASHER 2 SPRING Pour out the fork fluid by pumping the fork up and down sever 220 al times 3 SPACER Hold the fork slider in a vise with soft jaws or a shop towel 1 HOLDER HANDLE CAUTION Do not distort the fork slider in the vise Install the special tool into the fork tube and hold the piston then remove the socket bolt TOOLS Bottom holder pipe 07930 KA50000 Not available in U S A 2 holder attachment 07930 KA50100 2 2 Not available in U S A 3 HOLDER ATTACHMENT 2 SOCKET BOLT bottom holder handle 07930 KA40200 Not available in U S A Remove the dust seal and stop ring 2 1 DUST SEAL CAUTION careful not to damage the fork tube 2
194. s card contaminated pads and clean a contaminated disc with a high quality brake degreasing agent BRAKE PAD DISC FRONT BRAKE PAD REPLACEMENT AWARNING Acontaminated brake disc or pad reduces stopping power Dis card contaminated pads and clean a contaminated disc with a high quality brake degreasing agent NOTE Always replace the brake pads in pairs to assure even disc pressure 88 89 91 93 Remove the pad pin plugs and loosen the pad pins Remove the caliper mounting bolts then remove the brake cal iper and bracket Pry one old pad against the caliper with a screwdriver to push the pistons into the caliper 1 CASTING LEDGE x a PIN PLUGS 1 BRAKE PADS 4 HYDRAULIC DISC BRAKE Pull the pad pins out of the caliper and remove the brake pads Position the pad spring in the caliper as shown d 1 PAD SPRING Install new pads in the caliper NOTE Always replace the brake pads in pairs to assure even disc pressure Install the pad pins first one pin then the other by pushing the pads against the caliper to depress the pad spring Position the retainer spring in the bracket Apply silicone grease to the caliper and bracket pin bolts Install the bracket 14 6 HYDRAULIC DISC BRAKE Install the brake caliper over the disc being careful not to 1 CALIPER MOUTING i f P a 2 PAD PINS damage the pads then tighten the cali
195. s or other sharp ob jects Check the front and rear wheels for trueness Section 12 and 13 i Measure the tread depth at the center of the tires Replace the tires if the tread depth reaches the following limit MINIMUM TREAD DEPTH Front 1 5 mm 0 06 in Rear 2 0 mm 0 08 in Tighten the wheel spokes periodically TORQUE front rear 4 Nem 0 4 kg m 2 9 ft lb TOOL Spoke wrench 07JMA MR60100 Not available in U S A 3 20 MAINTENANCE STEERING HEAD BEARINGS ASS STEERING HEAD BEARINGS NOTE Check that the control cables do not interfere with handle bar rotation Raise the front wheel off the ground Check that the fork pivots freely from side to side If the fork pivots unevenly binds or has vertical movement inspect the steering head bearings Section 12 3 21 FUEL SYSTEM 19 Nem 1 9 kg m 13 7 ft lb 4 0 4 FUEL SYSTEM SERVICE INFORMATION CARBURETOR INSTALLATION TROUBLESHOOTING PILOT SCREW ADJUSTMENT FUEL TANK HIGH ALTITUDE ADJUSTMENT AIR CLEANER HOUSING UA CONDE CARBURETOR REMOVAL EVAPORATIVE EMISSION PURGE CONTROL VALVE INSPECTION CARBURETOR DISASSEMBLY California model only 4 16 CARBURETOR ASSEMBLY EVAPORATIVE EMISSION CARBURETOR AIR VENT CONTROL VALVE CARBURETOR SEPARATION ASSEMBLY INSPECTION California model only 4 17 SERVICE INFORMATION Gasoline is extremely flammable and is explosive under certain conditions work
196. s pipe bolt 8 mm 23 Nem 2 3 kg m 17 ft lb 7 mm 10 Nem 1 0 kg m 7 2 ft Ib TOOLS Special Clutch center holder 07923 KE10000 or 07HGB 001000A U S A only Gear holder 07724 0010100 Common Luck nut wrench 17 x 27 mm 07716 0020300 Equivalent commercially available in U S A 7 1 CLUTCH GEARSHIFT LINKAGE TROUBLESHOOTING Faulty clutch operation can usually be corrected by adjusting the clutch lever free play Clutch slips when accelerating No free play Discs worn Springs weak Clutch will not disengage Too much free play Plates warped Motorcycle creeps with clutch disengaged Too much free play Plates warped Excessive lever pressure Clutch cable kinked damaged or dirty Lifter mechanism damaged Clutch operation feels rough Clutch outer slots rough Dirty clutch cable CLUTCH GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL 88 89 Drain the engine oil page 2 4 Remove the clutch cable holder and disconnect the clutch cable from the clutch lifter arm Loosen the oil pipe holder and remove the oil pipe bolt and seal ing washers from the right crankcase cover Remove the right crankcase cover bolts and cover After 89 Drain the engine oil page 2 4 Remove the clutch cable holder and disconnect the clutch cable from the clutch lifter arm 2 CLUTCH CABLE HOLDER Remove the right crankcase cover bolts and cover WU DOWEL PINS e
197. s pipe i bolts and the pipe holder bolt Tighten the bolts TORQUE Oil pass pipe bolt 7 mm 10 1 0 kg m 7 2 ft lb 8 mm 23 2 3 kg m 17 ft lb 3 OIL PIPE 2 HOLDER 9 17 CYLINDER HEAD VALVE Install the following cam chain tensioner with washers and bolts TORQUE 10 N m 1 0 kg m 7 2 ft lb camshaft page 9 18 camshaft holders page 9 19 cylinder head cover page 9 2 1 1 CHAIN TENSIONER __WASHERS BOLTS NN CAMSHAFT INSTALLATION 1 WAVE WASHERS Apply molybdenum disulfide oil to the rocker arm shafts Install the ocker arms rocker arm shafts and wave washers in the camshaft holders 2 ARM EX NOTE Install the wave washers in the proper position as shown 5 ARMS IN 4 SHAFT IN 3 SHAFT EX ing the bolt holes of the holder with the holes of the shafts Position the grooves in the rocker arm shafts vertically align MoS2 Apply molybdenum disulfide oil to the rocker arm slipper faces FRONT CYLINDER 1 GROOVES NOTE f 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 clockw
