HOW TO USE THIS MANUAL Follow the Maintenance Schedule (Section 3) recommendations to ensure that the vehicle is in peak operating concition and the emission levels are within the standard set by U.S. Environmental Protection Agency and California Air Resources Board. Performing the first scheduled maintenance is very impor- ‘tant. It compensates for the initial wear that ‘occurs during the break-in period. Sections 1 through 3 apply to the whole Motorcycle, while sections 4 through 20 describe parts of the motorcycle, grouped ac- cording to location Find the section you want on this page, then turn to the table of contents on page 1 of that section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The sub- sequent pages give detailed procedures. If you don’t know the source of the trouble, go to section 21 TROUBLESHOOTING. tie and without ncuringany abigetion whatever No parca hs publication may be produced with | out writin po HONDA MOTOR CO., LTD. SERVICE PUBLICATIONS OFFICE CONTENTS GENERAL INFORMATION | LUBRICATION __ a 2| | mamvTENANcE E FUEL SYSTEM | CYLINDER/PISTON CLUTCH ALTERNATOR/STARTER CLUTCH TRANSMISSION CHassis. ELECTRICAL "| FRONT WHEEL/SUSPENSION/ |_ STEERING a _E _Atrenwaroristanren c.uron ES) | orancsHartisarancen TG) _ _ FAIRING/EXHAUST SYSTEM m3 L HYDRAULIC BRAKE _ Ww [15] BATTERY/CHARGING SYSTEM IGNITION SYSTEM Lm ELECTRIC STARTER SYSTEM | 13] LIGHTS/INSTRUMENTS/SWITCHES. E BH Date of Issue: September, 1088 @HONDA MOTOR CO., LTD.1. GENERAL INFORMATION GENERAL SAFETY 1 SERVICE RULES 11 MODELIDENTIFICATION 4-2 SPECIFICATIONS 13 TORQUE VALUES 15 GENERAL SAFETY If the engine rust be running io do some work, make sure the area is well-ventilated. Never run the engine in a closed area. The exiucist contains poisonous carbon monoxide gas that can cause loss af consciousness and may lead to death, Gasoline’ exiremely flammable and i explosive under certain conditions, Work in well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in your ‘working area or where gasoline Is stored. Brake dust may contain asbestos, + Inhalted ashestos fibers have been found to eause respirato- ry disease and cancer. Never use an air hoseor diy brash 0 ‘lean brake assembles. + In the Untied States, we an OSHA approved vacuin cleaner or aliemate method approved by OSHA designed 0 minimize the hazard caused by airborne asbestos fibers. SERVICE RULES ToOLs 17 CABLE & HARNESS ROUTING 19 EMISSION CONTROL SYSTEMS 1-16 EMISSION CONTROL INFORMATION LABELS |U.S.A. only) a + The battery gives off explosive gases: keep sparks, flames sand cigareites away. Provide adequate venttation when charging + Phe bertery concains sulfrie acid (electrolyte). Coneact wht skin or eves may cause severe burns. Wear protective clothing an a face shield. = W electrotte gets on vour skin, fush with water. = If electrolyte gets in your eyes, Pash with water for at least 15 minutes ond cal a physician. + Beare is poisonous. —If swallowed, drink large quantities of water or milk ‘and follow sith milk of magnessia or vegetable oil and call a physician. cauTion + Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods, Although this is unlikely unless you haredle used vil on © daily basi, 1 & st edtvisable to thoroughly wask your hands with soap and water as soon as possible ater hand: ing used oi 1. Use genuine HONDA or HONDA:recommerded parts end lubricants oF vieir equivalent, Parts that do not meet HONDA’s ‘design specifications may camage the motoroycle, 2. Use the special tools designed for this product. 3. use only metric tools when servicing this motoreyele. Metric belts, nurs, 1d serews are not interchangeable with English fasteners. The use o! incorrect tools and fasteners may damage the motorcycle. 4. Install nevr gaskets, Ovings, cotter gins, lock plates, etc. when reassembling 5. When tightening a series ot bolts or nuts, begin with the larger-clameter or inner bolts first, end tighten to the specified torque ciagonally, unless a particular sequence is specified. cate any sliding surfaces bafare razssombly. After reassombly, chec all parts for propor inctallation and operation. Clean parts in cleaning solvent upon disassembly. Lub 1-1GENERAL INFORMATION MODEL IDENTIFICATION "88: ABTER ‘28: ‘The frame serial number 's stamped on theright side af the “The vehicle identification number (VIN/ Is on the right side steering head. of the trame pipe. ULIDENTIFIGATION NUMBER ‘The engine serial number is stamped on the right erank- The cerburator icentification number is stamped on the case. carburetor body. 1-2 (iGENERAL INFORMATION SPECIFICATIONS <_>:Calfornia mocet DIMENSIONS — | Overall Iength 2,195 mm (86.4 in) ores meen Curd weight 168 kg (379.3 Ib} pressures 150 kPa (1.50 kgicm*, 22 psi? one passenger | Rear 200 kPa (2.00 kgicm®, 29 psi) | Displacement 844.0 cc (39.29 cu in) | Be |S an pes #5, ie, Main jet #155 1-3GENERAL INFORMATION TEM foRive TRAIN [Cuth Transmission ‘SPECIFICATIONS Wet, mati-plate speed constant mash 1 | Primary deiven 2,029 169/94) Final reduction 3.000 145/75) Gear ratio | 2,666 (82/12) | Gear ratio It 1.750 (28/16) Gear ratio Il 1.250 125/20) Goar ratio IV 1.000 123/23) Gew ratio V 0.840 121/25) Goar shift pattern Lett foot operated return system, 1-N—2—3—4—5 ELECTRICAL | Ignition Tpe-cor Ignition timing Inia | 8° BTDC at idle Full advance 28? BTDC at 4,000 rpm Alternator AC ganarater 0.18 kw/5,000 rpm Battery capacity 12v 8AH Spark plug NGK ND. Standard DPREEA 9 xzacPR U9 For extencied high OPRIEA—9 X27EPR—U apeed riding Spark phic aap 0.80.9 mm {0.031—0.036 in) Fuse Main 20a Sub TOA x 24158 Starting system Electical stater Headlight 12v 80/55W Tailibrake light 12V 32/3cp Front turn signalirunning fight 12V 32ep x2 | Flea: turn signel light BV B2ep x 2 | meter lights nav 1rwee | High beam indicator 12v1.7W Turn signal indicator 52v 3.4W x2 Noutral indicator sav a4wGENERAL INFORMATION TORQUE VALUES ENGINE | rem cry | THREAD | ponaue hom tem, fib newares Crentcase dain lua ie 265 18) titer cor bat 8 3108 7 ave aducingseow ock net 4B 228 10) Cyne hed bt oO} 230 201 pny ot the tend Cam spose et 2) 3 o\z0, 1a bey aching agar ote Rocke sm sat 2) 4 2328 201 ‘heats Suc am shat NI 2] 2828 20 tbo 2] 1 aias 17 cyte bead cover but Bini | ot] 8 ales 17 om| 1 | 8 tonon | (6mm SH | 11 6 12(1.2, 8) | spar ps i] 2 aire 13 neo b] te 0180 se psy ot tho shsede Cine 2] 'e ro110. ten ook nut i] as Homie 8 Primary dvs gar mut i | te toini.9, 80) Gearshift cam bolt 1 6 1211.2, Sb | Apply @ locking agent to the eeese stepper rm bol 8 25125 18) Rigrtcrmessecoverseunt | 8 wine Starter clutch bolt | 8 3013.0, 221 Apply a locking agent to the tora Tyee! ble 1) ow 125.425,00) | Apply MoSe poste othe teeeus Let crartoase cover bl >| 6 ware Steer gar cover 8 atta 8 trance oh ufos Bua 8 oer ek bot if 3 tee FRAME wrew ary | THREAD | ronaue wm ign, ri earns Down tke drain 7] 10 wae Oi seamer ma | te ors, 21 Otece fore nc 2] te ‘ole, 2 Fuel vaive cup 1 — 4 (0.4, 3) Spoke 2) = flag 3 ame hangernut rome) | 5 | 10 coven 23 (& mm) 8 8 2413.4, 25) | sk late to 3] 8 ono, Ope ae ut i} oa fols0 28 Waebar wove olde: i's e206. 18) fanaa over hole ar) zelz6 18 Beate dae tot s 8 sola 27 Fron nt no too e508 «7 fret ante her ut 2 wine a Fork slider socket bolt 2 8 2012.0, 14) Apoly a locking agent to the eas Lower lok inch bot +8 (3.9, 24) ron cap bo 2) ates 17 Uppe tore nich bo 48 wiles 20) ara calbr bracket to 28 22. 20 Stconng aise ut ae Boe 0 Steering stem nut ba 24 100 (10.0, 72) 1-5ENERAL INFORMATION rem aw | THREAD] ronaue ean. ewanKs Beer oe mt +) de 359.3691 Bes aster sin ck mat | 4 3019.9, 65) Seca ee | wera, eH Sr Seater eer net ber 1! 4 ess. 90 Becomtoatucctinknn =) 1 | 8 sous 2) se evans emmt | 4 |r was sal eh emo ware nr 1) 3 Sass | Sieger vet 1 | ot “pitt. 8 Beane coer brocat pot) 2 | 8 29129201 Fnae 9 >| 6 ae) eo saw >| 4 230025, 18 Broke hows ut trees on 1 | % 3838, 25 Bee noc int mt ilo Bie io bree pe mr tf iat 10) Brake hase boit | a | 10 35125, 25) | roots alps tact in bl 1) 8 nae Tre acta open oo cue pe font nt s|e 2202.18 tte bond bl 2| 8 202.9,18) ue urna ble 3) el 18) Sue send pet bot 2) Bo 80,28) ppv abekin agent io Ne one (arren 88) | es STANDARD TORQUE VALUES: tem T Torque Values T tem Torque Values. Sram bat ard Sones | Samwew 104.3 @ blared net wna Smmacen | 3883 | Sint om re a man bl ar vt 22.22,19 | @mmfange oe ana ene 10mm bolt and nut 35 25. 25) Srmflengebottand nut | 27127. 201 [12mm bet aa mt 2G 20)___| so mm feng ble andr foro. 20TOOLS D SPECIAL GENERAL INFORMA‘ DESCRIPTION Dd Needle bearing remover Compression gauge attachment | 07931-A70000 ‘TOOL NUMBER (07908 —KK60000 a1 equivalem commercially avcilabel in U.S.A, 07973 M3002 or 07873—MG30003 (07884551 0000 or 07984—€57010C (U.S.A. orly| 07631—0010000 07931—MK20100 | or oquivatont commercially 07939-MK50100 Favatable in U.S.A. 07836—KC10100 07741 —0010201 076MC—MKé0100 (077480060100 (07831 ~ME40000 or 07931 —mE4000A 07831 —KFOO100 07831 -KF00200 07GAD—sp40 191 07847—KA5O100, 0784?