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Honda CBR150 Manual

1. eire remettre eie SPECIFICATIONS STARTER CLUTCH t STARTER MOTOR STARTER RELAY SWITCH sese 19 10 STEERING HEAD 3 22 STEERING 5 2 000 444 14 19 SUB AIR CLEANER 5 4 SUSPENSION t 5 3 20 55 55 0 15 10 SYSTEM DIAGRAM CHARGING SYSTEM 17 0 IGNITION SYSTEM we 18 0 ELECTRIC STARTER we 19 0 SYSTEM LOCATION 20 0 SYSTEM 8 2 2 2422102 6 3 TRHERM OSTAT 5 6 6 THROTTLE 002200 0 02 3 4 TOOLS eet 2s 1 14 TORQUE VALUES wee 1 12 TRANSMISSION ASSEMBLY 12 10 TRANSMISSION DISASSEMBLY 12 3 TROUBLESHOOTING ALTERNATOR STARTER 9 1 COOLING SYSTEM eene 6 2 CHARGING SYSTEM 17 3 BRAKE SYSTEM 2 16 2 CLUTCH GEARSHIFT LINKAGE 8 2 CRANKSHAFT BALANCER e 13 1 CYLINDER HEAD VALVES wee 10 2 CYLINDER PISTON wee 11
2. 1 17 CARBURETOR ASSEMBLY CARBURETOR CHOKE CARBURETOR DISASSEMBLY CARBURETOR INSTALLATION CLUTCH SYSTEM COMBINATION METER COOLANT REPLACEMENT COOLANT TEMPERATURE GAUGE THERMOSENSOR 20 15 COOLING FAN MOTOR SWITCH COOLING 5 5 04000 CRANKCASE ASSEMBLY CRANKCASE BREATHER CRANKSHAFT INSTALLATION CRANKSHAFT REMOVAL seen CYLINDER INSTALLATION CYLINDER REMOVAL CYLINDER COMPRESSION CYLINDER HEAD ASSEMBLY CYLINDER HEAD 15 5 5 10 8 CYLINDER HEAD INSTALLATION CYLINDER HEAD REMOVAL DRIVE CHAIN DRIVER SEAT ENGINE IDLE SPEED ENGINE LACKS POWER ENGINE QIL niise ateen raain iiis ENGINE OIL STRAINER SCREEN ENGINE INSTALLATION ENGINE REMOVAL ue EXHAUST SYSTEM eese FLYWHEEL INSTALLATION eene FLYWHEEL REMOVAL FORK Sy FRONT BRAKE CALIPER FRONT FENDER 2 FRONT MASTER CYLINDER FRONT WHEEL PUBL SEINE n ee toties FUEL METER FUEL UNIT 444442212 FUEL TANK 3555 GEARSHIFT LINKAGE GENERAL SAFETY
3. 6 8 COOLING SYSTEM Remove the nut and cooling fan COOLING Release the motor wire from the clamp Remove the screws and washers Remove the fan motor from the shroud CLAMP SCREWS WASHERS ASSEMBLY RADIATOR FAN MOTOR COOLING FAN FAN SHROUD 6 9 COOLING SYSTEM Install the fan motor to the shroud MOTOR Install and tighten the washers screws securely Insatll the motor wires to the clamp Apply locking agent to the motor shaft threads Install the cooling fan onto the motor shaft by aligning the flat surfaces Install and tighten the nut securely Install the cooling fan assembly to the radiator Install and tighten the bolts and ground terminal as shown Connect the fan motor switch connector 6 10 COOLING SYSTEM INSTALLATION lt lt a Instali the radiator assembly by aligning its grommet with the frame boss Install the collars and mounting bolts B BOLTS E A COLLARS install the upper radiator hose and tighten the band screw securely securely Install the lower radiator hose and tighten the band screw SIPHON TUBE x Connect the siphon tube Connect the fan motor 3P connector Fill and bleed the cooling system page 6 5 Install the following left middle cowl page 2 4 fuel tank page 5 3 COOLING SYSTEM RADIATOR RESERVE TANK REMOVAL INST ALLATION Remove the
4. 11 8 CYLINDER PISTON Insert the cam chain guide into cylinder and crankcase Install it by aligning the its bosses with the grooves in the cylinder and crankcase securely Install the cylinder head page 10 19 11 9 TRANSMISSION 12 0 12 TRANSMISSION SERVICE INFORMATION 12 1 INSPECTION TROUBLESHOOTING 12 2 TRANSMISSION ASSEMBLY TRANSMISSION DISASSEMBLY 12 3 CRANKCASE ASSEMBLY SERVICE INFORMATION GENERAL This section covers service of the transmission including the shift fork and shift drum For crankshaft and balancer service refer to section 13 The crankcase halves must be separated to service the transmission To service these parts the engine must be removed from the frame section 7 The following parts must be removed before disassembling the crankcase Cylinder head section 10 Cylinder and piston section 11 Clutch primary drive gear gearshift linkage section 8 Oil pump section 4 Flywheel section 9 Be careful not to damage the crankcase mating surfaces when servicing SPECIFICATIONS Unit mm in STANDARD SERVICE LIMIT Transmission Gear I D 17 016 17 034 0 6699 0 6706 17 08 6 724 18 000 18 021 0 7087 0 7095 18 07 0 711 23 020 23 041 0 9063 0 9071 23 09 0 909 C3 C4 22 020 22 041 0 8669 0 8678 22 1 0 87 15 000 15 018 0 590 0 591 15 1 0 59 C1 C2 1 2 20 020 20 041 0 7882 0 78
5. Gear I D Bushing 1 0 Bushing O D bushi CE Gear to bushing clearance C1 Mainshaft O D M5 Countershaft O D Transmission 17 9 0 70 22 9 0 90 0 10 0 004 0 10 0 004 Ci gear bushing 1 8 GENERAL INFORMA TION FRONT WHEEL SUSPENSION STEERING eam ITEM STANDARD SERVICE LIMIT 200 kPa 2 00 kgf cm 29 psi Driver and passenger 200 kPa 2 00 kgf cm 29 psi Axle runout 0 20 0 008 Wheel im runout Rem o Wheel balancer weight 60 g 2 1 oz max Fork Spring free length 412 4 16 24 404 1 15 91 Spring direction With the tightly wound end facing down Recommended fork fluid Honda Ultra Cushion Oil No 10 Fluid level 131 5 2 Fluid capacity 206 2 5 cm 7 0 0 08 US oz 7 3 0 09 Imp oz REAR WHEEL SUSPENSION Minimumtiretreaddeph __ indicator Cold tire pressure Driver only 200 kPa 2 00 kgf cm 29 psi Driver and passenger 225 kPa 2 25 kgf cm 33 psi menna O le Wheel rim runout 2 0 0 08 jaia Ts 2 0 10 08 Wheel balancer weight 60 g 2 1 oz max Size link 010428 13 1241 25 35 1 0 1 4 Minimum tire tread depth To the indicator Cold tire pressure Unit mm 1 9 GENERAL INFORMA TION Unit mm I
6. Support the motorcycle securely and raise the front wheet off the ground Check that the handlebar moves freely from side to side If the handlebar moves unevenly binds or has vertical movement inspect the steering head bearings Section 14 3 22 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM 4 0 4 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM 4 0 TROUBLESHOOTING SERVICE INFORMATION 4 1 OIL PUMP SERVICE INFORMATION GENERAL O 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 may lead to death Run the engine in an open area or with an exhaust evacuation system in enclosed area Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods Although this is unlikely unless you handle used oil on a daily basis it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil KEEP OUT OF REACH OF CHILDREN The oil pump be serviced with the engine installed in the frame The service procedures in this section must be performed with the engine oil drained When removing and installing the oil pump use care not to allow dust or dirt to enter the engine If any portion of the oil pump is worn beyond the specified ser
7. Faulty spark plug or leaking ignition coil secondary current Faulty ignition coil 2 1 The multimeter impedance is too low below 10 MQ DCV 2 Cranking speed is too low 3 The sampling timing of the tester and measured pulse were not synchronized system is normal if measured voltage is over the standard voltage at least once 4 Faulty ignition pulse generator in case when above No 1 3 are normal Ignition pulse generator Low peak voltage Faulty peak voltage adaptor or Imrie tester Faulty ignition pulse generator No peak voltage 18 2 IGNITION SYSTEM IGNITION SYSTEM INSPECTION NOTE f there is no spark at plug check all connections for loose or poor contact before measuring peak voltage Use commercially available digital multimeter with an impedance of 10 MO DCV minimum The display value differs depending upon the internal impedance of the multimeter If using Imrie diagnostic tester model 625 follow the manufacturer s instructions Connect the peak voltage adaptor to the digital multim eter or use the Imrie diagnostic tester TOOLS Imrie diagnostic tester model 625 or Peak voltage adaptor 07HGJ 0020100 with Commercially available digital multimeter impedance 10 MW DCV minimum IGNITION COIL PRIMARY PEAK VOLTAGE NOTE Check all system connections before inspection If the system is disconnected incorrect peak voltage
8. Apply engine oil to the countershaft oil seal lips Instali the mainshaft and countershaft as an assembly into the right crankcase Be sure to install the three end washers mainshaft left side only countershaft both ends Each shift fork has an identification marks PR right center PL left Install the shift forks into the shifter gear grooves with the marks facing down r ght crankcase side Apply molybdenum oil solution to the guide grooves in the shift drum and install it by aligning the shift fork guide pins with the guide grooves Apply molybdenum oil solution to the shift fork shaft in sert it through the shift forks into the left crankcase 12 12 TRANSMISSION CRANKCASE ASSEMBLY Clean the left and right crankcase mating surfaces throughly being careful not to damage them and check for damage Install the dowel pins onto the right crankcase Apply a light but through coating of sealant to left crank case mating surface except the oil passage area Make sure all the parts are installed the left and right RIGHT CRANKCASE I crankcases COVER 4 CAUTION Do not force the crankcase halves together If there is ex cessive force required something is wrong Remove the right crankcase and check for misaligned parts Install the left crankcase over the right crankcase Install the right crankcase bolts and washer and tighten the bolts in a crisscro
9. Install the removed parts in the reverse order of removal IGNITION COIL REMOVAL INSTALLATION IGNITION COIL Remove the fuel tank page 5 3 Disconnect the spark plug cap from the spark plug page 3 6 Disconnect the primary wire connector Remove the two bolts and ignition coil Installation is in the reverse order of removal IGNITION CONTROL MODULE ICM REPLACEMENT Remove the fuel tank page 5 3 Disconnect the connector Remove the ICM from the rubber bracket Install the ICM in the reverse order of removal IGNITION SYSTEM SYSTEM INSPECTION Disconnect the ICM 6P connector and check it for loose contact or corroded terminals Turn the ignition switch ON Measure the voltage between connector terminals wire harness side as follows Terminal Specification Battery line Black and Battery voltage Green should exist Green and Continuity ground should exist Ground line Install the removed parts in the reverse order of removal IGNITION TIMING nS 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 Theexhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death NOTE Read the instruction for timing light operating Warm up the engine Stop the engine and remove
10. Check the gearshift spindle for vent or damage Mc y GEARSHIFT SPINDLE INSTALLATION Apply molybdenum oil solution to the gearshift spindle shaft and install the gearshift spindle to the gearshift return spring pin GEARSHIFT SPINDLE 8 10 CLUTCH GEARSHIFT LINKAGE Install the return spring washer between the arm and spring stopper arm and bolt and tighten the bolt to the specified torque TORQUE 12 N m 1 2 kgf m 9 Ibf ft Lower the stopper arm and install the pins Install the gearshift cam plate by aligning the pin hole in the cam plate with the pin Apply locking agent to the gearshift cam plate bolt threads See 73 Install the bolt and tighten it to the specified torque GEARSHIFT CAM PLATE BN 3 m TORQUE 12 1 2 kgf m 9 Ibf ft Install the following clutch assembly page 8 9 t right crankcase cover page 8 14 gearshift arm WASHER 8 11 CLUTCH GEARSHIFT LINKAGE PRIMARY DRIVE GEAR x CLUTCH CENTER HOLDER LOCK NUT WASHER REMOVAL Remove the oil pump page 4 3 Remove the four bolts lifter plate and clutch springs install the clutch center holder and tighten the bolts Remove the primary drive gear lock nut and washer while holding the clutch center holder IMARY IVE TOOL Clutch center holder G7GMB 70101 Lock nut wrench 20 x 24 mm 07716 0020100 Remove the clutch assembly p
11. PLATE CLUTCH PLATES CLUTCH DISC A CLUTCH GEARSHIFT LINKAGE w INSTALLATION WASHER B CLUTCH OUTER GUIDE Install the washer T ry Apply molybdenum oil solution to the clutch outer guide Install the washer clutch outer guide the main shaft CLUTCH CENTER HOLDER Xs t a 7 Install the clutch assembly i Instali the clutch center holder and tighten the four bolts Install the washer and lock nut Hold the clutch assembly and tighten the lock nut to the specified torque TOOLS Clutch center holder 07GMB KT70101 Lock nut wrench 20 x 24 mm 07716 0020100 TORQUE 74 N m 7 5 kgf m 54 Ibf ft Remove the four bolts and clutch center holder Install the clutch springs lifter plate four bolts and clutch lifter bearing NOTE Tighten the lifter plate bolts in crisscross pattern in 2 steps CLUTCH GEARSHIFT LINKAGE GEARSHIFT LINKAGE REMOVAL Remove the following gearshift arm right crankcase cover page 8 3 clutch assembly page 8 4 Remove the bolt washer and gearshift cam plate Remove the pins from the shift drum GEARSHIFT SPINDLE Remove the bolt washer stopper arm and return spring g ee Remove the gearshift spindle oe ARM Check the gearshift cam plate and stopper arm for wear or damage Check the stopper arm return spring for fatigue or dam E
12. Ramove the terminal nut and starter motor cable Remove the two mounting bolts and ground cable Remove the starter motor from the left crankcase MOUNTING BOLTS STARTER MOTOR CABLE DISASSEMBLY INSPECTION BOLT O RING Remove the o ring Remove the starter motor case bolts and O rings O RING Remove the front cover lock washer and seal ring SEAL RING FRONT COVER LOCK WASHER Remove the shims SHIMS 7 19 4 ELECTRIC STARTER Remove the rear cover shims and seal ring x if REAR COVER SEAL RING ms Remove the armature from the motor case Record the location and number of shims A i SHIMS ARMATURE Check the needle bearing and dust seal in the front cover for wear or damage DUST SEAL NEEDLE BEARING FRONT COVEF Check the commutator bars of the armature for discolora tion ARMATURE NOTE Do not use emery or sand paper on the commutator v COMMUTATOR Check for continuity between pairs of commutator bars There should be continuity ELECTRIC STARTER Check for continuity between each commutator bar and the armature shaft There should be no continuity Check for continuity between the insulated brush and cable terminal f There should be continuity Check for continuity between the cable terminal and rear cover There should be no continuity Remove the following nut washers
13. eese GRAB RAIL careret nennt tanta retur rete nate HANDLEBAR ciiisean saarea 14 3 HANDLEBAR SWITCHES eee 20 8 HEADLIGHT AIM eese 3 19 uH 20 13 IGNITION COIL 18 5 IGNITION CONTROL MODULE ICM IGNITION SWITCH sees 20 7 IGNITION SYSTEM INSPECTION 2 18 3 IGNITION TIMING seen 18 6 LEFT CRANKCASE COVER INSTALLATION 9 8 LEFT CRANKCASE COVER REMOVAL 9 2 LUBRICATION amp SEAL POINTS 2s 1 15 LUBRICATION SYSTEM 4 0 MAINTENANCE SCHEDULE 3 3 MIDDLE COW 2 4 MODEL IDENTIFICATION eee 1 3 NUTS BOLTS FASTENERS 3 21 OIL PUMP seccion PASSEN GEAR SEAT PILOT SCREW ADJUSTMENT 5 14 PISTON INSTALLATION essere 11 7 PISTON REMOVAL POOR HANDLING eee eg POOR PERFORMANCE AT HIGH SPEED 22 4 POOR PERFORMANCE AT LOW AND IDLE SPEED eee 22 3 PRIMARY DRIVE GEAR we 8 12 RADIATOR COOLANT 3 13 RADIATOR COOLING FAN eere 6 8 RADIATOR RESERVE TANK 6 12 REAR BRAKE CALIPER sese 16 19 REAR COWL nei erae 2
14. HOW TO USE THIS MANUAL This service manual describes the service procedures for the CBR150R Follow the Maintenance Schedule Section 3 recom mendations to ensure that the vehicle is in peak oper ating condition and the emission levels are within the standards Performing the first scheduled maintenance is very important It compensates for the initial wear that oc curs during the break in period Sections 1 and 3 apply to the whole motorcycle Section 2 illustrates procedures for removal installa tion of components that may be required to perform service described in the following sections Section 4 through 21 describe parts of the motorcycle grouped according to location Find the section you want on this page then turn to the table of contents on the first page of the section Most sections start with an assembly or system illus tration service information and troubleshooting for the section The subsequent pages give detailed procedure If you don t know the source of the trouble go to sec tion 22 TROUBLESHOOTING ALL INFORMATION ILLUSTRATIONS DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICA TION ARE BASED ON THE LATEST PRODUCT IN FORMATION AVAILABLE AT THE TIME OF AP PROVAL FOR PRINTING Honda Motor Co Ltd RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION THIS M
15. e When removing the brake hose bolt cover the end of 5 5 A A 0 the hose prevent contamination Secure the hose to prevent fluid from leaking out 4 BOLTS A Drain the brake fluid from the rear brake hydraulic system page 16 3 Remove the brake hose bolt sealing washers and brake hose Remove the rear master cylinder mounting bolts Remove the mounting bolts and right main step holder with the rear brake light switch installed Remove the cotter pin joint pin and rear master cylinder Remove the bolt and reservoir COTTER PIN JOINT PIN DISASSEMBLY O RING Remove the screw O ring and joint pipe Mog i eh 3 JOINT PIPE SCREW Remove the boot 16 12 BRAKE SYSTEM Remove the snap ring using the special tool TOOL Snap ring pliers 07914 5 50001 Remove the following push rod assembly master piston assembly spring Check the spring and replace if necessary INSPECTION Check the boot primary cup and secondary cup for fatigue or damage Check the master cylinder and piston for scoring scratches or other damage Replace if necessary NOTE Replace the piston assembly and spring as a set if dam aged Measure the master cylinder bore I D SERVICE LIMIT 12 755 mm 0 5022 in Measure the master piston O D SERVICE LIMIT 12 645 mm 0 4978 in SNAP RING SNAP RING PLIERS
16. vx d gt STEM DRIVER TOP THREAD UPPER BEARING TOP CONE RACE TOP BALL RACE 14 21 FRONT WHEEL SUSPENSION STEERING Apply grease to all bearing area STEERING STEM Install the lower bearing Install the steering stem upper bearing and top cone race TOP CONE RACE CAUTION Be careful not to lose any of the bearing Install the top thread Tighten the top thread to the initial torque using the spe cial tool while holding steering stem securely STEERING STEM SOCKET TOOL Steering stem socket 07916 3710101 TORQUE 27 N m 2 8 kgf m 20 Ibf ft Move the steering stem right and left lock to lock five times for races and bearings to get to fit enough Loosen the top thread completely 5 Retighten the top thread to the specified torque using the 51 EERING STEM SOCKET special tool RS TOOL Steering stem socket 07916 3710101 TORQUE 1 0 N m 0 1 kgf m 0 7 Ibf ft 14 22 FRONT WHEEL SUSPENSION STEERING Install the horn stay Install the following top bridge front fork page 14 18 washer stem nut Tighten the stem nut to the specified torque TORQUE 88 N m 9 kgf m 65 Ibf ft Install the following front fender page 2 3 front wheel page 14 12 handlebar page 14 5 upper cowl page 2 5 STEERING BEARING PRELOAD Raise the front wheel off the ground Position the steering stem to the
17. 0 10 mm 0 004 in Bushing to Shaft C1 C2 0 10 mm 0 004 in Shift Drum Drum Journal Inspect the shift drum end for scoring scratches or evi dence of sufficient lubrication Check the shift drum grooves for abnormal wear or dam age Measure the shift drum O D at right end SERVICE LIMIT 25 08 mm 0 987 in Check the shift drum journal in the right crankcase for ex cessive wear or damage Measure the shift drum journal I D SERVICE LIMIT mm in Shift Fork Check the shift forks for deformation or abnormal wear Measure each shift fork claw thickness SERVICE LIMIT 4 90 mm 0 193 in Measure I D of each fork SERVICE LIMIT 10 03 mm 0 395 in 12 6 TRANSMISSION Shift Fork Shaft Check for damage and straightness Measure the shift fork shaft O D SERVICE LIMIT 9 93 mm 0 391 in Transmission Bearing Turn the inner race of each bearing with your finger The bearings should turn smoothly and quietly Also check that bearing outer races fit tightly in the crank cases 12 7 TRANSMISSION TRANSMISSION BEARING REPLACE Z sous MAINSHA MENT 47 2 Remove the bolts mainshaft bearing setting plate from the right crankcase Remove the mainshaft bearing from the inside of the right crankcase Remove the oil seal from the left crankcase Remove the countershaft bearing from the inside of the left crankcase c MAINSHAFT SEAL BE
18. Brake disc runout Master cylinder To groove 0 1 0 004 12 755 0 5022 31 94 1 257 12 700 12 743 0 5000 0 5017 12 657 12 684 0 4983 0 4994 32 030 32 080 1 2610 1 2630 31 948 31 998 1 2578 1 2598 Master piston O D Caliper cylinder I D Caliper piston O D 16 1 BRAKE SYSTEM TORQUE VALUES Brake hose bolt Front master cylinder cover screw Front brake light switch screw Brake lever pivot nut Front brake caliper mounting bolt Brake caliper pad pin Rear brake reservoir cover screw Rear master cylinder mounting bolts Rear master cylinder push rod nut Bleed valve Main step holder mounting bolt TOOL Snap ring pliers TROUBLESHOOTING Brake lever pedal soft or spongy Air in hydraulic system Leaking hydraulic system Contaminated brake pads disc Worn caliper piston seal Worn master cylinder piston cups Worn brake pads disc Contaminated caliper Caliper not sliding properly Low brake fluid level Clogged fluid passage Warped deformed brake disc Sticking worn caliper piston Sticking worn master cylinder piston Contaminated master cylinder Bent brake lever pedal 34 N m 3 5 kgf m 25 Ibf ft 1 5 N m 0 15 kgf m 1 1 Ibf ft 1 2 N m 0 12 kgf m 0 9 Ibf ft 5 9 N m 0 6 kgf m 4 3 Ibf ft
19. CHAMBER COVER SPRING AGEL O RING o E STARTING O RING bd ENRICHMENT SE QE VALVE COVER Re 4 SPRING NEEDLE J FLOAT WASHER PILOT SCREW CHAMBER ORAIN MAIN J ET gt SCREW SY O RING FLOAT CHAMBER Install the pilot screw and return it to its original position as noted during removal Perform the pilot screw adjustment if new pilot screw is installed page 5 14 CAUTION Damage to pilot screw seat will occur if the pilot screw is tightened against the seat Handle the jets with care They easily be scored or scratched Install the needle jet main jet and slow jet O RING NEEDLE J SPRING h SLOW J ET PILOT SCREW MAIN J ET WASHER uo 5 9 FUEL SYSTEM Hang the float valve onto the float arm lip Install the float valve float and float pin FLOAT FLOAT LEVEL INSPECTION NOTE Set the float level gauge so that it is perpendicular to the float chamber face at the highest position of the float With the float valve seated and the float arm just touching the valve measure the float level with the float level gauge TOOL Float level gauge 07401 0010000 FLOAT LEVEL 13 mm 0 5 in FLOAT LEVEL GAUGE The float cannot be adjusted Replace the float assembly if the float level is out of specification Install a new O ring into the groove in the float chamber cover Install the float c
20. Contaminated deteriorated fuel Intake air leak Misadjusted idle speed Misadjusted pilot screw Clogged air cleaner Clogged slow circuit Starting enrichment valve open Faulty ignition system section 18 Afterburn when engine braking is used Lean mixture in slow circuit Faulty ignition system section 18 Backfiring or misfiring during acceleration Lean mixture Faulty ignition system section 18 Poor performance driveability and poor fuel economy Clogged fuel system Faulty ignition system section 18 FUEL TANK FUEL TANK REMOVAL INSTALLATION Remove the driver seat page 2 2 Remove the bolt and collar Raise the rear of fuel tank while releasing the bosses of the rear cowl from the grommets of the fuel tank Pull the fuel tank backward and support it Disconnect the fuel unit 3P connector Disconnect the fuel and vacuum tube from the fuel auto valve Installation is in the reverse order of removal FUEL AUTO VALVE INSPECTION Remove the fuel tank See above Connect a commercially available vacuum pump to the diaphragm vacuum outlet Fuel should flow out from the fuel tube when vacuum is applied If fuel flow is restricted replace the fuel auto valve FUEL SYSTEM FUEL AUTO VALVE 5 3 FUEL SYSTEM AIR CLEANER HOUSING REMOVAL INSTALLATION Remove the fuel tank page 5 3 FUEL OVERFLOW TUBE Disconnect the crankcase breather crankcase breather drain and fuel ove
21. Driven sprocket nut 64 N m 6 5 kgf m 47 Ibf ft 3 16 MAINTENANCE REPLACEMENT COVER Remove the swingarm page 15 10 Remove the two bolts and drive sprocket cover Remove the drive chain Install the new drive chain REPLACEMENT CHAIN DID428VI3 124LE Install the drive sprocket cover and tighten the bolts Install the swi page 15 13 M j d nstall t e swingarm page a 9 17 BOLTS BRAKE FLUID CAUTION Donot mix different types of fluid as they are not com patible with each other allow foreign material to enter the system when filling the reservoir Avoid spilling fluid on painted plastic or rubber parts Place a rag over these parts whenever the system is serviced NOTE When the fluid level is low check the brake pads for wear page 3 20 A low fluid level may be due to wear of the brake pads If the brake pads are worn the caliper pistons are pushed out and this accounts for a low reservoir level If the brake pads are not worn and the fluid level is low check entire system for leaks page 3 20 UPPER LEVEL FRONT BRAKE Turn the handlebar to the left side so that the reservoir is level and check the fluid through the sight glass if the level is near the lower level mark remove the screws Cover set plate and diaphragm and fill the reservoir with DOT 3 or 4 brake fluid from a sealed container to the upper level Install the diaphragm set pla
22. Dry weight Curb weight Frame type Front suspension Front axle travel Rear suspension Rear axle travel Rear damper Front tire size Rear tire size Tire brand Front brake Rear brake Caster angle Trail length Fuel tank capacity ENGINE Bore and stroke Displacement Compression ratio Valve train Intake valve opens closes Exhaust valve opens closes Lubrication system Oil pump type Cooling system Air filtration Crankshaft type Engine dry weight Cylinder arrangement 1 910 mm 75 2 in 652 mm 25 7 in 1 065 mm 41 9 in 1 286 mm 50 6 in 776 mm 30 6 in 312 mm 12 3 in 172 mm 6 8 in 115 kg 253 53 Ibs 123 kg 271 17 Ibs Diamond type Telescopic fork 190 mm 4 29 in Swingarm 120 mm 4 72in Single effected tube type 80 90 17 44 100 80 17 52 Front Rear IRC Hydraulic disc brake Hydraulic disc brake 25 88 mm 3 46 in 10 0 liter 2 64 US gal 2 2 Imp gai 63 5 x 47 2 mm 2 50 x 1 86 in 149 4 cm 9 1 cu in 11 0 1 Multi link chain drive and DOHC 5 BTDC 35 ABDC 30 BBDC 0 ATDC Forced pressure and wet sump Trochoid Liquid cooled Paper filter Assembled type 26 1 kg 57 55 Ibs Single cylinder inclined 40 from vertical GENERAL INFORMA TION SPECIFICATIONS CARBURETOR Carburetor type CV Constant velocity type Venturi dia 25 mm 0 98 i
23. Loose spark plug cap or spark plug wire connection Water got into the spark plug cap leaking the ignition coil secondary voltage If there is no spark at cylinder temporarily exchange the ignition coil with the other good one and perform the spark test If there is spark the exchanged ignition is faulty No spark at plug Unusual condition Probable cause Check in numerical order Ignition coil Low peak voltage The multimeter impedance is too low primary 2 Cranking speed is too low voltage Battery under charged 3 The sampling time of the tester and measured pulse were not synchronized System is normal if measured voltage is over the standard voltage at least ones Poorly connected connector or an open circuit in ignition System Faulty ignition coil Measure the peak voltage Faulty ICM in case when above No 1 5 are normal gt Incorrect peak voltage adaptor connections Faulty ignition switch Loose or poor connected ICM connector An open circuit or loose connection in Green wire Open circuit or poor connection in ground wire of the ICM Faulty peak voltage adaptor or Imrie tester Faulty ignition pulse generator measure the peak volt age Faulty ICM in case when above 1 7 are normal Peak voltage is normal but spark jumps at plug
24. NLGI 42 or equivalent Example Molykote Paste manufactured by Dow Corning U S A Honda Moly 60 U S A only Rocol ASP manufactured by Rocol Limited U K Rocol Paste manufactured by Sumico Lubricant Japan Use silicone grease Apply a locking agent Use a middle strength locking agent unless otherwise specified Apply sealant Use DOT 4 brake fluid Use the recommended brake fluid unless otherwise specified Use Fork or Suspension Fluid 1 GENERAL INFORMATION GENERAL SAFETY SERVICE RULES MODEL IDENTIFICATION SPECIFICATIONS TORQUE VALUES GENERAL SAFETY CARBON MONOXIDE If the engine must be running to do some work make sure the area is well ventilated Never run the engine in an enclosed area 10 o lL 8 The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may lead to death Runthe engine in an open area or with an exhaust evacu ation system in an enclosed area GASOLINE Work in a well ventilated area Keep cigarettes flames or sparks away from the work area or where gasoline is stored 1 Gasoline is extremely flammable and is explosive un der certain conditions KEEP OUT OF REACH OF CHIL DREN HOT COMPONENTS 0 0 S Engine and exhaust system parts become very hot and remain hot for some time after the engine is run Wear insulated gloves or wait until the engine and exhaust system have cooled before handling th
25. ait AE mz 5 2 BRAKE FLUID NOTE 4 BRAKE PADS WEAR BRAKE SYSTEM BRAKE LIGHT SWITCH HEADLIGHT AIM CLUTCH SYSTEM SIDE STAND SUSPENSION NUTS BOLTS FASTENERS WHEELS TIRES STEERING HEAD BEARINGS Ww 3 20 3 2 1 Should serviced an 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 an authorized Honda dealer NOTES 1 For higher odometer readings repeat at the frequency interval established here 2 Service more frequently when riding in unusually wet or dusty areas 3 Service more frequently when riding in rain at full throttle 4 Replace every 2 years Replacement requires mechanical skill 5 Replace every 3 years or 24 000 km Replacement requires mechanical skill MAINTENANCE FUEL LINE FUEL LINE lt Remove the fuel tank page 5 3 Check the fuel lines for deterioration damage or leakage Replace the fuel line if necessary THROTTLE OPERATION Check for smooth throttle grip full operating and automatic full closing in all steering positions Check the throttle cable and replace it if it is deteriorated kinked or damaged Lubricate the throttle cable if throttle operation is not smooth Measure the free play at the throttle grip flange FREE PLAY 2 6 mm 1 12 1 4 in Throttle grip free play can be a
26. 0 43 64 6 5 47 42 4 3 31 39 4 0 29 44 4 5 33 88 9 0 65 ARP 34 3 5 25 1 5 0 15 1 1 1 2 0 12 0 9 5 9 0 6 4 3 30 3 1 22 17 1 7 12 5 4 0 6 4 1 5 0 15 1 1 12 1 2 9 17 1 7 12 27 2 8 20 ANH 8 5 9 0 6 4 3 1 13 GENERAL INFORMA TION TOOLS NOTES 1 Equivalent commercially available 2 Alternative tool DESCRIPTION TOOL NUMBER REMARKS REF SEC Float level gauge Universal bearing puller Lock nut wrench 20 x 24 mm Flywheel holder Bearing remover weight Attachment 32 x 35 mm Attachment 37 x 40 mm Attachment 42 x 47 mm Attachment 72 x 75 mm Pilot 12 mm Pilot 15 mm Pilot 17 mm Pilot 20 mm Pilot 35 mm Bearing remover shaft Bearing remover head 12 mm Fork seal driver Fork seal driver attachment Oil seal remover Driver Valve spring compressor Valve seat cutter Seat cutter 27 5 mm 45 IN Seat cutter 24 mm 45 EX Flat cutter 24 mm 32 IN Flat cutter 27 mm 32 EX Interior cutter 30 mm 60 IN Interior cutter 26 mm 60 EX Cutter holder 3 8 mm Snap ring pliers Steering stem socket Bearing remover head 12 mm Bearing remover shaft Bearing remover shaft Bearing remover head 15 mm Attachment 36 mm Steering stem driver Assembly collar Assembly shaft Clutch center holder Ball race remover Valve