198. screws are in stalled NOTE Do not install new plugs on new pilot screw holes until after adjustment has been made f you replace the pilot screw one carburetor you must replace the pilot screw in the other carburetor for proper pilot screw adjustment FLOAT CHAMBER FLOAT AND JETS Install the pilot screw and turn it in until it seats lightly Turn the pilot screw out the number of turns recorded during removal CAUTION Damage to the pilot screw seat will occur if the pilot screw is tightened against the seat Install the valve seat slow jet needle jet holder and main jet Install the float with float valve in the carburetor body then in stall the float arm pin through the body and the float FLOAT LEVEL Measure the float level with the float tang just contacting the float valve TOOL Float level gauge 07401 0010000 FLOAT LEVEL 7 mm 0 28 in Adjust the float level by carefully bending the float tang rw wes 1 O RING 2 WASHER 4 PILOT SCREW 3 SPRING 2 MAIN JET 3 NEEDLE JET HOLDER 4 11 FUEL SYSTEM Install the O ring on the float chamber groove 1 O RING 4 6 Install the float chamber and tighten the screws securely NOTE Install the fuel tube clamp VACUUM CHAMBER 2 DIAPHRAGM 3 PISTON Install the washer jet needle spring and needle holder to the 4 vacuum piston Push the jet needle holder in and t
199. se Slider binding Insufficient fluid in fork legs Loose fork leg fasteners 12 2 FRONT WHEEL SUSPENSION STEERING HANDLEBAR GRIP REPLACEMENT Remove the right handlebar switch screws and disconnect the throttle cables from the throttle pipe Remove the grip end cap and right handlebar grip Remove the grip from the throttle pipe Apply Honda Bond A or Honda Grip Cemment U S A only to the inside surface of the throttle grip to the clean surface of the throttle pipe Wait 3 5 minutes and install the grip Rotate the grip for even application of the adhesive Connect the throttle cables to the throttle pipe and install the right handlebar switch Install the grip end cap Remove the grip end cap and pull the grip off of the left handle bar Apply Honda Bond A or Honda Grip Cemment U S A only to inside surface of the left grip to the clean surface of the handlebar Wait 3 5 minutes and install the grip Rotate the grip for even application of the adhesive NOTE Allow the adhesive to dry for an hour before using Check for smooth throttle operation after the right grip is installed Install the grip end cap REMOVAL Disconnect the clutch switch wires from the switch terminals Remove the following rear view mirror from the clutch lever holder clutch lever holder mounting bolts and holder left handlebar switch wire bands left handlebar switch screws and switch 1 TH
200. seat page 13 18 and fuel tank page 4 3 air cleaner housing Disconnect the air hoses carburetors to sub air cleaner cov er Remove the sub air cleaner mounting bolt and cover and remove the element 4 4 FUEL SYSTEM Wash the element in non flammable or high flash point sol vent squeeze out the solvent thoroughly and allow the ele A ment to dry Soak the element gear oil SAE 80 90 and squeeze out the excess Reinstall the element and cover and tighten the bolt Reconnect the air tubes from the carburetors 2 EES 2 AGUA c s b 1 2 WASH IN SQUEEZE OUT SOLVENT SOLVENT THOROUGHLY 9C J 4 4 4 5 GEAR OIL SQUEEZE OUT SAE 80 90 EXCESS OIL AIR CLEANER CHAMBER 1 INTAKE DUCT REMOVAL INSTALLATION HOSE BANDS Remove the air cleaner housing and sub air cleaner element page 4 4 Loosen the intake duct hose bands at the carburetors and unhook the air cleaner chamber drain tube from the frame Remove the air cleaner chamber from the frame To reinstall the chamber position it in the frame and connect the intake ducts to the carburetors and tighten the band screws Install the sub element and cover page 4 4 Install the air cleaner housing page 4 4 10 INTAKE DUCT HOSES 7 DRAIN TUBE Gape 8 PLUG 9 ELEMENT 1 AIR CLEANER CHAMBER 4 AIR CLEANER ELEMENT 6 HOLDER 2 BRACKET
201. several times Check the entire fork leg assembly for signs of leaks or dam age Replace any components which are unrepairable Tighten all nuts and bolts to the specified torque value AWARNING Do not ride a vehicle with faulty suspension Loose worn or damaged suspension parts may affect stability and rider con trol REAR Check the action of the rear suspension components by com pressing them several times Check the entire suspension assembly being sure it is securely mounted and not damaged or distored Tighten all nuts and bolts to the specified torque value MAINTENANCE NUTS BOLTS FASTENERS Tighten the bolts nuts and fasteners at the intervals shown in the Maintenance Schedule page 3 3 Check that all chassis nuts and bolts are tightened to their cor rect torque values page 1 5 6 and 7 Check all cotter pins and safety clips WHEELS TIRES TIRE PRESSURE NOTE Tire pressure should be checked when the tires are COLD Front Rear Tire size 100 90 19 57S 170 80 15 77S Up to pressures vehicle kPa capacity kg cm2 load 200 2 00 29 250 2 50 36 psi Up to 90 kg 1 SPOKE 200 Ibs 200 2 00 29 200 2 00 29 2 SPOKE WRENCH load Maximum weight capacity 161 kg 355 Ibs lt C Tire Bridgestone L309 G 546 oF brand Dunlop F24 K555 Check the tires for cuts imbedded nail