—KF00160 07816—KA80100 07846 — 4300101 or 07245 —MB00000 07853 —MJ10000 (07653—MJ00100 (07953—MJo0z00 07248—MJ001 00 Net available in U.S.A. 07914—3230001 97GMJ— 0010000 Me 1012/2 077020020001 GNHTS4 |US.A. only) 07936—3710800 07936 3710100 07936-3710200 REFER TO SECTION 1-7GENERAL INFORMATION COMMON DESCRIPTION. TOOL NUMBER REFER TO SECTION Spoke wrench C, 6.8.x 6.1 mm Float level gauge \Valve spring compressor Valve quice remover, 6.6 mm. Clutch center holder Geer howder Flywheel holder Rotor puller Tore bit (40) Driver Pilot, 36 men Attachment, 52 x 55 mm Pilot, 25 mm Attachment, 42 x 47 mm Pilot, 40 mm Attachment, 32% 36 mm Attachment, 62 x 88 mm ‘attachment I.D., 35 mm Bearing remover head, 15 mm Bearing remover shait Attachment, 72 376 mm Pilot, 20 mr Pilot, 15 mm Lock nut wrench, 30 x 32 mm Extension bar Bosring remover head, 17 mm Attachment, 97 x 40 mm Filet, 17 mm Attachment, 24x 26 mm Filot, 20 mm Pilot, 22 mm 977010020300 (07401 -0010000 07757—0010000 077420010200 077240050001 077240010100 0725 -0040000 077330020001 07933 — 3290001 97703-0010100 07749~0010000 07748—0040800 077480010400 07746 - 0040800 07746—0010300 07746 —0040800 077460010190 077460010800 077400030400 07746— 0050400 077480050100 077480010800 077460040500 077460040300 07716—0020400 07716—0020500- 07746—0050500 077460010200 07748~0040400 0748—0010700 07748—0040500 07746—0041000 ‘or equivalent commercially available in U.S.A. or 07984—6570100 fr equivalent commercially available in U.S.A Not availble in U.S.A. ‘or equivalent commercially avalable in U.S.A. (U.S.A. only) oF equivatant commercially available in U.S.A. \_ oF equivalent commercially available in U.S.A. 10, 12, 10 10 10, 12, 10 10.12, 10 10 10 10,13 10 10 2 2 2 13 13 13 VALVE SEAT CUTTER [ DESCAIPTION I TOOL NUMBER | REFER TO SECTION F Cutter holder, 6.6 mm (97781—-0010201 Float cutter. IN/EX 98.5 mm {32*) | 077800012400 | Not available in U.S.A. Interior cuttor IN/EX 37.5 mm (60°) | 07780—0014100. | Equivalent commercially 9 Seat cutter IN 40.0 mm (45°) | 07780—0019500 | available in U.S.A. Seat cuttor EX 38.0 mm (45°) | 97780-9019400— TESTERS DESCRIPTION TOOL NUMBER REFER TO SECTION Digital mult-tester (KOWA) CCiroult vester (SANWA) oF Circuit tester (KOWAL 1074110020000 KS AHM. 22-0 973080020000 TH-5H 02 U.S.A. only! 16, 17,18, 19 1-8CABLE & HARNESS ROUTING Note the following when routing cables and wire harnesses: © Aloose wire, hemes or cable can be a salety hazard, After clamping, check each wire to ba sure it ic secure, © Do not squeeze wires against a weld or the end of @ clamp. © Secure wires and wire harnesses 1 the frame with bands at the designated locations. Tightan the bands to that only the ineulated surfaces contact the wires ot wire harnesses, © Route hamesses so they are not pulled taut ar have no ex- cessive slack © Protect wires and harnesses with electrical tape or tubing whee they contact a sharp edge or comer, # Do not use wires or harnesses with damaged insulation. Repair by wrapsing thom with protective tape or replace them. © Route wire harnesses to avoid sharo edges or corners. © Alco avoid the projected onde of bolte end sorows. © Keep wire harnesses away trom the exhaust pipes and other hot parts. © Be cure grommets are seated in their grooves properly. After clamping, check each harness to be certain thet it is not interfering with any moving or sliding perts, © Aftor routing, check hat the wire hamosses are not twisted or kinked Wire harnesses routed a long the handlebar should not be pulled taut, have excessive slack, or interfera with edjacert or currounding parte in all steering positions, © Do not bend or twist control cables. Damaged contre! cables will not operate smoothly and may stick or bind GENERAL INFORMATION (0: CORRECT >! INCORRECT 1-9GENERAL INFORMATION (1) FRONT BRAKE (2) CLUTCH HOSE CABLE 14 THROTTLE CABLES (3) TURN SIGNAL LIGHT RELAY (2) HEADLIGHT: CONNECTOR «) cb UNIT. (4) SPEEDOMETER CONNECTOR (BLACK) (5) SPEEDOMETER CABLE 1-10GENERAL INFORMATION (2) FUSE BOX i om 13) IGNITION (4) CARBURETOR CHOKE Com CABLE (6) PURGE CONTROL VALVE (California medel 11) FRONT BRAKE, only! HOSE 46) CLUTCH CABLE (8) PULSE GENERATOR (7) AIR INTAKE HOSE CONNECTOR "88: (3) REAR BRAKE LIGHT SWITCH (2) VACUUM TUBE CONNECTOR (1) PURGE CONTROL VALVE (California model ~~ ontys (4) AIR CLEANER CASE DRAIN TUBE (7) CARBURETOR (6) SEPARATOR (5) REAR SHOCK ABSORBER OVERFLOW TUBE DRAIN TUBE DRAIN TUBE 1-11GENERAL INFORMATION (2) CYLINDER HEAD COVER BREATHER TUBE (2) THROTTLE CABLES (1) REAR @RAKE LIGHT SWITCH WIFE 14) TURN SIGNAL LIGHT RELAY (5) SPEEDOMETER CABLE (6) CANISTER (California model only) (8) IGNITION SWITCH Wine (7) ENGINE STOP SWITCH CONNECTOR (WHITE) WIRE CONNECTOR (RED) (1) BATTERY POSITIVE (2) AIR INTAKE (3) BATTERY NEGATIVE WIRE HQSE WIRE CONNECTORGENERAL INFORMATION (2) REAR RIGHT TURN SIGNAL Rt (2) CLAMPS. LIGHT WIRE ) we (4) REAR LEFT TURN SIGNAL UGHT WIREGENERAL INFORMATION AFTER ‘88: (1) PURGE CONTROL VALVE (California medel onty) —™ (3) REAR BRAKE UGHT SWITCH CONNECTOR (4) AIR CLEANER E cas DRAIN TUBE 2) AIR INTAKE HOSE ‘ (6) SEPARATOR (5) SHOCK ABSORBER DRAIN TUBE (2) TAILIBRAKE LIGHT (6) CLAMPS WIRE U1) REAR RIGHT TURN SIGNAL LIGHT WIRE (4) REAR LEFT TURN SIGNAL LIGHT WIREGENERAL INFORMATION » Le exon \ NZ a= a L (2) SPEEDOMETER (3) SPEEDOMETER CONNECTOR =GENERAL INFORMATION EMISSION CONTROL SYSTEMS The U.S. Environmental Protection Agency and Califomia Air Resources Board (CARE) require manutacturers to certify that ‘their motorcycles comply with applicable axhcust emissions standards during their useful life. whan operated and maintained according to the instructions provided, and that motorsyoles built after January 1, 1983 comply with applicable noise omic. sion standerds fer one year oF 6,000 km (2,730 miles} after the sime of sale to the ultimate purchaser, when operated and ‘maintained according o the instructions provided. Compliance with the terms of the Distributor's Limled Warranty for Honda Motorcycle Emission Control Systems is necessary in order to keep the emissions systam warranty in effect. SOURCE OF EMISSIONS. ‘The combustion process produces carbon monoxide and hydrocarbons. Control of nydracarbons is very Important because, Under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but itis toxic Honda Motor Co., Ltd. uilizes lean cerburetor settings as well as other systems, to reduce carbon monoxide and hydro- carbons. EXHAUST EMISSION CONTROL SYSTEM Except for California: ‘The exhaust emission control system is composed of a lean carburetor setting, end no acjustments should be made except icle speed adjustment with the throttle stop screw. The exhaust emission control system is separate fiom the crenkcase emission control system. California only: ‘The exhaust emission control system consists of a secondary air supply system which intraduces fitered air into the exhaust ‘gases in the exheust port. No adjustments to this system should be made, although periodic inspection of the components is recommended. The sacordary air supply systam helps improve emission performance. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with « closed crankcase system which routes crankcase emissions through the air cleaner into the ‘combustion chamber (1) BREATHER (2) AIR CLEANER "38: SEPARATOR, SS Frosh air = Blow by gee (4) AIR SUCTION VALVE (3) DRAIN PLUGS,GENERAL INFORMATION AFTER ‘88: a SepanaTon (2) AIR CLEANER 4) ainEuction SS Fresh air VALVE {31 DRAIN PLUG. > Bowby gas EVAPORATIVE EMISSION CONTROL SYSTEM (California model only) Tha model complies with California Alr Resources Board evaporative emission requirements. Fuel vapor from the tuel tank and carburator is directed into the chareoal canister where itis adsorbed and storad while the {engine is stopped. When the engine is running and the purge control diaphragm velve is open, fuel vaporin the charcoal sanie- ter is drawn into the engine through the carburetor (1) FUEL TANK (2) CARBURETOR |9) AIR CLEANER, (6) CANISTER (4) PURGE CONTROL VALVE Revs 1-17GENERAL INFORMATION EMISSION CONTROL INFORMATION LABELS (U.S.A. only) [An Emission Control Information Label Is located on the inside of the right side cover as shown. It contains basic tune-up specifications. (1) EMISSION CONTROL: INFORMATION LABEL EMISSION CONTROL INFORMATION UPDATE LABEL [After making a high altitude carburetor edjustment (page 4-17), attach an update label on the right side frame down pips. In structions for obtaining the update label ere given in Sarvioe Letter No. 132. [1] EMISSION CONTROL INFORMATION UPDATE LABEL, VACUUM HOSE ROUTING DIAGRAM LABEL (California model only) ‘The Vacuurn Hose Routing Diagram Label is on the inside of the lett side cover. Route the vacuum hhoses 2s shown on this label "BB: SHOWN, AFTER ‘88: Similar (1) VACUUM HOSE ROUTING DIAGRAM LABELGENERAL INFORMATION NOISE EMISSION CONTROL SYSTEM thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair oF raplace: ‘mont, of any device or clement of design incorporated into any new vehicle for the purpose of noise control pir to its sele oF delivery to the ultimate purchaser or wile itis in use; or (2) the use of the vehicle after such deviee or element of design has been removed or rendered inoperative by any person, D TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROH/BITED: Federal law prohibits the following acts ro the causing AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: 1. Removal cf, or puncturing of the muffler, baffles, header pipes or eny other component which conducts exhaust gases. 2. Removal of, of puncturing of any aart of the intake system. 3. Lack of proper maintenance. D 4, Replacing ary moving parts of the vehicle, of parts of the exhaust or intake system, with parts other than those specified by the manufacturer. 1-192. LUBRICATION ‘SERVICE INFORMATION 22 OILPIPEINSPECTION 24 D TROUBLESHOOTING 2-2 OIL STRAINER SCREEN CLEANING 24 ENGINE OIL LEVEL CHECK 23° OILSTRAINER NUT 25 ENGINE OIL CHANGE 23 Om PUMP 25 4 ENGINE OIL FILTER REPLACEMENT 2.4 — LUBRICATION POINTS 214 (3) OW INLET PIPE (A CHECK VALVE (6) Ol SCREEN 46) GIL PUMP 2-1LUBRICATION SERVICE INFORMATION GENERAL © This section descrives inspection and replacerrent of engine cil and the oil ft, the clearing of the oll strainer and oil pump servicing procedures. CAUTION + Used enzine oil may cause skin cancer if repeatedly left in contact with the skin Jor protonged periods. Although this is unlikely uuntess you handle used oil en a daily bass, 1 ie still advisable to thorowghly wash your hands with soap and water as soon as posi ble afler handling uacd oi. SPECIFICATIONS Oil capacity 2.3 liters (2.4 U.S. qt, 2.0 Imp at) at engine assembly 1.9 liters (2.0 U.S. at, 1.7 Imp atl at oil change 1.95 liters (2.06 US. ct, 1.72 Imp qt) at ail and oil fiter change Recommended oll Honde 4-Stroke Oil or equivalent API Servica Classification: SE or SF VISCOSITY: SAE 10 W—40 ar 20 W~50 NOTE «Use SAE 10 W—40 oil when the outside temperature is below O° C (32°F Other viscosities shown in the chart may be used when the average tempera- Sun yourtuing rene wiin tha maleate [ ITEM. STANDARD ‘SERVICE LIMIT Oil pump tip clearance - ~ 0.18 mm (0.006 in) MAX. I 9,20 mm (0.008 in) Oi pump bey eearanco 2:18--0.21 rm 10.006 0.008 in) “0.26 rm (0.010 i) Oil pum end coaancs 0.02--0.08 rm (0.001 ~0.008 in) 12 mm (0-005 mn) Oi pump celery Panp Ar 7.8 tes (7-8 US. etman. 