27. 0 0018 0 0030 0 10 0 004 Top groove clearance Piston ring end gap 0 15 0 30 0 004 0 010 0 7 0 030 Oil side rail 0 20 0 70 0 008 0 028 1 1 0 04 Cylinder to piston clearance 0 01 0 04 0 0004 0 0016 0 90 0 035 Connecting rod small end 1 0 15 010 15 028 0 5909 0 5917 15 09 0 594 Connecting rod small end to piston pin clearance 0 010 0 034 0 0004 0 0013 Top 0 05 0 20 0 002 0 008 0 3 0 01 0 015 0 050 0 0006 0 0020 0 08 0 003 0 075 0 0030 1 7 GENERAL INFORMA TION Unit mm in 17 016 17 034 0 6699 0 6706 22 020 22 041 0 8669 0 8678 15 000 15 018 0 590 0 591 17 969 17 980 0 7074 0 7079 22 984 23 005 0 9049 0 9057 0 020 0 052 0 0008 0 0020 0 036 0 057 0 0014 0 0022 16 966 16 984 0 6680 0 6687 14 966 14 984 0 5892 0 5899 C2 gear bushing 19 978 19 989 0 7866 0 7870 Gsieshdesone MS 0032 0068 000120002 01000000 Bushing to shaft clearance 9 986 9 995 0 3931 0 3935 Shift drum O D at right end 25 959 25 980 1 0220 1 0228 25 90 1 020 Shift drum journal R crankcase 26 000 26 021 1 0236 1 0244 25 08 0 987 Unit mm in CRANKSHAFT BARANCER ITEM STANDARD SERVICE LIMIT Connecting rod 0 6 0 02 Big end radial clearance 0050 002 Crankshaft runout Pf 9 03 0 001 TRANSMISSION ITEM
28. 14 3 STEERING STEM 14 19 SERVICE INFORMATION GENERAL A WARNING A contaminated brake disc or pad reduces stopping power Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent This section covers maintenance of the front wheel fork and steering stem Refer to section 16 for front hydraulic brake service Support the motorcycle securely using a hoist or work stand SPECIFICATIONS Unit mm in Minimum tire tread depth To the indicator Cold tire pressure Driver only Driver and passenger 200 kPa 2 00 kgf cm 29 psi 200 kPa 2 00 kgf cm 29 psi 0 20 0 008 2 0 0 08 2 0 0 08 Fork Spring free length 412 4 16 24 404 1 15 91 Spring direction With the tightly wound end facing down 0 20 0 008 Axle runout Wheel rim runout Radial Recommended fork fluid Honda Ultra Cushon oil No 10 Fluid level 131 5 2 00 Fluid capacity 206 2 5 cm 7 0 0 08 US oz 7 3 0 09 Imp oz TOROUE VALUES Front axle nut 59 N m 6 0 kgf m 43 Ibf ft U nut Front brake disc bolt 42 N m 4 3 kgf m 31 Ibf ft ALOC bolt Fork bolt 23 N m 2 3 kgf m 17 Ibf ft Fork socket bolt 20 N m 2 0 kgf m 14 Ibf ft Apply a locking agent to the threads Steering stem nut 88 N m 9 kgf m 65 Ibf ft Top thread See page 14 22 Top bridge pin
29. 2 ELECTRIC STARTER eese 19 2 FRAME BODY PANELS EXHAUST SYSTEM 2 1 FRONT WHEEL SUSPENSION STEERING 14 2 5 2 IGNITION SYSTEM 18 2 LIGHTS METERS SWITCHES wes 20 2 LUBRICATION 5 5 4 1 REAR WHEEL SUSPENSION we 15 2 TRANSMISSION wee 12 2 TURN SIGNAL RELAY 20 13 UNDER COWL eerte trente 2 3 UPPER COWL 5 o estt etae thee 2 5 VALVE CLEARANCE eese 3 8 VALVE GUIDE REPLACEMENT 10 13 VALVE SEAT INSPECTION essere 10 14 VALVE SEAT REFACING 4242242 2 WATER PUMP WHEELS TIRES 23 2 To print chapters click on the printer icon and fill in the page range General information 14298 0 Frame Body panels Exhaust system 29 36 Lubrication system 59 65 T OX nderPiston 185 164 2 Transmission 165 179 1 Grankshaf Balancer 180 185 14 Frontwheel Suspension Steering 186 209 15 RearwheeliSuspension 210 224 16 Brkesysem 225 248 7 249 257 ignition system 258 265 266 277 278 295 297 300 me SSS
30. 28 in Big End Side Clearance Measure the side clearance of the connecting rod big end SERVICE LIMIT 0 6 mm 0 02 in UNIVERSAL BEARING PULLER 2 22 in 50 0 50 5 mm 1 97 1 99 in 13 2 CRANKSHAFT BALANCER Big End Radial Clearance Measure the radial clearance of the connecting rod big end SERVICE LIMIT 0 05 mm 0 002 in Balancer Gear Check the balancer gear for wear or damage m BALANCER GEAR Crankshaft Balancer Bearing Turn the inner race of each bearing with your finger The bearings should turn smoothly and quietly Also check that bearing outer races fit tightly in the crankcase 13 3 CRANKSHAFT BALANCER CRANKSHAFT BALANCER BEARING REPLACEMENT REMOVAL Drive the right crankshaft bearing and balancer bearings out of the right and left crankcases INSTALLATION Crankshaft bearings Clean the crankcase mating surface thoroughly be careful not to damage the mating surface Apply engine oil to the new crankshaft bearings and place it on the crankcase CAUTION Check the each bearing stamp mark before Install the crankshaft bearing Right side TM SC07A87CS26 Left side TM SC07A87CS42 Drive the crankshaft bearing to the right crankcase using the special tools TOOLS Driver 07749 0010000 Attachment 72 x 75 mm 07746 0010600 Pilot 35 mm 07746 0040800 Install the crankshaft bearing to the left crankcase Assemble the s
31. 30 N m 3 1 kgf m 22 Ibf ft 17 N m 1 7 kgf m 12 Ibf ft 1 5 N m 0 15 kgf m 1 1 Ibf ft 12 N m 1 2 kgf m 9 Ibf ft 17 1 7 kgf m 12 Ibf ft 5 4 N m 0 6 kgf m 4 Ibf ft 27 N m 2 8 kgf m 20 Ibf ft ALOC bolt 07914 5 50001 Brake lever pedal hard Clogged restricted brake system Sticking worn caliper piston Caliper not sliding properly Clogged restricted fluid passage Worn caliper piston seal Sticking worn master cylinder piston Bent brake lever pedal Brake drags Contaminated brake pads disc Misaligned wheel Clogged restricted brake hose joint Warped deformed brake disc Caliper not sliding properly Clogged restricted brake hydraulic system Sticking worn caliper piston Clogged master cylinder port 16 2 BRAKE FLUID REPLACEMENT AIR BLEEDING ll A contaminated brake disc or pad reduces stopping power Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent CAUTION Donotallow foreign material to enter the system when filling the reservoir Avoid spilling fluid on painted plastic or rubber parts Place a rag over these parts whenever the system is serviced NOTE The pedal brake line air bleeding procedure is per formed in the same manner as in the Jever brake line air bleeding procedure Once the hydraulic system has been opened or if the brake feels spongy the system must be bled Whe
32. 5 3 rear cowl page 2 3 Disconnect the rear brake light switch connector and check for continuity between the terminals There should be continuity with the brake pedal applied and there should be no continuity with the brake pedal is released NEUTRAL INDICATOR SWITCH eee INSPECTION Make sure that the neutral indicator come on with the ignition switch ON and neutral position If the indicator does not come on inspect as follows Release the neutral switch connector from the clamp of the frame Disconnect the neutral switch connector Shift the transmission into neutral and check for continuity between the Light green Red wire terminal and ground There should be continuity with the transmission in neutral and no continuity with the transmission in gear except neutral LIGHTS METERS SWITCHES REMOVAL Disconnect the neutral switch connector page 20 9 Remove the drive sprocket cover Remove the bolt and neutral switch Remove the drive piece and spring Check the gear position switch for wear or damage Replace it if necessary Check the drive piece for wear or damage Replace it if necessary CAUTION Donot bent or tap drive piece when install the drive piece Bent the drive piece by force or crush the contact point will cause poor electricity connection INSTALLATION Install the spring and drive piece Apply engine oil to the new O ring and install it into the g
33. 6 Connect the alternator 4P connector page 17 7 f CYLINDER HEAD VALVES 10 1 0 kgf m 7 Ibf ft 4 N m 0 4 kgf m 2 o 2 N N ja lt 2 gt e o o z e Zu z eo Ed QA f p gt SS 9 gt 10 0 10 CYLINDER HEAD VALVES SERVICE INFORMATION VALVE GUIDE REPLACEMENT TROUBLESHOOTING VALVE SEAT INSPECTION CYLINDER COMPRESSION VALVE SEAT REFACING CYLINDER HEAD REMOVAL CYLINDER HEAD ASSEMBLY CAM CHAIN TENSIONER LIFTER CYLINDER HEAD INSTALLATION CYLINDER HEAD DISASSEMBLY SERVICE INFORMATION GENERAL This section covers service of the cylinder head valves Thecylinder head and valves services can be done with the engine installed in the frame When disassembling mark and store the disassembled parts to ensure that they are reinstalled in their original locations Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection Clean the oil passages before assembling cylinder head Becareful not to damage the mating surfaces when removing the cylinder head cover and cylinder head ET SPECIFICATIONS Unit mm in STANDARD 1 370 13 9 kgf cm 197 7 psi at 680 rpm SERVICE LIMIT Cylinder compression Cylinder head warpage Valve
34. BATTERY MATE or equivalent Correct Disconnect the regulator rectifier 4P connec tor and recheck the battery current leakage Install the battery page 17 4 Check the battery current leakage Leak test page 17 7 Incorrect Incorrect Correct Faulty regulator rectifier SPECIFIED CURRENT LEAKAGE 0 1 mA max Correct Shorted wire harness Faulty ignition switch Check the alternator charging coil page 17 7 Incorrect Faulty charging coil STANDARD 0 2 1 0 20 C 68 F Correct Measure and record the battery voltage using a digital multimeter page 17 4 Start the engine Measure the charging voltage page 17 5 Compare the measurements to result of the following calculation Correct Faulty battery MEASURED BATTERY VOLTAGE lt MEASURED CHARGING VOLTAGE lt 15 5 V Incorrect Perform the regulator rectifier wire harness Incorrect Open circuit in related wire inspection page 17 8 Loose or poor contacts of related terminal Shorted wire harness Correct Faulty regulator rectifier 17 3 CHARGING SYSTEM BATTERY BATTERY COVER REMOVAL NOTE Always turn the ignition switch OFF before removing or installing the battery Disconnect the battery negative cable first then positive cable from the battery Remove the driver seat page 2 2 Remove the trim clip and
35. CAUTION Using coolant with silicate inhibitors may cause prema ture wear of water pump seals or blockage of radiator passage Using tap water may cause engine damage NOTE The effectiveness of coolant decreases with the accu mulation of rust or if there is a change in the mixing proportion during usage Therefore for best perfor mance change the coolant regularly as specified in the maintenance schedule Mixonly distilled low mineral water with the antifreeze RECOMMENDED MIXTURE 50 50 Distilled water and antifreeze im RADIATOR CAP E ANTIFREEZE SOLUTION ETHYLENE GLYCOL BASE SOLUTION LOW MINERAL OR DISTILLED WATER COOLANT COOLING SYSTEM REPLACEMENT AIR BLEEDING The engine must cool before servicing the cooling sys tem or severe scalding may result RADIATOR CAP NOTE When filling the system or reserve tank with a coolant checking the coolant level place the motorcycle upright ona flat level surface Remove the following under cowl page 2 3 right middle cowl page 2 4 Remove the radiator cap Remove the drain bolt and sealing washer on the water pump and drain the coolant from the system Remove the reserve tank cap Disconnect the siphon tube from the radiator and drain the coolant from the reserve tank Connect the siphon tube Install the drain bolt with new sealing washer Fill the system with the recommended coo
36. LOCK PIECE Instali the lock piece and fork tube into the fork slider FP m e FORK PIPE Install the fork piston and rebound spring into the fork pipe REBOUND SPRING gt WS FORK PISTO 14 16 FRONT WHEEL SUSPENSION STEERING Clean and apply a locking agent to the fork socket bolt f threads FORK SLIDER SOCKET BOLT Install a new sealing washer and socket bolt Hold the fork slider in a vise with piece of woods or shop towel i Tighten the fork socket bolt to the specified torque TORQUE 20 N m 2 0 kgf m 14 Ibf ft NOTE If the socket bolt turn together with the fork piston tem porarily install the fork spring and fork bolt SEALING WASHER 2 Apply fork fluid to the lip of the oil seal Drive the seal using the oil seal driver DRIVER TOOLS Fork seal driver 07747 0010100 Fork seal driver attachment 07747 0010300 ATTACHMENT Install the oil seal stopper ring into the groove of the fork slider DUST SEAI Install the dust seal Compress the fork pipe all the way and pour in the speci fied amount of fork fluid OIL CAPACITY 206 2 5 cm 7 0 0 08 US oz 7 3 0 09 imp oz Pump the fork pipe slowly several times to stabilize the fork oil level Compress the fork all the way and measure the oil level from the top of the pipe OIL LEVEL 131 mm 5 2 in FRONT WHEEL SUSPENSION STEERIN
37. PLIERS 16 10 BRAKE SYSTEM Install the front brake light switch onto the master cylin P mue der with aligning the boss of the switch with hole of the BRAKE LIGHT SWITCH master cylinder Install and tighten the front brake light switch screw to SCREW the specified torque TORQUE 1 2 N m 0 12 kgf m 0 9 Ibf ft Apply silicone grease to the brake lever contacting area of the master piston and pivot bolt sliding surface Install the brake lever Install and tighten the pivot boit and nut to the specified torque TORQUE Pivot nut 5 9 N m 0 6 kgf m 4 3 Ibf ft amp 5 5 BOLT BRAKE LEVE facing up Align the end of the master cylinder with the punch mark on the handlebar and tighten the upper bolt first then tighten the lower bolt Install the master cylinder and holder with the UP mark MASTER CYLINDER y PUNCH MARN Connect the brake hose to the master cylinder with the bolt and new sealing washers as shown Adjust the brake hose angle and tighten the bolt to the specified torque TORQUE 34 N m 3 5 kgf m 25 Ibf ft Connect the front brake light switch connectors Fill and bleed the front brake hydraulic system page 6 3 CONNECTOR BRAKE SYSTEM REAR MASTER CYLINDER REMOVAL CAUTION Avoid spilling fluid on painted plastic or rubber parts Place a shop towel over these parts whenever the sys tem is serviced NOTE 85 58 WEN
38. Refer to page 16 3 for brake bleeding procedures BRAKE LIGHT SWITCH NOTE The front brake light switch does not require adjustment WITCH Adjust the brake light switch so that the brakelight comes on just prior to the brake actually being engaged If the light fails to come on adjust the switch so that the light comes on at the proper time Hold the switch body and turn the adjuster Do not turn the switch body gt SGA a ADJUSTER JA 3 18 HEADLIGHT AIM 100 1 An improperly adjusted headlight may blind on coming drivers or it may fall to light the road for a safe distance NOTE Adjust the headlight beam as specified by local laws and regulations Place the motorcycle on a level ground Adjust the headlight beam vertically by loosening the screw and move the headlight unit CLUTCH SYSTEM Check the cable and clutch lever for loose connections excessive play or other damage Replace or repair if necessary Inspect the clutch cable for kinks or damage and lubri cate the cable Measure the free play at the tip of the clutch lever FREE PLAY 10 20 mm 3 8 13 16 in 10 Adjust as follows Minor adjustment can be done with the upper adjuster LOCK NUT Loosen the lock nut and turn the adjuster After adjustment tighten the lock nut Major adjustment are made with the lower adjusting nut If the major adjustment is required turn the upp
39. brake pads and disc EA A contaminated brake disc or pad reduces stopping power Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent Never allow contaminates dirt water etc to get into an open reservoir Once the hydraulic system has been opened or if the brake feels spongy the system must be bleed Always use fresh DOT 3 or 4 brake fluid from a sealed container when servicing the system Do not mix different types of fluid they may not be compatible CAUTION Spilled brake fluid will severely damage instrument lenses and painted surfaces It is also harmful to some rubber parts Be careful whenever you remove the reservoir cap make sure the front reservoir is horizontal first Always check brake operation before riding the motorcycle 16 SPECIFICATIONS Unit mm Front Specified brake fluid DOT 3 or DOT 4 Brake pad wear indicator To groove 3 8 4 2 0 15 0 17 3 0 0 12 0 1 0 004 12 700 12 743 0 5000 0 5017 12 755 0 5022 12 657 12 684 0 4983 0 4994 25 318 25 368 0 9968 0 9987 25 300 0 9960 DOT 3 or DOT 4 3 8 4 2 0 15 0 17 Brake disc thickness Brake disc runout Master cylinder I D Master piston O D Caliper cylinder 1 0 Caliper piston O D Specified brake fluid Brake pad wear indicator Brake disc thickness
40. 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 SYMBOLS The symbols used throughout this manual show specific service procedures If supplementary information is required pertaining to these symbols it would be explained specifically in the text without the use of the symbols Replace the part s with new one s before assembly Use recommended engine oil unless otherwise specified Use molybdenum oil solution mixture of the engine oil and molybdenum grease in a ratio of 1 1 Use multi purpose grease Lithium based multi purpose grease NLGI 2 or equivalent Use molybdenum disulfide grease containing more than 396 molybdenum disulfide NLGI 2 or equivalent Example Molykote BR 2 plus manufactured by Dow Corning U S A Multi purpose M 2 manufactured by Mitsubishi Oil Japan Use molybdenum disulfide paste containing more than 40 molybdenum disulfide
41. clutch is released Engine speed does not increase Incorrect Incorrect Clogged Fouled or discolored Incorrect Valve train not lubricated properly Possible cause Brake dragging Worn or damaged wheel bearing Faulty tire valve Punctured tire Clutch slipping Worn clutch discs plates Warped clutch discs plates Weak clutch spring Additive in engine oil Starting enrichment SE valve ON position open Clogged air cleaner Restricted fuel flow Clogged muffler Pinched fuel tank breather Faulty ignition control module ICM Faulty ignition pulse generator Valve stuck open Worn cylinder and piston rings Leaking cylinder head gasket Improper valve timing Carburetor not serviced frequently enough Plug not serviced frequently enough Spark plug is the incorrect heat range Dil Jevel too high Oil level too low Contaminated oil Clogged oil passage Clogged oil pump TROUBLESHOOTING sf Se s 11 Check for engine overheating Not overheat 12 Accelerate or run at high speed Y Eng ne does not knock Overheat Engine knocks Coolant level too low Fan motor not working Faulty fan motor or fan motor switch Excessive carbon build up in combustion chamber Use of poor q
42. countercllockwise and remove it While pushing in turn the bulb counterclockwise to remove it Remove the tail brake light bulb and replace it with a new one LICENSE LIGHT Turn the bulb socket countercliockwise and remove it Remove the bulb and replace it with a new one Installation is in the reverse order of removal 20 4 LIGHTS METERS SWITCHES COMBINATION METER REMOVAL Disassemble the upper cowl page 2 5 BULB REPLACEMENT Pull the indicator and instrument bulb socket out of the combination meter Remove the bulb from the socket and replace it with a new one DISASSEMBLY Remove the six screws and speedometer front panel Remove the indicator and instrument light bulbs Remove the screws and combination meter sub harness from the rear panel Remove the speedometer tachometer fuel meter and coolant temperature gauge BULB SOCKET SCREWS SUB HARNESS j x screws V o SPEEDOMETER MOUNTING SCREWS 20 5 LIGHTS METERS SWITCHES ASSEMBLY SUB HARNESS SPEEDOMETER FUEL METER COOLANT TEMPERATURE GAUGE TACHOMETER Assemble the speedometer in the reverse order of disassembly NOTE Route the sub harness as shown INSTALLATION Assemble the upper cowl page 2 4 NOTE Route the combination meter wire and cable properly page 1 17 20 6 LIGHTS METERS SWITCHES IGNITION SWITCH INSPECTION Remove the
43. damage THERMOSTAT Heat the water with an electric heating element to operat ing temperature for 5 minutes Suspended the thermostat in heated water to check its operation Yea THERMOSTAT BEGINS TO OPEN THERMOMETER 69 5 72 157 1 1622 VALVE LIFT 3 5 mm 0 14 in minimum at 80C 176F 6 6 COOLING SYSTEM INSTALLATION Apply coolant to the new seal rubber and install it to the SEAL RUBBER thermostat flange v Install the thermostat into the housing with its hole facing up Install the thermostat housing cover and two bolts Tightn the bolts securely BOLTS 7 Fill and bleed the cooling system page 6 5 6 7 COOLING SYSTEM RADIATOR COOLING FAN SIPHON TUBE CONNECTOR REMOVAL Drain the coolant page 6 5 Remove the following fuel tank page 5 3 left middle cowl page 2 4 Disconnect the fan motor 3P connector Disconnect the siphon tube from the radiator Loosen the hose band screw and disconnect the lower ra diator hose Loosen the hose band screw and disconnect the upper radiator hose Remove the radiator mounting bolts and collars Slide the radiator to the right side then release the upper grommet from the frame boss Remove the radiator assembly BOLTS COLLARS DISASSEMBLY Disconnect the fan motor switch connector Remove the two bolts and ground terminal Remove the cooling fan assembly from the radiator
44. element gently Then blow away any remaining dust on the surface of the filter with compressed air from the inside toward outside Replace the element if the surface of it is still dirty after cleaning Install the air cleaner element and removed parts in the reverse order of removal Tighten the air cleaner cover screws Install the fuel tank page 5 3 CRANKCASE BREATHER Remove the cap from the crankcase breather tube and drain deposites into a suitable container Install the cap to the tube securely NOTE Service more frequently when ridden in rain at full throttle or after the motorcycle is washed or over turned Service if the deposites level can be seen in the transparent sec tion of the breather tube CAP BREATHER TUBE SPARK PLUG REMOVAL Remove the right middle cowl page 2 4 Remove the radiator lower monting bolt and move the bottom of radiator forward Disconnect the spark plug cap 3 6 MAINTENANCE Remove the spark plug using a equipped spark plug wrench or an equivalent Inspect or replace as described in the maintenance sched ule page 3 3 INSPECTION Check the following and replace if necessary recom mended spark plug page 3 1 Insulator for damage Electrodes for wear Burning condition coloration dark to light brown indicates good condition excessive lightness indicates malfunctioning ignition System or lean mixture wet or black sooty de
45. explosive under certain conditions Work in well ventilated area Smok ing or allowing flames or sparks in the work area or where the gasoline is stored can cause a fire or explosion e 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 may lead to death Run the engine in an open area or with an exhaust evacuation system in enclosed area Place the motorcycle on a level ground before starting any work SPECIFICATIONS Spark plug ITEM Throttle grip free play 2 6mm 1 12 1 4 in SPECIFICATIONS 0 7 0 8 mm 0 028 0 032 in 3 1 MAINTENANCE Engine oil capacity 1 0 liter 1 06 US qt 0 88 Imp qt At disassembly 1 3 liter 1 37 US qt 1 14 Imp qt Recommended engine oil Honda 4 stroke oil or equivalent motor oil service classification SE SF or SG Viscosity SAE 10W 30 Valve clearance in _ 016 009mm 000650001im i Tire size 80 90 17 M C 44 Rear 100 80 17 52 200 kPa 2 00 kg cm 29 psi Tire air pressure Driver and passen Front 200 kPa 2 00 kg cm 29 psi ger 225 kPa 2 25 kg cm 33 psi Minimum tire tread dept To the indicator TORQUE VALUES Rear 200 kPa 2 00 kg cm 29 psi drain bolt Spark plug Rear axle nut C
46. ft Recheck the drive chain slack and free wheel rotation Check the drive chain wear indicator label If the arrow mark of the chain adjuster reaches the red zone on the label replace the drive chain with a new one page 3 17 3 15 MAINTENANCE CLEANING AND LUBRICATION NON FLAMMABLE OR HIGH FLASH POINT SOLVENT Clean the chain with non flammable or high flash point solvent and wipe it dry Be sure the chain has dried completely before lubricating Inspect the drive chain for possible damage or wear Replace any chain that has damaged rollers loose fitting links or otherwise appears unserviceable Installing a new chain on badly worn sprockets will cause the new chain to wear quickly Inspect and replace sprocket as necessary Lubricate the drive chain with 80 90 gear oil or drive chain lubricant designed specifically for use with O ring LUBRICATE chains Wipe off the excess oil or chain lubricant 80 90 GEAR OIL OR PRO HONDA CHAIN LUBE SPROCKETS INSPECTION Inspect the drive and driven sprocket teeth for wear or damage replace if necessary Never use a new drive chain on worn sprockets Both chain and sprockets must be in good condition or the new replacement chain will wear rapidly NORMAL Check the attaching bolts and nuts on the drive and driven 2 sprockets If any are loose torque them D eS TORQUE Drive sprocket fixing plate bolt 10 N m 1 0 kgf m 7 Ibf ft
47. fuel tank page 5 3 Disconnect the ignition switch 2P connector Check for continuity between the wire terminals of the ig nition switch connector in each switch position Continuity should exist between the color coded wires as follows 1 x INM IGNITION SWITCH WIRE 2P CONNECTOR IGNITION SWITCH REMOVAL INSTALLATION Disconnect the ignition switch 2P connector Remove the two bolts and ignition switch Install the ignition switch in the reverse order of removal LIGHTS METERS SWITCHES HANDLEBAR SWITCHES Remove the fuel tank page 5 3 am 1 E Disconnect the right handlebar switch 3P connector Disconnect the left handlebar switch 9P and 2P Black connector Check for continuity between the wire terminals of the han dlebar switch connector Continuity should exist between the color coded wire ter minals as follows LIGHTING SWITCH DIMMER SWITCH LIGHTING SWITCH DIMMER SWITCH TURN SIGNAL SWITCH HORN SWITCH STARTER SWITCH BRAKE LIGHT SWITCH CONNECTORS FRONT Disconnect the front brake light switch connector and check for continuity between the terminals There should be cont nuity with the brake lever applied and there should be no continuity with the brake lever is released BRAKE LIGHT SWITCH 20 8 LIGHTS METERS SWITCHES REAR Remove the following driver seat page 2 2 fuel tank page
48. good condition or the replacement chain or sprocket will wear rapidly ROTATING DIRECTION MARK INSPECTION STAND WHEEL BEARING NO GOOD 15 4 REAR WHEEL SUSPENSION DISASSEMBLY SIDE COLLAR Remove the brake disc bolts and brake disc Remove the side collar and dust seal by BRAKE DISC DUST SEAL lt b 4 Remove the side collar and dust seal Remove the driven flange from the left wheel hub DUST SIDE COLLAR NOTE if you will be disassemble the driven flange remove the driven sprocket nuts before removing the driven flange from the wheel hub DRIVEN FLANGE Remove the damper rubbers and O ring DAM 0 PER RUBBERS 15 5 REAR WHEEL SUSPENSION Driven flange bearing removal BEARING Remove the driven flange bearing and collar A a P Wheel bearing removal Install the bearing remover head into the bearing From the opposite side instali the bearing remover shaft and drive the bearing out of the wheel hub TOOLS Bearing remover head 12mm 07746 0050300 Bearing remover shaft 07746 0050100 Remove the distance collar and drive out the other ing DISTANCE COLLAR 15 6 REAR WHEEL SUSPENSION ASSEMBLY BOLT DISC BEARING DRIVEN COLLAR FLANGE BEARING Q BEARING O RING NUT DAMPER RUBBER D DUST SEAL DUST SEAL lt
49. if neces sary Coolant gravity char t Coolant C F 15 20 30 ees ratio i 59 68 77 86 104 RENNES 109 1 008 1 008 1 007 1006 1 005 1 003 1 001 0 999 0 997 ee pe puer pues va sam ue uae Lue uz COOLING SYSTEM RADIATOR CAP SYSTEM PRESSURE INSPECTION NOTE Before installing the cap in the tester wet the sealing sur faces Pressure test the radiator cap using the tester Replace the radiator cap if it does not hold pressure or if relief pressure is too high or too low it must hold speci fied pressure for at least 6 seconds RADIATOR CAP RELIEF PRESSURE 108 kPa 1 1 kgf eni 16 psi Pressure the radiator engine and hoses using the tester and check for leaks CAUTION Excessive pressure can damage the cooling system com ponents Do not exceed 137 kPa 1 4 kgf cm 20 psi Repair or replace components if the system will not hold specified pressure for at least 6 seconds COOLANT REPLACEMENT PREPARATION Radiator coolant is toxic Keep it away from eyes mouth skin and clothes if any coolant gets in your eyes rinse them with wa ter and consult a doctor immediately ff any coolant is swallowed induce vomiting gargle and consult a physician immediately coolant gets on your skin or clothes rinse thor oughly with plenty of water KEEP OUT OF REACH OF CHILDREN
50. necessary BALANCE MARK 15 3 REAR WHEEL SUSPENSION NOTE Note the rotating direction marks on the tire Remove the dust seals from the wheel Mount the wheel tire driven flange and brake disc as sembly in an inspection stand Spin the wheel allow it to stop and mark the lowest heavi est point of the wheel with a chalk Do this two or three times to verify the heaviest area If the wheel is balanced it will not stop consistently in the same position To balance the wheel install wheel weights on the high est side of the rim the side opposite the chalk marks Adjust enough weight so the wheel will no longer stop in the same position when it is spun Do not add more than 60 grams to the wheel Wheel bearing Turn the inner race of each bearing with your finger Bearings should turn smoothly and quietly Also check that the bearing outer race fits tightly in the hub Remove and discard the bearings if the races do not turn smoothly and quietly or if they fit loosely in the hub and flange NOTE Replace the wheel and flange bearings in pairs Driven sprocket Check the condition of the final driven sprocket teeth Replace the sprocket if worn or damaged NOTE Ifthe final driven sprocket requires replacement inspect the drive chain and drive sprocket Never install a new drive chain a worn sprocket or a worn chain on new sprockets Both chain and sprocket must be in
51. open the battery cover Remove the bolt and disconnect the battery negative cable Remove the positive terminal cover NEGATIVE Remove the bolt and disconnect the battery positive CABLE cable Remove the battery out of the battery case INSTALLATION Install the battery into the case Coat the battery terminal with clean grease Place the battery into the case and connect the battery IN positive cable to the battery then connect the negative aN EN gt cable L E Install the positive terminal cover NOTE POSITIVE Pull the cover over the positive terminal CABLE INSPECTION NEGATIVE PROBE Measure the battery voltage using a commercially avail able digital multimeter VOLTAGE 20 C 68 F Fully charged 13 0 13 2 V Under charged Below 12 3 V bh xv 17 4 CHARGING SYSTEM BATTERY CHARGING AWARNING The battery gives off explosive gases keep sparks flames and cigarettes away Provide adequate ventilation when charging Turn power ON OFF at the charger not at the battery terminals Remove the battery page 17 4 Connect the charger positive cable to the battery positive 4 terminal Connect the charger negative cable to the battery negative terminal CHARGING CURRENT TIME Standard Quick CAUTION Quick charging should only be done an emergency slow charging is preferred For battery char