202. side covers Remove the battery case cover Measure the battery voltage using a digital multimeter VOLTAGE Fully charged 13 0 13 2V Under charged Below 12 3V TOOL Digital multimeter 07411 0020000 KS AHM 32 003 U S A only BATTERY TESTING NOTE Always clear the work area of flammable materials such as gasoline brake fluid electrolyte or cloth towels when operating the tester the heat generated by the tester may cause a fire Remove the battery page 15 4 Securely connect the tester s positive cable first then connect the negative cable NOTE For accurate test result be sure the tester s cables and clamps are in good working condition and that a secure connection can be made at the battery Set the temperature switch to HIGH or LOW depending on the ambient temperature Push in the appropriate test button for three second and read the condition of the battery on the meter NOTE Be sure you ve selected the test button of 5 5 Ah 9Ah For the first check DO NOT charge the battery before testing test it is an as is condition BATTERY HIGH 60 F 15 C or higher LOW Lr 60 F 15 C lower Test Buttons 000000 00 15 5 BATTERY CHARGING SYSTEM CAUTION To avoid damaging the tester only test betteries with an amperage rating of less than 30A Tester damage can result from
203. ssion canister California model only Place a clean container under the reserve tank Disconnect the radiator siphon tube at the reserve tank Remove the reserve tank mounting bolt filler mounting nut and the reserve tank Hold the overflow tube upright and remove the reserve tank from the frame Empty the tank if necessary Install the reserve tank in the reverse order of removal Fill the tank with coolant if necessary CAUTION The tab of the reserve tank should be aligned with the grommet in the frame 1 GROMMET 2 TAB 4 SIPHON 3 RESERVE TUBE TANK ENGINE REMOVAL INSTALLATION 25 Nem 2 5 kg m 18 ft lb 27 Nem 2 7 kg m 20 ft lb 6 ENGINE REMOVAL INSTALLATION SERVICE INFORMATION 6 2 ENGINE INSTALLATION 6 5 ENGINE REMOVAL 6 3 55 Nem 5 5 kg m 40 ft lb 27 Nem 2 7 kg m 20ft Ib ENGINE REMOVAL INSTALLATION SERVICE INFORMATION GENERAL Support the motorcycle using a hoist a floor jack or other adjustable support The following parts be serviced with the engine installed the frame Clutch Gearshift linkage Camshafts Front cylinder head cylinder To service the water pump body oil pump and rear cylinder head cylinder the engine must be removed from the frame SPECIFICATIONS Engine dry weight Oil capacity Coolant capacity TORQUE VALUES Rear axle Shock absorber lower mounting bolt Gearshift arm bolt Foot
204. t driver handle Main bearing driver attachment Valve guide reamer 5 510 mm IN Valve guide reamer 6 612 mm EX Attachment 28 x 30 mm Drive chain cutter Shock absorber compressor at tachment New for this model 07506 3000000 07510 4220100 7 PJ70100 07404 0030000 07908 KE90000 A937X 041 XXXXX 07914 3230001 07916 3710100 07923 KE10000 07930 KA50000 07930 KA50100 07930 KA40200 07936 3710001 07936 3710100 07936 3710600 07741 0010201 07943 MF50100 07943 MF50200 07946 3710500 07946 MBOO000 07946 MJ0O0 100 07947 4630100 07953 MJ10000 07953 MJ10100 07953 MJ10200 07HMF MM90400 07984 2000001 07984 2 20001 07746 1870100 O7HMH MR10103 07JME MR10100 Alternate tool Equivalent commercially available in U S A Vacuum gauge Not available in U S A Vacuum pump Pressure pump Equivalent commercially available in U S A Not available in U S A Remover weight Attachment Driver Driver handle Attachment 32 x3bmm Not available in U S A Tool number Refer to section 2 2 2 07LMJ 001000A 3 07908 KE90100 4 ST AH 260 MC7 4 ST AH 255 MC7 2 13 14 12 07HGB 001000A 7 12 11 07936 3710200 9 9 12 12 13 12 07953 MJ1000A 12 07953 MJ1000B or 07949 3710001 07746 0010100 11 9 07984 2000000 07984 ZE2000D 9 O7HM
205. t 5 5 mm IN 07943 MF50100 6 6 mm EX 07943 MF50200 9 11 CYLINDER HEAD VALVE VALVE GUIDE PROJECTION HEIGHT 19 4 19 6 mm 0 76 0 77 in 1 VALVE GUIDE EX 17 9 18 1 mm 0 70 0 71 in 2 GUIDE PROJECTION HEIGHT v 2 Ream the new valve guides after installation 1 VALVE GUIDE REAMER NOTE Use cutting oil on the reamer during this operation t is important that the reamer always be rotated in the same direction when it is inserted or removed Clean the head thoroughly after reaming the valve guides TOOLS Valve guide reamer IN 07984 2000001 or 07984 200000D EX 07984 ZE20001 or 07984 ZE2000D VALVE SEAT INSPECTION REFACING Clean all intake and exhaust valves thoroughly to remove carbon deposits Apply a light coating of Prussian Blue to each valve seat Lap each valve and seat using a rubber hose or other hand lapping tool Remove and inspect each valve CAUTION Thevalve cannot be ground If the valve face is burned or badly worn or if it contacts the seat unevenly replace the valve Inspect the width of each valve seat STANDARD 0 9 1 1 mm 0 035 0 043 SERVICE LIMIT 1 5 mm 0 06 in If the seat is too wide too narrow or has low spots the seat must be ground 9 12 CYLINDER HEAD VALVE VALVE SEAT CUTTERS Honda Valve Seat Cutters grinder or equivalent valve seat refacing equipment are recomm