5.00 1pm _ amp 8: 10.0 ltats (10.6 U.S min 5.300 pm TORQUE VALUES Crankease drain plug 25 Nem (2.8 ka-m, 18 tb} Down tube drain plug BB Nem (3.8 keg-m, 25 ‘tsb) Oil filter cover bot Nem (0.9 kgm, 7 fb) Ol strainer nut 440 Nem (4.0 kg-m, 29 tb} i inlet nase nut 40 Nem (4.0 kg-m, 29 it-b} TROUBLESHOOTING 1 level too low + Normal oil consumption + Extarnal ol leaks + Worn piston rings Ol contamination + Gil not changed often enough + Faulty heed gasket Low oil pressure + Faulty oil pump + Oil puma driven gear broken 2-2 [ere peLUBRICATION ENGINE OIL LEVEL CHECK ‘Support the motorcycle uoright on level ground, Start the engine and let iticle for approximately § minutos ‘Stop the engina then chock tho ail lovel with the ail filer cap/ Aipotick by inserting itin until the threads touch che Filler neck. Do not screw the cap in when making this check {f the oil level is below the lower merk on the dipstick, filo the Upper level mark with the recemmancied oil ENGINE OIL CHANGE Nore + Change the engine oil with the engine warm ane the motor ycle on its side stand to assure complete and rapid ¢rain- eee — Femove the oll filer cap and drain plugs on the frame cown tube end the left crankcase. CAUTION + Used engine oil may couse skin cancer F repeatedly left in con: tnci with the skin for protonged periods, Although this is wa key unless you handie used of! an daily basis, i is stilt advis able to firoughty wash your hands with soap and witer 25 500% 5 possible ajter handling used vil After the oil has drained, check tat the drain plug sealing washers are in good condition, then install the plugs ‘TORQUE: Crankease drain plug: 25 N-m (2.5 kg-m, 18 feb) Downtube drain plug: 35 Nem (3.5 kg-m, 25 ft-lb) NOTE + It maintenance is slso scheduled for the cil filter ane the strainer, do these befor filling the frame oll tank with oil + Theengine takes about 1.9 Iters(2.0U.S. qt, 1,7 imp at) at ol change. But cince orly a portion ef thet ois held in the frame's oil tenk, you cannot add the Tull amount inhialy, Pour one liter (1.06 U.S. qt} of cacommended eil (page 2-1) into tho oil tank. Install the of titer capidipstick, Start the engine anc let it idle for a few minutes, ‘Stop the engine and add the recommended cil up to the uppar level mark with the metoreyele upright. CRANKCASE OIL CHECK BOLT NOTE The crankcase oil level check bolt is useful when checking the lubrication system: the ail pump adjusts the oil level so. that the crankcase is slways kept at the prope level. If this check shows otherwise, some portion of the lubricaticn system Is not working properly. Run the engine first, then stop the engine and wait a few min- utes. Remove the oll check bolt, ‘The crankcase oll level is correct if the cil is flush with the bottom of the check bolt hole. Install the oll chack bolt. Re- check the cil level with the ol filtar cepidipstick iy on ruuen can 0% i Uppen weet (3) Lowen LEVEL °C) OIL CHECK BOLT aera 2-3LUBRICATION ENGINE OIL FILTER REPLACEMENT NOTE + Change the oil filter before filing the frame oil tank with ol Remove the oil filter cover trom the right crankcase, then remove the filter elament Digcard the oil fiter element ‘Check that the O-ring on the oil filter cover is in good cond tion. Inatall tho spring, now oil iter olamant and cil fikor cover. + Install the element with the “QUT SIDE" mark facing out. + Install the al fiter cover aligning the tabs on the filter cover and right crankcase cover. Tighten the cover bo'ts, TORQUE: 9 Nom (0.9 kgm, 7 Ft 1b) Pour in the recommenced oll (page 2-3) to the upper level on the filter cap/dipstick OIL PIPE INSPECTION Inspect tha oil pipes for damage, bends or eloging and replace if nocassary. Refer to the following page for oll pipe replacement. — Oil pass pine (pane 6-3) Oil outiet pipe (page 6-4. 5) — Oil info: hose [page 5-4, 6) OIL STRAINER SCREEN CLEANING Nore ‘with ol. + Perform this maincenance before filing the engi Femove the right crankcase cover (page 8-3) Femove the ol strainer and clesn it. Install and secure the cil strainer with a bolt. Install the right crenkease cover (nage 8-9) Fill the srankeago with the recommended oil (page 2-1), (2) OIL FILTER ae "| outs oft PN wore 4 | * iso ten cane (7) SPRING 2-4_— _ ai ane LUBRICATION OIL STRAINER NUT i Bits 5 VSI BRAN BOLT 4 NOTE Zs © Clean ihe screen on the il strainer nut beFore filing tha frame oll tank with ol Remove the oil drain bolt on the frame down tube to drain the oil, Remove the skid plate Ipage 6.2) Loosen the oil joint rut and disconnect the hose from the oil sttainer nut Remove the oi strainer nut from the frame dovin tube. Clean the screen on the ol strainer nut in solvent and blow dry with compressed cir Chock thet the O.ring ie in good condition. Reinstall and tighten the oil strainer nut. TORQUE: 40 Nem (4.0 kg-m, 29 ft-lb) Connset the oll hose and secure it with the mute TORQUE: 40 N-m (4.0 kg-m, 29 fb) \ Reinscal the skid plate (nage 5-5) (2) OIL STRAINER NUT 42) O-RING Fill tho oil tank 10 tho upper lovel with the roeammended oil (page 2-1) OIL PUMP REMOVAL Femave the following: = clutch Ipage 8-2 = oll pump driven gear = orifice and O-ring Fomove the Following: = bolt, nut and oil pipe = oil pump atiaching bots and oll pumpLUBRICATION CHECK VALVE (1) COTTER PIN Remove the cotter pin, valve retainer, spring and check valve from the check valve housing Discard the removed cotter pin Inspect the valve and valve bore for scoring or contamination, (1) CAP Clean or replace as necessary. 2} VALVE, Install the check valve, spring and valve retainer into the check valve Pousing, and secure them with a new cotter pin. * (2) VALVE RETAINER (8) SPRING (4) COTTER Pin DISASSEMBLY 11) SCREWS: Remove the oil pump screws. Romove tho following from the oll purnp bocy. |1) COVER A i (2) UTES ROTOR A =0il pump cover A 2 —Duter rotor A —Inner rotor A, 2-6—— LUBRICATION Remove the following: =Hock pin thrust washer ‘Separate the cil pum body from the cil pump cover 8. Remove the following from the caver 8. =Dil pump shaft and lock pin “inner rotor B Outer rotor 8 INSPECTION Measure the tip clearance between the inner and outer rotor As. SERVICE LIMIT: 0.20 mm (0.008 in} Measure the ol pump body. rance bo!woen the outer rotor A and the SERVICE LIMIT: 0.26 mm (0.010 in} (1) LOCK PIN (1) PUMP BODY 2) SHAFT (21 WASHERLUBRICATION Wipe oll from the rotors and put a place of plastigauge across, (IP PLASTIGAUGE them as shown, Install the oil pump cover A and tighten the ol pump screws. Remove the oll pump cover A and measure the width of the Plastigauge. ‘The wildest thickness determines the pump end clearence, SERVICE LIMIT: 0.12 mm (0.005 in). Measure the tip clearance betwoan the inner anc outer rotor Bs with the pump shaft installed. SERVICE LIMIT: 0.20 mm (0.008 in)LUBRICATION Measure tho cloarance betwoen ths outer roter Band the pump B body. SERVICE LIMIT: 25 mm (0.010 in} Measure the end clearance of pump B. | SERVICE LIMIT: 0.12 mm (0,005 in} AFTER "38: re Rerlace the ail sais they show any signe of wear or dom: 51.1 mm stone the Y vee 40.020—0.043 int se nore + When removing the oil seal, note which surlace of the ol | seal faces out. Install new cll seals into the noles squarely in the specified depth from the outer surfaces as shown. ) SPECIFIED DEPTHS: 0.5— 1.1 mm (0.020—0.043 inp (2) 01 SEALS O.5—1.1mm (1) PuMe BODY (9.920. 0.043 in}LUBRICATION ASSEMBLY (1) Dowel PIN (SHORT) (2) DOWEL PIN (LONG) (6) CHECK VALVE 43) PUMP SHAFT (7) SPRING Bey (e) THRUST WASHER (6) VALVE RETAINER o wocorren PN \é Va, \ \C. (10h gure a | {21 LOCK PINS. 4177 INNER. ROTOR A (13) OL PUMP RoDY (14) INNER (1g/ouTER ROTOR "ROTOR B (16) PUMP COVER B AFTER '88: (7) PUMP COVER A (2) OUTER ROTOR B Jn) Pum COVER B “vy 18) CHECK VALVE (10) SEALSd » LUBRICATION Install :ho outer rotor Bin the oil pump cover B with the punch mark on the rotor facing insiae. CAUTION ‘Before installation, poor the clean engine oil inio the oil pass hole in the oil pump body B until the oll flows out of the ofl ‘pass hole in the check valve housing side as turning che pump shaft. Instal the inner rotor B in tie pump cover B. Insert the lock pin through the oll pump shaft, and insert the shaft through the inner rotor ard pump cover with the lock pin algrod with the groove in the inner rotor. Install the oil pump body onto the pump cover B. Insert the dowel pins through the pump body end pump cover 8 Install the thrust washer onto the pump sheft Insert the lock pin through the hole in the shat. Install the innerrotor A onto the sheft, aligning its groove with tha lock pin. Install the outer rotor A with the punch mark on the rotor faced outside, Intell the pump cover A onto the pump body. (1) PUNCH MARK (1) PUMP BODY (2) SHAFT (1) INNER (2) LOCK PINLUBRICATION Tighten the oil pump screws securely. _——— (1) SCREWS AFTER ‘88: CAUTION + Before installation, pour the clean engine oi into the oil pass hole in the oil pump body B until the off flows our of the oil (pass hole in the cheek valve housing side as turning the pump shaft counierclockwis. INSTALLATION Install the orifice with @ now O-ring into the right crankcase Install the oil pump onte the right erankease. Tighten the two oil pump bolts loosely Apply elaan sngine oll to now O-rings Install the oll pipe with the new O-rings, ‘Tighten the oil pipe nut and oil pump bolts eecurely.Apply clean engine oll ta new O-ring, Install the orifice with the new O-ring Install the oil pump driven gear onto the oll pump sheft. Inetall the following: clutch ipege 8-9) right crankcase cover (page 8-9) Fill the engine with the recommended aii (page 2-3) AFTER ‘o3: After ints lation, support the motorcycle upright on firm, level ground ard start the engine and let it idle ‘or a minut, Loosen the oil pipe bolt on the right erankcate cover (page 8-10) and choak that the oll flows aur. Tighten the oil pipe bolt. TORQUE: 12 Nem (1.2 ko-m, 9 ft-lb) 2-13LUBRICATION LUBRICATION POINTS Unless otherwise specified, use general purpose grease. Apply oil or groase to any other sliding surfeces not shown here. CONTROL CABLE LUBRICATION Periodically disconnect the throttle ard clutch cables at their ‘upper ends, Clean the cable end mount in the throtte and clutch lever, then ollthe cable ends and reinstall. Iris not nec: essary to oll the cables; if a cable begins to bind, it must be re- placed "BB: SHOWN, AFTER '88: Similar tas SHOCK ABSORBER a UPPER MOUNT BUSHING \ SAF @ 8008 # 80 | GEAR OIL DRIVE CHAIN BRAKE CAM. Wneet aeadics DUST SEALS SHOCK ARM PIVOT NEEDLE BEARINGS; SHOCK LINK PIVOT NEEDLE BEARING; DUST SEAL COLLARS SIDE STAND Pivot ERAKE PEDAL PIVOT WHEEL BEARING Grease new wheel bearings and dust seals before installa- tion. Do rot reinstall used wheel boaringe or coal. Note ‘Some sources of MoS: paste grease with 40% or more molybdenum are + Molykote® G-n Paste manufactured by Dow Corning, USA. + Honda Maly 45 (U.S.A. only) + Rocol ASP manufactured by Rocol Limited, UK. + Recol Paste manufactured by Sumico Lubricant, Japan, Any other manufacturer's paste grease equivalent to the above may also be used. THROTTLE