52. removal The following components be serviced with the engine installed in the frame Oil pump section 4 Clutch gearshift linkage section 8 Alternator starter clutch section 9 Cylinder head valves section 10 Cylinder piston section 11 Starter motor section 19 The following components require engine removal for service Transmission section 12 Crankshaft balancer section 13 SPECIFICATIONS SPECIFICATIONS Engine dry weight 26 1 kg 57 55 Ibs Engine oil capacity At draining 1 0 liter 1 06 US qt 0 88 Imp qt At disassembly 1 3 liter 1 37 US qt 1 14 Imp qt Recommended engine oil Honda 4 stroke oil or equivalent motor oil service classification SE SF or SG Viscosity SAE 10W 30 TORQUE VALUES Drive sprocket fixing plate bolt 9 8 N m 1 0 kgf m 7 Ibf ft Apply a locking agent to the threads Engine hanger nut 59 6 0 kgf m 43 Ibf ft Rear axle nut 59 6 0 kgf m 43 Ibf ft U nut 7 1 ENGINE REMOV AL INST ALLATION ENGINE REMOVAL Drain the coolant page 6 5 Drain the engine oil page 3 11 Remove the following exhaust system page 2 5 spark plug cap page 3 6 left middle cowl page 2 4 fuel tank page 5 3 air cleaner housing page 5 4 carburetor page 5 4 starter motor terminal and ground cable page 19 4 Disconnect the vacuum tube from the PAIR control valve and
53. sure it does not interfere with the movement of the shock absorber JOINT PIN Install the reservoir and tighten the bolt Install the joint pin Secure the joint pin with a new cotter pin BOLT ER PIN 16 15 BRAKE SYSTEM Temorarily install the rear master cylinder and mounting bolts Install the right main step holder and tighten the mounting bolts to the specified torque TORQUE 27 N m 2 8 kgf m 20 ibf ft Tighten the rear master cylinder mounting bolts Install the new sealing washers and brake hose and tighten the bolt to the specified torque TORQUE 34 N m 3 5 kgf m 25 ibf ft dq WASHERS Fill and bleed the rear brake hydraulic system page 16 3 FRONT BRAKE CALIPER MOUNTING BOLT OIL BOLT REMOVAL Te CAUTION m Avoid spilling fluid on painted plastic or rubber parts A Place a shop towel over these parts whenever the sys tem is serviced Drain the brake fluid from the front brake hydraulic sys 16 3 Wer Place a clean container under the caliper and remove the WASHERS s A A oil bolt sealing washers and eyelet joint from the caliper Remove the brake caliper mounting bolts and caliper assembly Remove the brake pads page 16 5 DISASSEMBLY Remove the following caliper bracket pad spring bracket pin boots Remove the caliper pistons If necessary lightly ap
54. the fork spring and fork bolt Remove the fork piston and rebound spring REBOUND SPRING x 5 D lt a FORK PISTON Remove the fork pipe and oil lock piece OIL LOCK PIECE b X b 2 FORK PIPE 14 14 FRONT WHEEL SUSPENSION STEERING Remove the oil seal from the fork slider TOOL Oil seal remover 07748 0010001 INSPECTION Fork Spring Measure the fork spring free length SERVICE LIMIT 404 1 mm 15 91 in Fork Pipe Slider Piston Check the fork pipe slider and piston for score marks scratches or excessive or abnormal wear Check the rebound spring for damage Check the piston ring for wear damage Replace any components that are worn or damage Set the fork pipe in V blocks and read the runout with a dial indicator SERVICE LIMIT 0 20 mm 0 008 in The actual runout is 1 2 of the total indicator reading OIL SEAL REMOVER w men FORK PISTON FORK PIPE f REBOUND SPRING FORK SLIDER 14 15 FRONT WHEEL SUSPENSION STEERING ASSEMBLY DUST SEAL FORK PIPE FORK BOLT STOPPER RING SEAL 5 i y RING 8 REBOUND SPRING 4 gt FORK SPRING SEALING WASHER OIELOCK PIECE Before assembly wash ali parts with a high flash point or non flammable solvent and wipe them off completely SPRING SEAT SPRING COLLAR OIL
55. to the threads and seating surface TOOLS Valve spring compressor 07757 0010000 Attachment 07JME KY20100 Valve guide driver 3 8 mm 07GMD KT70100 Valve guide reamer 07JMH KY20100 Valve seat cutter Seat cutter 24 mm 45 EX 07780 0010600 Seat cutter 27 5 mm 45 IN 07780 0010200 Flat cutter 24 mm 32 EX 07780 0012500 Flat cutter 27 mm 32 IN 07780 0013300 Interior cutter 26 mm 60 IN 07780 0014500 Interior cutter 30 mm 60 EX 07780 0014000 Cutter holder 3 8 mm 07JMH KY20200 Tapet hole protector 07JMG KY20100 TROUBLESHOOTING Engine top end problems usually affect engine performance These can be diagnosed by a compression or leak down test or by tracing engine noises to the top end with a sounding rod stethoscope Ifthe performance is poor at low speeds check for white smoke in the crankcase breather tube If the tube is smoky check for a seized piston ring section 11 Compression too low hard starting or poor performance at low speed Valves Incorrect valve adjustment Burned or bent valves Incorrect valve timing Broken valve spring Weak valve spring Cylinder head Leaking or damaged cylinder head gasket Warped or cracked cylinder head Compression too high overheating or knocking Excessive carbon build up in cylinder head or on top of piston Excessive smoke Worn valve stem or valve guide Damaged stem seal Faulty cylinder piston or pist
56. 153 EX 0 020 0 047 0 0008 0 0019 0 085 0 0033 Valve guide projection IN O 15 5 0 61 above cylinder head E Valve spring free length 39 7 1 56 38 5 1 52 Valve lifter OD 22478 22 493 0 8850 0 8855 22 47 0 885 22 510 22 526 0 8862 0 8869 22 5 0 89 Camshaft Cam lobe height IN 35 12 35 20 1 383 1 386 35 073 1 3808 34 71 34 79 1 367 1 370 34 662 1 3646 Runout 002 0 001 Camshaft holder I D IN EX 17 000 17 018 0 6693 0 6700 17 02 0 6703 16 966 16 984 0 6680 0 6687 16 960 0 6677 Camshaft to camshaft IN EX 0 016 0 052 0 0006 0 0020 0 067 0 0026 holder clearance right side 2 13 1 0 52 Valve seat width IN EX 1 2 1 6 0 05 0 06 1 9 0 07 Unit mm in CYLINDER PISTON i 6350 6351 2 5000 2 5004 63 55 2 502 Ouofrund oo 000200 7 000 2 7 005 0 02 IN mark facing toward the intake side 63 47 63 49 2 4988 2 4996 63 40 2 496 Piston O D measurement point 6 5 0 36 from bottom of skirt Cylinder Warpage Piston piston Piston mark direction rings Piston pin bore 1 0 15 002 15 008 0 5960 0 5909 15 055 0 5927 Piston pin O D 14 994 15 000 0 5903 0 5906 14 98 0 590 Piston to piston pin clearance 0 002 0 014 0 0001 0 0006 0 04 0 0016 Piston ring to ring 0 045 0 075
57. 18 3 The ignition timing does not normally need to be adjusted since the Ignition Control Module ICM is factory preset The Ignition Control Module ICM may be damaged if dropped Also if the connector is disconnected when current is flowing the excessive voltage may damage the module Always turn off the ignition switch before servicing Afaulty ignition system is often related to poor connections Check those connections before proceeding Make sure the battery is adequately charged Using the starter motor with a weak battery results in a slower engine cranking speed as well as no spark at the spark plug Use spark plug of the correct heat range Using spark plug with an incorrect heat range can damage the engine SPECIFICATIONS SPECIFICATIONS Optional DENSO U24ESR U27ESR N 0 7 0 8 mm 0 028 0 032 in 100 V minimum Spark plug Spark plug gap Ignition coil peak voltage 0 7 V minimum 12 BTDC at 1 400 100 min rpm Ignition pulse generator peak voltage Ignition timing TORQUE VALUE Timing hole cap 6 N m 0 6 kgf m 4 3 Ibf ft TOOLS Imrie diagnostic tester model 625 or Peak voltage adaptor 07HGJ 0020100 with Commercially available digital multimeter impedance 10 MQ DCV minimum 18 1 IGNITION SYSTEM TROUBLESHOOTING Inspect the following before diagnosing the system Faulty spark plug
58. 2 REAR FENDER REAR MASTER CYLINDER eene 16 12 REAR WHEEL cirios ertet rentas pee do 15 3 REGULATOR RECTIFIRE eene 17 8 RIGHT CRANKCASE COVER INSTALLATION 8 13 RIGHT CRANKCASE COVER REMOVAL 8 3 SECONDARY AIR SUPPLY SYSTEM MAINTENANCE 3 14 SECONDARY AIR SUPPLY SYSTEM SYSTEM 0 1 41 44244 0444044 5 15 SERVICE INFORMATION ALTERNATOR STARTER CLUTCH 9 1 COOLING 5 5 2 2 22 4 6 1 CHARGING SYSTEM e 17 1 BRAKE SYSTEM vee 16 1 CLUTCH GEARSHIFT LINKAGE 8 1 CRANKSHAFT BALANCER vee 13 1 CYLINDER HEAD VALVES wee 10 1 CYLINDER PISTON eee es 11 1 ENGINE REMOVAL INSTALLATION 7 1 ELECTRIC STARTER 2 2 1 1 19 1 FRAME BODY PANELS EXHAUST SYSTEM 2 1 FRONT WHEEL SUSPENSION STEERING 14 1 FUEL 5 5 0 22 444000 IGNITION SYSTEM 4 2 LIGHTS METERS SWITCHES LUBRICATION SYSTEM Ze MAINTENANCE eese nennen REAR WHEEL SUSPENSION TRANSMISSION SERVICE RULES SHOCK ABSORBER essent SIDE STAND iccirco entra Duos arent
59. 6 Clutch center Check the grooves of the clutch center for damage or wear caused by the clutch plates Replace if necessary Clutch outer Check the clutch outer for nicks indentations or abnormal wear made by the clutch discs Check the serrated teeth of the primary driven gear for wear or damage Clutch outer guide Measure the clutch outer guide SERVICE LIMIT I D 17 04 mm 0 671 in O D 22 93 mm 0 903 Judder spring spring seat Check the judder spring and spring seat for distortion wear or damage Mainshaft Measure the mainshaft O D at the clutch outer guide SERVICE LIMIT 16 935 mm 0 6667 in CLUTCH GEARSHIFT LINKAGE CLUTCH CENTER CLUTCH OUTER SPRING SEAT N OUTER GUIDE JUDDER SPRING CLUTCH GEARSHIFT LINKAGE ASSEMBLY CLUTCH SPRINGS CLUTCH DISK A LIFTER PLATE CLUTCH DISK B LIFTER BEARING 4 BOLTS WASHER WASHER JUDDER SPRING SPRING SEAT ew 6 OUTER GUIDE LOCK NUT gt CLUTCH OUTER CENTER WASHER PRESSURE PLATE Install the pressure plate in the clutch outer Install the clutch discs and plates alternately in the clutch outer Install the tabs of outside clutch disc A into the shallow slots of the clutch outer Disc A has larger than Disc SEAT B install the judder spring with its tapered side facing out regia Y Md Install the spring seat washer and clutch center x WM bel PRESSURE 3 N 9
60. 7 x 40 mm 07746 0010200 Pilot 12 mm 07746 0040200 ATTACHMENT PILOT Install the distance collar Drive the new left bearing in using the same tools DISTANCE COLLAR ASSEMBLY BRAKE DISC RIGHT WHEEL BEARING SPEEDOMETER GEAR DUST SEAL E Q Sams RETAINER Som LEFT WHEEL BEARING SPEEDOMETER GEARBOX 14 10 FRONT WHEEL SUSPENSION STEERING If removed the front tire inspect the wheel balance page 7 15 3 Apply grease to the speedometer gear retainer and in stall it into the left side hub aligning its tabs with the slots in the hub TABS RETAINER Apply grease to a new left dust seal lips then install it into p the wheel hub DUST SEAL ay install a new right dust seal and brake disc with the stomped mark MIN TH 3 5 mm facing out side BRAKE DISC Apply greese to the dust seal lips Tighten the brake disc mounting bolts to the specified torque TORQUE 42 N m 4 3 kgf m 31 Ibf ft Install the right side collar 14 11 FRONT WHEEL SUSPENSION STEERING Install the speedometer gear box in the wheel hub align ing the tangs of the retainer with the slots in the speed ometer gear box GEAR BOX INSTALLATION 3 Position the front wheel between the fork legs and align the stopper of the left fork leg and groove of the speed ometer gear box Install the front axle from the right side CAUTION When instal
61. 8 mm 07JMH KY20200 Using 32 degree cutter remove 1 4 of the existing valve seat material TOOLS OLD SEAT WIDTH Flat cutter 24 mm EX 07780 0012500 Flat cutter 27 mm IN 07780 0013300 Cutter holder 3 8 mm 07JMH KY20200 Using 60 degree cutter remove the bottom 1 4 of the oil seat Remove the cutter and inspect the area you have just re OLD SEAT WIDTH moved TOOLS Interior cutter 26 mm EX 07780 0014500 Interior cutter 30 mm IN 07780 0014000 Cutter holder 3 8 mm 07JMH KY20200 10 15 CYLINDER HEAD VALVES Install a 45 degree seat cutter and cut the seat to proper width Make sure that all pitting and irregularities are removed Refinish if necessary STANDARD SEAT WIDTH 1 2 1 6 mm 0 05 0 06 Apply thin coat 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 vaive face is very important for good sealing If the contact area is too high on the valve the seat must be lowered using a 32 degree flat cutter If the contact area is too low on the valve the seat must be raised using a 60 degree inner cutter Refinish the seat to specifications using a 45 degree seat cutter CAUTION Excessive lapping pressure may deform or damage the seat Change the angle of lapping tool frequently to prevent uneven seat wear Lapping compound c
62. 90 20 10 0 791 1 2 1 2 C 17 969 17 980 0 7074 0 7079 17 9 0 70 C C Bushing I D Bushing O D 0 020 0 052 0 0008 0 0020 0 10 0 004 0 036 0 057 0 0014 0 0022 0 10 0 004 16 966 16 984 0 6680 0 6687 16 93 0 667 14 966 14 984 0 5892 0 5899 14 90 0 587 22 984 23 005 0 9049 0 9057 22 9 0 90 Gear to bushing clearance Mainshaft 0 D Countershaft O D 5 C1 gear bushing Bushing to shaft clearance C1 Shaft O D Fork I D 10 03 0 395 C2 gear bushing 19 978 19 989 0 7866 0 7870 19 92 0 784 0 031 0 063 0 0012 0 0025 9 93 0 391 Fork claw thickness 4 93 5 00 0 194 0 197 4 90 0 193 Gear to shaft clearance M5 0 032 0 068 0 0012 0 0027 0 10 0 004 0 016 0 052 0 0001 0 0020 9 986 9 995 0 3931 0 3935 10 000 10 018 0 3937 0 3944 Shift fork Shift drum journal R crankcase 26 000 26 021 1 0236 1 0244 12 1 TRANSMISSION TOOLS Bearing remover head 15 mm Bearing remover shaft Bearing remover weight Driver Attachment 37 x 40 mm Attachment 42 x 47 mm Attachment 32 x 35 mm Pilot 17 mm Pilot 15 mm Pilot 20 mm Pilot 12 mm Bearing remover head 12 mm Bearing remover sha
63. ACUUM TUBE VACUUM INITIAL OPENING 2 1 8 turns out 2 Warm up the engine to operating temperature Stop and go riding for 10 minutes is sufficient 3 Stop the engine and connect the tachometer accord ing to the manufacturer s instructions 4 Disconnect the vacuum tube of PAIR control valve then it connect the vacuum pump and plug the vacuum port 5 Apply the specified vacuum to the PAIR control valve vacuum tube more than 37 kPa 280 mmHg 5 14 6 Start the engine adjust the idle speed with the throttle stop screw TENTATIVE IDLE SPEED 1 400 100 min rpm 7 Turn the pilot screw in or out slowly to obtain the high est engine speed 8 Lightly open the throttle 2 or 3 times then adjust the idle speed with the throttle stop screw 9 Turn the pilot screw in until the engine speed drops by 50 min rpm FINAL OPENING 3 4 tums out 10 Disconnect the plug from the vacuum port then remove the vacuum pump and connect the vacuum tube of PAIR control valve 11 Readjust the idle speed with the throttle stop screw IDLE SPEED 1 400 100 min rpm SECONDARY AIR SUPPLY SYSTEM SYSTEM INSPECTION Start the engine and warm it up to normal operating temperature Remove the fuel tank page 5 3 Check that the secondary air intake port is clean and free of carbon deposits Checkthe pulse secondary air injection PAIR check valves if the port is carbon fouled Disconnect the PAIR control valve vac
64. AKELIGHT SWITCH 2P CONNECTOR gt qe M FI LN PES SAS REGULATOR RECTIFIER DIODE w TURN SIGNAL RELAY REAR BRAKE HOSE REAR BRAKE REAR BRAKE SWITCH RESERVOIR HOSE 1 22 Q ta o 2 GENERAL INFORMA TION 10 X 2 SPARE FUSE 10A STARTER RELAY SWITCH MAIN FUSE 20A ADIATOR RESERVE TANK CAP 1 23 GENERAL INFORMA TION EMISSION CONTROL SYSTEMS SOURCE OF EMISSIONS The combustion process produces carbon monoxide and hydrocarbons Controlling hydrocarbon emission 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 Moter Co Ltd utilizes lean carburetor settings as well as other systems to reduce carbon monoxide and hydrocarbons CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmospher Blow by gas is returned to the combustion chamber through the air cleaner and carburetor lt a FRESH AIR Gums BLOW BY GAS 1 24 GENERAL INFORMA TION EXHAUST EMISSION CONTROL SYSTEM PULSE SECONDAR Y AIR INJECTION SYSTEM The exhaust emission contro system consists of a secondary air supply system which introduces filtered air into the exhaust gases in the exhaust port Fresh air is drawn in
65. ALTERNATOR ST ARTER CLUTCH Flywheel nut 64 6 5 47 Stator bolt 10 1 0 7 Ignition pulse generator bolt 5 2 0 53 3 8 Starter clutch bolt 30 3 1 22 OTHER FASTENERS Reed valve cover bolt 5 2 0 53 3 8 1 12 GENERAL INFORMA TION THREAD TORQUE DIA mm N m kgf m Ibf ft FRAME BODY PANELS EXHAUST SYSTEM Muffler mounting nut 13 1 3 9 Exhaust pipe cover volt 13 1 3 9 ENGINE REMOV AL INST ALLATION Engine hanger nut 59 6 0 43 Drive sprocket fixing plate bolt 10 1 0 7 FRONT WHEEL SUSPENSION STEERING Steering stem nut Top thread Handlebar pinch bolt Top bridge pinch bolt Bottom bridge pinch bolt Front axle nut Fork bolt Fork socket bolt Front brake disk bolt Grip end screw REAR WHEEL SUSPENSION Rear axle nut Driven sprocket nut Rear brake disc bolt Shock absorber upper mounting bolt Shock absorber lower mounting nut Swingarm pivot nut BRAKE SYSTEM Brake hose bolt Front master cylinder cover screw Front brake light switch screw Brake lever pivot nut Front brake caliper mounting bolt Brake caliper pad pin Bleed valve Rear brake reservoir cover screw Rear master cylinder mounting bolts Rear master cylinder push rod nut Main step holder mounting bolt OTHER FASTENERS Chain slider screw 88 9 65 See page 14 22 27 2 8 20 23 2 3 17 26 2 7 20 59 6 0 43 23 2 3 17 20 2 0 14 42 4 3 31 8 8 0 9 6 5 NM OO DO AO DODD AD 59 6
66. ANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON Honda MO TORCYCLES MOTOR SCOOTERS OR ATVS Honda Motor Co Ltd SERVICE PUBLICATION OFFICE CONTENTS GENERAL INFORMA TION FRAME BODY P ANELS EXHAUST SYSTEM MAINTENANCE GENERAL INFORMATION N B LUBRICATION SYSTEM FUEL SYSTEM COOLING SYSTEM o ENGINE REMOV AL INST ALLATION 001 CLUTCH GEARSHIFT LINKAGE ALTERNATOR ST ARTER CLUTCH CYLINDER HEAD V ALVES ENGINE amp DRIVE TRAIN EY CYLINDER PISTON TRANSMISSION CRANKSHAFT BALANCER FRONT WHEEL SUSPENSION f STEERING 2 REAR WHEEL SUSPENSION I BRAKE SYSTEM m CHARGING SYSTEM COIN Kori ug BR IGNITION SYSTEM ELECTRIC STARTER ELECTRICAL NO ES m Ojo LIGHTS METERS SWITCHES WIRING DIAGRAM 1 2 TROUBLESHOOTING 22 23 Date of Issue February 2002 Honda Motor Co Ltd IMPORTANT SAFETY NOTICE Indicates a strong possibility of severe personal injury or death if instructions are not followed CAUTION Indicates a possibility of equipment damage if instructions are not followed NOTE Gives helpful information Detailed descriptions of standard workshop procedures safety principles and service operations are not included It is important to note that this manual contains some warnings and
67. ARING Remove the bearings with following tools TOOLS Right crankcase countershaft beraing Bearing remover head 15 mm 07936 KC10200 Remover shaft 07936 KC10100 Remover weight 07741 0010201 Left crankcase mainshaft bearing Bearing remover head 12 mm 07936 1660110 Remover shaft 07936 1660120 Remover weight 07741 0010201 12 8 TRANSMISSION Drive new bearings into the left crankcase with following tools TOOLS RIGHT CRANKCASE Mainshaft bearing Driver Attachment 37 x 40 mm Pilot 17 mm Countershaft bearing Driver Attachment 32 x 35 mm Pilot 15 mm LEFT CRANKCASE Mainshaft bearing Driver Attachment 32 x 35 mm Pilot 12 mm Countershaft bearing Driver Attachment 42 x 47 mm Pilot 20 mm After installing the bearings install a new countershaft oil seal Check the gearshift spindle oil seal for damage and re place if necessary Apply locking agent to the threads of the setting plate bolts and install the mainshaft bearing setting plate by tighten ing the bolts 07749 0010000 07746 0010200 07746 0040400 07749 0010000 07746 0010100 07746 0040300 07749 0010000 07746 0010100 07746 0040200 07749 0010000 07746 0010300 07746 0040500 Lubricate the all bearings with engine ATTACHMENT COUTERSHAFT OIL SEAL ww 1 e T GEARSHIFT SPINDLE OIL SEAL e a mos TRANSMISSION TRANS
68. DISTANCE COLLAR Wheel bearing installation DRIVER CAUTION Never nstall an old bearing has been removed the bear ing must be replaced with a new one Drive a new right bearing squarely with its marking side facing out TOOLS Driver 07749 0010000 Attachment 37 x 40 mm 07746 0010200 Pilot 12 mm 07746 0040200 c Install the distance collar then drive in the left side bear ing with its marking side facing out DISTANCE COLLAR 15 7 REAR WHEEL SUSPENSION Driven flange installation DRIVER Pack all bearing cavities with grease install the driven flange collar into a new driven flange bearing Drive new driven flange bearing into the driven flange using the special tools TOOLS Driver 07749 0010000 Attachment 37 x 40 mm 07746 0010200 Pilot 12 mm 07746 0040200 4 ATTACHMENT 8 Wheel assembly BRAKE DISC SIDE COLLAR Install the rear brake disc with the stamped mark MIN TH 3 5 mm facing outside and install the brake disc bolts Tighten the brake disc bolts to the specified torque TORQUE 42 N m 4 3 kgf m 31 Ibf ft Install a new dust seal and apply grease to the dust seal lip Install the right side collar 0o ol c B Do not get grease on the brake disc or stopping power BOLTS i DUST 5 will be reduced Apply grease to the new O ring Install the wheel damper rubbers and O ring into the wheel hub
69. FUSE 20A ALTERNATOR oz gt REGULATOR RECTIFIER Y Yellow G Green R Red W White 5 2 ui H lt 17 0 17 CHARGING SYSTEM SYSTEM DIAGRAM 17 0 CHARGING SYSTEM INSPECTION 17 5 SERVICE INFORMATION 17 1 ALTERNATOR INSPECTION 17 7 TROUBLESHOOTING 17 3 REGULATOR RECTIFIER 17 8 BATTERY 17 4 SERVICE INFORMATION GENERAL A WARNING The battery gives off explosive gases keep sparks flames and cigarettes away Provide adequate ventilation when charging The battery contains sulfuric acid electrolyte Contact with skin or eyes may cause severe burns Wear protective clothing and a face shield If electrolyte gets your skin flush with water If electrolyte gets in your eyes flush with water for at least 15 minutes and call a physician immediately Electrolyte is poisonous If swallowed drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and call a physician KEEP OUT OF REACH OF CHILDREN Always turn off the ignition switch before disconnecting any electrical components CAUTION Some electrical components may be damaged if terminals or connectors are connected or disconnect while the ignition switch is ON and a current is present For extended storage remove the battery give it a full charge and store itin a cool dry space For maximum service life charge the stored battery every two wee
70. G Wipe oil off the spring thoroughly using a clean cloth Install the fork spring with the tightly wound end facing down Install the spring seat and spring collar Apply fork fluid to a new O ring Install a new O ring onto the fork bolt and install it loosely NOTE Install the fork bolt but do not tighten yet INSTALLATION Install the fork leg and temporarily tighten the fork bot tom pinch bolt install the following handlebars page 14 5 Loosen the handlebar pinch bolt Loosen the fork bottom pinch bolt and align the stopper ring groove with upper surface of the handlebar om y SPRING SEAT FORK BOLT 14 18 FRONT WHEEL SUSPENSION STEERING z TOP PINCH BOLT Tighten the fork bottom pinch bolts to the specified torque TORQUE 26 N m 2 7 kgf m 20 Ibf ft Tighten the fork top pinch bolt to the specified torque TORQUE 23 2 3 kgf m 17 Ibf ft Tighten the fork bolt to the specified torque TORQUE 23 N m 2 3 kgf m 17 Ibf ft Tighten the handlebar pinch bolt EU M TORQUE 27 N m 2 8 kgf m 20 Ibf ft S Install the following front fender page 2 3 front wheel page 14 12 brake cariper page 16 19 STEERING STEM STEM NUT REMOVAL Remove the following handlebars page 14 3 upper cowl page 2 4 front wheel page 14 8 front fender page 2 3 Remove the st
71. Install the driven flange assembly into the left wheel hub DRIVEN FLANGE SIDE COLLAR If the driven sprocket was removed instali the driven sprocket and tighten the nuts to the specified torque TORQUE 64 N m 6 5 kgf m 47 Ibf ft Apply grease to the new dust seal lips then install it into the driven flange Install the side collar DUST SEAL 15 8 REAR WHEEL SUSPENSION INSTALLATION CA Install the drive chain adjusters into the swingarm Place the rear wheel into the frame Insert the rear axle through the right drive chain adjuster right side collar rear wheel left side collar and left chain adjuster Install the drive chain onto the driven sprocket Install the rear axle nut Adjust the drive chain slack page 3 15 SHOCK ABSORBER REMOVAL Remove the rear cowl assembly page2 2 Support the motorcycle securely using a hoist or equiva lent Remove the shock absorber lower mounting bolt and nut Remove the shock absorber upper mounting bolt Remove the shock absorber SHOCK ABSORBER INSPECTION Visually inspect the shock absorber for damage Check the following Damper unit for deformation or oil leaks Upper and lower bushings for wear or damage CAUTION Do not disassemble the shock absorber Replace the shock absorber if any component is dam aged BUSHINGS 15 9 REAR WHEEL SUSPENSION INSTALLATION Install the shock absorber to t
72. M page 18 6 If there is continuity and ICM is normal replace the tachometer For tachometer replacement see 20 5 combination meter disassembly and assembly GREEN WIRE YELLOW GREEN WHITE GREEN o WIRE TERMINAL WIRE TERMINAL 20 17 Form gar perocs i I IE xPoe Foo lt lt 1 0030Z KPP 9000 1 12 INIHIM 22 TROUBLESHOOTING ENGINE DOES NOT START OR IS POOR PERFORMANCE AT HIGH HARD TO START SPEED ENGINE LACKS POWER POOR HANDLING POOR PERFORMANCE AT LOW AND IDLE SPEED ENGINE DOES NOT START OR IS HARD TO START Possible cause 1 Check the fuel flow to carburetor Not reaching Clogged fuel line and fuel auto valve carburetor Clogged fuel tank breather Reaching carburetor 2 Perform a spark test Weak no spark Faulty spark plug Fouled spark plug e Faulty ignition control module ICM Broken or shorted spark plug wire Good spark e Faulty ignition switch e Faulty ignition pulse generator Loose or disconnected ignition system wires 3 Remove and inspect spark plug Wet plug Flooded carburetor e Starting en
73. MISSION ASSEMBLY Clean all parts in solvent Apply molybdenum oil solution to the gear and bushing sliding surface and shift fork grooves to ensure initital lu CORRECT INCORRECT brication Assemble all parts into their original positions NOTE Check the gears for freedom of movement or rotation the shaft Install the washers and snap rings with the chamfered edges facing the thrust load side Do not reuse worn SNAP RING snap ring which could easily spin in the groove Checkthatthe snap rings are seated in the grooves and align their end gaps with the grooves of the spline THRUST WASHER MAINSHAFT M6 GEAR 26T SNAP RING SNAP RING M5 GEAR 24T M2 GEAR 17T MAINSHAFT M1 12T SPLINE WASHER SPLINE WASHER M3 4 GEAR 20 22T WASHER AND SNAP RING DIRECTION Gear and bushing sliding surfaces and shift fork grooves 12 10 TRANSMISSION COUNTERSHAFT C3 GEAR 30T SPLINE WASHER C5 GEAR 25T LOCK WASHER SPLINE WASHER THRUST WASHER C1 GEAR BUSHING SNAP RING THRUST C1 GEAR 37T WASHER C2 GEAR 33T C2 GEAR BUSHING THRUST WASHER C6 GEAR 24T SPLINE SNAP RING WASHER C4 GEAR 27T WASHER AND SNAP RING DIRECTION Gear and bushing sliding surfaces and shift fork grocves 12 11 TRANSMISSION If the crankshaft removed install the crankshaft and bal ancer first page 13 5
74. MPRESSION GAUGE 2 N 10 3 CYLINDER HEAD VALVES CYLINDER HEAD REMOVAL CYLINDER HEAD COVER REMOVAL Remove the following right and left middle cowl page 2 4 fuel tank page 5 3 Remove the two bolts and radiator with water hoses installed Disconnect the upper radiator hose from the cylinder head Disconnect the vacuum tube Remove the bolt and PAIR control valve Disconnect the air injection hose from the PAIR check valve Cover Remove the two bolts and rubber washers Remove the cylinder head cover gasket dowel pin and O ring CYLINDER HEAD COVER DOWEL PIN O RING 10 4 CYLINDER HEAD VALVES CAMSHAFT REMOVAL Remove the following under cowl page 2 3 cylinder head cover page 10 4 Remove the timing hole cap and crankshaft hole cap Turn the crankshaft counterclockwise and align the index line of the T mark on the flywheel with the index notch on the left crankcase cover The index lines on the cam sprockets must be flush with the cylinder head surface as shown Make sure the piston is at TDC Top Dead Center on the compression stroke If the piston is at TDC on the exhaust stoke rotate the crankshaft counterclockwise 360 1 full turn and align the T mark with index notch Remove the cam chain tensioner lifter plug Turn the tensioner shaft clockwise with the stopper tool page 10 8 to retract the tensioner then insert the stopper fully t
75. ORQUE 25 N m 2 5 kgf m 18 Ibf ft Fill the crankcase with recommended engine oil m OIL FILLER CAP DIPSTICK OIL CAPACITY 7 1 0 liter 1 06 US qt 0 88 Imp qt at draining i Install the oil filler cap dipstick 3 Start the engine and let it idle for a few minutes a Stop the engine and recheck the oil level Make sure there are no oil leaks 3 11 MAINTENANCE ENGINE OIL STRAINER SCREEN Remove the right crankcase cover page 8 3 Remove the oil strainer screen and clean it Reinstall the oil strainer screen and right crankcase cover page 8 14 Fill the crankcase with recommended engine oil page 3 11 ENGINE IDLE SPEED Rm 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 car bon monoxide gas that may cause loss of consciousness and may lead to death Run the engine in an open area or with an exhaust evacuation system in enclosed area NOTE Inspect and adjust the idle speed after all other engine maintenance items have been performed and are within specifications The engine must be warm for accurate idle speed in spection and adjustment Ten minutes of stop and go riding is sufficient Warm up the engine for about ten minutes Turn the throttle stop screw as required to obtain the speci fied idle speed IDLE SPEED 1 400 100 mirr rpm 3 12 pa THROT
76. R WATER PUMP IMPELLER MECHANICAL SEAL WASHER OIL SEAL Install the new oil seal into the right crankcase cover Apply sealant to the new mechanical seal flange and drive it into the right crankcase cover using the special tools DR TOOLS b ATTACHMENT Driver 07749 0010000 Attachment 36 mm 07945 4150400 A INSTALLATION Check the water pump shaft for damage SHAFT Check the water pump gear for damage of the teeth Install the pin to the water pump shaft Install the water pump gear and washer to the water pump shaft Apply engine oil to the water pump shaft Install the water pump shaft to the right crankcase cover a f WASHER A D 2 6 14 COOLING SYSTEM 4 IMPELLER Install the washer and impeller to the shaft A WASHER 1 Hold the water pump shaft and tighten the impeller to the specified torque IMPELLER TORQUE 10 N m 1 0 kgf m 7 Ibf ft Install the following right crankcase cover page 8 14 water pump cover page 6 12 Fill and bleed the cooling system page 6 5 Fill the engine oil page 3 10 6 15 1 ENGINE REMOVAL INSTALLATION SERVICE INFORMATION 7 1 ENGINE INST ALLATION ENGINE REMOV AL 7 2 SERVICE INFORMATION GENERAL During engine removal and installation support the motorcycle securely using a hoist Support the engine using a jack or other adjustable support to ease of engine hanger bolts
77. R MOUNTING BOLTS Arop 51 UN E 4 STARTOR MOUNTING BOLTS em PULSE GENERATOR ae j FLYWHEEL HOLDER lt gt i ALTERNATOR ST ARTER CLUTCH Remove the flywheel using the special tool TOOL Rotor puller O7KMC 00100 Remove the woodruff key STARTER CLUTCH REMOVAL Remove the flywheel page 9 3 Remove the starter reduction gear Remove the starter driven gear while turning it coun T terclockwise DRIVEN GEAR ALTERNATOR ST ARTER CLUTCH Hold the flywheel with the special tool and remove the starter clutch bolts TOOL Flywheel holder 07725 0040000 Remove the starter clutch assembly from the flywheel Remove the sprag clutch from the starter clutch outer INSPECTION Check the starter reduction gear for wear or damage Check the starter clutch outer and sprag clutch for abnor mal wear or damage Check the starter driven gear teeth for wear or damage FLYWHEEL HOLDER REDUCTION GEAR CLUTCH OUTER SPRAG CLUTCH STARTER DRIVEN GEAR ALTERNATOR ST ARTER CLUTCH INSTALLATION Apply engine oil to the sprag clutch rolling surface Install the sprag clutch into the starter clutch outer with the flange side facing the flywheel side Apply locking agent to the starter clutch bolt threads install the starter clutch assembly onto the flywheel and install the bolts Hold the flywheel with the special tool and tighte