206. ten the lower holder nuts to the specified torque TORQUE 23 N m 2 3 kg m 16 ft Ib 1 LOWER HOLDER NUTS Loosen the upper holder socket bolts and align the punch marks on the handlebar with the splits of the handlebar holders Tighten the forward bolts first then tighten the rear bolts 3 CAPS TORQUE 30 N m 3 0 kg m 22 ft Ib Install the upper holder bolt caps 2 SOCKET Install the left handlebar switch set collar on the upper switch housing Align the locating pin in the lower switch housing with the hole in the handlebar Install the left handlebar switch attaching screws and tighten the forward screw first then tighten the rear screw SCREWS 12 5 FRONT WHEEL SUSPENSION STEERING Install the clutch holder lever and with the 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 TORQUE 12 1 2 kg m 9 ft Ib Connect the clutch switch wires Install the right rear view mirror in the holder Secure the wires with wire bands Apply grease to the throttle cable ends and connect the cables to the throttle pipe Install the right handlebar switch onto the handlebar aligning the locating pin with the hole in the handlebar Install the right handlebar switch screws and tighten the for ward screw first then tighten the rear screw Install the front brake master cyl
207. th a space of two holes in between Measure the distance B and make a calculation A 79 mm 3 110 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 in 2 or 3 progressive steps TOOL 2 Spoke wrench 07JMA MR60100 3 110 in or equivalent commercially 7 dr 1 available in U S A TORQUE 4 0 4 kg m 2 9 ft Ib Check the wheel runout page 13 3 2 DRIVEN Install the tube and tire EM Geog FLANGE BEARING Install the collar in the driven flange bearing Install the damper rubbers on the flange and place flange in the hub Apply grease to a new O ring and install it onto the flange groove 2 O RING 1 DRIVEN SPROCKET MOUNTING NUT Apply grease to the dust seal lip and install it Install the driven sprocket if removed and a new seal Tighten the driven sprocket mounting nuts TORQUE 65 N m 6 5 kg m 47 ft lb 13 6 REAR WHEEL BRAKE SUSPENSION Install the axle collar INSTALLATION Install the brake panel on the wheel hub Position the rear wheel between in swingarm and install the drive chain over the driven sprocket 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 Install the adjuster collar and axle nut Tighten the axle nut lightly Adjust the drive chain
208. the armature shaft There should be no continuity Check the front cover oil seal for wear or fatigue 1 OIL SEAL 2 FRONT COVER 17 4 ELECTRIC STARTER ASSEMBLY 2 CASE 14 LOCK WASHER 3 ARMATURE 5 BRUSH HOLDER 7 O RING 6 BRUSH SPRINGS 4 SHIMS lt 05 13 SHIMS 209909 GAP CASE 1 FRONT COVER 11 O RING 10 CABLE TERMINAL AND BRUSHES 9 REAR COVER Set the brushes on the brush holder Align the starter motor case notch with the brush holder tab 5 1 ALIGN Install the armature the case 1 HOLDER 2 SHIMS Set the brush springs Install the rear shims in the same location and number when disassembled Install the O ring on the case Install the rear cover aligning its slot with the brush holder pin 3 SLOT ELECTRIC STARTER Install the front shims in the same location and number when 1 DUST SEAL 2 FRONT disassembled COVER Install the O ring on the case Install the lock washer aligning its tabs with the slots of the front cover Apply grease to the dust seal and install the front cover 5 LOCK WASHER 3 O RING Align index marks of the front cover case and rear cover as 1 shown Install and tighten the starter motor case screws and apply oil to the O ring and install it on the front cover 4 4 CASE 3 REAR COVER SCREWS 2 O RING INSTALLATION Install the starter motor
209. the carburetors are overhauled The pilot screw plugs are factory installed to prevent pilot screw misadjustment Do not remove the plugs unless the pilot screws are being removed Cover all openings with tape to keep metal particles out when the plugs are drilled 4 8 FUEL SYSTEM Center punch the pilot screw plug to center the drill point Drill through the plug with a 4 mm 5 32 in drill bit Attach a drill stop to the bit 3 mm 1 8 in 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 Force a self tapping 4 mm screw P N 93903 35410 into the drilled plug and continue turning the screwdriver until the plug rotates with the screw Pull on the screw head with pliers to remove the plug Use compressed air to clean the pilot screw area and remove metal shavings Turn each pilot screw in and carefully count the number of turns until it seats lightly Make a note of this to use as a refer ence when reinstalling the pilot screws CAUTION Damage to the pilot screw seat will occur if the pilot screw is tightened against the seat Remove the pilot screws and inspect them Replace them if they are worn or damaged AIR CUT OFF VALVE Remove the two screws the set plate and the air cut off valve cover NOTE The air cut o