GRP BRAKE/CLUTCH LEVER PIVOT BOLTS Say 7 STEERING HEAD 27 BEARINGS/DUST SEAL S. SPEEDOMETER GEAR/ = DUST SEAL SWING ARM PIVOT/DUST SEALS/COLLAR NEEDLE BEARINGS3. MAINTENANCE SERVICE INFORMATION MAINTENANCE SCHEDULE FUEL LINE/FUEL STRAINER | THROTTLE OPERATION CARBURETOR CHOKE AIR CLEANER SPARK PLUG VALVE CLEARANCE CYLINDER COMPRESSION CARBURETOR IDLE SPEED DRIVE CHAIN DRIVE CHAIN SLIDER SERVICE INFORMATION GENERAL Engine oil level check Engine oll change Engine oil filter replacemant » Engine oil strainer nut cleaning SPECIFICATIONS 3-1 BRAKE FLUID 3.10 3-3 BRAKE SHOE/PAD WEAR 3.10 3-4 BRAKE SYSTEM 341 3-4 BRAKELIGHT SWITCH 314 3-6 HEADLIGHT AIM 3-12 fe 36 CLUTCHSYSTEM 3-12 36 — SIDESTAND 3-13 3-6 SPARK ARRESTERIU.S.A. only) 3-13 3-7 SUSPENSION 314 3-8 NUTS, BOLTS, FASTENERS 3.15 3-8 — WHEELS/TIRES 345 3-10 STEERING HEAD BEARINGS 3-15 Page 2-3 Pege 2-3 Page 2-4 Pege 2-5 ENGINE Spark rug: Plug ap: 0.8 0.9 mm (0.031 0.035 in) Plug typo: Standard For extended high speed riding ND N@K NO NGK X2aEPR.US DPRBEA.O X27EPR US DPROEA.O. Valve clearance INTAKE 0.10 mm (0.904 in} Carburetor idle speed: Cylinder compression: EXHAUST: d Throttle grip fre play FRAME Choke valve vavel: Chain slider service lit: Drive chain slack: Rear brake padel free pley: Clutch lever free play: Tire pressures (rider only): Frort: Rear Powe Front Rear 0.12 mm (9.008 in| 26 mm (1/8~ 1/4 in) 1,300 + 100 rpm 12.5 kg-cm? (177.75 psi) with the right exhaust valve clearance about 1 mm (0.04 in) 10—11 mm (0.39~0.43 in} 3 mm (1/8 in} 30—A40 mm |1-1.4—1-5/8 in) 20-30 mm (418 —1-1/4 in) 10-20 mm |3'8~ 3/4 in) 150 kPa (1.5 kg’er®, 22 psil 150 kPa (1.5 kg/er?, 22 psil 90/90—21'5as, 1209017 648MAINTENANCE TORQUE VALUES Fuel cup Valve adjusting screw lock nut Roar exle nut ‘Spoke nipple TOOLS Special Compression gauge ettachment ‘Common Spanner C, 5.8 x 6.1 mm 4.Nem 10.4 kam, 3 tb) 26 Nir {2.8 kgemn, 18 feb) 95 Nem {9.5 kgim, 69 feb} 4.Nem 0.4 kgm, 3 11D) 07908 -KK60000—or equivalent commercially available In U.S.A. 07701 -0020300—or equivalent commercially availabla in U.S.A |MAINTENANCE MAINTENANCE SCHEDULE Perform the PRE-RIDE INSPECTION at each scheduled meintonance period. I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. G:CLEAN A: REPLACE A:ADJUST L:LUBLICATE FREQUENCY ‘ODOMETER READING [NOTE (7)] T x1,000mi 06| 4 | 8 12|16| 20] 24 eter TEMS ~ notes [x1,000km | 1 |6.4 12.8 19.2[25.6|32.0/38.4| to page [= [Fue une I 1 1 ‘p34 = FUEL STRAINER SCREEN L_ cl elefcle.c|s4_| = THROTTLE OPERATION 1 1 i | oe «¢ E_ CARBURETOR CHOKE — 1 Clr pss [Tancucanen wore a celelrfe cj lal os || cRankcase eREATHER (38) (OTE 9 cle cic cle] 47 2 | [seank rus r[rRiR{[R aja | 90 § |= [ vatve clearance fo =| | ENcIne ou. f_| EVERY 2,000 mi (3,200 km) R 3 | [eae ou ACTER t — i f a 7 ~PeNGINE OL ST 3)” | SR Gt Sone c c c | 3s “V+ | CARBURETOR IDLE SPEED. 1 1 1 1 1 1 1 38 SECONDARY AR SUPPLY [_ - rot [pa | TRARSRATESNSSION | wore Di fan | » DAVE CHAN wore RY 60 (DCO RTL DAIVE CHAN SUDER I reed |__| emake rLvio nore 7 Cheba eps E | [erake sHoz/PAD WEAR Cee g|_[enak: sverem 1 1 1 E [= | erake ucHr swirc 1 1 fan 2 [= [ Heaouicr aim I Tt vf saz 3 |_[oures system 1 viet fag § |_| sioe stano 1 1 fosas 215 Teuspansion — i 1 Tate] © TT spank annesTEn (wore & cle ec cle|le|] as ’ & [= [Nuts Bouts, FASTENERS | (NOTE sy 1 1 1 1) aaa =| waeetsrnines (nore st 1 \ vif | sas **| STEERING HEAD BEARINGS. 1 1 i nm 315 Sra te sereedb an eihorzed Honda dealer, unless he ownerhes pope tools and sevice dato ands mechancaly avattog ++ fhe inteest of suet, we rsommend these tums be seca ONLY by an authvized Mond desler otis anther eng pan oth tomo neva eas hee 2. Service more frequently when riding in unusually wet or dusty areas. 3. Service more frequently when riding in rain or ar full throttle 4, Californie type only 5. Service more fraquently when riding OFF-ROAD. 6. USA only. ) 7. Replace every twe years, or et incicated odometer interval, whichever comes frst. Replacement requires mechan ical skilMAINTENANCE FUEL LINE/FUEL STRAINER Check the fuel line for damage, cracks or fatigue. and replace if necessery. ‘Tum che fuel valve “OFF. Remove the fuel cup, O-rng end stra gasoline into 2 suitable container. + Gasoline is extreamely flammable and is explosive under cirtain conditions. Work in a well ventilated area. Do not smoke or allow flantes or sparks in the work ar ‘er screen and drain the Wesh the cup and strainer sere hight flash point solvent. Roinstall the screen, aligning the index marke on the fuel valve body and strainer screen, Install 8 new O-ring into the fuel vaive body. Reinstall the fuel cup, making ure the O-ring is in olace. Hand tighten the fuel cup and then torque it to specification, in clean non-flammable or TORQUE: 4.Nem (0.4 kgm, 3 fib) CAUTION + Do noi overtighten the fuel cup. ‘After Installing, curn the fuel valve “ON” and check thar there: are no fual leaks. THROTTLE OPERATION Chock that the throttle arin opens smoothly to ful throttle and fully closes automatically in all steering positions. Make sure there is no deterioration, damage, or kirking in the throttle cables, and that the throttle grip free play ts 2—6 man (1/8—1/4 in) at the throttle gro ‘lange. Throttle grip free play can be adjusted at oither ond of the throttle cable. Replace any damaged parts before beginning ths adustment. Minor adjustments are made with the upper throttle cable ed- suster Adjust free play by loosening the feck nut and turring the ed- juster, Tighten the lock nut. Recheck thrattla oparatian,MAINTENANCE Mejor adjuetment is made with the lower adjuster. ‘Adjust free play by loosening the tock nut and turning the ad- Alter adjustment. tighten the lock nut. Recheck the throttle operation. Replace eny damaged parts, if necessary. CARBURETOR CHOKE Check that the choke lever moves smoothly Lubricete the choke cable if the operation is not emaath, Remove the fuel tank ipage 4-3). Loosen the choke cabie nut and from tho carburetor fisconnect the choke cable Measure the choke valve stroke, moving the choke lever from the full open position to the close position. Choke valve stroke: 10-11 mm (0.29—0.43 in} If me choke valve stroke is out of the standard, adjust by loos: ning the lock nut and turning the adjuster Operate the choke lever and make sure the choke valve stioke 's whhin ine stancard, Connect the choke cable to the carburetor and tighten the shoke eable nist Tighten the adjuster lock nut Connect the choke cable co the carburetor and tighten the choke cable nut, Install the fuel tank ipage 4-3), seat and side cover {nage 16 .MAINTENANCE AIR CLEANER Remove the laft side cover. Remove the air clesner cover screws and tho cover. Unhook the upper element retainer from the lower retainer, land remove the element. Acéarding to the maintenace schedule, clean the element by applying compressed air from the outside and if necessary, re- place the element with a new one. Install the elament in the reverse orcer of removal. SPARK PLUG Disconnact the spark plug cap end remove the spark olug, Visually inspect the spark plug. Discard it if the insulator is, ‘cracked of chipped. Measure the spark plug gap with a wite-type feeler gauge, ‘Adjust the gap by bending the side electrode carefully. SPARK PLUG GAP: 0.80.9 mm (0.031—0.035 in} RECOMMENDED SPARK PLUGS. X24EPR-UO NO Standard — __DPRBEAD NGK For extended high | _X27EPR-US ND speed riding Der@rao | _NGK Mako sure the sealing washer is in good condition. Install the ‘spark plug. tighten it by hand . then tighten with a spark plug wrench Connect the spark plug cap. VALVE CLEARANCE NOTE © Inspect and adjust valve clearance while the engine is cold (35°C/95°C). Remove the fuel tenk (page 4-3). Remove the crankshaft and timing hole caps. Remove the valve adjuster caps Fotate the crankshaft counterclockwise to align the "7" matk fon the flywheel with the notch on the left crankcase cover. iio a) CRANKSHAFT HOLE CAP Bo 0.80.9 mm (0.031 0.035 in} 3-6MAINTENANCE Make sure the piston is at TOC(Tap Dead Center) cn the com- Beession stroke, Check the claaranca of the left exhaust, and left and ‘ight Intake valves by inserting a feolor gouge between the adjusting sserew and the sub-rocker arm, NOTE + When cheoking the clearance, slide the fesler gauge from the inside out in the direction of the enow. Valve clearance: Int 0.10 mm {0.004 ind Exhaust: 0.12 mm (0.005 ini Adjust by loosening the lock nut and turning the adjusting serew until there is a slight drag on the feeler gauge. Hold the adjusting screw and tighten the lock nut. TORQUE: 25 Nem (2.5 kg-m, 18 ft] Fight exhaust valve: NOTE + Special cere must be taken when measuring valve clear ‘ance at the right-hand exhaust valve. The Hall-decompressor slightly lifts the right hand, exhaust, valve when the crankshaft pesiticn is before compression toe. ‘Therefore itis necessary to position the crankshaft where there is no valve lft in order to obtain the correct vaive dlearanc ‘CAUTION © Wthe crankshaft passed the “T” mark (aligning marke), rotate the crankshaft counlerclockwice again et align it with the “D" mark. This must be dore (o prevent the one-way decont pressor systent from functioning and to obtain the correct vatve elearance, ‘After tightening the valve adjusting lock nut, recheck the valve clearance. Install the removed parts in the reverse order of the removal CYLINDER COMPRESSION Bofore measuring cylinder compression, adjust the right ox: aust valve with the valve clearance aaproximately 1 mm (0.04 ini (page 3:6) Warm up the engine, Stop the engine and remove the spark plug, Install the attachment to the compression gauge. ToL: Compression gauge attachment 07908—KK6000 or equivalent commercially available in U.S.A. Connect the comprossion gauge. Position the engine stop switch OFF. Open the throttle grip all the way. Crank the engine with the starter motor until she gauge stops rising. Check the gauge reading, NOTE + Check thet there is no leakage at the gauge connection. COMPRESSION: 12.6 kg/er (177.75 psidMAINTENANCE. Low compression can be eaused by: + Improper valve clearance adjustment + Valve leakage + Losking cylinder head gasket + Worn piston rings or cylinder High compression can be caused by: + Carbon deposits in the combustion chamber or on the piston head. NOTE TAtter Inspection, reinstall the apork plug and adjust the valve clearance (page 36), CARBURETOR IDLE SPEED NOTE (1) THROTTLE STOP SCH! T inopact and sdjust ie speed after all other engine adjust ments are within