78. RS SWITCHES COOLING FAN MOTOR SWITCH INSPECTION Remove the right middle cowl page 2 4 Fan motor does not stop Turn the ignition switch OFF disconnect the connector from the fan motor switch and turn the ignition switch ON again If the fan motor does not stop check for a shorted wire between the fan motor and switch i FAN MOTOR SWITCH If the fan motor stops the fan motor switch is faulty Fan motor does not start Before testing check for a blown fan motor fuse 10A Warm up the engine to operating temperature Disconnect the connector from the fan motor switch and ground the connector termina to the body ground Turn the ignition switch ON and check the fan motor If the motor starts check the connection at the fan motor switch terminal If it is OK the fan motor switch is faulty If the motor does not start remove the fuel tank page 5 4 and check for voltage between the Blue and Green terminals at the fan motor switch 2P connector of the main harness side Battery voltage Faulty fan motor No battery voltage Open circuit or poor connection in Blue or Green wire f REMOVAL INSTALLATION Drain the coolant page 6 5 Disconnect the fan motor switch connector and remove the fan motor switch Install a new O ring onto the switch Install and tighten the switch Connect the switch connector Fill and bleed the cooling system page 6 5 Install the removed parts in the
79. SPRING MASTER PISTON PRIMARY CUP MASTER SECONDARY MASTER CYLINDER PISTON CUP 16 13 BRAKE SYSTEM ASSEMBLY CY s PLATE NOTE Make sure that each part is free from dust or dirt before reassembly Coat the piston cups with the recommended brake fluid Apply silicone grease to the push rod contacting area of the master cylindcr Install the spring onto the master piston install the spring master piston and push rod into the master cylinder Install the snap ring using the special tool TOOL Snap ring pliers 07914 SA50001 Install the boot 2 l PISTON 7 SPRING JOINT PIPE MASTER CYLINDER RING CUPS Uo a hl x iy SPRING ec 16 14 BRAKE SYSTEM Apply silicone grease to the boot groove in the push rod and install the piston boot into the master cylinder If the push rod joint is reinstalled adjust the push rod length so that the distance from the center of the master cylinder lower mounting hole to the center of the joint pin hole is 84 86 mm 3 3 3 4 in After adjustment tighten the lock nut TORQUE 17 N m 1 7 kgf m 12 Ibf ft Apply brake fluid to the new O ring Install the new O ring and joint pipe Tighten the screw securely JOINT PIPE SCREW INSTALLATION CAUTION After installing the brake hose to the master cylinder make
80. TEM STANDARD SERVICE LIMIT Front Specified brake fluid DOT 3 or DOT 4 Brake disc thickness 3 8 4 2 0 15 0 17 3 0 0 12 BRAKE SYSTEM 12 700 12 743 0 5000 0 5017 12 755 0 5022 12 657 12 684 0 4983 0 4994 12 640 0 4976 25 450 1 0020 Caliper piston O D 25 318 25 3968 09968 0 9987 25200 09960 Rear DOT 3 or DOT 4 To groove 30 012 Brake dise runout 1 0 110 004 1225505029 12 645 0 4978 32 030 32 080 1 2610 1 2630 32 090 1 2634 CHARGING SYSTEM AL TERNATOR ee Lighting resistance 20 8 31 94 1 257 1 10 GENERAL INFORMA TION IGNITION SYSTEM ITEM SPECIFICATIONS Spark plug NGK DENSO Standard U24ESR N U27ESR N Spark plug gap 0 7 0 8 mm 0 028 0 032 Ignition coil peak voltage 100 V minimum Ignition pulse generator peak voltage Ignition timing 12 BTDC at 1 400 100 min rpm Unit mm in ELECTRIC STARTER ITEM STANDARD SERVICE LIMIT Starter motor brush length 10 00 10 05 0 393 0 396 3 5 0 14 LIGHTS METERS SWITCHES ITEM High beam indicator TA eee ie ee ee a T 1 11 GENERAL INFORMA TION TORQUE VALUES STANDARD FASTENER TYPE TORQUE TORQUE kgf m Ibf ft FASTENER kgf m Ibf ft 5 0 5 3 6 5 mm screw 4 0 4 2 9 10 1 0 7 6 mm screw 9 0 9 6 5 6 mm
81. TLE STOP SCREW RADIATOR COOLANT LEVEL CHECK Ei Wait until the engine is cool before removing the ra diator cap Remove the cap while the engine is hot and coolant is under pressure may cause serious scalding Radiator coolant is poisonous Take care to avoid get ting coolant n your eyes on your skin or on your clothes If coolant gets in your eyes flush repeatedly with wa ter and contact a doctor immediately coolant is accidentally swallowed induce vomiting and contact a doctor immediately KEEP OUT REACH OF CHILDREN Check the coolant level of the reserve tank with the en gine running at normal operating temperature The level should be between the UPPER and LOWER level lines with the motorcycle in a vertical position on a flat level surface If necessary remove the driver seat page 2 2 then remove the reserve tank cap and fill to the UPPER level line with a 50 50 solution of distilled water and recommended antifreeze coolant mixture preparation page 6 4 CAUTION Using coolant with silicate inhibitors may cause prema ture wear of water pump saels of blockage of radiator passages Using tap water may cause engine damage Checkto see if there are any coolant leaks when the coolant level decreases very rapidly If the reserve tank becomes completely empty there is a possibility of air getting into the cooling system Be sure to remove all air from the cooling system as de
82. VICE INFORMATION HORN TROUBLESHOOTING TURN SIGNAL RELAY BULB REPLACEMENT COOLING FAN MOTOR SWITCH COMBINATION METER COOLANT TEMPERATURE GAUGE IGNITION SWITCH THERMOSENSOR HANDLEBAR SWITCHES CLUTCH SWITCH BRAKE LIGHT SWITCH TACHOMETER NEUTRAL INDICATOR SWITCH SERVICE INFORMATION GENERAL WARNING Use an electric heating element to heat the water coolant mixture for the thermosensor inspection Keep all flammable materials away from the electric heating element Wear protective clothing insulated gloves and eye protection Check the battery condition before performing any inspection that requires proper battery voltage A continuity test can be made with the switches installed on the motorcycle The following color codes used are indicated throughout this section Bu Blue G Green Lb Light Blue R Red BI Black Gr Gray O Orange W White Br Brown Y Yellow SPECIFICATIONS SPECIFICATIONS Headlight Hi low beam 12 V 18 18 W x 2 Brake tail light 12V 10 5W x2 License light 12V 5W Front turn signal light 12V 10Wx2 Rear turn signal light 12V 10W x2 Instrument light 12V 17Wx4 Turn signal indicator 12V 17W High beam indicator 12V 1 7W Neutral indicator 12V 1 7W Fuse Main 20A Sub WAx2 Thermosensor 50 C 122 F 133 9 178 9 Q resistance 120 C 248 F 149 1730 20 1 LIGHTS METERS SWITCHES TROUBLESHOOTING Headlight do not come on or bulb
83. age 8 4 amamma un WOODRUFF KEY Remove the primary drive gear Remove the woodruff key INSTALLATION Install the washer install the woodruff key onto the crankshaft Install the primary drive gear by aligning the groove with the woodruff key X Install the clutch assembly page 8 9 Apply engine oil to the threads and seating surface of the primary drive gear lock nut and install it with the washer Hold the clutch assembly using the clutch center holder Tighten the primary drive gear lock nut to the specified torque TORQUE 64 N m 6 5 kgf m 47 Ibf ft Remove the four bolts and clutch center holder Install the clutch springs and lifter plate Tighten the four bolts Install the following oil pump page 4 6 right crankcase cover page 8 14 LOCK NUT WRENCH 4 LOCK NUT WASHER 8 12 CLUTCH GEARSHIFT LINKAGE CLUTCH LIFTER ARM INSTALLATION 9 IT UFTER ARM SPINDLE 7 Apply molybdenum oil solution to the lifter arm spindle Insert the return spring to the lifter arm spindle Align the cover hole and cut out of the lifter arm spindle by turning the lifter arm spindle spindle Apply engine oil to the lifter piece I Insert the lifter piece to the cover hole and lifter arm m uF ER PIECE NN T RIGHT CRANKCASE COVER INSTALLATION Install the new gasket and dowel pins Install the right crankcase cover clamp and ten bolts T
84. air injection hose from the PAIR check valve cover Disconnect the neutral switch and alternator 4P connectors Remove the pinch bolt and gearshift arm from the gear shift spindle Loosen the hose band screws and disconnect the radiator hoses a RADIATOR HOSES a 7 2 ENGINE REMOV AL INST ALLATION Loosen the lock nut and adjusting nut then remove the NUTS clutch cable from the clutch cable guide Disconnect the clutch cable end from the clutch lifter arm CABLE END Loosen the rear axle nut R L drive chain adjusting lock nuts and adjusting nuts Push the rear wheel forward and make a drive chain slack fully D AL REAR AXLE NUT ADJUSTING NU SS ce Lay Remove the two bolts and sprocket cover Remove the fixing plate bolts fixing plate and dr ve Ns sprocket DRIVE SPROCKET Um wae 7 3 ENGINE REMOV AL INST ALLATION Support the engine using a jack or other adjustable sup 7 7 port to ease of engine hanger bolts removal Remove the front engine hanger nut and bolt Remove the four bolts and engine hanger plates ENGINE HANGER wo Loosen the rear engine hanger nuts Remove the rear engine hanger bolts nuts and engine from the frame Note the direction of the hanger bolts ENGINE INSTALLATION NOTE Use a floor jack or other adjustable support to carefully maneuver the engine int
85. all the grip end Tighten the grip end screw to the specified torque TORQUE 8 8 N m 0 9 kgf m 6 5 Ibf ft Install the left handlebar switch housing aligning its locat ing pin with the hole on the handlebar Install the screws and tighten the forward screw first then the rear screw SCREWS 14 7 FRONT WHEEL SUSPENSION STEERING Place the clutch lever bracket on the handlebar and install the clutch lever holder with its UP mark facing up BRACKET Align the end of the holder with the punch mark on the handlebar Tighten the upper bolt first then the lower bolt Connect the clutch switch connectors MARK LJ FRONT WHEEL f SPeevomerer GEAR BOX SPEEDOMETER CABLE v REMOVAL esten Raise the front wheel off the ground by suitable support Press the boss of speedometer cable in the speedometer gear box Disconnect the speedometer cable from the speedometer gear box Remove the nut axle and front wheel NOTE AXLE NUT Do not operate the front brake lever after the front wheel is removed The caliper piston will move out and make assembly difficult INSPECTION Axle Place the axle in V blocks and measure the runout with a dial indicator SERVICE LIMIT 0 2 mm 0 008 in The actual runout is 1 2 of the total indicator reading Wheel Bearing Remove the dust seal 14 9 Turn the inner race of each bearing with your fin
86. alve and operate the brake lever pedal If it still feels spongy bleed the system again brake bleeder is not available use the following pro cedure Pump up the system pressure with the brake lever pedal until lever pedal resistance is felt 1 Pump the brake lever or pedal several times then squeeze the brake lever or push the brake pedal all the way and loosen the bleed valve 1 2 turn Wait several seconds and close the bleed valve NOTE Do notrelease the brake lever or pedal until the bleed valve has been closed 2 Release the brake lever or pedal slowly until the bleed valve has been closed 3 Repeat steps 1 2 until there are no air bubbles in the bleed hose UPPER LEVEL After bleeding air completely tighten the bleed valve to the specified torque TORQUE 5 4 N m 0 6 kgf m 4 Ibf ft Fill the reservoir with DOT3 or DOT 4 brake fluid to the upper level A UPPER LEVEL 16 4 BRAKE SYSTEM Install the diaphragm set plate and reservoir cover SCREWS Tighten the reservoir cover screws to the specified torque wo COVER SCREWS TORQUE 1 5 N m 0 15 kgf m 1 1 Ibf ft DIAPHRAGM DIAPHRAGM SET PLATE BRAKE PAD DISC FRONT BRAKE PAD REPLACEMENT 1 D A contaminated brake disc or pad reduces stopping power Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent NOTE Always replace the brake pads in pairs to assure e
87. alve lifters with oil Install the valve lifters in their original lifter bores being careful not to damage the sliding surfaces of the lifters and bores CAMSHAFT INSTALLATION Apply molybdenum oil solution to the camshaft journals and cam lobes 10 19 CYLINDER HEAD VALVES Install the camshaft into the right camshaft holder in their CAMSHAFT proper locations w NOTE The camshaft holders have the following identification marks IN Intake camshaft holder EX Exhaust camshaft holder Install the snap ring RIGHT CAMSHAFT HOLDER SNAP RING Install the dowel pins camshaft holders and camshafts in their proper locations DOWEL PINS CAMSHAFT Apply oil to the threads and saeting surface of the camshaft holder bolts Install the bolts and tighten them in a crisscross pattern in 2 or 3 steps TORQUE 12 N m 1 2 kgf m 9 Ibf ft Turn the camshaft by your hand with the cam lobe facing up The camshafts should turn smoothly Remove the bolts camshaft holders and camshafts if the camshafts do not turn smoothly Reinstall the camshaft camshaft holders and bolts and retighten the bolts see above Recheck the camshaft rotation TORQUE 12 1 2 kgf m 9 Ibf ft 10 20 CYLINDER HEAD VALVES Install the cam chain guide Tighten the two bolts BOLTS CAM CHAIN 5 GUIDE Turn the crankshaft counterclockwise and align the index M line of the T mark on the flywhe
88. an cause damage if it enters be tween the valve stem and guide After cutting the seat apply lapping compound to the valve face and lap the valve using light pressure After lapping wash any residual compound off the cylin der head and valve Recheck the seat contact after lapping 10 16 1 2 1 5 mm 0 05 0 06 in CONTACT TOO HIGH OLD SEAT WIDTH CONTACT TOO LOW OLD SEAT WIDTH IEEE HAND LAPPING TOO CYLINDER HEAD VALVES CYLINDER HEAD ASSEMBLY RETAINER VALVE LIFTER SPARK PLUG ho SHIM _ EXHAUST VALVE INTAKE VALVE Clean the cylinder head assembly with solvent and blow through all oi passages with compressed air Install the valve spring seat and new valve stem seal Lubricate each valve stem with molybdenum oil Insert the intake and exhaust valve into the valve guides SPRING SEAT To avoid damage to the seal turn the valve slowly when inserting SPRING Wem s Install the valve springs with the blue painted side facing up and the springs tightly wound coils should face toward the combustion chamber Install the retainers COMBASTION CHAMBER SIDE 10 17 CYLINDER HEAD VALVES Compress the valve spring and install the valve cotters ATTACHMENT CAUTION To prevent loss of tension do not compress the valve spring more than necessary TOOL Valve spring compressor 07757 0010000 Attach
89. and nuts for all suspension pivot and mounting points SPECIFICATIONS ITEM Minimum tire tread depth Unit mm in To the indicator 200 kPa 2 00 kgf cm 29 psi 225 kPa 2 25 kgf cm 33 psi Cold tire pressure Driver only Driver and passenger 0 20 0 008 2 0 0 08 2 0 0 08 60 g 2 1 oz max Axle runout Wheel rim runout Radial Wheel balancer weight Size link DID428VI3 124LE 25 35 1 0 1 4 Drive chain TORQUE VALUES Rear axle nut 59 N m 6 0 kgf m 43 Ibf ft U nut Driven sprocket nut 64 N m 6 5 kgfm 47 Ibf ft U nut Rear brake disc bolt 42 N m 4 3 kgf m 31 Ibf ft ALOC bolt Shock absorber upper mounting bolt 39 N m 4 0 kgf m 29 Ibf ft Shock absorber lower mounting nut 44 4 5 kgf m 33 Ibf ft U nut Swingarm pivot nut 88 N m 9 0 kgf m 65 Ibf ft U nut Chain slider screw 5 9 N m 0 6 kgf m 4 3 Ibf ft 15 1 REAR WHEEL SUSPENSION TOOLS Bearing remover head 12 mm 07746 0050300 Bearing remover shaft 07746 0050100 Driver 07749 0010000 Attachment 37 x 40 mm 07746 0010200 Pilot 12 mm 07746 0040200 TROUBLESHOOTING Wobble or vibration in motorcycle Bentrim Bent spokes Damaged tire Axle not tightened properly Chain adjusters not adjusted equally Soft suspension Weakspring Oil leakage from damper unit Tire pressure too low Hard su
90. ar cowls as an aseembly 2 2 LZ ee REAR COWL SCREWS BOLTS FRAME BODY P ANELS EXHAUST SYSTEM Remove the four screws and rear center cowl from the rear cowls SCREWS Installation is in the reverse order of removal REAR CENTER REAR COWL COWL REAR FENDER SCREWICOLLAR AES REMOVAL INST ALLATION REAR COMBINATION P res Remove the following battery page 17 4 rear cowl page 2 2 starter relay switch and fuses Disconnect the rear combination light 6P connector Remove the screw and collar Release the rear combination light bosses from frame grommets then remove the rear combination light Remove the two bolts and rear fender REAR FENDER Installation is in the reverse order of removal UNDER COWL REMOV AL INST ALLATION Hold the lower cowl securely and remove the six screws from the both sides Remove the under cowls as an assembly SCREWS 2 3 FRAME BODY P ANELS EXHAUST SYSTEM Remove the three screws and under cowl center cover Remove the screw and separate the right and left under cowls UNDER COWL 2 UNDER COWLS CENTER COVER Installation is in the reverse order of removal SCREWS MIDDLE COWL REMOV AL INST ALLATION At first remove the screws and then release the bosses of the middle cowl from the grommets of the frame and radiator Release the speedometer cable from the guide left middle cowl only and remove the middle c
91. ch bolt 23 N m 2 3 kgf m 17 Ibf ft Bottom bridge pinch bolt 26 2 7 kgf m 20 Ibf ft Handlebar pinch bolt 27 N m 2 8 kgf m 20 Ibf ft Grip end screw 8 8 0 9 kgf m 6 5 Ibf ft 14 1 FRONT WHEEL SUSPENSION STEERING TOOLS Bearing remover head 12 mm Bearing remover shaft 07746 0050300 07746 0050100 07749 0010000 Attachment 37 40 mm Attachment 42 x 47 mm Pilot 12 mm Steering stem socket Ball race remover Steering stem driver Fork seal driver Fork seal driver attachment Oil seal remover TROUBLESHOOTING Hard steering Steering top thread too tight Damaged steering head bearing Insufficient tire pressure Faulty tire Steers to one side or does not track straight Bentfork Bentfront axle Wheel installed incorrectly Faulty steering head bearing Bentframe Faulty wheel bearing Worn swingarm pivot components Front wheel wobbling Bentrim Worn wheel bearings Bent loose spoke Faulty tire 14 2 07746 0010200 07746 0010300 07746 0040200 07916 3710101 07GMD 540100 07946 4300101 07747 0010100 07747 0010300 07748 0010001 Wheel turns hard Faulty wheel bearing Faulty speedometer gear Soft suspension Weakfork spring Insufficient fork oil Hard suspension Bentfork pipe Clogged fluid passage Front suspension noisy Insufficient fluid in fork Loose front suspension fa
92. clearance Valve stem O D 0 05 0 002 Valve valve guide 0 16 0 03 0 006 0 001 0 25 0 03 0 010 0 001 3 775 3 790 0 1486 0 1492 EX 3 7 0 15 3 765 3 780 0 1482 0 1488 0 010 0 037 0 0004 0 0015 0 075 0 0029 15 5 0 61 EX 1310 52 IN EX 1 2 1 6 0 05 0 06 1 9 0 07 Valve spring free length IN EX 39 7 1 56 38 5 1 52 op ee Bore I D 21 1 21 3 0 83 0 84 22 5 0 89 Cam lobe height 35 12 35 20 1 383 1 386 34 71 34 79 1 367 1 370 34 662 1 3646 17 000 17 018 0 6693 0 6700 17 027 0 6703 16 966 16 984 0 6680 0 6687 16 960 0 6677 IN EX 0 016 0 052 0 0006 0 0020 0 067 0 0026 Valve guide 1 Stem to guide clearance Valve guide projection above cylinder head Valve seat width Valve lifter Camshaft Camshaft holder I D Camshaft O D Camshaft to camshaft holder clearance 10 1 CYLINDER HEAD VALVES TORQUE VALUES Cylinder head cover bolt 10 N m 1 0 kgf m 7 Ibf ft Cam sprocket bolt 8 8 N m 0 9 kgf m 6 5 Ibf ft Apply a locking agent to the threads Cam chain tensioner plug 4 2 N m 0 43 kgf m 3 1 Ibf ft Camshaft holder bolt 12 N m 1 2 kgf m 9 Ibf ft Apply oil to the threads and seating surface Cylinder head nut 30 N m 3 1 22 Ibf ft Apply oil
93. commended parts and lubricants or their equivalents Parts that don t meet HONDA s design specifications may cause damage to the motorcycle 2 Use the special tools designed for this product to avoid damage and incorrect assembly 3 Use only metric tools when servicing the motorcycle Metric bolts nuts and screws are not interchangeable with English fasteners Install new gaskets O rings cotter pins and lock plates when reassembling 5 When tightening bolts or nuts begin with the larger diameter or inner bolt first Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified Clean parts in cleaning solvent upon disassembly Lubricate any sliding surfaces before reassembly After reassembly check all parts for proper installation and operation 8 Route all electrical wires as show on pages 1 17 through 1 23 Cable and Harness Routing A 1 2 GENERAL INFORMA TION MODEL IDENTIFICATION ENGINE SERIAL NUMBER The frame serial number is stamped on the right side of The engine serial number is stamped on the lower left side the steering head of the crankcase 7 gt CARBURETOR IDENTIFICATION NUMBER The carburetor identification number is stamped on the left side of the carburetor body GENERAL INFORMA TION SPECIFICATIONS GENERAL Overall length Overall width Overall height Wheelbase Seat height Footpeg height Ground clearance
94. current is kept flowing through the starter motor to turn it while the engine is not cranking over the starter motor may be damaged Refer to page 9 4 for starter clutch servicing Refer to section 20 for following components Ignition switch Starter switch Neutral switch Clutch switch SPECIFICATION Unit mm in ITEM STANDARD Starter motor brush length 10 00 10 05 0 393 0 396 SERVICE LIMIT 3 5 0 14 19 1 ELECTRIC STARTER TROUBLESHOOTING Starter motor will not turn Check for a blown main fuse 20A or sub fuse 10A Checkthat the battery is fully charged and in good condition section 17 Check for loose or poorly connected battery Abnormal Poorly connected battery cable cable and open circuit in battery cable Opencircuit in battery cable Normal Check for loose or poorly connected starter relay switch terminals and connectors Normal Abnormal Poorly connected terminals or connectors Abnormal Poorly connected starter motor cable Opencircuit in starter motor cable Check for loose or poorly connected starter motor cable and open circuit in starter motor cable Normal With the ignition switch ON push the starter Clicks Connect the starter motor terminal switch and check for a Click sound from directly to the battery positive terminal the starter relay switch Because a large amount of curre
95. djusted at either end of the throttle cable Minor adjustment are made with the upper adjuster Adjust the free play by loosening the lock nut and turning the adjuster LOCK NUT Major adjustments are made with the lower adjuster Remove the fuel tank page 5 3 Remove the bolt and PAIR control valve with tubes connected Disconnect the air injection hose from the cylinder head cover 1 12 1 4 in ADJUSTER MAINTENANCE Adjust the free play by loosening the lock nut and turning the adjusting nut After adjustment tighten the lock nut securely Recheck the throttle operation Replace any damaged parts if necessary CARBURETOR CHOKE This model s choke system uses a fuel enriching circuit controlled by a starting enrichment SE valve The SE valve opens the enriching circuit v a a cable when the choke knob on the fork top bridge is pulled Check for smooth choke knob operation and lubricate the choke cable if required Inspect the cable for cracks which could allow moisture to enter Replace the cable if necessary AIR CLEANER Remove the fuel tank page 5 3 Remove the five screws and air cleaner housing cover Remove and clean the air cleaner element in accordance with the maintenance schedule Also replace the air cleaner element any time it is exces sively dirty or damage MAINTENANCE If the surface of the element is dirty remove the dust first by tapping the
96. dlebar in the same manner as for the left handlebar If the left handlebar grips were removed apply Honda Bond A or its equivalent to the inside surface of the grip and to the clean surface of the left handlebar Wait 3 5 minutes and install the grip Rotate the grip for even application of the adhesive NOTE Allow the adhesive to dry for an hour before using 14 5 FRONT WHEEL SUSPENSION STEERING Apply grease to the throttle pipe sliding surface and throttle cable contact point Install the throttle grip to the handlebar Install the grip end Tighten the grip end screw to the specified torque TORQUE 8 8 N m 0 9 kgf m 6 5 Ibf ft Apply grease to the throttle cable end Connect the throttle cable to the throttle pipe Install the throttle housing and align its locating pin of the throttle housing cover with the hole on the handlebar Install the screws and tighten the forward screw first then the rear screw Place the front master cylinder on the handlebar and in stall the master cylinder holder with its UP mark facing up Align the end of the holder with the punch mark on the handlebar Tighten the upper bolt first then tighten the lower bolt GRIP END THROTTLE GRIP THROTTLE CABLE 14 6 FRONT WHEEL SUSPENSION STEERING Connect the front brake switch connectors Install the left handlebar grip onto the handlebar refer to page 14 5 GRIP END Inst
97. e the stator coil to make this test Release the alternator 4P connector from the clamp of the frame Disconnect the alternator 4P connector Check the resistance between following terminals STANDARD Charging coil White Ground White Ground 0 2 1 0 Q at 20 C 68 F Lighting coil Yellow Ground Yellow Ground 0 1 0 8 Q at 20 C 68 F Replace the alternator stator if readings are far beyond Jz the standard Refer to page 9 2 for stator removal CHARGING SYSTEM REGULATOR RECTIFIER m AMI reos R RECTIFIER SYSTEM INSPECTION Remove the rear cowl page 2 2 Disconnect the regulator rectifier 4P connector and check it for loose contact or corroded terminals If the regulated voltage reading see page 17 4 is out of the specification measure the voltage between connec tor terminals wire harness side as follows ltem Termina Specification Battery Red 4 and Battery voltage should charging line ground resister White and ground Yellow and Green Green and ground Standard resistance 1k 20 20 C 68 F Standard resistance 10 k 200 20 C 68 F Charging coil line Lighting coil line Ground l ne Continuity should exist if all components of the charging system are normal and there are no loose connections at the regulator rectifier connectors r
98. ead bearing dust seal lips Front fork oil seal lips Front wheel dust seal lips Rear wheel duat seal lips Rear wheel hub O ring Clutch lever pivot bolt sliding surface Speedometer gear and pinion gear teeth Speedometer gear pinion sliding surface Side stand pivot surface Throttle grip sliding surface Speedometer outer cable inside Seat lock sliding surface Brake pad pin sliding surface MATERIAL Multi purpose grease Brake caliper pin bolt Brake lever pivot bolt sliding surface Brake lever to master piston contacting area Rear brake master piston to push rod contacting area Throttle cable inside Clutch inner cable surface Molybdenum compound oil Choke inner cable surface Fork socket bolt threads Locking agent Cooling fan motor shaft threads Handle grip rubber inside Honda Bond or equivalent Brake master piston and cups DOT 3 or 4 brake fluid Brake caliper piston and piston seals Brake caliper dust seal Honda Ultra Cushion Oil No 10 Air cleaner housing tube joint Silicone grease 1 16 GENERAL INFORMA TION CABLE amp HARNESS ROUTING CLUTCH CABLE FRONT BRAKE HOSE THROTTLE CABLE RIGHT HANDLEBAR SWITCH WIRE IGNITION SWITCH WIRE MAIN WIRE HARNESS LY gt LA ron CONNECTOR v NE y HEAD LIGHT TURN SIGNAL LIGHT 6P CONNECTOR 1 17 CLUTCH CABLE X
99. earshift linkage All service can be done with the engine installed in the frame Transmission oil viscosity and level have an effect on clutch disengagement When the clutch does not disengage or the motorcycle creeps with clutch disengaged inspect the transmission oil level before servicing the clutch system SPECIFICATIONS Unit mm Clutch Lever free play 10 20 3 8 13 16 36 6 1 44 3 1 0 12 292 308 0 15 01 7 2 60 0 102 pPeewapage 2 02000 amm gates _ 22 93 0 903 10 16 991 17 009 0 6689 0 6696 17 04 0 671 0 30 000 30 021 1 1811 1 1819 23 06 0 908 Mainshaft O D at clutch outer guide 16 996 16 984 0 6680 0 6687 16 935 0 6667 TORQUE VALUES Shift drum stopper arm bolt 12 N m 1 2 kgf m 9 Ibf ft Gearshift cam plate bolt 12 Nem 1 2 kgf m 9 Ibf ft Apply locking agent to the threads Clutch center lock nut 74 N m 7 5 kgf m 54 Ibf ft Apply to the threads and seating surface Primary drive gear lock nut 64 N m 6 5 kgf m 47 Ibf ft Apply oil to the threads and seating surface 8 1 CLUTCH GEARSHIFT LINKAGE TOOLS Clutch center holder 07GMB KT70101 Lock nut wrench 20 x 24mm 07716 0020100 TROUBLESHOOTING Faulty clutch operation can usually be corrected by adjusting the clutch system Clutch slips when accelerating Transmission jumps out of gear Incorrect clutch adjustment Damaged sto
100. eering stem nut and washer Remove the fork page 14 12 Remove the top bridge Remove the horn stay mounting bolts and horn stay FRONT WHEEL SUSPENSION STEERING Remove the top thread using the special tool STEERING TOOL STEM SOCKET Steering stem socket 07916 3710101 Remove the following top cone race STEERING STEM upper bearing steering stem lower bearing CAUTION Be careful not to lose any of the bearing BEARING RACE REPLACEMENT NOTE Replace the bearing and races as a set Remove the ball races using the special tool TOOL Ball race remover 07GMD KS40100 BALL RACE REMOVER Install the new ball races using the special tools TOOLS Driver 07749 0010000 Attachment 42 x 47 mm 07746 0010300 RIVER 14 20 FRONT WHEEL SUSPENSION STEERING BOTTOM CONE RACE REPLACEMENT Avoid damaging the steering stem thread temporarily install the stem nut Remove the bottom cone race dust seal and dust seal washer Install the new dust seal and bottom cone race Drive a new bottom cone race onto the steering stem us ing the special tool TOOL Steering stem driver 07946 4300101 INSTALLATION Suum BOTTOM BALL RACE LOWER BEARING BOTTOM CONE RACE 69 DUST SEAL i STAY g HORN STEM NUT b gt 4 BOTTOM CONE RACE DUST SEAL WASHER 4 STEERING
101. el with the index notch INDEX NOTCH on the left crankcase cover gt Wu Make sure the piston is at TDC Top Dead Center on the compression stroke Attach the cam sprockets to the cam chain by aligning the cam sprocket marks with the cylinder head surface as CAM CHAIN shown Temporarily align the index line on the sprockets with the surface of the cylinder head without moving the cam chain Install the cam sprockets onto the camshafts NOTE Be sure that the index lines on the cam sprocket align with the surface of the cylinder head when the index line of the T mark on the flywheel is aligned with the index notch on the crankcase cover Apply locking agent to the cam sprocket bolt threads Align the bolt holes in the cam sprocket with camshaft flange Install the cam sprocket bolts and tighten them to the specified torque TORQUE 8 8 0 9 kgf m 6 5 Ibf ft CYLINDER HEAD VALVES Install the timing hole cap and crankshaft hole cap page 3 10 Install the following exhaust system page 2 7 under cowl page 2 3 carburetor assembly page 5 13 CYLINDER HEAD COVER INSTALLATION uer CYLINDER HEAD COVER TE Install the gasket new O ring and dowel pin to the cylinder head cover Install the cylinder head cover onto the cylinder head Install the rubber washers with the UP marks facing up Install and tighten the head cover bolts to the specified to