210. the chart below ITEM Battery charging line TERMINALS STANDARDS Red White and Green Battery voltage should come Alternator coil line Yellow and Yellow 0 1 1 0 Q 20 C 68 F Check the resistances between the leads with an ohmmeter If the resistance is out of the specifications replace the regulator rectifier NOTE Use a SANWA SP 10D or TH 5H tester or KOWA DIGI TAL VOLTOMETER 0741 1 0020000 The regulator rectifier has a semi conductor If a different tester is used the results will be out of specification You ll get a false reading if your finger touches the tester probe f the pointer of the tester fails to swing to zero when the adjusting knob is turned fully clockwise or counter clockwise replace the battery in the tester Tester SP 10D 88 89 91 Red White Probe Yellow Yellow Unit KQ Red White After 91 Red White Red White Yellow 0 5 10 Yellow 0 5 10 Yellow 0 5 10 Yellow Green 0 7 15 15 8 BATTERY CHARGING SYSTEM ALTERNATOR MSS INSPECTION SH me cS NOTE Ss gt f eG is not necessary to remove the stator coil to make this LY Sas test Remove the left side cover Disconnect the alternator 3P WHITE connector d 1 ALTERNATOR WHITE CONNECTOR
211. the clip and slide the cylinder joint collar toward eigther the front or rear cylinder Remove the cylinder to be serviced Remove the cylinder gasket and dowel pins from the crank case INSPECTION Clean the top of each cylinder thoroughly Inspect the cylinder walls for scratches and wear Measure and record the cylinder I D at three levels in both an and Y axis Take the maximum reading to determine the inder wear SERVICE LIMIT 75 10 mm 2 957 in Calculate the piston to cylinder clearance Take the maximum reading to determine the clearance SERVICE LIMIT 0 10 mm 0 004 in Calculate the cylinder for taper at three levels in an X and Y axis Take the maximum reading to determine the taper SERVICE LIMIT 0 06 mm 0 002 in Calculate the cylinder for out of round at three levels in an X and Y axis Take the maximum reading to determine the out of round SERVICE LIMIT 0 06 mm 0 002 in The cylinder must be rebored and an oversize piston fitted if the service limits are exceeded The following oversize piston are available 0 25 mm 0 010 in and 0 50 mm 0 020 in The cylinder must be rebored so that the clearance to an over size piston is 0 010 0 050 mm 0 0004 0 0020 10 2 1 WATER HOSE 4 MIDDLE 5 BOTTOM CYLINDER PISTON Inspect the cylinders for transverse warpage across the top NOTE Measure warpage using a straight edge feeler gauge
212. the flywheel holder and remove the fly wheel bolt and washer TOOL Flywheel holder 07725 0040000 Equivalent commercially available in U S A NOTE The flywheel bolt has left hand threads Remove the flywheel with the rotor puller TOOL Rotor puller 07733 0020001 or 07933 3290001 U S A only Remove the starter driven gear washer and needle bearing from the crankshaft Remove the woodruff key ii i 3 WOODRUFF KEY TS 2 DRIVEN GEAR ALTERNATOR STARTER CLUTCH STARTER CLUTCH DISASSEMBLY Reinstall the starter driven gear into the flywheel Inspect the starter clutch by turning the starter driven gear The gear should turn counterclockwise freely and should not turn clockwise if it turns incorrectly replace the starter clutch Hold the flywheel with the flywheel holder and remove the torx bolts using a torx bit Remove the starter clutch outer and oneway clutch TOOLS Flywheel holder 07725 0040000 Equivalent commercially available in U S A Torx bit 07703 0010100 Equivalent commercially available in U S A INSPECTION Measure the O D of the starter driven gear SERVICE LIMIT 57 60 mm 2 268 in Inspect the oneway clutch for wear or damage and replace if necessary 1 STARTER DRIVEN GEAR 2 FLYWHEEL 2 TORX BIT 1 STARTER DRIVEN GEAR 1 ONEWAY CLUTCH 8 4 ALTERNATOR STARTER CLUTCH ASSEMBLY 1 CLUTCH OUTER
213. 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 PLASTIC BAG 3 DAMPER UNIT 13 12 REAR WHEEL BRAKE SUSPENSION ASSEMBLY 1 DAMPER SH 12 ADJUSTER ADJUSTER 4 SPRING 5 LOWER SPRING SEAT V 3 UPPER SPRING SEAT 5 11 SPRING GUIDE 8 PLUG 10 STOPPER RUBBER 7 LOWER JOINT E Install the following 9 LOCK NUT stop rubber onto the damper rod spring adjuster seat and spring adjuster onto the damper so that it rests in the softest position 1 LOCK NUT upper spring seat spring with the tightly wound end upward and lower spring seat lock nut Compress the spring with the compressor O7GME 0010000 and attachment 07 J ME MR10100 Screw the lower joint onto the damper rod fully hold it and tighten the lock nut TORQUE 70 N m 7 0 kg m 51 ft Ib INSTALLATION Install the rear shock absorber with the drain tube pointing down Install and tighten the upper and lower mounting bolts and nuts TORQUE 45 N m 4 5 kg m 33 ft Ib Route the drain tube into the tube guide in the swingarm Install the removed parts in the reverse order of removal Adjust t