specifiestions. The engine must be waim {for accurate idle inspection and adjustment. Ten minutes of stop and go riding is suffi Warm up the engine, shift to neutral, and hold the motorcycle Upright. Connect a tachometer. ‘Turn tho throttle step screw to obtain the specified ice speed. IDLE SPEED: 1,300 2 100 rom DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION Spector adjust he drive stain hile the engin “Turn the ignition switch OFF, place the motorcycle on it stand and shift the transmission into neutral. Check drive hein lack in the lower run midway between the sprockets. STANDARD SLAGK: 30-40 mm (1-1/4—1-6/8 in DRIVEN CHAIN ADJUSTMENT Loosen the rear axle nut Loosen both lock nuts and turn both adjusting nuts as noces- saty. CAUTION 1 Be sure the index marks of the same position are cligned with the rear edges of the swing arm holes. Tighton the raar axle nut. TORQUE: 95 Nem (9.5 kum, 69 felbl ‘Soug she adjuster nuts up against the swing arm end caps. Tighton bath lack nuts. J 3-8 DiMAINTENANCE Check the chain wear label. If the red zone on the label aligns With the arcow of the chain edjuster after the chain has been atjusted, the chain must be replaced. When the crive chain becomes extremely dirty, it should be ‘leaned prior to lubrication, Remove the rear whee! {page 19-3) Remove the drive sprocket cover and chain cover. lean the d ard wipe dry chain with a non-flammable er hich flesh point Lubricate only with SAE #80 a 80 gear ol Commercial chain lubricants may contain solvents which could damage the rubber O-rings, Inspect the drive chain and O-rings for possible wear or dam- 29°. Roplace the chain if it '@ worn excessively or damage, Inspect the sprocket teeth fer excessive wost or damage. Re ploce if neceesary. Drive sprocket replacement: page 5-4 Driven sprocket replacement: page 13-6,6 NOTE + Never install a new drive chain on worn sprockets or a worn cchain on new sprockets. Both chain and sprockets must bo in good condition, or the now replacement chein or sprockes will weer tapidly Reinstall the rear wheel (pege 19-7) and chain cover. | | L t (1) MASTER LINK (2) O-RINGS (1) Goon (2) REPLACEMAINTENANCE DRIVE CHAIN SLIDER Check the chain slider for wear or dameae. Replace the drive chain slicer ifthe thickness exceeds the ser: vice limit. SERVICE LIMIT: 3 mm (1/8 in) CAUTION If the chain slider becomes worn down through 10 the swing arm, the chain will vear against the swing erm BRAKE FLUID ii cover Chock the front brake fluid reservoir level IF the level is near the lower level mark, remove the cover and slaphragm, Fill the reservoir with DOT 3 or DOT 4 BRAKE FLUID to the upper level Check the entire system for leaks, if the level 1s low. CAUTION + Do not remove the cover until the handlebar hus been tuned so that the reservoir is fevel + Avoid operating the brake lever with the cap removed. Brake Fluid wil squirt out if the lever is pulled + "Do not mix differert types of uid, they are not competible wich each otter. Refer to section 14 for brake bleeding procedures. BRAKE SHOE/PAD WEAR BRAKE PAD WEAR Check the brake pads for wear by looking though slct incicat- 8d by arrow cast on the caliper sesembly. Replace the brake pads if the weer line an she pads reaches the feage af the brake dise (page 14-4) + Always replace the brake pads in pars to assure even disc pre.MAINTENANCE BRAKE SHOE WEAR Replace the brake shoes if the arrow on the indicator plato aligns with the “A” mark on the brake panel when the brake is applied BRAKE SYSTEM BRAKE PEDAL HEIGHT Loosen the lock nur and adjust the podal height by turning the stopper bolt. Tighton the lock nut Adjust the brake pedal free play. BRAKE PEDAL FREE PLAY NOTE ‘Adjust the rear brake peda ree play alter adjusting the brake pedel heiaht ‘Moasure the rear brake pedal free play, FREE PLAY: 20-30 mm (3/4—1-1/4 in Adjust the free play by turning the adjuster. BRAKE LIGHT SWITCH lage es nurg NOTE + Perform this agjustment after adjusting brake pedal height and frae play. The brake light should go on when the brake pedal is de- pressed 10 mm (3/8 in), ‘Adjust by turning the adjusting nut. CAUTION ‘Do noi turn the switch body.MAINTENANCE HEADLIGHT AIM (1) VERTICAL a | Ce = Tuin tho adjuster countorclockwiew (clockwise) to direct the beam down, Adjust horizontally by turning the horizontal adjuster. Turn the adjuster clockwise (counterclackwise} to direct the bboam toward the right sido of the ridar. NOTE = Adjust the heedlight beam as specified by local laws and regulations, ‘An improperly adjusted headiight may blind oncoming drivers, (rit may fall to Ught the road for a.safe distance. CLUTCH SYSTEM Massure the cluteh lever fra play at the lever end. FREE PLAY: 10-20 mn |3/8—3/4 in) 1020 mm (ie arti Adjust as follows: (tock NUT (2) ADJUSTER Minor a¢juetmente aro made with tha uppor adjuster, Pull the cover back, Loosen the lock nut end turn the adjuster to obtain the spect: fied free play. Tighten the lock nut end install the cover. Check clutch opera ton, livotmente are made with the lower adjusting nut. If ajar aejustment is required, turn the upper edjuster in all the way eno back out 1 tum. Loosen the lock nut and turn the lower adjusting nut to obtain ‘the specified free play. Tighten tho lock nut. Check cluteh eperetion,MAINTENANCE SIDE STAND [ (WEAR MARK Check the tuber pad on the side stand for deterioration and wear. Replace the rubbor pad if woar oxtende to the wear Fine. heck the side stand operation: When lowerd, the stand should move easily to the first ston, then lock forward to suppor: the motoreyele when the pad touches the ground and tho weight of the motoroyele is eu ported, When the motorcycle is raised, the stand should automatically | —- ff move to the frst ston, then ratract easily when kicked Lo SI FIRST CLICK Ifthe side stand does not operate smoothly, disassemble and [~ (4) RETURN SPRING—tae5) (5) PIVOT BOLT check the side stanc assambly as following procadura: Remove the return soring at the retracted posiion. la Remove the pvot bolt ard side stand. wag) Jatin Lubricate the pivot area with clean grease and reassemble the side stend. Apply a locking agent to the belt threads. Tighten the pivot bolt securely. 1 TORQUE: 50 N-m (5.0 kg-m, 36 ft-lb) 2) DUST SEALS: caution Install the cust seat with its mark side facing in + Make sure that the dust seal tip spring is seated on the outside Of the dust seat lips securely. Check the side stand operation as indicated above. SPARK ARRESTER (U.S.A. only) (iy MUFFLER L105; Remove the mute ta Start the engine and increase rpm's to blow carbon out of the exhaust pipe while momentarily creating exhaust system back pressure by blocking tha end ef th muffler with a chap towel Repeat until carbon stops coming out. + Do not perform this operation while che exhaust pipe is hot. + Perform thts operation in a well venttiawed area, free from fire hazard. + Use edequaie eve protectionMAINTENANCE ‘Attar cleaning the spark arrester, install the mufiler tid and gas: (GASKET kot Note + Check that the muffle lid and gasket are in good condition and the balte are tishtored socurely SUSPENSION FRONT Check the action of the front suspension by compressing It several times with the front brake applied Chock the entire fork assembly for signs of leaks or damage. Replace any components which are unropairable. Tighten all nuts and bolts to thelr specitied torque veluss. + Do nos ride a vehicle wiih Faity suspension, Loose, worn oF damnaged suspension parts may affect stability and rider con rol REAR Check the action af the rear suspension components by com- pressing the suspension several times. Check the entire suspension assembly, to be sure that all of the components ere securely mounted ené that none are dam ‘aged or aistorted, Tighten all nuts and bolts to their specified toraue. Place the vehicle on a support to raise the rear wheel Move the reer wheel sideways viith force to see if the swing arm pivot or wheal bearings are worn. Replace if excessively vroin, Chock tho ontito suspension aystem to be cure itis securely mounted and not damaged or distertzd. Tighten all nuts ano bokss to thetr specified torque values. 3-14MAINTENANCE Grease the swing erm and shack linkage pivot beerings through their crease nipples. NUTS, BOLTS, FASTENERS Tighten the bolts, nuts and fasteners at the incervels shown in the Maintenance Schedule (Page 2-2) Check that ail chassio nuts and bolts are tightened to their cor fect torque values (Page 1-5 end 6) Check all comter pins and satezy clips. WHEELS/TIRES TIRE PRESSURE Nore oT pressure should be checked when the thes are COLD. PRESSURE: FRONT: 150 kPa (1.5 kgicm?, 22 pst) REAR: 150 kPe (1.5 kgicm?, 22 psi) ‘size: FRONT: 90/90—21 54s REAR: 120/80—17 648 Check the tires for cuts, embedded neils, or other sharp ab- jects Tighten the wheel spokos periocically. Mare frequent inspec tionis necessary whan ricing off-road. TORQUE (trontrear: 4 Nem (0.4 ftlb, 3 ft-lb) TOOL: Spaner C, 8.8 x 6.1 mm 077010020300 Equivalent commercialy ble in U.S.A, STEERING HEAD BEARINGS NOTE + Check that tie comirol cables do net intarfere with the ro tion of the handlebars, False tho front wheel off the ground and check that the handlebars rotates freely. Ifthe handlebars moves unevenly, bind or have vertical move- ‘mont, adjust sho etooring head bearings by turring the steering hhead adjustment nut wiih a pin spenner. ipage 12-20)FUEL SYSTEM 4-04, FUEL SYSTEM ‘SERVICE INFORMATION 4-1 HIGH ALTITUDE ADJUSTMENT TROUBLESHOOTING 4.2 (U.S.A only! a7 PURGE CONTROL VALVE INSPECTION BEL TANK 4-3 (California model) 4aq7 Ber CLEANER CASE 4-4 SECONDARY AIR SUPPLY SYSTEM CRANKCASE BREATHER 4-6 (California model} 419 CARBURETOR 4-7 PILOT SCREW ADJUSTMENT (IDLE DROP PROCEDURE) 4-16 SERVICE INFORMATION GENERAL * Gasoline is extremely flammable and i explosive under certain conditions, Work ina well venttated area, do not smoke or allow Slares or sparks in the work area or where gasoline is stored. ‘¢ When d'sessembling the fuel system parts, note the locations of the O-rings. Replace therm with new anes on reassembly, # The carauretor flost chamber hes a drain screw that can be loosened to drain residual gasoline CAUTION + Do.not bend or twist control cables. Damaged control cables will nat operate smoothly and may stick or Bind. NOTE + vehicle is to be stored for more than one month, drain the float chamber. Fuel left in the float chamber may cause clogged jets resulting in hard starting or poor driveability. SPECIFICATIONS