102. em When cleaning the cylinder mating surface place a shop amp OIL ORIFICES towel over the cylinder and cam chain openings to prevent dust or dirt enter the engine Clean any gasket material from the cylinder mating sur face of the crankcase Clean the oil orifices of the right crankcase CYLINDER PISTON jy ble MB IN MARK Apply molybdenum solution to the piston pin outer surfaces and connecting rod small end inner surfaces Apply engine oii to the piston pin hole Install the piston with its IN mark facing the intake side Install the piston pin install the new piston pin clips CAUTION Always use new piston pin clips Reinstalling used piston pin clips may lead to serious engine damage NOTE Place a shop towel over the crankcase opening to pre vent piston pin clips from falling into the crankcase Setthe piston pin clip in the groove properly Do notalign the clip s end gap with the piston cut out PISTON PIN CLIP Om 4 CYLINDER INSTALLATION NOTE Do not reuse the gasket replace with new one Install the dowel pins and a new gasket CAUTION Be careful not to damage the piston rings and cylinder CYLINDE A wall 729 Apply engine oil to the cylinder and piston lt Route the cam chain through the cylinder and install the cylinder over the piston while compressing the piston rings b 4 with your fingers LS EN
103. end I D SERVICE LIMIT 15 09 mm 0 594 in Calculate the connecting rod small end to piston pin clear ance SERVICE LIMIT 0 075 mm 0 0030 in NOTE Always replace the piston rings as a set Inspect the piston ring and replace them if they are worn Temporarily instail the piston rings page 11 7 into the piston grooves Push in the ring until the outer surface of the piston ring is nearly flush with the piston and measure the clearance using a feeler gauge SERVICE LIMIT Top 0 10 mm 0 004 in Second 0 08 mm 0 03 Using a piston push the ring securely into the cylinder and measure the end gap using a feeler gauge SERVICE LIMIT Top 0 3 mm 0 01 in Second 0 7 mm 0 03 in Oil 1 1 mm 0 04 in 11 6 CYLINDER PISTON PISTON INSTALLATION Clean the piston heads ring lands and skirts Carefully install the piston rings onto the piston with their markings facing up CAUTION Do not damage the piston ring by spreading the ends too far Be careful not to damage the piston when the piston ring installation NOTE Do not confuse the top and second rings After installing the rings they should rotate freely with out sticking Space the ring end gaps 120 degrees apart MARK SECOND RING PISTON SIDE RAIL TOP RING SPACER SECOND RING PISTON 55555555 OIL RING CLL Lu SS
104. ents are removed or serviced This section covers removal and installation of the body panels and exhaust system Always replace the exhaust pipe gaskets after removing the exhaust pipe from the engine Always inspect the exhaust system for leaks after installation TORQUE VALUES Muffler mounting nut 13 N m 1 3 kgf m 9 Ibf ft Exhaust pipe cover bolt 13 1 3 kgf m 9 Ibf ft TROUBLESHOOTING Excessive exhaust noise Broken exhaust system Exhaust gas leak Poor per formance Deformed exhaust system Exhaust gas leak Clogged muffler FRAME BODY PANELS EXHAUST SYSTEM PASSENGER SEAT PASSENGER SEAT REMOVAL INST ALLATION IGNITION KEY Unlock the passenger seat with the ignition key Remove the passenger seat Installation is in the reverse order of removal DRIVER SEAT REMOV AL INST ALLATION DRIVER SEAT Remove the driver seat See above Remove the mounting bolt and collars Raise the rear of the seat and remove the seat backward Installation is in the reverse order of removal GRAB RAIL REMOV AL INST ALLATION Remove the four bolts and grab rail Installation is in the reverse order of removal REAR COWL REMOV AL INST ALLATION Remove the grab rail See above Remove the two screws and body center cover Remove the bolts and collars Remove the screws Spread the front of the rear cowls carefully and release the rear cowl bosses from the fuel tank grommets Remove the re
105. eplace the regulator rectifier unit REMOVAL INSTALLATION xm BOLT Ge GULATOR RECTIFIER Remove the regulator rectifier unit mounting bolt Disconnect the connector and remove the regulator recti fier unit Install the regulator rectifier unit in the reverse order of removal 4P CONNECTOR 17 8 IGNITION SYSTEM SYSTEM DIAGRAM IGNITION SWITCH SPARK PLUG ALTERNATOR IGNITION PULSE GENERATOR To Tachometer IGNITION SWITCH aa BI O O R G 823680 3 a BATTERY IGNITON IGNITION CONTROL COIL MODULE ICM BI Black IGNITION PULSE ion SPARK GENERATOR Y Yellow PLUG Red i G Green BY gt H BVY 18 0 18 IGNITION SYSTEM SYSTEM DIAGRAM 18 0 IGNITION COIL 18 5 SERVICE INFORMATION 18 1 IGNITION CONTROL MODULE ICM 18 5 TROUBLESHOOTING 18 2 IGNITION TIMING 18 6 IGNITION SYSTEM INSPECTION 18 3 SERVICE INFORMATION GENERAL 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 poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death CAUTION Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is ON and current is present When servicing the ignition system always follow the steps in the troubleshooting sequence on page
106. er rotors SERVICE LIMIT 0 20 mm 0 008 in Measure the body clearance between the outer rotor and pump body SERVICE LIMIT 0 26 mm 0 010 in Measure the side clearance using a straight edge and feeler gauge SERVICE LIMIT 0 15 mm 0 006 in OUTER ROTOR iER ACTOR IMMER ROT F F 9 Fi LUBRICATION SYSTEM ASSEMBLY OUTER ROTOR INNER ROTOR OiL PUMP SHAFT LOCK OIL PUMP BODY DOWEL PIN OIL PUMP DRIVEN GEAR Install the oil pump shaft lock pin into the oil pump shaft Install the oil pump shaft into the oil pump driven gear OlL PUMP DRIVEN GEAR PUMP SHAFT Va Install the outer rotor and inner rotor Fili the oil pump with engine oil OUTER ROTOR INNER ROTOR 4 4 LUBRICATION SYSTEM Install the oil pump cover onto the oil pump body BOLTS Temporally install the dowel pins and tighten the two bolts OIL PUMP COVER A to the specified torque x us TORQUE 5 2 N m 0 53 kgf m 3 8 Ibf ft g 4 4 DOWEL PINS Install the oil pump shaft into the oil pump body aligning gt the flats between the shaft and inner rotor ALIGN Secure the oil pump shaft with E clip INSTALLATION Install the dowel pins LUBRICATION SYSTEM Install and tighten the three bolts securely Clean the oil strainer screen page 3 12 Install the right crankcase cover page 8 14 After installati
107. er adjuster all the way in and back out 1 turn Loosen the lock nut and adjusting nut and turn the adjusting nut to adjust free play Tighten the upper and lower lock nuts Check the clutch operation N YL If the free play cannot be obtained or the clutch slips AS during test ride disassemble and inspect the clutch 282 amp ti s section 8 gt B DJUSTING NUT ADJUSTING SCREW 20 mm 0 4 0 8 in ADJUSTER 3 19 MAINTENANCE SIDE STAND Support the motorcycle on a level surface Check the side stand spring for damage or loss of tension Check the side stand assembly for freedom of movement and lubricate the side stand pivot if necessary SIDE STAND lt SUSPENSION 2 Loose worn or damaged suspension parts impair motor cycle stability and control Repair or replace any damaged components before riding Riding a motorcycle with faulty suspension increases your risk of an accident and pos sible injury FRONT SUSPENSION INSPECTION Check the action of the forks by operating the front brake and compressing the front suspension several times Check the entire assembly for signs of leaks damage or loose fasteners Replace damaged components which cannot be repaired Tighten all nuts and bolts Refer to section 14 for fork service REAR SUSPENSION INSPECTION Check the action of the rear shock absorber by compress ing the rear end several times Check the entire s
108. er using the special tool TOOLS Clutch center holder 07GMB KT70101 Lock nut wrench 20 x 24 mm 07716 0020100 Remove the four bolts clutch center holder and clutch assembly LOCK NUT WRENCH Tes LOCK NUT WASHER CLUTCH GEARSHIFT LINKAGE CLUTCH OUTER GUIDE f 2 Remove the clutch outer guide and washer from mainshaft f WASHER oud DISASSEMBLY Remove the clutch center washer judder spring spring JUDDER SPRING seat clutch discs and plates SPRING SEAT Remove the pressure plate CLUTCH CENTER PRESSURE PLATE CLUTCH PLATES CLUTCH DISC A INSPECTION Clutch lifter bearing LIFTER BEARING Turn the inner rece of the lifter bearing with your finger The bearing should turn smoothly and freely without ex cessive play If necessary replace the bearing 8 5 CLUTCH GEARSHIFT LINKAGE Clutch spring Check the clutch spring for fatigue or other damage Measure the clutch spring free length SERVICE LIMIT 36 6 mm 1 44 in Clutch disc Check the clutch discs for signs of scoring or discolora tion Measure the thickness of the discs SERVICE LIMITS Disc A 3 1 mm 0 12 in Disc 2 60 mm 0 102 Replace the discs and plates as set Clutch plate Check the plate for excessive warpage or discoloration Check the plate warpage on a surface using a feeler gauge SERVICE LIMIT 0 2 mm 0 008 in 8
109. ers Remove the muffler and exhaust pipe as assembly Remove the exhaust pipe gasket MOUNTING RUBBERS Ld EXHAUST PIPE DISASSEMBL Y ASSEMBL Y MUFFLER 13 N m 1 3 kgf m 9 Ibf ft GASKET COLLAR MUFFLER EXHAUST PIPE 13 N m 1 3 kgf m 9 Ibf ft WASHER MOUNTING EXHAUST JOINT NUTS GUARD COVER RUBBERS PIPE 2 6 FRAME BODY P ANELS EXHAUST SYSTEM INSTALLATION JOINT NUTS Install the new gasket ij install the muffler and exhaust pipe assembly then temporarily install the all mounting fastners Tighten the exhaust pipe joint nuts ee BOLT NUT WASHER COLLAR MOUNTING RUBBER Tighten the exhaust pipe mounting bolt WY EXHAUST PIPE ict _ Tighten the muffler mounting bolt to the specified torque BOLT COLLAR MOUNTING RUBBER TORQUE 13 1 3 kgf m 9 Ibf ft 2 7 SERVICE INFORMATION MAINTENANCE SCHEDULE FUEL LINE THROTTLE OPERATION CARBURETOR CHOKE AIR CLEANER CRANKCASE BREATHER SPARK PLUG VALVE CLEARANCE ENGINE OIL ENGINE OIL STRAINER SCREEN ENGINE IDLE SPEED RADIATOR COOLANT COOLING SYSTEM SERVICE INFORMATION GENERAL 3 MAINTENANCE SECONDARY AIR SUPPLY SYSTEM DRIVE CHAIN BRAKE FLUID BRAKE PAD WEAR BRAKE SYSTEM BRAKE LIGHT SWITCH HEADLIGHT AIM CLUTCH SYSTEM SIDE STAND SUSPENSION NUTS BOLTS FASTENERS WHEELS TIRES STEERING HEAD BEARINGS eg es Gasoline is extremely flammable and is
110. es not turn Faulty starter clutch Damaged reduction gear shaft 9 1 ALTERNATOR ST ARTER CLUTCH LEFT CRANKCASE COVER REMOVAL Disconnect the alternator 4P connector page 17 7 Remove the drive sprocket cover page 7 3 Remove the bolts washer and left crankcase cover Remove the gasket and dowel pins ALTERNATOR STATOR STATOR REMOVAL Remove the two ignition pluse generator mounting bolts and ignition pluse generator Remove the three stator mounting bolts and wire grommet then remove the stator from the left crankcase cover BOLT WASHER STARTOR MOUNTING BOLTS PULSE GENERATOR ALTERNATOR ST CLUTCH STATOR INSTALLATION BOLTS IGNITION PULSE GENERATOR BOLTS Place the stator into the left crankcase cover Apply liquid sealant to the wire grommet seating surface and install the grommet into the cover groove Apply locking agent to the ignition pulse generator and stator mounting bolts threads Route the wire properly and tighten the two ignition pulse generator mounting bolts TORQUE 5 2 N m 0 53 kgf m 3 8 Ibf ft Tighten the three stator mounting bolts TORQUE 10 N m 1 0 kgf m 7 Ibf ft FLYWHEEL REMOVAL Remove the left crankcase cover page 9 2 Hold the flywheel with the special tool and loosen the fly wheel nut TOOL Flywheel holder 07725 0040000 Remove the flywheel nut and washer LEFT CRANKCASE COVER STATOR PULSE GENERATO
111. ese parts TOOLS LUBRICATION amp SEAL POINTS CABLE amp HARNESS ROUTING EMISSION CONTROL SYSTEMS USED ENGINE OIL np h h h3 y 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 ba sis it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil KEEP OUT OF REACH OF CHILDREN BRAKE FLUID CAUTION Spilling fluid on painted plastic or rubber parts will dam age them Place a clean shop towel over these parts whenever the system is serviced KEEP OUT OF REACH OF CHILDREN BATTERY HYDROGEN GAS amp ELECTROLYTE 0 b The battery gives off explosive gases keep sparks flames and cigarettes away Provide adequate venti lation when charging The battery contains sulfuric acid electrolyte Con tact with skin or eyes may cause severe burns Wear protective clothing and a face shield If electrolyte gets on your skin flush with water FH electrolyte gets in your eyes flush with water for at least 15 minutes and call a physician imme diately Electrolyte is poisonous f swallowed drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and call a physician KEEP OUT OF REACH OF CHIL DREN 1 1 GENERAL INFORMA TION SERVICE RULES 1 Use genuine Honda or Honda re
112. event any foreign material from dropping into the engine When disassembling the fuel system parts note the locations of the O rings Replace them with new ones on reassembly The float chamber can be serviced with the carburetors combined SPECIFICATIONS ITEM SPECIFICATIONS Carburetor identification number VK6AA Main jet 115 Slow jet 85 Pilot screw opening See page 5 14 Float level 13 mm 0 5 in Idle speed 1 400 100 min rpm Throttle grip free play 2 6mm 1 12 1 4 in TORQUE VALUES Reed valve cover bolt 5 2 N m 0 53 kgf m 3 8 Ibf ft TOOL Float level gauge 07401 0010000 5 1 FUEL SYSTEM TROUBLESHOOTING Engine cranks but won t start No fuel in tank No fuel to carburetor Clogged fuel strainer Clogged fuel line Too much fuel getting to the engine Clogged air cleaner Flooded carburetor Intake air leak Contaminated deteriorated fuel Improper choke operation Improper throttle operation No spark at plug faulty ignition system section 18 Lean mixture Clogged fuel jets Faulty float valve Float level too low Restricted fuel line Clogged carburetor air vent tube Intake air leak Faulty vacuum piston Rich mixture Starting enrichment valve open Clogged air jets Faulty float valve Float level too high Dirty air cleaner Faulty vacuum piston 5 2 Engine stalls hard to start rough idling Restricted fuel line Fuel mixture too lean rich
113. flange bolt and nut Include 12 1 2 9 NSHF 8 mm flange bolt and nut 10 mm flange bolt and nut 5 mm bolt and nut 6 mm bolt and nut Include SH flange bolt 8 mm bolt and nut 10 mm bolt and nut 12 mm bolt and nut 22 2 2 16 34 3 5 25 54 5 5 40 26 2 7 20 39 4 0 29 Torque specifications listed below are for important fasteners Others should be tightened to standard torque values listed above NOTES 1 Apply engine oil to the threads and flange surface 2 Apply molybdenum disulfide oil to the threads and flange surface 3 Apply locking agent to the threads 4 Apply sealant to the threads 5 Stake 6 UBS bolt 7 U nut 8 ALOC bolt ENGINE THREAD TORQUE DIA mm N m Ibt ft REMARKS MAINTENANCE Spark plug 10 12 1 2 9 Crankshaft hole cap 30 7 9 0 8 5 8 Timing hole cap 14 5 9 0 6 4 3 Oil drain bolt 12 25 2 5 18 LUBRICATION SYSTEM pump bolt 5 2 0 53 3 8 COOLING SYSTEM Water pump impeller 10 1 0 7 CYLINDER HEAD V ALVE Cylinder head cover bolt 10 1 0 7 Cylinder head nut 30 3 1 22 Cylinder head bolt 32 3 3 24 Cam sprocket 8 8 0 9 6 5 Cam chain tensioner plug 4 2 0 43 3 1 Camshaft holder bolt 12 1 2 9 CLUTCH GEARSHIFT LINKAGE Clutch center lock nut 74 7 5 54 Primary drive gear lock nut 4 64 6 5 47 Gearshift cam plate bolt 12 1 2 9 Shift drum stopper arm bolt 12 1 2 9
114. ft Bearing remover weight TROUBLESHOOTING Excessive noise 07936 10200 07936 10100 07741 0010201 07749 0010000 07746 0010200 07746 0010300 07746 0010100 07746 0040400 07746 0040300 07746 0040500 07746 0040200 07936 1660110 07936 1660120 07741 0010201 Worn sized or chipped transmission gear Worn or damaged transmission bearing Hard to shift Bentshift fork Bentshift fork shaft Damaged shift drum guide groove Damaged shift fork guide pin Transmission jumps out of gear Worn gear dogs or slots Worn shift drum guide groove Worn shift fork guide pin Worn shift fork groove in gear 12 2 TRANSMISSION TRANSMISSION DISASSEMBLY N TENSIONER GUIDE 7 PLATE Refer to Service Information page 12 1 for removal of necessary parts before disassembling the crankcase Remove the cam chain Remove the cam chain tensioner plate bolt plate and tensioner guide ri hy Remove the circlip washer spring and bearing push plug WASHER BEARING f the left kcase CIRCLIP OMe eee 69 4 PUSH PLUG Check for the bearing push plug for wear or damage and replace if necessary SPRING Remove the left crankcase bolts and clamp Remove the right crankcase bolts and washer TRANSMISSION TRANSMISSION Place the crankcase assembly with the right side down RIGHT CRANKCASE Carefully separate the left crankcase from the right crankcase whi
115. ft camshaft holder as a set and recheck the camshaft clearance Replace the right camshaft holder if the camshaft clearance still exceeds the service limit Measure the height of each cam lobe SERVICE LIMIT IN 35 073 mm 1 3808 in EX 34 662 mm 1 3646 in RIGHT CAMSHAFT HOLDER SNAP RING 10 10 CYLINDER HEAD VALVES Support both ends of the camshaft with V blocks and check the camshaft runout with a dial indicator SERVICE LIMIT 0 02 mm 0 001 in Valve lifter Check the valve lifter bore for scoring scratches or damage Measure the each valve lifter bore 1 0 SERVICE LIMIT 22 5 mm 0 89 in Check the valve lifter for scoring scratches or damage Measure the each valve lifter O D SERVICE LIMIT 22 47 mm 0 885 in Valve spring Measure the valve spring length SERVICE LIMIT 38 5 mm 1 52 in 10 11 CYLINDER HEAD VALVES Cylinder head Check the spark plug hole and valve area for cracks Check the cylinder head for warpage with a straight edge and a feeler gauge SERVICE LIMIT 0 05 mm 0 002 NOTE Be careful not to damage the gasket surface Valve Inspect the valve for trueness burning scratches or ab normal stem wear Measure the valve stem SERVICE LIMIT IN EX 3 7 mm 0 15 Insert each valve into the valve guide and check the valve movement in the guide Valve guide NOTE Ream the valve guide to remove the carbo
116. ged __ Incorrect Incorrect Weak 1 if steering is heavy 2 If either wheel is wobbling 3 If the motorcycle pulled to one side Possible cause Clogged fuel line and fuel auto valve Clogged fuel tank breather Carburetor not serviced frequently enough Cam sprockets not installed prop erly Faulty ignition control module ICM Faulty ignition pulse generator Faulty valve spring Possible cause Steering stem adjusting nut too tight Damaged steering head bearings Excessive wheel bearing play Bent rim Improper installed wheel hub Swingarm pivot bushing excessively worn Bent frame Faulty shock absorber Front and rear wheel not aligned Bent fork Bent swingarm Bent axle 22 4 23 INDEX AIR AIR CLEANER HOUSING ALTERNATOR STATOR ALTERNATOR 22 17 7 BODY PANEL LOCATIONS BRAKE FLUID BRAKE FLUID BLEEDING 16 3 BRAKE LIGHT SWITCH eese 3 18 BRAKE LIGHT SWITCH SYSTEM INSPECTION 20 8 BRAKE PAD WEAR irte tinta cintas BRAKE PEDAL aseo tenis BRAKE 5 00 BRAKE SYSTEM BULB REPLACEMENT CABLE amp HARNESS
117. ger the bearing should turn smoothly and quietly Also check that the bearing outer race fits tightly in the hub Remove and discard the bearings if the races do not turn smoothly quietly or if they fit loosely in the hub NOTE Replace wheel bearings in pairs WHEEL BEARING For bearing replacement see page 14 9 14 8 FRONT WHEEL SUSPENSION STEERING Wheel rim Check the wheel rim runout by placing the wheel in a turn ing stand Spin the wheel by hand and read the runout using a dial indicator SERVICE LIMIT Actual 2 0 mm 0 08 Radial 2 0 mm 0 08 in DISASSEMBLY GEARBOX DUST SEAL Remove the speedometer gearbox dust seal and speed ometer retainer Remove the side collar and dust seal from the right hub umae Remove the brake disc bolts and brake disc SIDE COLLAR BOLTS NOTE Check for disc warpage see page 16 8 x DUST SEAI WHEEL BEARING REPLACEMENT M Y NT Remove the wheel bearings and distance collar from the wheel hub TOOLS Bearing remover head 12 07746 0050300 Bearing remover shaft 07746 0050100 NOTE Never reinstall old bearings Once the bearings have been removed they must be replaced with a new one FRONT WHEEL SUSPENSION STEERING Drive the new right bearing in using the following tools DRIVER NOTE Install the bearings with its marking side facing out TOOLS Driver 07749 0010000 Attachment 3
118. ging do not exceed the charging current and time specified on the battery Using excessive current or extending the charging time may damage the battery CHARGING SYSTEM INSPECTION CHARGING VOLTAGE INSPECTION ff 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 conscious ness and may lead to death sure the battery is in good condition before perform ing this test 17 5 CHARGING SYSTEM CHARGING OUTPUT Warm up the engine to normal operating temperature Stop the engine and connect the multimeter as shown CAUTION To prevent short make absolutely certain which are the positive and negative terminals or cable Donot disconnect the battery or any cable in the charg ing system without first switching off the ignition switch Failure to follow this precaution can damage the tester or electrical components With the headlight on Hi beam restart the engine Measure the voltage on the multimeter when the engine k runs at 5 000 min rpm Standard Measured battery voltage page 17 4 Measured charging voltage See above lt 15 5 V at 5 000 rpm The battery is normal if voltage reads the regulated volt age on the multimeter NOTE The speed at which voltage starts to rise cannot be checked as it varies w
119. guide driver Peak voltage adaptor Valve spring compressor attachment Tapet hole protector Valve guide reamer Rotor puller 1 14 07401 0010000 07631 0010000 07716 0020100 07725 0040000 07741 0010201 07746 0010100 07746 0010200 07746 0010300 07746 0010600 07746 0040200 07746 0040300 07746 0040400 07746 0040500 07746 0040800 07746 0050100 07746 0050300 07747 0010100 07747 0010300 07748 0010001 07749 0010000 07757 0010000 07780 0010200 07780 0010600 07780 0012500 07780 0013300 07780 0014000 07780 0014500 07JMH KY20200 07914 A50001 07916 3710101 07936 1660110 07936 1660120 07936 10100 07936 10200 07945 4150400 07946 4300101 07965 VM00100 07965 VM00200 07GMB 70101 07GMD 540100 07GMO KT70100 07HGJ 0020100 07JME KY20100 07JMG KY20100 07JMH KY20100 07KMC HE00100 NOTE 2 Imrie diagnostic tester model 625 ia 8 9 12 12 13 12 13 14 15 12 14 13 13 14 15 12 12 12 13 14 15 14 15 14 14 14 12 13 14 15 10 10 GENERAL INFORMA TION LUBRICATION amp SEAL POINTS ENGINE LOCATION MATERIAL Valve stem valve guide sliding surface Molybdenum oil solution Clutch outer guide outer surfaces a mixture of 1 2 engine oil Piston pin outer surface and 1 2 molybdenum Connecting rod small end inner surface disulfide grease Shift f
120. hamber cover and tighten the three SCREWS screws 5 10 Starting enrichment SE valve cover Install a new O ring to the valve cover Install the valve cover to the carburetor body Install and tighten the two screws washers securely Air cut off valve Install the diaphragm to the carburetor body Install a new O ring spring and cover Tighten the screws securery Throttle cable stay Install the throttle cable stay and tighten the two screws securely SCREWS FUEL SYSTEM 5 11 FUEL SYSTEM aA DIAPHRAGM VACUUM PISTON Install the jet needle with washer into the vacuum piston Install the spring onto the needle holder and set the needle J ET NEEDLE holder into the vacuum piston HOLDER WASHER SPRING Install the needle holder by aligning the cut out of the holder and boss of the vacuum piston DIAPHRAGM VACUUM PISTON ALIGN Install the diaphragm vacuum piston into the carburetor body DIAPHRAGM VACUUM PISTON COVER Lift the bottom of the piston with your finger to set the diaphragm rib in the groove in the carburetor body and install the spring and vacuum chamber cover CAUTION Be careful not to pinch the diaphragm under the chamber cover SPRING Install and tighten the two screws securely SCREWS 4 5 12 FUEL SYSTEM CARBURETOR INSTALLATION FUEL TUBE Connect the fuel air vent and fuel drain tubes AIR VENT TUBE DRAIN TUBE Insta
121. he frame Install and tighten the shock absorber upper mounting bolt to the specified torque TORQUE 39 N m 4 0 kgf m 29 Ibf ft Install the shock absorber lower mounting bolt and nut and tighten the nut to the specified torque TORQUE 44 4 5 kgf m 33 Ibf ft Check the operation of the shock absorber page 3 20 Install the rear cowl page 2 2 SWINGARM REMOVAL Remove the rear wheel page 15 3 Remove the swingarm pivot caps Remove the screw and brake hose guide 15 10 REAR WHEEL SUSPENSION Remove the rear brake caliper bracket assembly from the swingarm Remove the bolts and drive chain cover Remove the shock absorber lower mounting bolt and nut Remove the swingarm pivot nut Remove the swingarm pivot bolt from the left side and remove the swingarm DISASSEMBLY S Remove the drive chain adjusters ADJUSTERS 15 11 REAR WHEEL SUSPENSION Check the chain slider for wear or damage Remove the screw collar and chain slider Check the rubber bushings for wear damage or fatigue ASSEMBLY CHAIN SLIDER SCREW COLLAR N E 0 BUSHING SWING ARM CHAIN ADJUSTER 15 12 REAR WHEEL SUSPENSION Install the chain slider Install the collar and tighten the screw to the specified CHAIN SLIDER V torque i TORQUE 5 9 N m 0 6 kgf m 4 3 Ibf ft SCREW COLLAR Place the dr
122. he ignition switch ON Move the fuel unit float up and down and make sure that the fuel gauge needle moves smoothly FLOAT UP Needle in FULL FLOAT DOWN Needle in EMPTY FUEL UNIT INSTALLATION Install the new O ring Install the fuel unit Install and tighten the four nuts FUEL UNIT FUEL UNIT FUEL UNIT 20 12 LIGHTS METERS SWITCHES Route the fuel unit wire and connect the 3P connector Install the fuel tank page 5 3 FUEL UNIT CONNECTOR HORN Disconnect the wire connectors from the horn Connect the battery voltage to the horn terminals The horn is normal if it sounds when the battery connected across the horn terminals TURN SIGNAL RELAY TURN SIGNAL RELAY INSPECTION Check the following battery condition burned out bulb or non specified wattage burned fuse ignition switch and turn signal switch function loose connectors If above items all normal check the following Remove the rear cowl page 2 3 2PCONNECTOR Disconnect the connector from the relay 1 Short the White Green and Gray terminals of the turn signal relay connector with a jumper wire Check the turn signal light by turning the switch R or L Lights comes on Lights does not on e Broken wire harness Faulty turn signal relay Poor connection of the connector 20 13 LIGHTS METE
123. he inside of the master cylinder and reservoir with brake fluid NOTE Clean the disassembled parts with clean brake fluid and make sure air can ventilate the master cylinder port by compressed air INSPECTION Check the boot primary and secondary cups for wear de terioration or damage Check the master cylinder and piston for scoring or other damage Replace if necessary Measure the master cylinder I D SERVICE LIMIT 12 755 mm 0 5022 in Measure the master piston O D SERVICE LIMIT 12 640 mm 0 4976 in NOTE The master piston piston cups spring and snap ring must be replace as a set SNAP RING SNAP RING PLIERS SECONDARY CAP WASHER 16 9 BRAKE SYSTEM ASSEMBLY BOOT SNAP RING MASTER PISTON SPRING BRAKE LEVER CAUTION When installing the cups do not allow the lips to turn inside out Dip the piston cups in clean brake fiuid before assembly Install the spring onto the master piston Install the spring master piston and washer into the mas ter cylinder Install the snap ring using the special tool TOOL Snap ring pliers 07914 SA50001 CAUTION Be certain the snap ring is firmly seated in the groove Apply silicone grease to the inside of the boot Install the boot to the master cylinder E E COVER SET PLATE DIAPHRAGM MASTER PISTON SNAP RING SPRING VA a A 171 WASHER SNAP RING SNAP RING
124. he piston Inspect the piston rings for movement by pressing the rings The rings should be able to move in its groove with out catching PISTON PIN CLIP NEN 11 4 CYLINDER PISTON Spread each piston ring and remove it by lifting it up at a point just opposite the gap CAUTION Do not damage the piston ring by spreading the ends too far Becareful not to damage the piston when the piston ring removal Clean carbon deposits from the piston NOTE Clean carbon deposits from the piston ring grooves with a ring that will be discarded Never use a wire brush it will scratch the grooves INSPECTION Inspect the piston for cracks or other damage Inspect the ring grooves for excessive wear and carbon build up Measure each piston O D NOTE Take measurements 6 5 mm 0 36 in from the bottom and 90 to the piston pin hole SERVICE LIMIT 63 40 mm 2 496 in Calculate the cylinder to piston clearance Take the maxi mum reading to determine the clearance Cylinder 1 0 page 11 4 SERVICE LIMIT 0 90 mm 0 035 in Measure each piston pin 1 0 in an X and Y axis Take the maximum reading to determine I D SERVICE LIMIT 15 055 mm 0 5927 in 11 5 CYLINDER PISTON Measure the piston pin O D at three points SERVICE LIMIT 63 40 mm 2 496 in Calculate the piston to piston pin clearance SERVICE LIMIT 0 04 mm 0 0016 in Measure the connecting rod small
125. head may cause warping Be careful not to damage the mating surface Support the cylinder head and drive the valve guides out of the cylinder head from the combustion chamber side TOOL Valve guide driver 3 8 mm 07GMD KT70100 While the cylinder head is still heated drive new valve guides in the cylinder head from the camshaft side until 2 the exposed height following dimensions amp TOOL guide driver 3 8 mm 07GMD KT70100 VALVE GUIDE PROJECTION IN 15 5 mm 0 61 in EX 13 1 mm 0 52 in Let the cylinder head cool to room temperature Ream the new valve guides TOOL Valve guide reamer 07 JMH 20100 VALVE GUIDE REAMER N Take care not to tilt or lean the reamer in the guide while reaming Otherwise the valve is installed slanted that causes oil leaks from the stem seal and improper valve seat contact and results in the valve seat refacing not a able to be performed Insert the reamer from the combustion chamber side of the head and always rotate the reamer clockwise Use cutting oil the reamer during this operation Clean the cylinder head thoroughly to remove any metal N particles after reaming and reface the valve seat CYLINDER HEAD VALVES VALVE SEAT INSPECTION 7C Clean the intake and exhaust valves thoroughly to remove the carbon deposits Apply light coating of Prussian Blue to