214. the thermostat into the housing Install a new O ring on the housing cover and install the hous ing cover onto the housing 1 THERMOSTAT 2 THERMOMETER M oie 1 THERMOSTAT O RINGR COOLING SYSTEM Tighten the thermostat housing cover mounting bolts NOTE Be sure to secure the thermostat ground wire with the cover mounting bolt shown Install a new O ring on the radiator filler and connect the upper radiator hose to the radiator Install the radiator filler onto the thermostat housing Tighten the filler and thermostat housing mounting bolts Install the remaining removed parts in the reverse order of re moval Fill the system with coolant RADIATOR COOLING FAN REMOVAL NOTE For fan motor inspection refer to section 18 Remove the steering cover and disconnect the fan motor con nector 2P BLACK Remove the horn mounting bolt and horn then disconnect the horn wires Remove the radiator mounting bolt and disconnect the lower radiator hose from the radiator by loosening the hose band 1 GROUND WIRE AND BOLT EN 2 HOUSING MOUNTING BOLT 3 FILLER ATTACHING POLT 2 1 RADIATOR MOUNTING BOLT COOLING SYSTEM Unhock the radiator mounts from the grommets from in frame Unclamp the upper radiator hose and disconnect the hose from the radiator X gt e d DISASSEMBLY 1 GROUND TERMINAL
215. then remove the turn signal relay from the rubber bracket Check the turn signal circuit for proper connections before making this test Connect each terminal as indicated below White Green D C 12 V Positive Green D C 12 V Negatvie Gray Turn signal wire of one side connect the other side to ground frame Check for correct lighting ON and OFF If the turn signal relay fails this test replace it HORN Disconnect the wire connectors from the horn and connect a 12 V battery to the horn wire terminals The horn is normal if it sounds 18 12 88 89 LIGHT SWITCH SIDE STAND SWITCH t it HH ere sex AR 3 FRONT BRAXE STARTER ENGINE STOP SWITCH FRONT TURN VIE fex dc 7 MGH BEAM INDICATOR Ji an HUE LE 19 WIRING DIAGRAM 0030Z 6700 19 1 WIRING DIAGRAM 00 9 0A N Z0 00 440 430 3383 20H DH 18 191 zo I5 9I 16 AUD a JOLAS IONAS AINNIS IONAS 9015 HOLAS 038 u AUHIND N3389 N3385 5 30718 1991 3170 INYA 0 MOTTBA A MONE 8 T 2 ILAS WHOS FOLIES TS IANO HOLAS 5102 Loron ws Fabi m m
216. tion Alternator Starter Clutch 8 1 Battery Charging System 15 2 Clutch Gearshift Linkage 7 1 Cooling System 5 1 Crankshaft Transmission 11 1 Cylinder Head Valve 9 1 Cylinder Piston 10 1 Electric Starter eee cecinit 17 1 Engine Removal Installation 6 2 Front Wheel Suspension Steering 12 2 Fuel scene io beers Tor ai en 4 1 Hydraulic Disc Brake 14 2 Ignition System 16 2 Lights Meter Switches 18 1 Lubrication 2 2 2 Maintenance iii cs eee eere eps pn 3 1 Rear Wheel Brake Suspension 13 1 Service 1 1 Shock Absorber 13 11 Side Stand iui eee n iM iere 3 19 HE ne mE 16 6 Spark Plugs eue rre Ree teure mu 2228 Specifications e reve Yer 1 3 Speedometer 18 4 Starter Clutch ent eei er ed 8 4 MOtOF eeu t e eed ep e YE wes ees 17 3 Relay Switch 2 2 17 6 Steering Head Bearings 3 21 eere 12 20 SUSPENSION
217. tion SF or SG VISCOSITY SAE 10W 40 Install the oil filler cap dipstick Start the engine and let it idle for 2 or 3 minutes Stop the engine and wait a few minutes then check that the oil level is at the upper level mark with the motorcycle upright Check that there are no oil leaks 1 FILLER CAP DIPSTICK a 3 LOWE 1 DRAIN BOLT 1 DRAIN BOLT i 2 SEALING WASHER 2 4 LUBRICATION OIL FILTER CHANGE TORQUE WRENCH Drain the engine oil page 2 4 CAUTION Do not replace the oil filter when the exhaust system is hot Remove the oil filter with a filter wrench TOOL Oil filter wrench 07HAA PJ70100 2 OIL FILTER WRENCH Apply oil to the new oil filter O ring and install the new oil filter 1 OIL FILTER Tighten the oil filter with a filter wrench TORQUE 10 N m 1 0 kg m 7 2 ft lb Fill the engine with recommended oil page 2 4 OIL PRESSURE CHECK Remove the following drive sprocket cover page 13 14 drive sprocket cover bracket 2 O RING switch cover and switch screw Disconnect the wire from the oil pressure switch remove the switch and connect oil pressure gauge to the switch hole KET a 2 PRESSURE SWITCH TOOLS 0 Oil pressure gauge 07506 07506 3000000 Attachment 07510 4220100 or equivalent commercially available in U S A Check the oil level Start the engine and allow it to warm up t
218. tomobile 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 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 SPECIFICATION Unit mm in ITEM STANDARD SERVICE LIMIT Rear wheel runout 2 0 mm 0 08 in 2 0 0 08 Rear axle runout 0 2 mm 0 01 in Rear brake drum 1 0 Rear brake lining thickness 160 mm 6 3 in 5 mm 0 2 in 161 mm 6 3 in 2 mm 0 08 in Shock absorber spring free length 137 5 mm 5 41 in 135 0 mm 5 31 in Rear suspension damper compression TORQUE VALUES Spokes Sprocket nut Shock absorber mounting bolt Swingarm pivot bolt Rear axle Damper rod lock nut Brake torque rod nut 13 4 17 4 kg 29 54 38 36 Ib 4 Nem 0 4 k