Fuel tank capacity Fuel reserva capacity 13.0 liters (3.43 US gal, 2.86 Imp gal! 2.5 liters (0.66 US gal, 0.85 imp gall <_>+ Californie mde! Throttle bore a2.5 mm lwentTiearion Ne. VESTA Flot lovel 18.5 mum (0.73 i) Main jet #155 - [Siow jet ee lle speed _ 1,300 = 100 rpm Throttle grip tree play 2-6 mm (1/8— 1/4 inh Pilot secow opening Air cutoff valve operating pressure ‘3 turns out 390 + 20 mm He TOOL Common Float level gauge ~~ ow (07401 ~091 0000 EEEFUEL SYSTEM TROUBLESHOOTING Engina Turns But Won't Start + No fual in tank + No fuel to eytineer + Too much fuel getting te cylinder + No spark at plug lignitian malfunction or fouled spark plugl Air clocner clogged + Improper thro operation Engine Idles Faster, Roughly, Stalls, or Runs Poorly + Idle speed incorrect + Ignition malfunction + Rich mixture + Lean mixture + Airclezner clogged + Air leaking into manifold + Fuel contaminatec + Incorrect air screw adjustment + Fual tank breather tube clogged {California model only: + Faulty purge coateal valve + Faulty emission contrel system hoseo. Lean Mixture + Carburetor fuel jets clogged + Fuel tank breather tuba clogged Fuel fiker clogged Fust (ube kinked oF restricted Float valve faulty Float level too low + Yecuum stuck piston ich Mixture + Worn or damaged starter valve + Float valve faulty + Float level 100 high Carburetor air jets clogged + Sticking ‘loat + Dirty air cleaner + Vacuum diaphragm demaced Idle Speed Too High + Incorrect throttle stop corow adjustment + Faulty choke valve + Starter valve stuck open Engine Does Not Slow Down Smoothly + Incorrect pilot screw adjustmant Engine Lacks Power st Low and Idle Speeds + Incorrect air screw adjustment Aftor buming during docoloration + Faulty ignition system + Faulty air cut off valve + Lean mixture (California model only:| : Fautty e2condory air supply eystom Faulty hosas of the emission control system Poor performance (driveability! and poor fuel economy + Clogged fuel system + Faulty ignition system + bint air cleaner (Califormia mode! onty: Faulty purge control valve Fauity hoses in the emission control systemRemove the fuol tank mounting bolt and rameve the fuel tenk by sliding it backward. stricted, clean the fuel strainer (nage 3-4), INSTALLATION Install the fuel tank in the reverse order of removal NOTE ‘After assemoling, make sure there are no fuel leaks. + Donot overtighten the fuel valve aur. f S&S (0) FUEL FILTER, & 4 Nem (0.4 kgm, (2) FUEL STRAINER SCREEN ; FUEL SYSTEM JEL TANK es REMOVAL Remove the side covers and seat (pege 15-2) ; Tumthe fuel vaive OFF and discennect :he fuel tube atthe fuel . ave. Gasoline is extremely flammable and is explosive under certain ‘ : AS Conditions. Work in c well ventilated are, do not smoke oF : allow fames or sparks in the work area oF where gasoline is . sored. S BOLI Remove the richt and left font faiing mounting soraves Pull the faring studs out of the gramots of the fuel tank hore Whon removing tho faring, b> careful not to brock them Check that fuel flows out of the fuel valve freely. flow is re 3 Feb) >FUEL SYSTEM AIR CLEANER CASE REMOVAL, Femove the sice covers and seat (page 18-21 Remove the rear fender (page 15-8) Remove the battery from the air cleaner case (nage 16-3). Loosen the air sleaner cage duct band. Disconneci the separator-io-air cleaner case tube. Disconnacr the regulstoritectitier 3P connector. Separate the wire hameae from the holder en the air cleaner case, Remove the air cleaner elment cover by removing three Disconnect the starter relay switch connector. Disconnect the negative and positive batiery cebles at the starter relay switch. Remove the alt cleaner cese from the frame 8s shown, ‘Check the air cleaner case for cracks or other damage. Refer to pace 3-6 for the air cleaner service.FUEL SYSTEM a INSTALLATION Installation is the raverse order of removal Route the wire harness properly (page 1-11 and 12h, 1) Alp DUCT (2) AIR CLEANER ELEMENT 0. a (3) Al CLEANER. \ (4) AIK CLEANER CASE COVER Hi CASE 4-5FUEL SYSTEM CRANKCASE BREATHER INSPECTION ‘Check the erankease breather tubes for secure conneciion. Check the crankcase breather tubes and separator for dam- aga, cracks, deterioration or blockage. Rofer to page 1-11 for correct crankease breather tube rout- ing, ‘Be: 5 a a (1) SEPARATOR, ar = é s (3) BREATHER HOLDER (2) DRAIN PLUG WaFUELSYSTEM AFTER "88; 44) TO- an CLEANER | CASE y. (2) THREE WAY JOINT (3) BREATHER, (5) FROM HOLDER CRANKCASE CARBURETOR REMOVAL Remove the fuel tank page 4-3) Disconnect the crankcase breather tubes and pull the eopara, tot out of the rubber holder. Loosen the nut and disconnect the choke cable at the cerbure- tor.FUEL SYSTEM Check the valve end needle ‘or wear or damage. I necessary, replace the starter valve Compress the spring into the choke valve nut and remove the ‘choke velvo from the choke cablo, Install a new choke valve in the reverse orcer of removal Remove the throttle cable holder by removing two screws. Disconnect the throttia cablas from the throttle drum. Loosen the air cleaner case duct band Fomove tho corhurotor insulator mounting bolte and rmeve ‘he cerburetor from the left side with the carburetor insulator. DISASSEMBLY (AV AIR VENT TUBES 2] FUEL TUBE Loosen the carburetor insulator bend. Remove the fellowing parts from the carburetor. Carburetor insulator Fuel tube Air vent tubes Overflow tube (3) OVERFLOW "TUBE 15) BAND (4) INSULATOR 4-8FUEL SYSTEM Fimove the throztle stop screw. (1) SCREWS (2} FLOAT CHAMBER Remove the four screws, float chamber and O-ring ? Remove the following. = float pin ~ float = float valve = battle place Inspect tha float valve and valve saar for waer ar damaga, Remove the Following. = main jet = neadle jet holder (2) NEEDLE JET (3) MAIN JeT © nesdet jo: HOLDER = slow jet (1) NEEDLE: “Tuin the pilot screw in and carefully count the number ofturns: JET ~~. before it seats lightly. Make a nete of this te use ae areference when reinstalling the plot screw. CAUTION + Damage 09 the pilot screw seat wilt cccur Uf te plot screw fs tightened against the seat. Remove the pilot screw,FUEL SYSTEM Remove the following. — four screws — vacuum chamber cover — compression spring Inspect the vacuum piston for weer, nicks or other damaue. Make sure the piston moves up and down tresly in the piston bore. Remove the diaphragm/vacuum piston, (3) DIAPHRAGI VACUUM PISTON Push the jet needle holder and tum it clockwise 90 degrees with an 8 mm socket. Then remove the needle holder, spring and jot noodle ‘rom the vecuum piston, Inspect the jet needle for excessive wear at the tin or other damage. Check for diaphregm for tear or deterisration, (1) JET NEEDLE (3) NEEDLE HOLOER (4) DIAPHRAGM’ VACUUM PISTON Remove the following. air cut oft valve cover = spring = daphragm Check the diaphragm and spring for wear, damage or deter: 4-10Remove tho two scraws and carburetor link arm. Draw out the carburetor link shaft with fs spring. CCheck the link arm and link shaft for bends or otner camage, Check the spring and roller for wear or damage. lfthe inksha‘t, spring and roller are dirty. clean them through: he Insert the link shaft with the spring and secure the link arm with two scrows, Check the link shaft and arm for smooth operation when turn ing the throttle deum. Blow compressed air through each jet to be sure itis clean FUEL SYSTEM (0) LINK ARM (2) ink SHAFT (4) ROLLER. (1) LINK AMFUEL SYSTEM ASSEMBLY (7) DIAPHRAGM! VACUUM PISTON (2) AiR CUT-OFF VALVE COVER (5) LINK ARM (1) VACUUM CHAMBER, cover, (6) LINK SHAFT (8) FLOAT VALVE (9) FLoaT. (10) FLOAT. PIN / rl (a) DIAPHRAGM can sranren © VALVE a& (23) SPRING RQ, § (11) FLOAT CHAMBER 22) JET NEEDLE (19) Waotrus (78) PILOT A HOLDER STOP SCREW (16) MAIN JET (78) BAFFLE 1) Slow Jer Install the dlaphragm, spring and air cut-off valve cover (1) SPRING sprocket helder. [1 INDENTATION Be sure that the one way clutch outer rotates in one direction only.CYLINDER HEAD/VALVES LINDER HEAD REMOVAL 11) gours the following components: Exhaus: pipes (page 15-7) ‘yjinder haod cover (page 6-3) Camsheft (page 0-9) = Gyfinder head nts = Gyinder head boits tor © Loosen the bolts in a crisscross pattern in two or more Ps. Remove the cylinder hoad, ‘CAUTION (2) GASKET Be careful not 0 damage the evlinder ead mating surfaces Remove the dowel pins, cylinder head gasket anc cam chain ulte. Inspect the cam chain guide for wear or damage. (1) CAM CHAIN GUIDE Replace the guide with a now one, if noceseary. CAM CHAIN TENSIONER REMOVAL Remove the tensioner shatt, Remove the cam chain tensioner and soring.CYLINDER HEAD/VALVES CAM CHAIN TENSIONER INSPECTION Insert the tensioner sheft into the tensioner and inspect the tensioner by turning the shaft The tensioner snatt turns clockwise freely and should not turn counterclockwise, Check the tonsionor lifter and toneioner ahatt for excessive or abnormal wear or damage. CYLINDER HEAD DISASSEMBLY Using a valve spring compressor, remove the valve spring cotters, retainers, sprigs, spring sezts and valves from the cy! inder heed. TooL: Velve spring compressor 07757—0010000 CAUTION + To prevent toss of tension, do not compress ihe valve springs ‘more ihen necessary to remove the colters. NOTE + Mark all parts to ensure that they are ‘eassembled in thelr ‘original positions. Remove the valve stem seals and discard them. NOTE + Whenover the stem seals are removed, replace them with nowieny CYLINDER HEAD INSPECTION Check the spark plug hole and valve areas for ctacks. Check tha eyiinder head fer warpage with a straight edge and 2 foclar gauge, SERVICE LIMIT: 0.10 mm (0.004 in} 6-10CYLINDER HEAD/VALVES VE SPRING INSPECTION 19 te frae length of the inner and outer valve springs. umtrs: INNER: 34.1 mm (1.34 in} “OUTER: 35.0 mm (1.38 in} pect each valve for bending, buing, scratches or oimal stem wear. ‘Check valve movement in tho guide, and measure end record gach valve stem 0.0. ‘SERVICE LIMITS: IN: 6.56 mm (0.268 in} EX: 6.55 mm (0.258 in} Fear the velve quides to remove any carbon deposits before checking clearances. NoTe + ita importent that the reamer ie alwaye rotated in the seme diection when it ' inserted! or removed. Tool: Vave guide rear (07984—5510000 or 07984—657010C (S.A. only) ‘ Meacuto and record each valve guide ID. SERVICE LIMITS: IN: 6.63 mm (0.261 in} EX: 6.63 mm {0.261 in} Caulate the valve stom-to-guide clearance. SERVICE LIMITS: IN: 0.085 mm (0.0026 in} EX: 0.080 mm (0.0031 in) If te stem-to-quide clearance exceeds the service limit, deter- mine ifa new