126. hock absorber assembly for leaks or dam age Tighten all nut and bolts Support the motorcycle securely and raise the rear wheel off the ground Check for worn swingarm bushings by grabbing the rear wheel and attempting to move the wheel side to side Replace the swingarm if any looseness is noted 3 20 MAINTENANCE Check for worn wheel bearing by grabbing the rear wheel and attempting to move the wheel side to side Replace the bearings if any looseness is noted page 15 6 NUTS BOLTS FASTENERS Check that all chassis nuts and bolts are tightened to their correct torque values page 1 13 Check that all safety clips hose clamps and cable stays are in place and properly secured WHEELS TIRES E NOTE Tire pressure should be checked when the tires are COLD RECOMMENDED TIRE PRESSURE AND TIRE SIZE Driver only Front 200 2 00 kgf cni 29 psi Rear 200 2 00 kgf cni 29 psi Driver and passenger Front 200 kpa 2 00 kgf cr 29 psi Rear 225 kpa 2 25 33 psi Check the tires for cuts embedded nails or other damage Check the front and rear wheels for trueness refer to section 14 and 15 Check the tread depth Replace the tires when the tread depth reaches the fol lowing limits MINIMUM TREAD DEPTH To the indicator 3 21 MAINTENANCE STEERING HEAD BEARINGS NOTE Check that the control cables do not interfere with handle bar rotation
127. ighten the bolts securely CLUTCH GEARSHIFT LINKAGE Connect the clutch cable end to the lifter arm Adjust the clutch lever free play page 3 2 CLUTCH CABLE END Install the under cowl page 2 3 Fill and bleed the cooling system page 6 5 Fill the recommended engine oil page 3 10 8 14 ALTERNATOR ST CLUTCH SYSTEM DIAGRAM 4 OS KON NIE 694 gt T A NS M ERI X NP oN WO RO B 2 9 0 9 ALTERNATOR STARTER CLUTCH SERVICE INFORMATION STARTER CLUTCH TROUBLESHOOTING FLYWHEEL INSTALLATION LEFT CRANKCASE COVER REMOVAL LEFT CRANKCASE COVER ALTERNATOR ST ATOR INSTALLATION FLYWHEEL REMOVAL SERVICE INFORMATION GENERAL This section covers service of the alternator stator flywheel and starter clutch All service be done with the engine installed in the frame Refer to section 17 for alternator stator inspection Refer to section 19 for starter motor servicing TORQUE VALUES Stator bolt 10 1 0 kgf m 7 Ibf ft Apply a locking agent to the threads Flywheel nut 64 N m 6 5 kgf m 47 Ibf ft Apply oil to the threads and seating surface Starter clutch bolt 30 N m 3 1 kgf m 22 Ibf ft Apply a locking agent to the threads Ignition pulse generator bolt 5 2 N m 0 53 kgf m 3 8 Ibf ft Apply a locking agent to the threads TOOLS Flywheel holder 07725 0040000 Rotor puller 07 00100 TROUBLESHOOTING Engine do
128. is frequently burned when the engine is started Faulty lighting and or dimmer switch Faulty bulb Faulty alternator lighting coil section 17 Faulty regulator rectifier section 17 Loose or poorly connected connector Headlight beam does not shift when Hi Lo switch is op erated Burned bulb Faulty dimmer switch Loose or poorly connected connector 20 2 LIGHTS METERS SWITCHES BULB REPLACEMENT HEADLIGHT Remove the dust cover While pushing in turn the bulb socket counterclockwise to remove it Remove the headlight bulb and replace it with a new one Install the headlight bulb in the reverse order of removal NOTE Install the dust cover tightly against the headlight housing MARK SOCKET with the mark facing up FRONT TURN SIGNAL LIGHT Remove the screws and upper cowl lid page 2 5 Turn the bulb socket counterclockwise and remove it Remove the bulb and replace it with a new one installation is in the reverse order of removal REAR TURN SIGNAL AND TAIL BRAKE LIGHT AND LICENSE LIGHT Remove the passenger seat page 2 2 Disconnect the rear combination light 6P connector Remove the screw and rear combination meter CONNECTOR SOCKET 20 3 LIGHTS METERS SWITCHES REAR TURN SIGNAL LIGHT Turn the bulb socket counterclockwise and remove it Remove the turn signal bulb and replace it with a new one TAIL BRAKE LIGHT Turn the bulb socket
129. is removed Remove the compression spring and diaphragm vacuum piston from the carburetor body Remove the needle holder Remove the spring jet needle and washer from the vacuum piston Check the following jet needle for stepped wear vacuum piston for wear or damage diaphragm for pin holes deterioration or damage NOTE Air can leak out of the vacuum chamber if the diaphragm is damaged in any way even if only a pin hole 5 6 DIAPHRAGM VACUUM PISTON i p SPRING F 1 a J HOLDER DIAPHRAGM VACUUM PISTON J ET NEEDLE HOLDER 7 WASHER SPRING Throttle cable stay Remove the two screws and throttle cable stay Air cut off valve Remove the two screws Remove the valve cover spring O ring and diaphragm NOTE The air cut off valve cover is under spring pressure Check the following diaphragm for pin holes deterioration or damage spring for deterioration needle of diaphragm for wear air passages for clogging Starting enrichment SE valve cover Remove the two screws wahsers Remove the valve cover and O ring FLOAT CHAMBER Remove the three screws and float chamber cover FUEL SYSTEM STAY SCREWS SCREWS O RING 5 7 FUEL SYSTEM Remove the float pin float and float valve FLOAT Check the float for damage or fuel in the float Check the following valve and valve
130. iter 0 20 US qt 0 17 Imp qt Reserve tank 0 24 liter 0 06 US qt 0 05 Imp 40 Radiator cap relief pressure 108 kPa 1 1 kgf cm 16 psi 69 5 72 5 157 1 162 5 F FUEL SYSTEM Fully open 80 C 176 F Valve lift 3 5 mm 0 14 in minimum Unit mm Lever free play 10 20 3 8 13 16 Clutch 37 6 1 48 36 6 1 44 Disc thickness 3 1 0 12 292 308 0115 0170 7 260 0 02 CLUTCH GEARSHIFT LINKAGE ITEM Patewarpage 02008 O D 22 959 22 980 0 9039 0 9047 22 93 0 903 LD 16 991 17 009 0 6689 0 6696 17 04 0 671 23 000 23 013 0 9055 0 9060 23 06 0 908 Mainshaft 0 0 at clutch outer guide 16 996 16 984 0 6680 0 6687 16 935 0 6667 Outer guide 1 6 GENERAL INFORMA TION CYLINDER HEAD V ALVES Unit mm in ITEM STANDARD SERVICE LIMIT 1 370 kpa 13 9 kgf cm 197 7 psi at 680 min rpm Cylinder compression Cylinder head warpage Valve clearance Lin Valve stem O D IN X X X X 0 16 0 03 0 006 0 001 0 25 0 03 0 010 0 001 0 05 0 002 Valve valve guide 3 775 3 790 0 1486 0 1492 3 7 0 15 3 765 3 780 0 1482 0 1488 3 7 0 15 IN 0 010 0 037 0 0004 0 0015 0 075 0 0029 E Valve guidel D IN EX 3 800 3 812 0 1496 0 1501 3 89 0
131. ith the temperature and loads of the genera tor LIGHTING OUTPUT NOTE Measure the voltage with the headlight wire connectors connected Connect the voltmeter positive probe to the headlight connector Blue terminal and negative probe to the Green wire terminal Start the engine and light switch is H position and the dimmer switch is Hi position and read the voltage REGULATED VOLTAGE 12 1 13 1 V at 5 000 rpm POSITIVE PROBE 17 6 CHARGING SYSTEM CURRENT LEAKAGE INSPECTION Turn the ignition switch off and disconnect the battery negative cable from the battery Connect the ammeter positive probe to the ground cable and the ammeter negative probe to the battery negative terminal With the ignition switch off check for current leakage NOTE When measuring current using a tester set it to a high range and then bring the range down to an appropri ate level Current flow higher than the range selected may blow out the fuse in the tester While measuring current do notturn the ignition switch ON A sudden surge of current may blow out the fuse in the tester SPECIFIED CURRENT LEAKAGE 0 1 mA max f current leakage exceeds the specified value a shorted circuit is likely Locate the short by disconnecting connections one by one and measuring the current ALTERNATOR INSPECTION NOTE It is not necessary to remov
132. ive chain adjusters into the swingarm X 4 ADJUSTERS INSTALLATION Install the swingarm onto the frame Install the swingarm pivot bolt to the frame from the left side Temporarily tighten the swingarm pivot nut Install the chain cover to the swingarm by aligning the chain cover boss with the groove on the swingarm CHAIN COVER REAR WHEEL SUSPENSION Install and tighten the bolts securely Tighten the shock absorber lower mounting bolt and nut to the specified torque TORQUE 44 4 5 kgf m 33 Ibf ft Install the brake hose guide and tighten the screw securely SL us CALIPER BRACKET ASSEMBLY 9 4 4 r Install the rear brake caliper bracket assembly on the swingarm aligning the siot on the bracket with boss on the swingarm Install the rear wheel page 15 9 then place the motor cycle on level ground Tighten the swingarm pivot nut to the specified torque TORQUE 88 N m 9 0 kgf m 65 Ibf ft Install the pivot caps 15 14 BRAKE SYSTEM A 34 N m 3 5 kgf m 25 Ibf ft EN Oe 30 N m 3 1 kgf m 22 Ibf ft 34 3 5 kgf m 25 Ibf ft 16 BRAKE SYSTEM SERVICE INFORMATION REAR MASTER CYLINDER TROUBLESHOOTING 16 2 FRONT BRAKE CALIPER 16 16 BRAKE FLUID REPLACEMENT REAR BRAKE CALIPER 16 19 AIR BLEEDING 163 BRAKE PEDAL 16 22 BRAKE PAD DISC 16 5 FRONT MASTER CYLINDER SERVICE INFORMATION GENERAL Keep grease off of
133. ks For battery remaining in a stored motorcycle disconnect the negative battery cable from the battery terminal The battery can be damaged if overcharged or undercharged or if left to discharge for long periods These same conditions contribute to shortening the life span of the battery Even under normal use the performance of the battery deteriorates after 2 3 years Battery voltage may recover after battery charging but under a heavy load battery voltage will drop quickly and eventually the battery will be completely discharged For this reason the charging system is often suspected to be the problem Battery overcharge often results in problems in the battery itself which may appear to be an overcharge symptom If one of the battery cells is shorted and the battery voltage does not increase the regulator rectifier supplies excess voltage to the battery Under these conditions the electrolyte level drops quickly EH Before troubleshooting the charging system check for proper use and maintenance of the battery Check if the battery is frequently under a heavy load such as having the headlight and taillight ON for long periods of time without riding the motorcycle The battery will self discharge when the motorcycle is not use For this reason charge the battery every two weeks to prevent sulfation from forming When checking the charging system always follow the steps in the troubleshooting flow chart page 17 3 Alternat
134. lant through the filler opening up to filler neck Fill the reserve tank to the upper level line Bleed air from the system as follows 1 Shift the transmission into neutral SIPHON TUBE RESERVE TANK Start the engine and let it idle for 2 3 minutes 2 Snap the throttle 3 4 times to bleed air from the sys tem 3 Stop the engine and add coolant up to the filler neck Reinstall the radiator cap 4 Check the level of coolant in the reserve tank and fill to the upper level if it is low Install the following right middie cowl page 2 4 under cowl page 2 5 6 5 COOLING SYSTEM THERMOSTAT REMOVAL Drain the coolant page 6 5 Remove the following fuel tank page 5 3 air cleaner housing page 5 4 Remove the two bolts and thermostat housing cover Remove the thermostat from the housing NOTE The thermostat may be damaged if dropped or conflicted to shock If dropped or conflicted inspect the thermostat and re place if necessary NN THERMOSTAT Fa INSPECTION Wear insulated gloves and adequate eye protection Keep flammable materials away from the electric heat ing element NOTE Donotlet the thermostat or thermometer touch the pan or you will get false readings Replace the thermostat if valve stays open at room tem perature or if it responds at temperatures other than those specified Visually inspect the thermostat for
135. le tapping them at several locations with a soft hammer Do not ply the crankcase halves Remove the dowel pins Pull the fork shaft and remove it from the shift forks Remove the shift drum and shift forks Remove the mainshaft and countershaft as an assembly 12 4 TRANSMISSION Disassemble the mainshaft and countershaft INSPECTION Gears Check the gear dogs dog holes and teeth for damage or excessive wear Measure the D of each gear SERVICE LIMITS M5 6 17 08 mm 6 724 in C1 18 07 mm 0 711 in C2 23 09 mm 0 909 in Bushings Check the bushings for wear or damage Measure the O D of each bushing SERVICE LIMITS C1 17 9 mm 0 70 in C2 22 9 mm 0 90 in Measure the I D of each bushing SERVICE LIMITS C1 18 10 mm 0 713 in C2 20 10 mm 0 791 in Mainshaft Countershaft Check the spline grooves and sliding surfaces for abnor mal wear or damage Measure the O D of the mainshaft and countershaft at the gear and bushing sliding areas SERVICE LIMITS Mainshaft at M5 gear 16 93 mm 0 067 in Countershaft at C1 gear bushing 14 90 mm 0 587 in at C2 gear bushing 19 92 mm 0 784 in MAINSHAFT COUNTERSHAFT TENE SEER 4 C2 BUSHING C1 BUSHING 12 5 TRANSMISSION Calculate the gear to bushing gear to shaft and bushing to shaft clearance SERVICE LIMITS Gear to Bushing C1 C2 0 10 mm 0 004 in Gear to Shaft M5
136. lifter arm then install the clutch cable to the clutch cable guide GUIDE Install the radiator hoses and tighten the band screws b Lr X RADIATOR HOSES D 1 2 Install the gearshift arm by adjusting the change pedal height as shown Install and tighten the gearshift arm pinch bolt LC 43 mm 1 7 in 7 7 ENGINE REMOV AL INST ALLATION Connect the neutral switch and alternator connectors Connect the vacuum tube to the PAIR control valve and air injection hose to the PAIR check valve cover Install the following starter motor terminal and ground cable page 19 9 carburetor page 5 13 air cleaner housing page 5 4 fuel tank page 5 3 left middle cowl page 2 4 spark plug cap page 3 8 exhaust system page 2 7 Fill and bleed the cooling system page 6 5 Adjust the clutch lever free play page 3 21 CLUTCH GEARSHIFT LINKAGE 74 N m 7 5 kgf m 54 Ibf ft LA WA AO SANUS h yy PA Qe de 22 t Ti D Sour 2 12 N m 1 2 kgf m 9 Ibf ft 52 EN jS 3 e WAS 12 N m 1 2 kgf m 9 Ibf ft S 8 CLUTCH GEARSHIFT LINKAGE SERVICE INFORMATION GEARSHIFT LINKAGE TROUBLESHOOTING PRIMARY DRIVE GEAR RIGHT CRANKCASE COVER CLUTCH LIFTER ARM INSTALLATION REMOVAL RIGHT CRANKCASE COVER CLUTCH INSTALLATION SERVICE INFORMATION GENERAL This section covers service of the clutch and g
137. ling the front wheel fit the brake disc care fully between the brake pads to avoid damaging the pads GROOVE STOPPER Install and tighten the axle nut to the specified torque AXLE NUT y TOROUE 59 N m 6 0 kgf m 43 Ibf ft Insatll and connect the speedometer cable to the speed ometer gear box securely y d SPEEDOMETER CABLE FORK REMOVAL FOR sor MED Remove the following front wheel page 14 8 front fender page 2 4 handlebars page 14 3 brake caliper page 16 6 Loosen the fork bolts but do not remove it Loosen the fork top pinch bolts pa er EN TOP PINCH BOLT 14 12 FRONT WHEEL SUSPENSION STEERING Loosen the fork bottom pinch bolts and remove the fork pipe DISASSEMBLY Carefully remove the fork bolt The fork bolt is under spring pressure Use care when removing it and wear eye and face protection Remove the spring collar spring seat Remove the fork spring Pour out the fork fluid by pumping the fork pipe several times FORE BOLT SPRING COLLAA 14 13 FRONT WHEEL SUSPENSION STEERING Remove the dust seal and stopper ring DUST SEAL STOPPER RING Hold the fork slider in a vise with piece of woods or shop 7 towel d Remove the fork socket bolt and sealing washer m J NT If the socket bolt turn together with the fork piston tem porarily instal
138. ll the carburetor into the insulator by aligning the carburetor boss with insulator boss Tighten the insulator band screw Check the starting enrichment SE valve for scoring P scratches or wear WASHER Check the seat at the tip of the SE valve for stepped wear w Replace the SE valve set if necessary Installation is in the reverse order of removal After the installation check for the smooth operation of the choke lever page 3 5 Connect the throttle cable end to the throttle drum and tighten the adjusting nut 5 13 FUEL SYSTEM Connect the air injection hose to the cylinder head cover Install the PAIR control valve and tighten the bolt Install the following air cleaner housing page 5 4 fuel tank page 5 3 Adjust the throttle grip free play page 3 4 PILOT SCREW ADJ USTMENT IDLE DROP PROCEDURE NOTE The pilot screw is factory pre set and no adjustment is necessary unless the carburetor is overhauled or the pilot screw is replaced e Usea tachometer with graduations of 50 rpm or smaller that will accurately indicate a 50 min rpm change PILOT SCREW 1 Turn the pilot screw until it seats lightly then back it out to the specification given This is an initial setting prior to the final pilot screw adjustment CAUTION Damage to the pilot screw seat will occur if the pilot screw is tighten against the seat V
139. magnet The shims be easily removed with a tweezers or magnet 10 6 CYLINDER HEAD VALVES Remove the cylinder head bolts Loosen the cylinder head nuts in a crisscross pattern in 2 to 3 steps and remove them and washers Remove the cylinder head Remove the gasket and dowel pins CAM CHAIN TENSIONER LIFTER REMOVAL Remove the two bolts and cam chain tensioner lifter INSPECTION Remove the tensioner lifter plug Check the lifter operation The tensioner shaft should not go into the body when it is pushed When it is turned clockwise with a screwdriver the tensioner shaft should be pulled into the body The shaft spring out of the body as soon as the screwdriver is released 10 7 CYLINDER HEAD VALVES Make a tensioner shaft stopper tool out of a thin piece of steel 0 8 mm thick using the diagram INSTALLATION Turn the tensioner shaft clockwise with the stopper tool to retract the tensioner then insert the stopper fully to hold the tensioner in the fully retracted position STOPPER TOOL Install a new gasket on the cam chain tensioner lifter Install the tensioner lifter into the cylinder and tighten the mounting bolts LIFTER PLUG Remove the stopper tool from the tensioner lifter Apply oil to the new O ring Install the lifter plug with a new O ring and tighten it TORQUE 4 2 N m 0 43 kgf m 3 1 Ibf ft CYLINDER HEAD DISASSEMBLY L
140. ment 07JME KY20100 Tapet hole protector 07JMG KY20100 VALVE SPRING COMPRESSOR Tap the stems gently with two plastic hammer to firmly seat the cotters PLASTIC HAMMERS CAUTION Support the cylinder head above the work bench surface to prevent valve damage Apply coolant to the new O ring and install it to the radiator hose joint Install the radiator hose joint to the cylinder head and tighten the bolt Connect the vacuum tubes Install the carburetor insulator to the cylinder head by aligning the insulator groove with cylinder head boss and tighten the insulator band screw A INSULATOR a VACUUM TUBES 10 18 CYLINDER HEAD VALVES CYLINDER HEAD INSTALLATION Clean any gasket material from the cylinder mating sur faces NOTE Do not allow dust and dirt to enter the engine Make sure that the cam chain guide bosses are in the grooves of the cylinder Install the dowel pins and new gasket V NUTS WASHERS ar BOLTS Route the cam chain through the cylinder head and install the cylinder head onto the cylinder Apply oil to the threads and seating surface of the four nuts and install them and washers Tighten the nuts to the specified torque in the specified sequence as shown TORQUE 30 N m 3 1 kgf m 22 Ibf ft Install and tighten the two bolts Install the valve shims in their original locations Coat the outer surfaces of the v
141. ment point Piston piston rings IN mark facing toward the intake side 63 47 63 49 2 4988 2 4996 63 40 2 496 6 5 0 36 from bottom of skirt BE 15 002 15 008 0 5960 0 5909 Piston O D 14 994 15 000 0 5903 0 5906 Piston to piston pin clearance 0 002 0 014 0 0001 0 0006 0 04 0 0016 0 015 0 050 0 0006 0 0020 0 05 0 20 0 002 0 008 0 15 0 30 0 004 0 010 0 7 0 030 Oil side rail 0 20 0 70 0 008 0 028 1 1 0 04 0 01 0 04 0 0004 0 0016 0 90 0 035 15 010 15 028 0 5909 0 5917 15 09 0 594 0 010 0 034 0 0004 0 0013 0 075 0 0030 Piston pin bore 1 0 Piston ring to ring groove clearance Piston ring end gap Cylinder to piston clearance Connecting rod small end I D Connecting rod small end to piston pin clearance 11 1 CYLINDER PISTON TROUBLESHOOTING Compression too low hard starting or poor perfor mance at low speed Leaking cylinder head gasket Worn stuck or broken piston ring Worn or damaged cylinder and piston Compression too high overheating or knocking Excessive carbon built up on piston or combustion chamber Excessive smoke Worn cylinder piston or piston rings Improper installation of piston rings Scored or scratched piston or cylinder wall Abnormal noise piston Worn piston pin
142. might be measured Check cylinder compression and check that the spark plug is installed correctly Disconnect the spark plug cap from the spark plug page 3 6 Remove the fuel tank page 5 3 Connect a good known spark plug to spark plug cap and ground the spark plug to the cylinder as done in a spark test DIGITAL MULTIMETER PEAK VOLTAGE ADAPTOR ET GOOD KNOWN SPARK PLUG 18 3 IGNITION SYSTEM With the ignition coil primary wire connected connect the peak voltage adaptor or Imrie diagnostic tester probe to PRIMARY TERMINAL the ignition coil primary wire terminal and ground Black Yellow terminal Body ground Turn the ignition switch ON Crank the engine with the starter motor and read ignition coil primary peak voltage PEAK VOLTAGE 100 V minimum WSs Avoid touching the spark plug and tester probes to pre vent electric shock N POSITIVE PROBE NEGATIVE PROBE If the peak voltage is abnormal check an open circuit or poorly connected connectors in Black Yellow wire If not defects are found in the harness refer to the trou bleshooting chart on page 18 2 Install the removed parts in the reverse order of removal IGNITION PULSE GENERATOR PEAK VOLTAGE NOTE Check cylinder compression and check that the spark plug is installed correctly Remove the fuel tank page 5 3 Disconnec
143. n AUN S il a N A s97 gt CHOKE CABLE THROTTLE CABLE RIGHT HANDLEBAR SWITCH WIRE MAIN WIRE HARNESS GENERAL INFORMA TION IGNITION CONTROL MODULE ICM FUEL TUBE IGNITION COIL FUEL UNIT 3P CONNECTOR FUEL TANK CARBURETOR AIR VENT TUBE OVERFLOW TUBE CHOKE CABLE RADIATOR OVERFLOW TUBE NEUTRAL SWITCH CONNECTOR 4P CONNECTOR ALTERNATOR FUEL AUTO VALVE VACUUM TUBE CARBURETOR DRAIN TUBE 1 19 GENERAL INFORMA TION SUB AIR CLEANER REAR BRAKE LIGHT SETAE CENNE C TOB RADIATOR SIPHON TUBE THROTTLE CABLE 2 LA gt 5 27707 r THERMO SWITCH SPARK PLUG WIRE STARTER MOTOR CABLE RADIATOR OVERFLOW TUBE GROUND CABLE CRANKCASE BREATHER TUBE CLUTCH CABLE 1 20 GENERAL INFORMA TION LEFT HANDLEBAR SWITCH RIGHT HANDLEBAR SWITCH 2P CONNECTOR 3P CONNECTOR IGNITION SWITCH 9 2 LEFT HANDLEBAR SWITCH 9P CONNECTOR Ng E SES M 5240 V h Vo K G COOLING FAN MOTOR liv web 2P CONNECTOR METTLE LAN O CS Se SS Az 493 STEPA CHOKE CABLE PAIR CONTROL VALVE FUEL AUTO VALVE VACUUM TUBE LL THROTTLE CABLE P FUEL TUBE RSR Raa lh THERMO SENSOR BAN WIRE CARBURETOR AIR SUB AIR CLEANER VENT TUBE Sisi 3 ay G REAR BRAKELIGHT SWITCH 2P CONNECTOR 1 21 GENERAL INFORMA TION REAR BR
144. n or equivalent DRIVE TRAIN Clutch system Multi plate wet Clutch operation system Mechanical type Transmission Constant mesh 6 speed Primary reduction 3 260 75 23 Final reduction 2 933 44 15 Gear ratio 3 083 37 12 1 941 33 17 GENERAL Cont d 1 500 30 20 1 227 27 22 1 041 25 24 0 923 24 26 Gearshift pattern Left foot operated return system 1 2 3 4 5 6 ELECTRICAL Ignition system Condenser Discharged Ignition CDI Starting system Electric starter motor Charging system Single phase output alternator Regulator rectifier SCR shorted single phase half wave rectification Lighting system Alternator 1 5 GENERAL INFORMA TION Unit mm LUBRICATION SYSTEM ITEM STANDARD SERVICE LIMIT Engine oil capacity 1 0 liter 1 06 US qt 0 88 Imp qt At disassembly 1 3 liter 1 37 US qt 1 14 Imp qt D 55 Recommended engine oil Honda 4 stroke oil or equivalent motor oil API service classification SE SF or SG Viscosity SAE 10W 30 Oil pump rotor 0 20 0 008 Body clearance 0 150 0 210 0 0059 0 0083 0 26 0 010 Side clearance 0 050 0 100 0 0020 0 0040 0 15 0 006 SPECIFICATIONS Carburetor identification number VK6AA Pilot screw opening See page 5 14 Float level 13 mm 0 5 in Idie speed 1 400 100 min rpm Throttle grip free play 2 6 mm 1 12 1 4 in COOLING SYSTEM ITEM SPECIFICATIONS Coolant capacity Radiator and engine 0 76 l
145. n build up before checking the valve guide Alwaysrotate the reamer clockwise never counterclock wise when installing removing and reaming TOOL Valve guide reamer 07JMH 20100 Measure and record each valve guide I D with a ball gauge or inside micrometer SERVICE LIMIT IN EX 3 89 mm 0 153 Calculate the stem to guide clearance SERVICE LIMIT IN 0 075 mm 0 0029 in EX 0 085 mm 0 0033 in NOTE Ifthe stem to guide clearance exceeds the service limit determine if a new guide with standard dimensions would bring the clearance within tolerance If so replace the guides as necessary and ream to fit Ifthe stem to guide clearance still exceeds the service limit with new guides replace the valve and guide Reface the valve seat whenever new valve guides are installed 10 12 CYLINDER HEAD VALVES VALVE GUIDE REPLACEMENT EB non Chill the valve guides in the freezer section of a refrigera a e tor for about an hour 4 3 RI Heat the cylinder head to 130 C 140 C 275 F 290 F 27 Wear insulated gloves to avoid burns when handling the heated cylinder head with a hot plate or oven Do not heat the cylinder head Sree esse beyond 150 C 300 Use temperature indicator sticks available from welding supply stores to be sure the cylin der head is heated to the proper temperature CAUTION e Using a torch to heat the cylinder
146. n the bolts to the specified torque TOOL Flywheel holder 07725 0040000 TORQUE 30 N m 3 1 kgf m 22 Ibf tt Install the starter driven gear while turning it counterclockwise Make sure that the starter driven gear turns counterclock wise smoothly and does not turn clockwise Install the flywheel page 9 7 CLUTCH OUTER D SPRAG CLUTCH FLYWHEEL HOLDER d sors Waal DRIVEN GEAR P4 9 6 ALTERNATOR ST ARTER CLUTCH Apply engine oil to the starter reduction gear both journal Install the starter reduction gear 7 REDUCTION GEAR 4 7 V FLYWHEEL INSTALLATION 4 Mist Clean any oil from the tapered portions of the crankshaft E d a and flywheel 3 S 4 4 Install the woodruff key in the crankshaft key groove Install the flywheel on the crankshaft aligning the key way with the woodruff key Apply oil to the flywheel nut threads and seating surface and install the washer and nut FLYWHEEL HOLDER Hold the flywheel with the special tool and tighten the nut to the specified torque 4 TOOL Flywheel holder 07725 0040000 TORQUE 64 N m 6 5 kgf m 47 Ibf ft Install the left crankcase cover page 9 8 ALTERNATOR ST ARTER CLUTCH LEFT CRANKCASE COVER INSTALLATION Install the dowel pin and a new gasket Install the left crankcase cover Install the washer and bolts and tighten them securely Install the drive sprocket cover page 7
147. n using a commercially available brake bleeder follow the manufacturer s operating instructions BRAKE FLUID DRAINING Make sure that the master cylinder is parallel to the ground before removing the reservoir cover Remove the screws reservoir cover set piate and dia phragm Connect a bleed hose to the bleed valve Loosen the bleed valve and pump the brake lever pedal Stop operating the brake when no more fluid flows out of the bleed valve BRAKE FLUID FILLING BLEEDING CAUTION Do not mix different types of fluid since they are not com patible Fill the reservoir with DOT 3 or DOT 4 brake fluid to the upper level BRAKE SYSTEM FRONT SET PLATE DIAPHRAGM SCREWS TL SET PLATE DIAPHRAGM UPPER LEVEL UPPER LEVEL BRAKE SYSTEM Connect a commercially available brake bleeder to the bleed valve Pump the brake bleeder and loosen the bleed valve Add brake fluid when the fluid level in the reservoir is low wa BLEED VALVE NOTE Check the fluid level often while bleeding the brake to prevent air from being pumped into the system When using a brake bleeding tool follow the manu facturer s operating instructions Repeat the above procedures until air bubbles do not ap pear in the bleed tube NOTE If air is entering the bleeder from around the bleed valve threads seal the threads with teflon tape Close the bleed v
148. ns may be forced out with excessive force that could cause injury Push the dust seal and piston seal in and lift them out PISTON SEAL CAUTION careful not to damage the piston sliding surface Clean the seal grooves caliper piston and caliper piston sliding surface with clean brake fluid DUST SEAL INSPECTION Check the caliper cylinder and pistons for scoring scratches or damage Measure the caliper cylinder D SERVICE LIMIT 32 090 mm 1 2634 Measure the caliper piston O D SERVICE LIMITS 31 94 mm 1 257 in 16 20 BRAKE SYSTEM ASSEMBLY BRACKET Coat the new piston seal and dust seal with clean brake fluid and install them in the seal grooves of the caliper Apply brake fluid to the caliper piston and install it into the caliper cylinder with the opening towards the pads If the caliper and bracket pin boots are hard or deterio rated replace them with new ones Apply silicone grease to the bracket pin boots and bracket pins and install them Make sure the boots are securely seated into the pin grooves Assemble the caliper bracket and caliper body PISTON SEAL PISTON 71 BRACKET BOOTS Su io T ox BRAKE SYSTEM Check the pad spring for damage and replace it if neces sary PAD SPRING Install the pad spring onto the caliper body INSTALLATION Install the rear brake caliper bracket assembly o
149. nt flows do not use a thin wire Starter motor does not turn Starter motor turns No clicks Faulty starter motor Loose or disconnected starter motor cable Faulty starter relay switch Abnormal Faulty neutral switch Faulty diode Faulty clutch switch Loose or poor connector contact Opencircuit in wire harness Check the starter relay switch ground line page 19 10 Normal To page 19 3 19 2 ELECTRIC STARTER From page 19 2 Check the starter relay voltage page 19 10 Abnormal Faulty ignition switch Blown fuse Faulty starter switch Loose or poor connector contact Normal Opencircuit in wire harness Check the starter relay switch operation Abnormal Faulty starter relay switch page 19 10 Starter motor turns slowly Weak battery Poorly connected battery cable Poorly connected starter motor cable Faulty starter motor Starter motor turns but engine does not turn Faulty starter clutch section 8 Starter relay switch Clicks but engine does not turn over Crankshaft does not turn due to engine problem Faulty starter reduction gear section 9 19 3 ELECTRIC STARTER STARTER MOTOR REMOVAL Always turn the ignition switch OFF before servicing the starter motor The motor could suddenly start causing serious injury Remove the under cowl page 2 3 Remove the rubber cap
150. nto the swingarm by aligning the bracket slot with the boss on the swingarm Install the rear wheel page 15 9 Install the brake pads page 16 5 Temporarily install the brake hose eyelet joint to the caliper body with new sealing washers and bolts Push the brake hose eyelet joint to the stopper on the caliper then tighten the bolt to the specified torque TORQUE 34 N m 3 5 kgf m 25 Ibf ft Fill and bleed the rear brake hydraulic system page 16 3 BRAKE PEDAL REMOVAL Remove the mounting bolts and right main step holder Remove the brake light switch return spring Remove the cotter pin and joint pin COTTER PIN Remove the cotter pin washer return spring and brake Ed JOINT PIN pedal gt A COTTER PIN WASHER BRAKE PEDAL 16 22 BRAKE SYSTEM INSTALLATION Apply grease to the pedal pivot sliding surface and install the brake pedal into the right main step holder Secure the brake pedal with the washer and a new cotter pin Install the joint pin and new cotter pin Install the brake light switch spring to the return spring as shown Install the right main step holder and mounting bolts Tighten the bolts to the specified torque TORQUE 27 N m 2 8 kgf m 20 Ibf ft Ex SPRING COTTER PIN B JOINT PIN COTTER PIN WASHER RIGHT MAIN STEP HOLDER 16 23 5 5 SYSTEM DIAGRAM REGULATOR RECTIFIER BATTERY