219. ts tightly in the flange Remove and discard the bearing if it does not turn smoothly and quietly or if the outer race fits loosely in the flange BEARING REPLACEMENT Wheel bearing Drive out the wheel bearings and the distance collar NOTE f the bearings are removed they must replaced TOOLS Bearing remover shaft 07746 0050100 Bearing remover head 17 mm 07746 0050500 or equivalent commercially available in U S A 13 4 REAR WHEEL BRAKE SUSPENSION First drive in a new left wheel bearing until it is fully seated in 1 DRIVER stall the distance collar then drive in a new right bearing TOOLS Driver 07749 0010000 Attachment 42 x 47 mm 07746 0010300 Pilot 17 mm 07746 0040400 NOTE Drive the wheel bearings in with the vendor mark facing out Flange bearing Drive out the bearing using a suitable tool Drive the new bearing in with its vendor mark facing out DRIVER TOOLS Driver 077490010000 Attachment 42 x 47 07746 0010300 Pilot 17 mm 07746 0040400 ve wa 2 DRIVEN 3 ATTACHMENT FRANGE ASSEMBLY 11 BEARING PRE 4 DRIVEN SPROCKET 10 DAMPER RUBBER 9 COLLAR 8 FLANGE 4 0 50 5 DUST SEAL 7 NOISE ARRESTER 6 BEARING 13 5 REAR WHEEL BRAKE SUSPENSION Place the rim and hub on the work bench and begin lacing with new spoke from the hole of inside the hub Install the spoke wi
220. urn it in 90 degrees cloc kwise Hold vacuum piston up to almost full open to avoid pinching the diaphragm with the chamber cover 1 JET NEEDLE HOLDER 4 FINGER The vacuum piston with the tab of the diaphragm aligned with 2 CAVITY the groove of the carburetor Install the chamber cover with the spring aligning the cover cavity with the hole in the carburetor and secure with at least two screws before releasing the vacuum piston 3 ALIGN 4 12 FUEL SYSTEM Install the right choke valve and choke knob 1 RIGHT CHOKE VALVE 2 CHOKE KNOB Install the fuel and air tubes as shown 1 FUEL TUBE 49 CARBURETOR SEPARATION ASSEMBLY SEPARATION Loosen the synchronization adjusting screw NOTE When separating the carburetors be take careful not to lose the thrust spring and synchronization adjusting spring 3 SYNCHRONIZATION 2 SYNCHRONIZATION SPRING ADJUSTING SCREW Separate the carburetors by removing two attaching screws 1 SCREWS Remove the synchronization spring 2 SYNCHRONIZATION SPRING 4 13 FUEL SYSTEM ASSEMBLY 1 THRUST SPRING Loosen the synchronization adjusting screw until there is no spring tension Install the thrust spring between the throttle links Secure the carburetors together with the two screws Install the synchronization spring and synchronization adjust ing screw Inspect throttle operation as descr
221. ushing 1 0 C1 20 016 20 037 0 7880 0 7889 20 06 0 790 2 25 000 25 021 0 9843 0 9851 25 04 0 986 Bushing to C1 0 023 0 057 0 0009 0 022 0 10 0 004 shaft clearance M2 0 020 0 062 0 0008 0 0024 0 10 0 004 Gear to M4 M2 0 002 0 062 0 0008 0 0024 0 10 0 004 bushing clearance C1 C3 Countershaft O D C1 bushing 19 980 19 993 0 7866 0 7871 19 96 0 786 Mainshaft O D M2 bushing 24 959 24 980 0 9835 0 9826 24 94 0 982 Backlash 1st 2nd 3rd 1 021 0 110 0 0008 0 0043 4th 1 023 0 117 0 0009 0 0046 Shift fork Claw thickness 5 93 6 00 0 233 0 236 5 63 0 222 fork shaft Right and left shift 88 89 91 95 13 000 13 018 0 5118 0 5125 13 04 0 513 fork 1 0 After 95 13 000 13 021 0 5118 0 5126 13 04 0 513 Su p 88 89 91 95 12 966 12 984 0 5105 0 5112 12 90 0 508 After 95 12 966 12 984 0 5105 0 5112 12 95 0 509 Shift drum O D at the left side journal 11 966 11 984 0 4711 0 4718 11 94 0 470 TORQUE VALUES Connecting rod bearing cap nut Crankcase 8 mm stud bolt 10 mm stud bolt TOOLS Special Main bearing driver attachment Bearing remover set remover handle bearing remover set remover weight Common Driver Attachment 42 x 47 mm Pilot 20 mm Attachment 52 x 55 mm Pilot 22 mm Pilot 25 mm 11 2 34 3 4 kg m 25 ft Ib 20 30 Nem 2 0 3 0 kg m 14 22 ft lb 30 50 N m 3 0 5 0 kg m 22 36 ft Ib 90400 07936 3710001 07936 371010
222. 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 Replace the EVAP CAV CONTROL VALVE if vacuum leaks TOOL Vacuum Pressure pump A937X 041 XXXXX or Vacuum pump ST AH 260 MC7 U S A only Connect the vacuum pump to the No 10 hose that goes to the right carburetor body Connect the pressure pump to the air vent port of the EVAP CAV CONTROL VALVE While applying the vacuum to the EVAP CAV CONTROL VALVE No 10 hose that goes to the right carburetor body pump air through the air vent port Air should flow through the EVAP CAV CONTROL VALVE and out the hose that goes to the carburetor air joint pipe TOOL Vacuum Pressure pump A937X 041 XXXXX or Vacuum pump ST AH 260 MC7 Pressure pump ST AH 255 MC7 U S A only Plug the hose that goes to the carburetor air joint pipe While applying vacuum to the EVAP CAV CONTROL VALVE E No 10 hose that goes to the right carburetor body apply air pressure 54 It should hold steady Replace the EVAP CAV CONTROL VALVE if pressure is not retained Remove the pumps install the EVAP CAV CONTROL VALVE on its mount route and reconnect the hoses according to the routing label TOOL Vacuum Pressure pump A937 X 041 XXXXX or 1 BLOCKED VACUUM