guide with standard dimansions weuld bring the tlearance within tolerance. IF eo, replace guides ae ne and rearn to fit If stom-to-quide clearances still exceeds the service limit when new guides are installed, replace tha vaives. Nore + Reface valve seats wherever new valve guices are in- stalled.CYLINDER HEAD/VALVES VALVE GUIDE REPLACEMENT Chill the replacement guides in the freezer for about an hour, Heat the cvlinder head to about 130— 140°C (275~290°F] with a hot plate or a oven. Do not heat the cylinder heed beyond 300°F (50°F), Use Temperature indicator sticks, avelleble from welding supply stores, to be sure the cylinder head is heated to the proper temperature. + To avoid burns, wear heavy gloves when handling the heated cylinder head. CAUTION + Da not use a torch to heat the cylinder, it may cause werping. Nore + To Gear the valve guides, set the cylinder head on proper blocks. Support the evlinder head and drive our the old guides from the combustion chamber side of the cylinder head, CAUTION + Be careful not to damage the eplinder head TooL: Valve guide remover, 6.6 mm 077420010200 or 07942—6570100 Place anew O-ring on the new valve guide Drive in the valve from the rackor arm side. Inspect the velve guides for damage. Too: Valve guide remover, 6.6 mm 077420010200 ot 07984—6570100 Roam the new valve guides after installation. NOTE + Use cutting oil on the reainer during this operation ‘lean the evinder need Hhroygly to vernove any ral pon cee Tele the valve soet (pogo 0:13) TooL: Valve guide reamer, 6.6mm _ 07984—6570000 or 07384—657010C (U.S.A. only) VALVE SEAT INSPECTION AND REFACING Clean all intaxe and exhaust valves thoroughly 10 remove caroan deposits Apaly « light coating of Prussian Blue to each valve face.Lap ach valve and cest using # rubber hose or other hand leppina ‘0h Remove end inspect each valve CAUTION + Watves cannot be ground. If the valve face & burned or badly worn or if it contacts the seat unevenly, replace the valve. 6-12tthe wlath of each valve seat NCE LIMITS: 2.6 mm (0.10 in} ithe seat is too wide, too nerravr or has low spots, the seat st be ground. JALVE SEAT CUTTERS nda Volvo Seat Curtere, grinder or equivalent valve facing equipment ere recommended to correct a worn valve ‘Follow the refacer manufacturer's operating instructons. VALVE SEAT REFACING Ure 2 45 degree cutter to remove any roughness or iregulari- tles itor the seat NOTE + Refece the seat with 45 degree cutter when a valve guide is reolaced C Uso 2 32 degree cutter to remove the top 1/4 of the oxieting vaive seat material 45° (1) SEAT CUTTER (2) FLAT CUTTER 43) INTERIOR CUTTER (1) ROUGHNESS/IRREGULARITIES 45° (2) VALVE SEAT CYLINDER HEAD/VALVES (1) VALVE SEAT WIDTH 50° (1) QLD SEAT WIDTHCYLINDER HEAD/VALVES Use = 60 degree cutter to remove the bottom 1/4 of the old seat. Remove the cutter and inspect the area you have rofaced, (1) OLD SEAT WIDTH | SS Insta 2.45 degree finish cutter and cut the saat to the proper ‘width. Make sure that all pitting and irregularities are removed. Fofinsh if nacessary. 09-11 mm (0,035 —0.083 in) Apply a thin coating of Prussian Blue to the valve seat. Press the value through the valve quica and onto the seat to make a ck (1) CONTACTY TOO HIGH loar pattorn. NOTE — —___ (2) OLo Sear WIDTH | +The location of the valve seat in relation to the velva face 16 | very important for good sealing 32 It the contact arga Is too high on the valve, the eat must be lowered using a 32 degree flat cutter. If the contact ares ie too low on the vaive, the raiged using @ 60 degree inner custer. (1) CONTACT TOO Low (2) OLD SEAT WIDTH 6-14irish the seat to specifications, using a 45 dagree finish te. 4 cutting the seat, apply lapping compound to the valve and lap the valve using ight pressure. J lapping, wash all residual compound off the cylinder and valve. Do rot allow lapping compound to enter the guides. CYLINDER HEAD ASSEMBLY Inctall the valve spring seats and new stem seals. Lubiioste cach valve stem with MoS2 paste arease (page 2:14) and insert the valve into the valve guide. Install the valve springs and retainers. NOTE T nstall the valve springs with their narrower pitches facing to the cylinder head. + Reploce the stem seals with new ones whenever they sre removed. + install the valves inte the valve guides, turning ther sjowly s0 you de not damage the stam seals. , Compress the value springs using the valve spring compres- for, then install the valve cotters. CAUTION [To prevent loos of tension, do not compress the valve springs more than necessary 10 install the vaive corters. TooL: Valve spring compressor 07787—0010000 “Gy stem o SEAL (6) OUTER SPRING CYLINDER HEAD/VALVES ae jsrcorters = CYLINDER. HEADCYLINDER HEAD/VALVES ‘Tap the valve stems gently with @ plastic hammer to firmly seat the cotters. CAUTION + Suppor the evlinder head above the work bench surface to pre- vent possible valve demage. CYLINDER HEAD INSTALLATION (SPRING ‘the spring on the cam chain tensiener aligning, the holo in the tensioner with the spring end. (2) HOLE AND. SPRING END Install the cam chain tensioner into the cyliner head, Apply angino oil to 0 now O-ring ond inetall it in the groove of ‘the cam chain tensiener shan. Insert the tensioner shatt through the tensioner and into the cylinder head. Install the cam chain guide, dowel pins anda new head gasket. 6-16CYLINDER HEAD/VALVES fall he following parts: (Gylindar head Camshaft beering set pins ‘Spring and reverse decompresso: cam stopper oilto the evlinder head balts and washers. the cylinder hoad bolts in a crisscrosspattemn in two or ‘steps. {QUE: 36N-m {3.6 kg-m, 26 ft-lb) ten the cylindor head nuts. il the exhaust pipes {page 15-7) ISHAFT INSTALLATION ply oll to the camshaft bearings and inetall them onto the shat encs wth thelr sealed ends facing out. ly MoS2 paste (page 2-14) to the cam jobe surfaces and yshaft journal le pushing down the tensioner's lever, sot the cam chain ioner hoder onto the tensioner, aligning the pin of the folder with the hole in the tensioner. Slowly release the tansioner lever until the holder rests against the oyinder head casting. Mos2 TOOL: Cam chain tensioner holder —-(07973—MG30002 or 07973—-MG30003 fi1) TENSIONER HOLDER Jaca the carn sorocket 10 the camshott over the aight oar fl theft bearing with the “OUT” mark facing the outside Intl the camshaft through the cam chain Aamove the crankshaft hola cap anc tinina hole cap, Tunthe trankshate countorclockwiso and align the T"” mark tn tho ywheal withthe index notch on the let erankease sover : Ral te cam chain over the cam sprocket chain so shat the fining morks on the sprocket alin with the unper surface of the oylindr head Instal the cam sprocket onto the sprackat holder of the cam- ii 9H shaft. (5) CAM SPROCKET NOTE + Do rot turn the sprocket when installing it onte the sprock et holder. ‘Apply locking agent to the threads of the cam sprocket bolts ard seraw one bolt in Ioosely, then screw the other bolt in etter ‘turning the crankshaft. Tighien Ure sprocket belts to the epecified torque TORQUE: 20 Nem (2.0 kg-m, 14 tt-b) Remove the tansioner holier.CYLINDER HEAD/VALVES ‘Turn tho erenkshett counterciockwiee 360° end align the “T"" (2) TIMING MARKS mark on the flywheel with the index notch en eft crankcase | (TF INGEX NOTCH cover again Make sure that the timing marks on the cam sprocket elion With the upper surface of the cylinder haad Align the holes in the cylincer head and tensioner shatt by turning the tensioner sheft clockwise. Install and tighten the bolt. CYLINDER HEAD COVER ASSEMBLY NOTE + Each rocker arm is stamped with its letter code in the loca- tion as shown. Install properly. (2) TAB 6-18CYLINDER HEAD/VALVES: leech rocker arm in the correct positon, referring to the (1) ROCKER sion on page 6-18. ARMS. cil to the rocker atm shat sliding surface. iy a lacking agent 10 the threads of the rocker arm shatts, the copper washers. insert the rocker arm shafts through jeyinder head cover and rocker arms, and tighton thom to specified torque. UE: 28 Nom (2.8 kg-m, 20 ft-lb) Apply MoS2 paste (page 2-14) to the rocker arm slippor eur- ces. (3) ROCKER ARM SHAFTS (2) SUB-ROCKER ARM SHAFTS ee E Hi Scop ie ‘petal tho cub-rocker arme and wave washers in the comrost postions, referring to the ilustiation on page 0-18. Apply oil to the sub-rocker atm shaft sliding surfaces. Apply a locking agent to the threads of the sub-tocker arm ‘shaft, thon inoar: tham through tho eyiindor head cover and Sibrocker arm with copper washers. Tighten the sub-rocker arm shaft. ‘TORQUE: INTAKE: 28 Nem (2.8 kg-m, 20 ft-lb) EXHAUST: 23 Nem (2.3 kgem, 17 ft-lb) (4) SUB ROCKER ARMS 12) SUB-ROCKER ARM SHAFTS Aoply MoSz paste (nage 2-14} to the sub-rocker arm slipper surfaces. CYLINDER HEAD COVER INSTALLATION Pour clan engine cil into the oil pockets in the cylinder head se ‘at the cain lobes are submerged. Install the dowel pins end @ new gasket.CYLINDER HEAD/VALVES Tay HEAD COVER] ‘Set the 8 mm bolt and 6 mm SH bolt on the head caver, then Slide the cylinder heed cover over the cylinder hoad. ‘Tighten the cylinder head cover bolts. {0} @ mm SH BOLT, TORQUE: mm bolt: 23 Nem (2.3 kg-m, 17 fd) Gm bolt: 12 Nem (1.2kgem, 9 feb) 6 mm SH Bott: 10 Nem (1.0 kg-m, 7 fel NOTE Tighten the cylinder head cover bolts n'a crisscross pattern in two or more steps. Install and tighten the spark plus. TORQUE: 18 Nem (1.8 kgm, 13 feb) Ingtall the engine hanger plates, bolts and nuts, ‘Tighten the nuts to the specified torque ‘TORQUE: 8 mm bolts: 34. Nem (3.4 kg-m, 25 ft} 410 mm bolt: 60 Nem (6.0 ko-m, 43 ft) Install the clutch cable clamp end tighten the bolt. 10 Nem 11.0 kgem, 7 ft-b) Connect the cylinder head cover breather tube, and secure it ‘with the clip. Install the spark plug cap. Adjust velve clearance (page 2-6). Install the ol pipe with four sealing washers, and tighten the oil pipe bolts, TORQUE: 10 Nem (1.0 kg-m, 7 ft1b) Install the following components: — Carburetor {page 4-15) — Fuol tank (page 4-3) — Seat and side covers (page 16-2) a 6-20 ——_—_—_—_——— j fae |CYLINDER/PISTON 50 Nem 15.0 kgm, 36 feb} AFTER’ 88: 7-07. CYLINDER/PISTON "SERVICE INFORMATION 7-1 PISTON REMOVAL 13 | TROUBLESHOOTING 7-1 PISTON INSTALLATION 15 CYLINDER REMOVAL 7-2 CYLINDERINSTALLATION 76 SERVICE INFORMATION GENERAL This section covers service of the cylinder and piston. These procedures can be performed with the ongine in the frame. @ ifthe connecting rod small end |.D. exceeds the service limit, see section 10 for the crankshaft remevel. SPECIFICATIONS I we STANDARD savceumt | Cy ve 760500 1GOI510 evn (8.09648 897E 100.12 rn OAH = 0.08 mn 1.002) = 905 mn (2.002 ir) ~ 0.10 mm |0.004 in_| Taper Out of round ‘Warpage across top - Prion 0.0. at skit 39.950-99.560 myn B9970—3.99021N) | 99.65 mn 9.991 i Piston pin bore | -24.002—24,008 mm {0-9450—0.0452 in) | 24.03 mm (0.946 i) Fistor pintopton | g.992-0,014 mm 0.0001-0.0090 m9) | 0.07 mm 10098 in) Pesos sna end gop | Tee 3992040 rm 10008-0.076 in) | 0.50 mm (020 Second 0,850.58 mm(0.014=0.0221) | 0.68 mm ©.026 in fortsise aan 0.3 0.8 mn (001-0 04 i — Piston rngto-groove | Top (0,030--0,065 mm (0,0012—0,0026 in} | 0.12 mm (0.008 in) Serene [Second 01015-0.088 ry (0.0006—0.0610 iy | _ 0.12 ram (0.005 in Cylinder-to-piston clearance 0.02 0.06 mm (0.0008— 9.0020 in} 0.10 mm (0.004 in) Pion in .. 