151. o hold the tensioner in the fully retracted position Remove the cam sprocket bolts NOTE Be careful not to let the sprocket bolts fall into the crank case eornm T MARK CYLINDER HEAD VALVES Remove the cam sprockets off the camshaft flanges Remove the sprockets from the cam chain CAM CHAIN CAM SPROCKETS A Attach a piece of wire to the cam chain to prevent it from med falling into the crankcase zl Remove the two bolts and cam chain guide Inspect the cam chain slipper surface of the cam chain guide for wear or damage and replace if necessary i 4 SF RIZ X CAM CHAIN GUIDE Remove the camshaft holder bolts camshaft holders dowel pins and camshafts NOTE Do not forcibly remove the dowel pins from the camshaft holders CYLINDER HEAD REMOVAL Drain the coolant page 6 5 Remove the radiator page 6 8 Remove the following camshaft page 10 5 exhaust system page 2 5 carburetor assembly page 5 4 VALVE LIFTERS x C Remove the valve lifters and shims careful not to damage the valve lifter bore Shim may stick to the inside of the valve lifter Do not allow the shims to fall into the crankcase Mark all valve lifters and shims to ensure correct reassembly in their original locations The valve lifter be easily removed with a valve lapping tool or
152. o place Place the engine into the frame and install the rear engine hanger bolts from the left side Temporarily install the rear engine hanger nuts CAUTION Be careful not to damage the frame 7 4 ENGINE REMOV AL INST ALLATION Install the engine hanger plates and four bolts and tighten the bolts Install the front engine hanger bolt and nut and tighten the nut to the specified torque TORQUE 59 N m 6 0 kgf m 43 Ibf ft ENGINE HANGER Tighten the rear engine hunger nuts to the specified torque TORQUE 59 N m 6 0 kgf m 43 Ibf ft n BOLTS NUTS 7 Install the drive sprocket onto the countershaft 5 88 Install the drive chain onto the drive sprocket DRIVE SPROCKET a Install the fixing plate and lock the plate by turning it 3 lE LX FIXING PLATE 7 5 ENGINE REMOV AL INST ALLATION Apply locking agent to the threads of the fixing plate bolts Tighten the fixing plate bolts to the specified torque TORQUE 9 8 N m 1 0 kgf m 7 Ibf ft Set the drive sprocket cover to the left crankcase Tighten the cover bolts securery BOLTS E Adjust the drive chain slack page 3 15 TN WM T REAR AXLE NUT Tighten the rear axle nut to the specified torque A TORQUE 59 N m 6 0 kgf m 43 Ibf ft ENGINE REMOV AL INST ALLATION Connect the clutch cable end to the clutch
153. of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water Remove the fuel tank page 5 3 Check the air injection hoses and pipes between the pulse secondary air injection PAIR control valve and exhaust port for deterioration damage or loose connections Make sure that the hoses are not cracked 3 14 MAINTENANCE NOTE If the hoses show any signs of heat damage inspect the PAIR check valves page 5 17 Check the air suction hose between the sub air cleaner and PAIR control valve for deterioration damage or loose connections Make sure that the hoses are not kinked pinched or cracked For PAIR control valve inspection see page 5 15 DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION Never inspect and adjust the drive chain while the engine is running Turn off the engine place the motorcycle on its side stand and shift the transmission into neutral Check the drive chain slack in the drive chain lower run er midway between the sprockets 25 35 mm 1 0 1 4 in CHAIN SLACK 25 35 mm 1 0 1 4 in ADJUSTMENT Loosen the rear axle nut Loosen both lock nuts and turn both adjusting nuts until the correct drive chain slack is obtained Make sure the index lines on the both adjusters are aligned with the rear edges of the axle slots in the swingarm Tighten both lock nuts Tighten the rear axle nut to the specified torque TORQUE 59 N m 6 0 kgf m 43 Ibf
154. on fill the crankcase with recommended oil page 3 10 and check that there are no oil leaks 4 6 FUEL SYSTEM 5 0 5 FUEL SYSTEM SERVICE INFORMATION CARBURETOR DISASSEMBLY TROUBLESHOOTING CARBURETOR ASSEMBLY FUEL TANK CARBURETOR INSTALLATION AIR CLEANER HOUSING PILOT SCREW USTMENT SUB AIR CLEANER SECONDARY AIR SUPPLY SYSTEM CARBURETOR REMOVAL SERVICE INFORMATION GENERAL Gasoline is extremely flammable and is explosive under certain conditions KEEP OUT OF REACH OF CHILDREN If the engine must be running to do some work make sure the area is well ventilated Never run the engine enclosed area The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death Run the engine in an open area or with an exhaust evacuation system in an enclosed area Work in a well ventilated area Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion CAUTION Be sure to remove the diaphragms before cleaning air and fuel passages with compressed air The diaphragms might be damaged Do not remove the sub air cleaner tube joint except the replacement Before disassembling the carburetor place an approved fuel container under the float chamber loosen the drain screw and drain the carburetor e After removing the carburetor cover the intake port of the cylinder head with shop towel to pr
155. on rings section 11 Excessive noise Cylinder Head Incorrect valve clearance Sticking valve or broken valve spring Faulty cylinder or piston section 11 Rough idle Low cylinder compression Intake air leak 10 2 CYLINDER HEAD VALVES CYLINDER COMPRESSION 0o D A if the engine must be running to do some work make sure that the area is well ventilated Never run the en gine in an enclosed area Theexhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death Warm up the engine to normal operating temperature Stop the engine Remove the spark plug page 3 6 Install the compression gauge into the spark plug hole Open the throttle all the way and crank the engine with the starter motor until the gauge reading stops rising STANDARD 1 370 kPa 13 9 kgf cm2 197 7 at 680 rpm If compression is high it indicates that carbon deposits have accumulated on the combustion chamber and or the piston crown if compression is low pour 3 5 cc 0 1 0 2 oz of clean engine oil into the cylinder through the spark plug hole and recheck the compression If the compression increases from the previous value check the cylinder piston and piston rings Leaking cylinder head gasket Worn piston ring Worn cylinder and piston If compression is the same as the previous value check the valves for leakage PP CO
156. oosen the band screw and remove the carburetor insulator Disconnect the vacuum tubes VACUUM TUBES 10 8 CYLINDER HEAD VALVES Remove the bolt radiator hose joint and O ring While compressing the valve spring with the valve spring compressor remove the valve cotters CAUTION To prevent loss of tension do not compress the valve spring more than necessary to remove the cotters TOOL Valve spring compressor 07757 0010000 Valve spring compressor attachment 07JME 20100 Tapet hole protector 07JMG KY20100 Loosen the valve spring compressor and remove the fol lowing spring retainers valve springs spring seats intake and exhaust valve valve stem seal NOTE Mark all disassembled parts to ensure correct reassem bly Remove the carbon deposits from the combustion cham ber Clean off any gasket materials from the cylinder head surface NOTE Being careful not to damage the gasket surface VALVE SPRING COMPRESSOR y NER vee CYLINDER HEAD VALVES INSPECTION Camshaft camshaft holder Remove the snap ring and right camshaft holder Measure the camshaft holder 1 0 SERVICE LIMIT 17 027 mm 0 6703 in Measure the camshaft O D Calculate the camshaft to camshaft holder clearance SERVICE LIMIT 16 960 mm 0 6677 in If the camshaft to camshaft holder clearance exceeds the service limit replace the camshaft and le
157. or piston pin hole Worn cylinder piston or piston ring Worn connecting rod small end 11 2 CYLINDER PISTON CYLINDER REMOVAL Remove the cylinder head page 10 4 Loosen the band screw and disconnect the water hose Remove the cam chain guide 4 WATER HOSE 77 Remove the cylinder Clean the top of the cylinder thoroughly CAUTION Avoid damaging the gasket surfaces Remove the dowel pins and gasket 11 3 CYLINDER PISTON INSPECTION Inspect the cylinder wall for scratches and wear Measure and record the cylinder at three levels in both the X and Y axis Take the maximum reading to determine the cylinder wear SERVICE LIMIT 63 55 mm 2 502 in Calculate the cylinder for out of round at the three levels in an X and Y axis Take the maximum reading to deter mine the out of round 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 10 mm 0 004 in BOTTOM Check the cylinder for warpage by placing a straight edge and a feeler gauge across the bolt holes as shown SERVICE LIMIT 0 05 mm 0 002 in om 65 PISTON PISTON REMOVAL NOTE Place a clean shop towel over the crankcase opening to prevent piston pin clips from falling into the crankcase Remove the piston pin clip using the pliers Remove the piston pin out and remove t
158. or servicing can be done with the engine in the frame 17 1 CHARGING SYSTEM This model comes with a maintenance free i e sealed and electrolyte filled type battery BATTERY TESTING Refer to the instructions in the Operation Manual for the recommended battery tester for details about the battery testing The recommended battery tester puts a load on the battery so that the actual battery condition of the load can be measured Recommended battery tester 210 or BATTERY MATE or equivalent CAUTION For battery charging do not exceed the charging current and time specified on the battery Using excessive current or extending the charging time may damage the battery SPECIFICATIONS ITEM SPECIFICATIONS Battery Capacity 12V 5Ah Current leakage 0 1 mA max 13 0 13 2 V Below 12 3 V 0 5Ax5 10h 2 5Ax1h 155 W 5 000 min rpm 0 2 1 00 01 080 Specific gravity Fully charged Needs charging Charging current Normal Alternator Capacity Charging coil resistance 20 C 68 F Lighting coil resistance 20 C 68 F 17 2 CHARGING SYSTEM TROUBLESHOOTING Battery is damaged or weak Remove the battery page 17 4 Check the battery condition using the recom mended battery tester incorrect Faulty battery RECOMMENDED BATTERY TESTER BM 210 or
159. ork shaft Transmission gear rotating surfaces Transmission gear shift fork grooves C1 C2 gear bushing Balancer driven gear inner surface Clutch lifter arm spindle Gearshift spindle outer surface Shift drum journal outer surface Camshaft Cam chain Camshaft holder bolt threads and seating surface Piston outer surface Piston rings Cylinder head nut threads and seating surface Valve lifter sliding surfaces Clutch disc lining surface Clutch center lock nut threads and seating surface Clutch lifter piece Crankshaft thrust surfaces Primary drive gear nut threads and seating surface Flywheel nut threads and seating surface Shift drum grooves Starter clutch rolling surface Starter reduction gear Oil pump inner and outer rotor Each bearing rotating area Each O ring whole surface Each oil seal lip Water pump shaft Each oil seal lip Multi purpose grease clutch lifter arm spindle gearshift spindle Timing hole cap threads Crankshaft hole cap threads Gearshift cam plate bolt threads Locking agent Ignition pulse generator bolt threads Mainshaft bearing setting plate bolt threads Starter clutch boit threads Camsprocket bolt threads Alternator ignition pulse generator wire grommet Liquid sealant seating surface Crankcase mating surface except the oil passage area 1 15 GENERAL INFORMA TION FRAME LOCATION Steering head bearing sliding surface Steering h
160. ot let the thermometer or thermosensor touch the pan THERMOSENSOR Temperature 50 C 122 F 120 C 248 F Resistance 133 9 178 9 2 14 9 17 3 QR Replace the sensor if it is out of specifications by more than 10 96 at any temperature listed Install the thermosensor Apply sealant to the thermosensor threads Do not apply sealant to the sensor head Connect the thermosesor connector Fill and bleed the cooling system page 6 5 CLUTCH SWITCH Disconnect the clutch switch connectors and check for continuity There should be continuity with the clutch lever applied and no continuity with it released 20 16 LIGHTS METERS SWITCHES TACHOMETER Disassemble the upper cowl page 2 5 Connect the combination meter 9P and tachometer 2P connector Checkthe continuity between the Green wire terminal and body ground There should be continuity If there is no continuity check for open circuit in the Green wire Turn the ignition switch ON and measure the voltage between the White Green and Green wire terminals There should be battery voltage If there is no voltage check for open circuit in White Green wire Start the engine and measure the voltage between the Yellow Green and Green wire terminals There should be at least 6V pulse voltage If there is no voltage check the following Yellow Green wire ignition control module IC
161. over Install and tighten the two bolts to the specified torque TORQUE 5 2 N m 0 53 kgf m 3 8 Ibf ft Install the removed parts in the reverse order of removal 5 16 COOLING SYSTEM SYSTEM FLOW PATTERN 6 0 6 COOLING SYSTEM SYSTEM FLOW PATTERN THERMOSTAT SERVICE INFORMATION RADIATOR COOLING F AN TROUBLESHOOTING RADIATOR RESERVE TANK SYSTEM TESTING WATER PUMP COOLANT REPLACEMENT SERVICE INFORMATION GENERAL CE Wait until the engine is cool before slowly removing the radiator cap Removing the cap while the engine is hot and the coolant is under pressure may cause serious scalding Radiator coolant is toxic Keep it away from eyes mouth skin and clothes coolant gets in your eyes rinse them with water and consult a doctor immediately coolant is swallowed induce vomiting gargle and consult a physician immediately coolant gets on your skin or clothes rinse thoroughly with plenty of water KEEP OUT OF REACH OF CHILDREN CAUTION Using Coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator pas sages Using tap water may cause engine damage Add coolant at the reserve tank Do not remove the radiator cap except to refill or drain the system cooling system services can be done with the engine in the frame Avoid spilling coolant on painted surfaces After servicing the system check for leaks wi
162. owl NOTE Do not damage the tabs of the upper cowl and speedom eter cable guide of the left middle cowl Installation is in the reverse order of removal RIGHT MIDDLE COWL SCREWS LEFT MIDDLE SPEEDOMETER CABLE FRONT FENDER REMOVAL INST ALLATION Remove the bolts collars front fender and stay Installation is in the reverse order of removal 2 4 FRAME BODY P ANELS EXHAUST SYSTEM UPPER COWL REMOV AL INST ALLATION Remove the middle cowl page 2 4 Disconnect the combination meter headlight turn signal light 6P and tachometer 2P connectors Remove the bolts and upper cowl as an assembly DISASSEMBL Y ASSEMBL Y INSTALLATION Remove the rear view mirrors Remove the screws and upper cowl lids Remove the two bolts and combination meter Remove the stay Remove the three screws and head light assembly Assemble is in the reverse order of removal Install the removed parts in the reverse order of removal HEADLIGHT ASSEMBLY EXHAUST SYSTEM Do not service the exhaust system while it is hot REMOVAL Remove the under cowl page 2 3 Remove the exhaust pipe joint nuts PANG a FRAME BODY PANELS EXHAUST SYSTEM Remove the muffler mounting bolt collar and mounting TD D rubber NTING RUBBER Remove the exhaust pipe mounting bolt nut washer BOLT NUT WASHER COLLAR collar and mounting rubb
163. pecial tools onto the crankshaft as shown Install the bearing to the left crankshaft by drawing it TOOLS Crankcase assembly tool assembly collar assembly shaft 07965 VM00100 07965 VM00200 Remove the crankshaft and bearing assembly from the left crankcase 1 BALANCER 4 BEARING e Locarno Si mi BEARING CRANKSHAFT E ASSEMBLY COLLAR ASSEMBLY SHAFT 13 4 CRANKSHAFT BALANCER DR VER x EN Balancer bearings Drive new barancer bearings into the right and left crank case with following tools P ATTACHMENT TOOLS Right crankcase side j Driver 07749 0010000 Attachment 37 x 40 mm 07746 0010200 ss Pilot 12 mm 07746 0040200 2 Left crankcase side gt Driver 07749 0010000 T aU 1 gt Attachment 32 x 35 mm 07746 0010100 PILOT y Ur BE ARI NG Pilot 12 mm 07746 0040200 CRANKSHAFT INSTALLATION Engage the balancer and crankshaft aligning the index lines on the balancer driven and drive gears as shown and set the crankshaft and balancer together into the right crankcase BALANCER CRANKSHAFT 13 5 FRONT WHEEL SUSPENSION STEERING 88 N m 9 kgf m 65 Ibf ft 30 N m 3 1 kgf m 22 Ibf ft 14 0 14 FRONT WHEEL SUSPENSION STEERING SERVICE INFORMATION 14 1 FRONT WHEEL 14 8 TROUBLESHOOTING 14 2 FORK 14 12 HANDLEBAR
164. ply compressed air to the fluid inlet to get the piston out PAD SPRING BRACKET 16 16 BRAKE SYSTEM Place a shop rag under the caliper to cushion the piston when it is expelled Use the air in short spurts Do not bring the air nozzle too close to the inlet or the pistons may be forced out with excessive force that could cause injury Push the dust and piston seals in and lift them out PISTON SEAL Clean the seal groove with clean brake fluid CAUTION Be careful not to damage the piston sliding surface DUST SEAL INSPECTION Check the caliper pistons for scoring or other damage Measure the caliper piston O D SERVICE LIMIT 25 300 mm 0 9960 in Check the caliper cylinder bores for scoring or other dam age Measure the caliper cylinder SERVICE LIMIT 25 400 mm 25 405 16 17 BRAKE SYSTEM ASSEMBLY PAD PIN Coat the new piston seals and dust seals with clean brake fluid and install them the seal grooves of the caliper Lubricate the caliper cylinders and pistons with clean brake fluid and install the pistons into the caliper cylinders with the opening towards the pads If the caliper and bracket pin boots are hard or deterio rated replace them with new ones Apply silicone grease to the bracket pin boots and bracket pins and install them making sure that they are seated in the bracket pin grooves properly Install the pad
165. posit indicates over rich mix ture REUSING A SPARK PLUG Clean the spark plug electrodes with a wire brush or spe cial plug cleaner Check the gap between the center and side electrodes If necessary adjust the gap by bending the side electrode carefully 0 7 0 8 mm 0 028 0 032 in SPARK PLUG GAP 0 7 0 8 mm 0 028 0 032 in CAUTION To prevent damage to the cylinder head hand tighten the spark plug before using a wrench to tighten to the specified torque Reinstall the spark plug in the cylinder head and hand tighten then torque to specification TORQUE 12 N m 1 2 kgf m 9 Ibf ft ELECTRODE INSULATOR 3 7 MAINTENANCE REPLACING A SPARK PLUG SPARK PLUG CAP CAUTION Do not overtighten the spark plug Install and hand tighten the new spark plug then tighten it about 1 2 of a turn after the sealing washer contacts the seat of the plug hole Connect the sprak plug cap and install the removed parts in the reverse order of removal VALVE CLEARANCE INSPECTION NOTE Inspect and adjust the valve clearance while the engine is cold below 35 C 95 F Remove the cylinder head cover page 10 4 Remove the timing hole cap and crankshaft hole cap Rotate the crankshaft counterclockwise and align the index line of the mark on the flywheel with the index notch on left crankcase cover The index lines on the cam sprockets must be flush with the cylinder head s
166. pper arm Worn clutch disc Damaged stopper plate Weakclutch springs Loose stopper plate bolt Motorcycle creeps with clutch disengaged Gearshift pedal will not return incorrect clutch adjustment Weak or broken gearshift spindle return spring Clutch plate warped Bent gearshift spindle Faulty clutch lifter Hard to shift Damaged gearshift spindle Damaged stopper plate and pin Loose stopper plate bolt Incorrect clutch adjustment CLUTCH GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL CABLE END Drain the engine oil page 3 11 Urain the coolant page 6 5 Disconnect the clutch cable end from the clutch lifter arm Loosen the hose band screws and disconnect hoses Remove the ten bolts clamp and right crankcase cover Remove the gasket and dowel pins CLUTCH GEARSHIFT LINKAGE CLUTCH LIFTER ARM Remove the lifter piece and return spring Remove the clutch lifter arm spindle Check the following lifter arm spindle for wear or damage return spring for fatigue or damage Replace the dust seal if necesally CLUTCH REMOVAL Remove the clutch lifter bearing and clutch lifter plate bolts NOTE Loosen the clutch lifter plate bolts in a cirsscross pattern in 2 3 steps Remove the lifter plate and clutch springs Install the clutch center holder and tighten the four bolts Hold the clutch assembly Remove the clutch center lock nut and wash
167. rankshaft hole cap Timing hole cap Drive sprocket fixing plate bolt Driven sprocket nut Front master cylinder cover screw Rear brake reservoir cover screw 25 2 5 kgf m 18 Ibf ft 12 1 2 kgf m 9 Ibf ft 59 N m 6 0 kgf m 43 Ibf ft 7 9 N m 0 8 kgf m 5 8 Ibf ft 5 9 N m 0 6 kgf m 4 3 Ibf ft 10 N m 1 0 kgf m 7 Ibf ft 64 N m 6 5 kgf m 47 Ibf ft U nut 1 5 N m 0 15 kgf m 1 1 Ibf ft 1 5 0 15 kgf m 1 1 Ibf ft MAINTENANCE SCHEDULE Perform the Pre ride inspection in the Owner s Manual at each scheduled maintenance period 1 Inspect and Clean Adjust Lubricate or Replace if necessary C Clean Replace A Adjust L Lubricate The following items require some mechanical knowledge Certain items particularly those marked and may require more techn cal information and tools Consult their authorized HONDA dealer WHICHEVER gt ODOMETER READING NOTE 1 X1 000 km FUEL LINE THROTTLE OPERATION Jun CRANKCASE BREATHER SPARK PLUG VALVE CLEARANCE NOTES ENGINE OIL It g sure Notes NOTE 3 EVERY 24 000 km 16 000 mi 1 ENGINE OIL STRAINER SCREEN EE ENGINE IDLE SPEED xd bos ad dos iod Lag bs gigjejg m RADIATOR COOLANT NOTE4 COOLING SYSTEM aa SECONDARY AIR SUPPLY SYSTEM DRIVE CHAIN re EVERY 1 000 km 600 mi 1 1 LT EBRLEBLELLLELBE gt
168. rear cowl page 2 2 Drain the coolant from the reserve tank page 6 5 Disconnect the over flow and siphon tubes Remove the bolt and radiator reserve tank from the frame Installation is in the reverse order of removal NOTE SIPHON TUBE Route the tubes properly page 1 19 1 20 Fill the reserve tank with recommended coolant to the upper level line page 6 5 7 INSPECTION HOSE gt WATER PUMP MECHANICAL SEAL INSPECTION Remove the under cowl page 2 3 Check the inspection hose for signs of coolant leakage If there is leakage the mechanical seal is defective and it should be replaced page 6 13 Install the under cowl page 2 3 WATER PUMP COVER REMOV AL INSTALLATION Drain the coolant page 6 5 Remove the three bolts sealing washer and water pump cover Apply coolant to the new O ring and install it to the water pump cover 6 12 COOLING SYSTEM Install the water pump cover sealing washer and three bolts Tighten the three bolts securely Fill and bleed the cooling system page 6 5 DISASSEMBLY Remove the right crankcase cover page 8 3 Hold the water pump shaft and remove the impeller and washer WASHER Remove the water pump shaft washer gear and pin from the right crankcase cover Remove the mechanical seal and oil seal from the right crankcase cover MECHANICAL SEAL OIL SEAL COOLING SYSTEM ASSEMBLY PIN WATER PUMP GEA
169. reverse order of removal FAN MOTOR SWITCH 20 14 LIGHTS METERS SWITCHES COOLANT TEMPERATURE GAUGE THERMOSENSOR SYSTEM INSPECTION Remove the fuel tank page 5 3 Disconnect the thermosensor connector and ground the connector terminal to the body ground Turn the ignition switch ON and check the coolant temperarute gauge needle The needle should move to COOLANT TEMPERATURE CAUTION Immediately tum the ignition switch OFF when the needle move to hot to prevent the gauge from damaging If the needle moves check the thermosensor If the needle does not move check for open circuit in Green Blue wire If the Green Blue wire is OK replace the coolant temperature gauge 20 15 LIGHTS METERS SWITCHES THERMOSENSOR INSPECTION Keep flammable materials away from the electric heat ing element Wear protective clothing insulated gloves and eye protection Drain the coolant page 6 5 Disconnect the thermosensor connector and remove the thermosensor Suspend the thermosensor in a pan of coolant 50 50 mixture on an electric heating element and measure the resistance through the sensor as the coolant heats up NOTE Soak the thermosensor in coolant up to its threads with at least 40 mm 1 57 in from the bottom of the sensor Keep temperature constant for 3 minutes before test ing A sudden change of temperature will result in in correct readings Do n
170. rflow tubes Loosen the caburetor connecting tube band screw and dis connect the connecting tube from the carburetor Remove the air cleaner mounting bolts and air cleaner housing Installation is in the reverse order of removal CRANKCASE BREATHER DRAIN TUBE CRANKCASE BREATHER TUBE SUB AIR CLEANER REMOVAL INSTALLATION SUB AIR CLEANER Remove the following fuel tank page 5 3 air cleaner housing See above Disconnect the tubes Remove the sub air cleaner from the frame Check the element and replace if necessary CARBURETOR REMOVAL Remove the following fuel tank page 5 3 air cleaner housing See above Remove the mounting bolt and PAIR control valve with the tubes connected Disconnect the air injection hose from the cylinder head cover AIR INJ ECTION HOSE PAIR CONTROL VALVE 5 4 FUEL SYSTEM Loosen the throttle cable adjusting nut and disconnect the throttle cable end from the throttle drum Loosen the nut and remove the starting enrichment SE valve and washer from the carburetor body Loosen the insurator band screw Remove the carburetor INSURATOR BAND SCREW Disconnect the fuel air vent and drain tubes FUEL TUBE AIR VENT TUBE DRAIN TUBE 5 5 FUEL SYSTEM CARBURETOR DISASSEMBLY VACUUM CHAMBER Remove the two screws and vacuum chamber cover NOTE As the compression spring is very long it will jump out of the carburetor when the cover
171. richment SE valve Good position open e Throttle valve open e Air cleaner dirty 4 Start by following normal procedure Engine starts but improper choke operation stops Carburetor incorrectly adjusted e Intake pipe leaking improper ignition timing Faulty ICM or ignition pulse generator e Fuel contaminated Engine does not start 5 Test cylinder compression Low compression Valve clearance too small e Valve stuck open Worn cylinder and piston ring e Damaged cylinder head gasket Seized valve e Improper valve timing 22 1 TROUBLESHOOTING ENGINE LACKS POWER 10 Accelerate lightly Remove spark plug hand Wheel pins freely Check tire pressure Pressure normal Accelerate rapidly from low to second Engine speed reduced when clutch is released Engine speed increase Check ignition timing i Test cylinder compression Normal i Check carburetor for clogging Not ciogged i Not fouled or discolored Check level and condition Remove cylinder head cover and inspect lubrication Valve tranin lubricated properly 22 2 Raise wheel off the ground and spin by Wheels do not spin freely Pressure low Engine speed doesn t change accordingly when
172. roove of the neutral switch Install the neutrai switch to the crankcase Tighten the bolt securely Install the removed parts in the reverse order of removal NEUTRAL SWITCH DRIVE PIECE E SPRING E aro NEUTRAL SWITCH re pne gt DRIVE PIECE 1 O RING 20 10 LIGHTS METERS SWITCHES FUEL METER FUEL UNIT FUEL METER INSPECTION Remove the fuel tank page 5 3 Disconnect the fuel unit 3P connector Connect the jumper wire between the Yellow White and Green wire terminals of the wire harness side Turn the ignition switch ON and make sure that the fuel meter needle swings to FULL Connect the jumper wire between the Blue White and Green wire terminals of the wire harness side Fuel meter is in good condition if the needle returns to EMPTY CAUTION Do not leave the terminals connected with the jumper wire for a long time as it causes damage to the fuel meter FUEL UNIT INSPECTION Disconnect the fuel unit 3P connector Remove the four nuts and fuel unit CAUTION Becareful not to damage the unit cable Becareful not to bent the float arm of the unit Som 8 FUEL UNIT i 20 11 LIGHTS METERS SWITCHES Measure the resistance between the terminals as follows T wem Green Blue White Green Yellow White Blue White Yellow White Reconnect the fuel unit 3P connector and turn t
173. rque TORQUE 10 N m 1 0 kgf m 7 Ibf ft Connect the air injection hose into the PAIR check valve cover Connect the vacuum tube Install the PAIR control valve and bolt AIR INJECTION HOSE PAIR CONTROL VALVE 10 22 CYLINDER HEAD VALVES Connect the upper radiator hose to the cylinder head install the radiator and two bolts Tighten the bolts Install the following right and left middle cowl page 2 4 air cleaner housing page 5 4 fuel tank page 5 3 Fill the cooling system with coolant page 6 5 10 23 CYLINDER PISTON 11 0 11 CYLINDER PISTON SERVICE INFORMATION 11 PISTON REMOVAL TROUBLESHOOTING 11 2 PISTON INSTALLATION CYLINDER REMOVAL 113 CYLINDER INSTALLATION SERVICE INFORMATION GENERAL The service procedures in this section can be performed with the engine installed in the frame Take care not to damage the cylinder wall and piston Be careful not to damage the mating surfaces by using the screw driver when removing the cylinder When disassembling mark and store the disassembled parts to ensure that they are reinstalled in their original locations SPECIFICATIONS Unit mm in 63 55 2 502 0 10 0 004 0 10 0 004 0 05 0 002 STANDARD 63 50 63 51 2 5000 2 5004 1 D Out of round Cylinder Warpage Piston mark direction Piston O D Piston O D measure
174. s and a new seal ring Install the front cover gj SEAL RING FRONT COVER SHIMS 19 8 ELECTRIC STARTER Align the index lines on the front cover and motor case Install the new O rings onto the motor case bolts ORINGS c Install and tighten the motor case bolts INSTALLATION Coat a new O ring with oil and instali it into the starter motor groove Install the starter motor into the crankcase Install the ground cable and mounting bolt then tighten the bolts securely Install the starter motor cable and terminal nut onto the motor terminal and tighten the nut securely Install the rubber cap over the motor terminal securely Install the under cowl page 2 3 19 9 ELECTRIC STARTER STARTER RELAY SWITCH INSPECTION NOTE Before checking the starter relay switch check for battery condition Remove the driver seat page 2 2 Shift the transmission into neutral Turn the ignition switch ON and depress the starter switch button The coil is normal if the starter relay switch clicks If you don t hear the switch CLICK inspect the relay switch using the procedure below GROUND LINE Disconnect the starter relay switch 4P connector Check for continuity between the Green Red wire ground line and ground If there is continuity when the transmission is in neutral or when the clutch is disengaged the ground circuit is normal In neutral there is a slight resis