223. ven CAUTION Damage to the pilot screw seat will occur if the pilot screw is tightened against the seat This is an initial setting prior to the final pilot screw adjust ment INITIAL OPENING 1 1 4 turns out 3 Warm up the engine to operating temperature Stop and go driving for 10 minutes is sufficient 4 Attach a tachometer according to the manufacturer s in structions 5 Adjust the idle speed to the specified rpm with the throttle stop screw IDLE SPEED 1 200 100rpm 6 Turn each pilot screw 1 2 turn out from the initial setting 7 If the engine speed increase 5 or more turn each pilot screw out by successive 1 2 turn increments until engine speed does not increase 8 Adjust the idle speed with the throttle stop screw 9 Turn the rear cylinder carburetor pilot screw in until the engine speed drops 50 rpm 10 Turn the rear cylinder carburetor pilot screw 1 turn out from the position obtained in step 9 11 Adjust the idle speed with the throttle stop screw 12 Perform steps 9 10 and 11 for the front cylinder carbu retor pilot screw 13 Drive new pilot screw plugs into the pilot screw bores with a 7 mm valve guide driver P N 07942 8230000 When fully seated the plug surfaces will be recessed 1 mm FUEL SYSTEM HIGH ALTITUDE ADJUSTMENT U S A only When the vehicle is to be operated continuously above 2 000 m 6 500 feet the carburetors must be read
224. witch in coolant up to its threads 1 THERMOSTATIC SWITCH Install a new O ring on the switch Apply sealant to the switch thread and install it Tighten the switch to the specified torque TORQUE 18 N m 1 8 kg m 13 ft lb NOTE 2 O RING Do not over tighten the switch COOLANT TEMPERATURE INDICATOR SYSTEM INSPECTION Remove the horn Disconnect the sensor wire from the thermosensor and short it to ground using a jumper wire Turn the ignition switch ON The temperature indicator light should come on If the indica tor light does not come on check the sub fuse 10 A and p wires for a loose connection or an open circuit if normal re 1 TEMPERATU place the meter with a new one LIGHT al 18 8 LIGHTS METER SWITCHES THERMOSENSOR INSPECTION Drain the coolant from the thermostat housing by removing the drain bolt in the housing Disconnect the wire from the thermosensor and remove the thermosensor Suspend the thermosensor in oil over a heater and measure the resistance through the sensor as the oil heats up Temperatur C F 50 122 80 176 120 248 Resistance Q 153 9 51 9 16 1 AWARNING Wear gloves and eye protection NOTE must be used as the heated liquid to check the function above 100 C 212 F You will get false readings if either the sensor or thermometer touches the pan Replace the sensor if it is out of specifications by more
225. y cables only when the Power Switch is OFF _ Connecting the cables with the Power Switch can pro duce a spark which could ignite or explode the battery 15 6 YELLOW 1 GREEN 1 2 3 BATTERY AMP HR SELECTOR SWITCH 5 510 9 0 3 5 t0 5 0 9 5 to 1 0 to 3 0 16 6 to 30 Set the appropriate amp hour rating BATTERY CHARGING SYSTEM 5 Turn the Power Switch to the ON position 6 When the timer reaches the Trickle position the charg ing cycle is complete Turn the Power Switch OFF and disconnect the clamps NOTE The charger will automatically switch to the Trickle mode after the set charging time has elapsed 7 Retest the battery using the Honda Battery Tester and recharge if necessary using the above steps NOTE Foraccurate test results let the battery cool for at least ten minutes or until gassing subsides after charging CHARGING SYSTEM NOTE When inspecting the charging system check the system components and lines step by step according to the troubleshooting on page 15 2 Measuring circuits with a large capacity that exceeds the capacity of the tester may cause damage to the tester Before starting each test setthetesteratthe high capacity range first then gradually down to low capacity ranges in order that you have the correct range and do not damage the tester When measuring small capacity circuits keep the ignition switch off If th
226. y cracking replace the master link O rings and plate CAUTION Drive chain with clip type master link must not be used DRIVE AND DRIVEN SPROCKET Inspect the sprocket teeth for excessive wear or damage Re place if necessary NOTE Never install new drive 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 BRAKE FLUID Check the front brake fluid through the sight glass if the level is visible remove the cover set plate and diaphragm Fill the reservoir to the upper level with DOT 4 fluid from a sealed con tainer Check the system for leaks CAUTION Do not remove the reservoir cover until the handlebar has been turned so that the reservoir is level Do not mix different types of fluid as they are not compatible with each other Do not allow foreign material to enter the system when filling the reservoir Avoid spilling the fluid on painted plastic or rubber parts Place a rag over these parts whenever the system is serviced Refer to section 14 for brake bleeding procedures 2 O RINGS MASTER 5 STANDARD LINK LENGTH 4 DRIVE CHAIN CUTTER LI 1 SLIDE CALIPER 2 GOOD 3 NO GOOD 4 CRACKED 2 NORMAL 3 DAMAG 3 UPPER LEVEL 1 COVER 5 DIAPHRAGM jest 4 SIGHT GLASS 3 15 MAINTENANCE

VLX VT600 88-89 91-96 Service Manual

Contents

Download Pdf Manuals

Related Search

Related Contents