175. s below or near the lower level mark remove lise LINE the oil filler cap and the recommended engine oil up to the upper level mark LOWER LEVEL LINE RECOMMENDED ENGINE OIL Honda 4 stroke oil or equivalent motor oil API service classification SE SF or SG Viscosity 10W 30 3 10 MAINTENANCE NOTE Other viscosities shown in the chart may be used when the average temperature in your riding area is within the indicated range Reinstall the oil filler cap dipstick ENGINE OIL CHANGE Wm 0 If the engine must be running to do some work make sure the area is well ventilated Never run the engine n an enclosed area The exhaust contains poisonous car bon monoxide gas that may cause loss of consciousness and may lead to death Run the engine in an open area or with an exhaust evacuation system in enclosed area Warm up the engine Stop the engine and remove the oil filler cap dipstick and drain bolt Drain the oil completely ES 1 9 Used engine 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 ba sis it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used KEEP OUT OF REACH OF CHILDREN Check that the sealing washer on the drain bolt is in good condition replace if necessary Install and tighten the drain bolt T
176. scribed on page 6 5 MAINTENANCE RESERVE TANK CAP 3 13 MAINTENANCE COOLING SYSTEM prevent injury keep your hands clothing away from the cooling fan It may start automatically without warn ing Check the radiator air passage for clogging or damage Straighten bent fins with a small flat blade screwdriver and remove insects mud or other obstructions with com pressed air or low pressure water Replace the radiator if the air flows is restricted over more than 20 of the radiating surface For radiator replacement refer to page 6 8 Remove the right middle cowl page 2 4 Check for any coolant leakage from the water pump page 6 12 water hose and hose joints Make sure the hoses are in good condition they should not show any signs of deterioration Replace any hose that shows any sign of deterioration Check that all hose clamps are tight Install the right middle cowl page 2 4 SECONDARY AIR SUPPLY SYSTEM NOTE This model is equipped built in secondary air supply system The pulse secondary air supply system is lo cated on the cylinder head cover The secondary air supply system introduces filtered air into exhaust gases in the exhaust port The secondary air is drawn into the exhaust port whenever there is negative pressure pulse in the exhaust system This charged secondary air promotes burning of the un burned exhaust gases and charges a considerable amount
177. seat for scoring scratches clogging or damage tip of the float valve where it contacts the valve seat for stepped wear or contamination operation of the float valve FLOAT VALVE Remove the main jet needle jet and slow jet MAIN J ET SLOW J ET CAUTION t Handle the jets with care They can easily be scored or scratched Turn the pilot screw in and carefully count the number of turns until it seats lightly Make a note of this to use as a PILOT SCREW reference when reinstalling the pilot screw SPRING WASHER CAUTION O RING Damage to the pilot screw seat will occur ifthe pilot screw is tightened against the seat Remove the pilot screw spring washer and O ring Check each jet for wear or damage Check the pilot screw for wear or damage O RING NEEDLE J ET SPRING stow ET PILOT zn MAIN J ET Pa 5 8 CARBURETOR CLEANING Remove the following diaphragm vacuum piston main jet needle jet and slow jet pilot screw air cut off valve CAUTION Cleaning the air and fuel passages with a piece of wire will damage the carburetor body Blow open all air and fuel passages in the carburetor body with compressed air CARBURETOR ASSEMBLY STAY SPRING DIAPHRAGM J ET NEEDLE AIR CUT OFF Co VALVE COVER Eo gt o nNG co FLOAT D FUEL SYSTEM DIAPHRAGM VACUUM PISTON VACUUM
178. shims O ring brush holder assembly Remove the brushes from the brush holder Measure the brush length SERVICE LIMIT 3 5 mm 0 14 BRUSH HOLDER pnan SHIMS d s e Pd O RING WASHERS 19 6 ASSEMBLY ELECTRIC STARTER Mees REAR COVER 5 5 TERMINAL ARMATURE WASHER o p SHIMS X BRUSH HOLDER N SHIMS DUST SEAL NEEDLE BEARING SEAL RING FRONT COVER BOLT Install the brushes into the brush holder O RING BRUSHES A BRUSH HOLDER Install the brush holder assembly into the rear cover by aligning the tab of the holder with the groove of the rear cover Install the new O ring a O RING BRUSH HOLDER 19 7 ELECTRIC STARTER Install the shims washers and nut NUT WASHERS Install the armature into the motor case while holding the armature tightly to keep the magnet of the case from pull ing the armature against it REAR COVER SEAL RING CAUTION mt The coil may be damaged if the magnet pulls the arma ture against the case Install the same number of washers and shims in the same locations as noted during disassembly NOTE The number of shims are different individually Install a new seal ring Install the rear cover by aligning the brush holder tab with SHIMS the motor case groove Install the lock washer to the front cover FRONT COVER Install the shim
179. spension Bent damper rod Bent frame or swing arm Tire pressure too high Suspension noise Faulty damper Loose fasteners Steers to one side or does not treck straight Rentrear axle Axle alignment chain adjustment not equal both sides 15 2 REAR WHEEL SUSPENSION ae ADJUSTING NUT NS REAR WHEEL REMOVAL 7 AXLE NUT Support the motorcycle securely using a hoist or equiva lent Loosen the drive chain adjusting nuts and fock nuts Loosen the rear axle nut Push the rear wheel forward Derail the drive chain Remove the axle nut Remove the rear axle from the right side Remove the rear wheel and side collars INSPECTION Axle Place the axle in V blocks and measure the runout Actual runout is 1 2 the total indicator reading SERVICE LIMIT 0 20 mm 0 008 Wheel rim runout Check the rim runout by placing the wheel in a turning stand Spin the wheel slowly and read the runout using a dial indicator Actual runout is 1 2 the total indicator reading SERVICE LIMITS Radial 2 0 mm 0 08 in Axial 2 0 mm 0 08 in Wheel balance VALVE STEM CAUTION Wheel balance directly affects the stability handling and over all safety of the motorcycle A 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 side wall must be located next to the valve stem Remount the tire if
180. spring on the caliper Assemble the caliper bracket and caliper body CALIPER CYLINDER PAD SPRING CALIPER BRACKET BRAKE PADS DUST SEAL 4 PISTON SEAL PISTON 4 EN PAD SPRING BRACKET 16 18 BRAKE SYSTEM INSTALLATION OIL BOLT E MOUNTING BOLT Install the brake pads page 16 6 h Install the brake caliper and mounting bolts Tighten the bolts to the specified torque TORQUE 30 N m 3 1 kgf m 22 Ibf ft Connect the brake hose eyelet joint with two new sealing washers then tighten the oil bolt to the specified torque TORQUE 34 N m 3 5 kgf m 25 Ibf ft Fill and bleed the front brake hydrauric system page16 3 REAR BRAKE CALIPER REMOVAL Drain the brake fluid from the rear brake hydraulic system page 16 3 Remove the brake pads page 16 5 Remove the bolt sealing washers and brake hose eyelet joint Remove the rear wheel page 15 3 Remove the brake caliper DISASSEMBLY Remove the brake pad spring from the caliper body Remove the caliper bracket from the caliper body BRACKET Remove the bracket pin boots CALIPER BODY 16 19 BRAKE SYSTEM If necessary lightly apply compressed air to the fluid inlet to get the piston out Place the shop rag under the caliper to cushion the piston when it is expelled Use the air in short spurts Do not bring the air nozzle too close to the inlet or the pisto
181. ss pattern 2 or 3 steps TRANSMISSION Make sure that the crankcase mating surfaces are touched evenly Install the left crankcase bolts and clamp then tighten the bolts in a crisscross pattern in 2 or 3 steps Install the chain to the chain drive sprocket um through the crankcase N TENSIONER GUIDE e rut Install the cam chain tensioner plate and bolt Tighten the bolt securely Install the remaining parts Install the engine in the frame section 7 Install the spring washer and 3 mm screw to the bearing push plug then install them into the left crankcase Install the circlip and remove the screw Assemble the crankcase halves page 12 12 PUSHING PLUG SPRING 12 14 CRANKSHAFT BALANCER 13 0 13 CRANKSHAFT BALANCER SERVICE INFORMATION 13 1 CRANKSHAFT REMOVAL 13 2 TROUBLESHOOTING 13 1 CRANKSHAFT INSTALLATION 13 5 SERVICE INFORMATION GENERAL This section covers service of the crankshaft and balancer The crankcase halves must be separated to service the crankshaft and balancer For crankcase separation and assem bly refer to section 12 Be careful not to damage the crankcase mating surfaces when servicing SPECIFICATIONS Unit mm STANDARD SERVICE LIMIT Connecting rod Big end side clearance 0 6 0 02 Big end radial clearance 0 05 0 002 Crankshaft runout 0 03 0 001 TOOLS Driver 07749 0010000 A
182. steners Lack of grease in speedometer gear FRONT WHEEL SUSPENSION STEERING HANDLEBAR REMOVAL MASTER HOLDER F CYLINDER Disconnect the front brake light switch connectors from the switch Remove the bolts master cylinder holder and master cylinder NOTE Keep the brake reservoir upright to prevent air from entering the hydraulic system Remove the throttle housing screws SCREWS Remove the throttle upper housing Remove the throttle cable from the throttle pipe Remove the grip end Remove the throttle grip from the handle bar THROTTLE GRIP 14 3 FRONT WHEEL SUSPENSION STEERING Remove the clutch switch connectors CONNESTORS Remove the clutch lever holder bolts Remove the clutch lever holder and clutch lever bracket assembly Remove the screws and left handlebar switch housing HOUSING Remove the grip end and left handlebar grip GRIP END 14 4 FRONT WHEEL SUSPENSION STEERING Remove the stopper ring Loosen the handlebar pinch bolt and remove the handle bar from the fork HANDLEBAR STOPPER RING INSTALLATION Install the handlebar onto the fork and align the boss on the handle bar with the cut out on the top bridge CUT OUT Tighten the handlebar pinch bolt to the specified torque TORQUE 27 N m 2 8 kgf m 20 Ibf ft Install the stopper ring into the groove on the fork pipe Install the right han
183. straight ahead position Hook a spring scale to the fork pipe between the fork top and bottom bridges Make sure that there is no cable or wire harness interfer ence Pull the spring scale keeping the scale at a right angle to the steering stem Read the scale at the po nt where the steering stem just starts to move STEERING BEARING PRELOAD 0 10 0 15 kgf 0 220 0 330 Ibf If the readings do not fall within the limits readjust the steering top thread Install the removed parts in the reverse order of removal 14 23 REAR WHEEL SUSPENSION 39 4 0 kgf m 29 Ibf ft 88 N m 9 0 kgf m 65 Ibf ft 44 N m 4 5 kgf m 33 Ibf ft 59 N m 6 0 kgf m 43 Ibf ft 15 0 15 REAR WHEEL SUSPENSION SERVICE INFORMATION SHOCK ABSORBER TROUBLESHOOTING SWINGARM REAR WHEEL SERVICE INFORMATION GENERAL Ll L contaminated brake disc or pad reduces stopping power Discard contaminated pads and clean contaminated disc with a high quality brake degreasing agent Wheel balance directly affects the stability handling and overall safety of the motorcycle Carefully check balance before reinstalling the wheel CAUTION To avoid damaging the rim when using the tire lever always use rim protectors When servicing the rear wheel swingarm or shock absorber support the motorcycle securely using a hoist or equivalent Useonly genuine Honda replacement bolts
184. t shim thickness by measuring the shim with the micrometer Reface the valve seat if carbon deposits result in a calculated dimension of over 2 900 mm 1 80 mm 1 825 mm 1 85 mm 1 875 mm 3 9 MAINTENANCE install the newly selected shims on the valve retainers Install the valve lifters and camshafts page 10 19 Rotate the camshafts by rotating the crankshaft counterclockwise several times Recheck the valve clearance Install the cylinder head cover page 10 22 Coat a new O ring with oil and install it onto the crankshaft hole cap Apply grease the crankshaft hole cap threads Install and tighten the crankshaft hole cap TORQUE 7 9 N m 10 8 kgt m 5 8 Ibf tt Coat a new O ring with oil and install it onto the timing hole cap Apply grease the timing hole cap threads Install and tighten the timing hole cap a TORQUE 5 9 N m 0 6 kgf m 4 3 Ibf ft O RING CRANKSHAFT HOLE CAP 00 OIL FILLER CAP DIPSTICK ENGINE OIL OIL LEVEL INSPECTION Start the engine and let it idle for a few minutes Stop the engine support the motorcycle upright on a level surface Wait for a few minutes Remove the oil filler cap dipstick and wipe off the oil from the dipstick with a clean cloth X With the motorcycle upright on level ground insert the A 7 oil filler cap dipstick into the stick hole without screwing it in Remove the oil filler cap dipstick and check the oil level Ifthe oil level i
185. t the 6P connector from the ICM Connect the peak voltage adaptor or Imrie diagnotic tester probes to the connector terminals ofthe wire harness side BLUE YELLOW 1 Ber comecton N Imrie diagnostic tester model 625 or Peak voltage adaptor 07HGJ 0020100 with Commercially available digital multimeter impedance 10 MQ DCV minimum CONNECTION Blue Yellow terminal Green Crank the engine with starter motor and read the peak voltage PEAK VOLTAGE 0 7 V minimum pM Avoid touching the spark plug and tester probes to pre vent electric shock 18 4 IGNITION SYSTEM If the peak voltage measured at ICM connector is abnor mal measure the peak voltage at the ignition pulse gen erator 4P connector 4P CONNECTOR Disconnect the ignition pulse generator 4P connector and connect the tester probes to the terminal Blue Yellow and Ground In the same manner as at the ICM connector measure the peak voltage and compare it to the voltage measured at the ICM connector If the peak voltage measured at the ICM is abnormal and the one measured at the ignition pulse generator is normal the wire harness has an open circuit or loose connection If both peak voltages measure are abnormal check each item in the troubleshooting chart If all items are nor mal the ignition pulse generator is faulty See section 9 for ignition pulse generator replacement gt BLUE YELLOW
186. tance due to the diode STARTER RELAY VOLTAGE Connect the starter relay switch 4P connector Shift the transmission into neutral Measure the voltage between the Yellow Red wire and ground at the starter relay switch 4P connector If the battery voltage appears only when the starter switch is pressed with the ignition switch ON it is normal OPERATION CHECK Disconnect the starter relay switch 4P connector and cables Connect a fully charged 12 V battery positive wire to the relay switch Yellow Red wire terminal and negative wire to the Green Red wire terminal There should be continuity between the large terminals while the battery is connected and no continuity when the battery is disconnected 19 10 STARTER RELAY SWITCH ELECTRIC STARTER CLUTCH NEUTRAL DIODE INSPECTION Remove the rear cowl page 2 3 Remove the diode Check for continuity between the diode terminals When there is continuity a small resistance value will reg ister If there is continuity in one direction the diode is normal 19 11 LIGHTS METERS SWITCHES SYSTEM LOCATION IGNITION SWITCH CLUTCH SWITCH FRONT BRAKELIGHT SWITCH 2 E Dp 36 y ges TETA TURN SIGNAL RELAY mer OLA AA Q THERMOSENSOR 3 Se OP yey lt 9 REAR BRAKE LIGHT SWITCH 20 0 20 LIGHTS METERS SWITCHES SYSTEM DIAGRAM FUEL METER FUEL UNIT SER
187. te and cover and tighten the Screws TORQUE 1 5 N m 0 15 kgf m 1 1 Ibf ft REAR BRAKE Place the motorcycle on a level surface and support it upright x Check the fluid level in the rear brake reservoir If the level is near the lower level line remove the bolt and reservoir with the brake hose connected Remove the screws cover set plate and diaphragm and fill the reservoir with DOT 3 or 4 brake fluid from a sealed container to the upper level line Install the diaphragm set plate cover and tighten the Screws to the specified torque TORQUE 1 5 N m 0 15 kgf m 1 1 Ibf ft install the reservoir tank onto the stay and tighten the bolt MAINTENANCE BRAKE PAD WEAR FRONT BRAKE PAD Check the brake pad for wear Replace the brake pads if either pad is worn to the bottom of wear limit groove Refer to page 16 5 for front brake pad replacement REAR BRAKE PAD WEAR INDICATOR Check the brake pads for wear Replace the brake pads if the wear limit groove of either pad is worn out Refer to page 16 6 for rear brake pad replacement BRAKE SYSTEM INSPECTION BRAKE HOSE Firmly apply the brake lever or pedal and check that no air has entered the system If the lever or pedal feels soft or spongy when operated bleed the air from the system Inspect the brake hose and fittings for deterioration cracks and signs of leakage Tighten any loose fittings Replace hoses and fittings as required
188. th a cooling system tester Refer to Section 20 for fan motor switch and thermosensor inspection SPECIFICATIONS Fully open 80 C 176 F Valve lift 3 5 mm 0 14 in minimum 6 1 COOLING SYSTEM TORQUE VALUES Water pump impeller 10 N m 10 kgf m 7 Ibf ft TOOLS Driver 07749 0010000 Attachment 36 mm 07945 4150400 TROUBLESHOOTING Engine temperature too high Faulty temperature indicator or thermo switch section 20 Faulty radiator cap Insufficient coolant Passages blocked in radiator hoses or water jacket Airin system Faulty water pump Thermostat stuck closed Faulty cooling fan motor Faulty fan motor switch Engine temperature too low Faulty temperature indicator or thermo switch section 20 Thermostat stuck open Faulty cooling fan motor switch Coolant leaks Faulty water pump mechanical seal Deteriorated O ring Damaged or deteriorated gasket Loose hose connection or clamp Damaged or deteriorated hose Faulty radiator cap 6 2 COOLING SYSTEM SYSTEM TESTING ay RADIATOR CAP COOLANT HYDROMETER TEST Be sure the engine is cool before removing the or you may be severely scalded Remove the following right middle cowl page 2 4 upper cowl page 2 5 Remove the radiator cap Check the coolant gravity using a hydrometer STANDARD COOLANT CONCENTRATION 50 Look for contamination and replace the coolant
189. the timing hole cap Connect the timing light to the spark plug wire Start the engine and let it idle IDLE SPEED 1 400 100 min rpm 18 6 IGNITION SYSTEM The ignition timing is correct if the F mark aligns with epe the index notch on the left crankcase cover 5 INDEX aek CH Apply oil to the O ring and install and tighten the timing hole cap to the specified torque TORQUE 6 N m 0 6 kgf m 4 3 Ibf ft 18 7 ELECTRIC STARTER SYSTEM DIAGRAM CLUTCH NEUTRAL DIODE STARTER RELAY SWITCH STARTER MOTOR cc IGNITION 25 SWITCH 0 o 0 Wa e 5 YR NEUTRAL INDICATOR CLUTCH 9 WIG SWITCH e S Black e t 6 0 un 1 0 2 NEUTRAL Green DIODE SWITCH R Red W White pae Lg Light Green 19 0 19 ELECTRIC STARTER SYSTEM DIAGRAM 19 0 STARTER MOTOR SERVICE INFORMATION 19 1 STARTER RELAY SWITCH TROUBLESHOOTING 19 2 CLUTCH NEUTRAL DIODE SERVICE INFORMATION GENERAL A WARNING Always turn the ignition switch OFF before servicing the starter motor The motor could suddenly start causing serious injury The starter motor can be serviced with the engine in the frame When checking the starter system always follow the steps in the troubleshooting flow chart page 19 2 A weak battery may be unable to turn the starter motor quickly enough or supply adequate ignition current If the
190. the valve seats Lap the valves and seats using a rubber hose or other hand lapping tool Remove the valve and inspect the width of each valve seat STANDARD 1 2 1 6 mm 0 05 0 06 in SERVICE LIMIT 1 9 mm 0 07 in Valve seat width is not within specification reface the valve seat page 10 15 VALVE SEAT CONTACT WIDTH CAUTION The valve cannot be ground If a valve face is burned or badly worn or it contact the seat unevenly replace the valve DAMAGED FACE NEVEN SEAT WIDTH if the valve seat is following conditions the seat must be ground Uneven seat width Bent or collapsed valve stem Replace the valve and reface the valve seat Damaged face Replace the valve and reface the valve seat Contact area too high or too low area Reface the valve seat TOO LOW TOO HIGH 10 14 CYLINDER HEAD VALVES VALVE SEAT REFACING Honda Valve Seat Cutters a grinder or equivalent valve seat refacing equipment are recommended to correct a worn valve seat NOTE Follow the refacer manufacture s operating instructions Be careful not to go grind the seat more than neces sary Use a 45 degree cutter to remove the roughness or irregu A larities from the seat NOTE Reface the valve seat with a 45 degree cutter when a valve guide is replaced TOOLS Seat cutter 24 mm EX 07780 0010600 Seat cutter 27 5 mm IN 07780 0010200 Cutter holder 3
191. to the exhaust port whenever there is a negative pressure pulse in the exhaust system This charge of fresh air promotes burning of the unburned exhaust gases and changes a consid erable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor This model has the pulse secondary air injection PAIR control valve and PAIR check valve Pair check valve prevents reverse air flow through the system The PAIR control valve reacts to high intake manifold vacuum and will cut off the supply of the fresh air during engine deceleration thereby preventing afterburn in the exhaust system No adjustment to the pulse secondary air injection system should be made although periodic inspection of the com ponents is recommended PULSE SECONDARY AIR INJECTION PAIR CARBURETOR CONTROL VALVE PULSE SECONDARY AIR INJECTION PAIR CHECK VALVE AIR CLEANER EXHAUST PORT 1 25 FRAME BODY PANELS EXHAUST SYSTEM BODY PANEL LOCATIONS DRIVER SEAT GRAB RAIL PASSENGER SEAT REAR FENDER UNDER COWL LEFT MIDDLE COWL 2 0 2 FRAME BODY PANELS EXHAUST SYSTEM BODY PANEL LOCATIONS SERVICE INFORMATION TROUBLESHOOTING PASSENGER SEAT DRIVER SEAT GRAB RAIL REAR COWL REAR FENDER UNDER COWL MIDDLE COWL FRONT FENDER UPPER COWL EXHAUST SYSTEM SERVICE INFORMATION GENERAL Serious burns may result if the exhaust system is not allowed to cool before compon
192. torque TORQUE 17 N m 1 7 kgf m 12 Ibf ft install the rubber plug BRAKE DISC INSPECTION Visually inspect the brake disc for damage or cracks Measure the brake disc thickness with a micrometer SERVICE LIMITS FRONT 3 0 mm 0 12 REAR 3 0 mm 0 12 in Replace the brake disc if the smallest measurement is less than the service limit BRAKE SYSTEM Measure the brake disc warpage with a dial indicator SERVICE LIMIT 0 1 mm 0 004 Check the wheel bearings for excessive play if the warpage exceeds the service limit Replace the brake disc if the wheel bearings are normal FRONT MASTER CYLINDER MASTER WASHERS REMOVAL BOLT CAUTION Avoid spilling fluid on painted plastic or rubber parts Place a rag over these parts whenever the system is ser viced Drain the brake fluid from the front brake hydraulic sys tem page 16 3 CONNECTORS Remove the front brake light switch connectors Remove the bolt sealing washers and disconnect the brake hose Remove the master cylinder holder blots holder and mas ter cylinder DISASSEMBLY Remove the pivot nut bolt and brake lever Remove the screw and front brake light switch BRAKE LIGHT SWITCH BOLT BRAKE LEVER 16 8 BRAKE SYSTEM Remove the boot Remove the snap ring using the special tool TOOL Snap ring pliers 07914 5 50001 Remove the washer master piston and spring from the master cylinder Clean t
193. ttachment 32 x 35 mm 07746 0010100 Attachment 37 x 40 mm 07746 0010200 Attachment 72 x 75 mm 07746 0010600 Pilot 12 mm 07746 0040200 Pilot 35 mm 07746 0040800 13 Crankcase assembly tool assembly collar 07965 VM00100 assembly shaft 07965 VM00200 Universal bearing puller 07631 0010000 TROUBLESHOOTING Excessive noise Worn crankshaft main journal bearings Worn or damaged connecting rod bearings Worn connecting rod small end Worn balancer bearings Improper balancer installation Abnormal vibration Improper balancer timing 13 1 CRANKSHAFT BALANCER CRANKSHAFT REMOVAL Separate the crankcase and remove the transmission section 12 Remove the crankshaft and balancer from the right crankcase CAUTION Be careful not to damage the crankcase mating surface and crankshaft assembly Remove the left crankshaft bearing using the bearing puller with a suitable protector CAUTION careful not to damage the barancer drive gear elf the barancer drive gear is scratched file off the scratched part TOOL Universal bearing puller 07631 0010000 NOTE Always replace the left bearing with a new one if it comes out with the crankshaft INSPECTION Crankshaft Runout Place the crankshaft on a stand or V blocks Set the dial indicator on the shafts Rotate the crankshaft two revolutions and read the runout SERVICE LIMIT 0 03 mm 0 001 in 2
194. uality fuel Clutch slipping Lean fuel mixture Wrong type of fuel Worn cylinder or piston Wrong type of fuel POOR PERFORMANCE AT LOW AND IDLE SPEED Excessive carbon build up in combustion chamber Ignition timing too advance Faulty ICM Lean fuel mixture Possible cause 1 Check carburetor pilot screw adjustment Incorrect 2 Check for leaking carburetor insulator Not leak 3 Perform spark test Good spark 4 Check ignition timing Good spark Leaking Weak or intermit e tent spark incorrect See section 5 Loose carburetor insulator bands Damaged carburetor insulator Faulty carbon or wet fouled spark plug Fouled spark plug Faulty ignition contro module ICM Faulty ignition coit Fauity alternator Broken or shorted spark plug wire Faulty ignition pulse generator Faulty ignition switch Loose or disconnected ignition system wires improper ignition timing faulty ICM 22 3 TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED 1 Disconnect fuel tube at carburetor and Fuel flow restricted check fuel flow 1 Fuel flows freely 2 Remove the carburetor and check for clogging Not clogged 3 Check valve timing Correct 4 Check ignition timing Correct 5 Check vaive spring Not weak POOR HANDLING Clog
195. urface as shown Make sure the piston is at TDC Top dead center on the compression stroke If the index lines are not flush rotate the crankshaft counterclockwise 360 1 full turn and align the index lines of the T mark with the index notch m4 INDEX LINES Measure the cylinder valve clearance by inserting feeler gauge between the valve lifter and cam lobe VALVE CLEARANCE 0 16 0 03 mm 0 00 amp 0 001 in 0 25 0 03 mm 0 01 0 001 in ADJUSTMENT Remove the camshaft page 10 5 Remove the valve lifters and shims Clean the valve shim contact area in the valve lifter with compressed air NOTE Shim may stick to the inside of the valve lifter Do not allow the shims to fail into the crankcase e Mark all valve lifters and shims to ensure correct reassembly in their original locations The valve lifter can be easily removed with a valve lapping tool or magnet The shims can be easily removed with a tweezers or magnet Measure the shim thickness and record it NOTE Sixty nine different thickness shims are available from the thinnest 1 200 mm thickness shim to the thickest 2 900 mm thickness in intervals of 0 025 mm Calculate the new shim thickness using the equation below A B C D A New shim thickness B Recorded valve clearance C Specified valve clearance D Old shim thickness NOTE Make sure of the carrec
196. uum tube from the cylinder head Connect the vacuum pump to the PAIR control valve vacuum tube Start the engine and open the throttle slightly to be cer tain that air is sucked in through the air supply hose If the air is not drawn in check the air supply hose for clogging With the engine running gradually apply vacuum to the PAIR control vale vacuum tube Check that the air supply hose stops drawing air and that the vacuum does not bleed SPECIFIED VACUUM 37 kPa 280 mmHg If the air is drawn in or if the specified vacuum is not main tained install a new PAIR control valve If afterburn occurs on deceleration even when the sec ondary air supply system is normal check the air cut off valve FUEL SYSTEM THROTTLE STOP SCREW s AIR INTAKE PORT PAIR CONTROL VALVE 5 15 FUEL SYSTEM PAIR CHECK VALVE INSPECTION Remove the following fuel tank page 5 3 air cleaner housing page 5 4 Remove the bolt and PAIR control valve with the tubes connected Disconnect the air injection hose from PAIR check valve cover Remove the two bolts and PAIR check vale cover from the cylinder head Check the reed for damage or fatigue Replace if neces Sary Replace the PAIR check valve if the seat rubber is cracked deteriorated or damaged or if there is clearance between the reed and seat Install the PAIR check valve and cover onto the cylinder head c
197. ven disc pressure Checkthe brake fluid level in the brake master cylinder reservoir as this operation causes the level to rise Push the caliper pistons all the way in to allow installation of new brake pads Remove the pad pin and brake pads PAD PIN i N BRAKE SYSTEM Install the new brake pads to the brake caliper coo WE Install the new O ring into the pad pin groove Apply grease to the pad pin sliding surface Push the brake pads against the pad spring then install the pad pin Tighten the pad pin to the specified torque TORQUE 17 N m 1 7 kgf m 12 Ibf ft REAR BRAKE PAD REPLACEMENT WARNING A contaminated brake disc or pad reduces stopping power Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent NOTE Check the brake fluid level in the reservoir as this operation causes the level to rise Always replace the brake pads in pairs to assure even disc pressure Push the caliper pistons all the way in to allow installation of new brake pads Remove the rubber plug 4 RUBBER PLUG ee 16 6 BRAKE SYSTEM Remove the pad pin and brake pads BRAKE PADS E Install the new O ring into the pad pin groove Apply grease to the pad pin sliding surface Push the brake pads against the pad spring then install the pad pin Tighten the pad pin to the specified
198. vice limits replace the oil pump as an assembly After the oil pump has been installed check that there are no oil leaks SPECIFICATIONS Unit mm in Recommended engine oil Engine oil capacity 1 0 liter 1 06 US qt 0 88 Imp qt DECRE service classification SE SF or SG Viscosity SAE 10W 30 Honda 4 stroke oil or equivalent motor oil Oil pump rotor Tip clearance 02000 TORQUE VALUES Oil pump bolt 5 2 N m 0 53 kgf m 3 8 Ibf ft TROUBLESHOOTING Engine oil level too low Normal consumption External leak Worn piston ring or incorrect piston ring installation Worn valve guide or seal Oil contamination External oil leak Worn piston ring or incorrect piston ring installation Worn valve guide or seal Clogged oil strainer screen LUBRICATION SYSTEM OIL PUMP REMOVAL Drain the engine oil page 3 11 Remove the right crankcase cover page 8 3 Remove the three bolts and oil pump assembly Remove the dowel pins DISASSEMBLY Remove the E clip Remove the oil pump shaft and gear Remove the two bolts and oil pump cover OIL PUMP COVER SHAFT GEAR pon 2 B 2 4 BOLTS 4 2 LUBRICATION SYSTEM Remove the inner and outer rotors INSPECTION Temporarily instal the outer and inner rotors into the oil pump body Install the oil pump shaft Measure the tip clearance between the inner and out

Honda CBR150 Manual

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