75.989—73.995 mm (0.9844-0.9407 m) [28.80 mr 10.949 1) | Connecting rod small end 1.D. [| 24,020~ 24.061 mm (0.9457 0.0485 in) | 24.07 mm (0.948 in} TORQUE VALUES Gylindar bolt 10 mm bott: 50 Nem (5.0 kg-m,36 ftlb} Apply cil to the threads 6 mm SH batt 10 Nem 1.0 kam, 7teib} TROUBLESHOOTING Low 0: Unstable Compression Overheating + Worn cylinder or piston rings + Excassive carbon build-up on piston head or cambus: + Faulty decompressor cam tion chamber Excostive Smoke Knocking oF Abnormal Noise + Worn evlinder, piston or piston rings + Worn piston and cylindsr + Improper instelletion of piston rings + Excessive carbon build-up on piston heed or combus- + Scored or scratched piston or cylinder wall tion chamber wore Fane pistan, anguar evindorShow oxsossve wear, eheok Tord pain he after due to nproporinstlietin oF sa wr 7-CYLINDER/PISTON CYLINDER REMOVAL Remove the cylinder head (Section 61 Remove the cam chain guide, Remove the two 6 mm smell head bolts on the right side of the cylinder. Remove the four cylinder mounting bolts, then remove the eyl- indet: NOTE + Loosen the bolts in a crisscross pactern In 1wo or more steps. Remove the dowel pins and cylinder gasket CYLINDER INSPECTION Inepact the oylindor wall for scratches end wear Measure and record the cylinder LD. at three levels in both an X and Y axis. Take the maximum reading to determine tie cyl- inder wear SERVICE LIMIT: 100.12 mm (3.942 in) Calculate the piston-to-cylincer clearance. Take the maximum reading to determine the clearance SERVICE LIMIT: 0.10 mm (0.004 in) Calculate the cylinder for taper at three levels in an X and Y axis. Take the maximum reading to datermine the taper SERVICE LIMIT, 0.05 run (0.002 in) Caloulate the ovlindar for out-of-round at three levels in an X and ¥ axis. Take the maximum reading to dotermine tha out- of rund, SERVICE LIMIT: 0.05 mm (0.002 in) The cylinder must be rebored and oversize piston fitted if the eylinder mite are oxoveded. The following oversize piston are available: 100.25 mm {3.947 in) and 100.50 mm (3.957 in} Tho cylinder must be roborad ee thet the clearence to an over size piston is 0.02 — 0.05 mm (9.0008 — 9.0020 in} 7-2CYLINDER/PISTON Clean the cylinder gasket surtace. Inspect the cvlinder for transverse warpage across the top. NOTE + Measure the warpage using a straight edge and footer ‘gauge in the diroctions ae shown. SERVICE LIMIT: 0.10 mm (0.004 in} PISTON REMOVAL Place a shop tows! into tha crankeaee opening and remove the pston clips and discerd them. NOTE {Do not let the ips fall into the crankcase. Push the piston pin cut and remove the piston. PISTON/PISTON RING INSPECTION Remeve the piston rings from the piston, NOTE Do not damage the pistan rings when removing them, Inspect the piston far cracks or other damage and the ring grooves for excessive wear of carbon bulld-up. Insert the outside surfece of the ring into the proper ring groove and roll ft around in the groove to make sure thar the ring has @ free fit around the piston's circumference and clean the ring grooves.CYLINDER/PISTON Install the piston rings into the piston ring Grooves ‘page 7-5i. Measure the pisten ring-to-groove clearance, pushing tho Picton rings into the ring grooves. ‘SERVICE LIMIT: TopiSecond: 0.12 mm (0.005 in) After measurement, remove the piston ring from the piston. Measure each piston ring end gap: using @ picton, push the ring into the cylinder squarely to the position as shown and ake the measurement, SERVICE LINITS: Top: 0.60 mm (0.0020 in} Second: 0.65 mm (0.0026 in} ‘Measure the piston 0.0. NOTE + Take measurement 10 rm (0.6 In) from the bottom, anc perpendicular to the piston pin hole. ‘SERVICE LIMIT: 99,85 mm (3.931 in) Calculate the piston-to-cylinder clearance by subtracting the piston O.D, from the cylinder I.D. (page 7-2) SERVICE LIMIT: 0.10 men (0.004 in} Measure the piston pin bore. ‘SERVICE LIMIT: 24.03 mm (0.946 in) Measure the piston pin 0.0, ‘SERVICE LIMIT: 23.96 mm (0.943 in) Calculate the piston-to-piston pin clearence. SERVICE LIMIT: 0.07 mm 0.0083 in) ZA 74CYLINDER/PISTON Measure the 1.D. of the comecting roc smell end. SERVICE LIMIT: 24.07 mm (0.948 in} PISTON RING INSTALLATION Apply clean engine oil to the piston rings. Install the piston rings inte the piston ring grooves with the marks facing up NOTE + Be careful not to damege the piston and piston rings during assembly. Stegger the ring ené gaps 120 degrees from each other as shown Do not align the oil ring (side rail) gepe. nore + To install the oll ring, install the spacer Fst, then install the ice ras ‘After installing the rings, check that they rotate traely without sticking. PISTON INSTALLATION Cover the crankcase opening with a shop towel. Analy MoS2 paste (age 2-14) to the siding surfaces of the piston pin and eonnecting rod amall end. Insert the piston pin through the piston and connecting rod, and secure them with new piston pin clips. NOTE * Install the piston with the mark “IN” facing the intake side. + After installing the piston pin clips, make sure that thay are seated properly and the end gape era not alignod with the cut-out in the piston. + Be careful not to let the clips fall Into the crankcase. lean any gasket meterial fram the cylinder base surface. SO ) 2 SECOND RING 11) TOP BING 43) OIL RING (ast (7) SIDE RAILS (6) 20 mm (0.8 inh ‘OR MORE 17 PISTON FING Sa =3398-+— 21 tor (3) SECOND 1) igt0W (4) PISTON PIN CLIPCYLINDER/PISTON CYLINDER INSTALLATION Install the dowel pins and a new gasket. Coat the outer surface of the piston and inner surtace of the cylinder with cleen engine cil. Position the piston at the T.0.C. (Top dead center on compres- sion sircke}, and install it into the eylinder while compressing ‘the piston rings with your fingers. NOTE + Be careful not to damage the piston rings during assembly. + When the cylinder is halfway over the piston, route the car: chain through the cylinder, Apply oil to the cylinder bolts (10 mm) end washers, and tight fn the bolts in a crisscross pattern in two or more steps, AND WASHERS. | TORQUE: 50 Nem (5.0 kgm, 36 fb) Tighten the cylinder bolts 46 mm) TORQUE: 10 Nem (1.0 kgm, 7 fb) Install the cam chain guide. NOTE + Fit the cam chain guide teb in the cylinder cut-out and push the guice until it bottoms in the crankease guide hola, Install the cylinder head (nage 6-16)CLUTCH 110 Nim (11.0 kg-m, 80 Teb) 110N lm (11.0 kg-m, 80 ft-lb) 12 Nem (1.2 kam, 9 frlb) 8-08. CLUTCH SERVICE INFORMATION 81 PRIMARY DRIVE GEAR 87 TROUBLESHOOTING 8-1 GEARSHIFT CAM 89 RIGHT CRANKCASE COVER RIGHT CRANKCASE COVER REMOVAL 8.2 INSTALLATION 8.9 CLUTCH a2 SERVICE INFORMATION GENERAL (This section covars removal and installation of the clutch, gearshift cam and right crankcase cover. All these operations ‘can ba performed with the angine in the framo. © Whan the clutch discs are replaced, coat new dises with engine oll prior to assembly. SPECIFICATIONS El i Tre STANDARD sevice UNIT hich Lever fice pay ft br endl Spring eo longi Z7mmi7in) | 43.4 wm (70) Sing pelod/enath 3021 FRE. 6 mr (6.2 + 831 bit i = se thickness 2.92~6.08 nen (0.115-0.12 Fomm (1A) Plate warege — 0.15 mm 0.06 i) [Tuten outer 1, Fi:000~27-024 men (1.08501.0688 n) | 27.08 mm (1.055 I [Sure ite OB. | 26.080 26.960 mn (1.0690 1.0622 in) _| 26,01 mun (1.060 mn) | 1.9, | 21.890 22.035 mm 0,£657-0,8675 in) | 22.05 mn (0.858 n) | TORQUE VALUES: | Clutoh took nut 110 Nem [11.0 kg.m, 80 ftby Prey dive ger ma 110 tem 11.0 keen, £0 Coast cam at Tan (12 kp 9 fsb) Apo fckng agent tote vac Stopper arm bolt 25 Nem (2.6 kg-m, 18 ft-lb) Right crankcase cover bolt/nut 12.Nem (1.2 ka-m, 9 ft-lb} TOOLS Common Garh eonter holier ©7724 0050001~oreauvelontcommerily avlebe in US.A. Goo hoor C7724 0010100" Net salable in Us TROUBLESHOOTING Faulty clutch operation can uouslly be corracted by adjusting the clutch lever Free play, Clutch Slips When Accelerating Excessive Lover Prossu + No free play + Clutch cable kinked, damaged, or dirty + Discs worn + Lifter mechanism damaged + Springs week Clutch Operation Feols Rough Clutch Will Not Disengage + Outer drum slots rough + Too much free play + Diny oluten cable + Plates warped Motorcycle Creeps With Clutch Disengaged + Too much free play ‘Laces warped 8-1CLUTCH RIGHT CRANKCASE COVER REMOVAL Drain oil from engine and oil tank (page 2-3) Remove the following components: © Breke pedal (eago 12-10) Oil pipe {page 6-3) Remove the right crankcase cover bolts, nuts and right crank- mare steps. Remove the dowel pins and gasket. OIL SEAL REPLACEMENT Check for tho oil e00! for damago or deterioration. Remove the snap ring and oil seal. Install the new cil seal ard snap ring. NOTE + Make sure the snep ring is seatad in the groove in the right erankease cover CLUTCH REMOVAL Remove the right crankcese cover. Remove the four clutch bolts and springs Nore + Loosen the bolts in a steps. 13) PRESSURE PLATE 8-2CLUTCH Femove the push rod tip and clusch iter roa. Unstake the clutch lock nut with a dill or grinder, Fomove tho clutch lock nut, plain washer and clutch center, holding with the clutch center holder. TOOL: Clutch conter holder 07724—0050001 (or equivalent commercially avallable in U.S.A, Remove the clutch outer and cluten outer quide Inepoct tho clutch liftor rod tor wear or damage. 41) LIFTER ROD. Check the lifter rod fer straightness by rolling the rod on a tlat surface,CLUTCH INSPECTION © CLUTCH SPRING Measure the fies length of each spring SERVICE LIME 3.1 mm (1.70 ind Replace if shorter than the service lima, nore + Cluteh springs should be replaced as asset if one er mere are beyond the service limit. * CLUTCH DISC Replace the discs if they show signs of scoring or discolora- ton Measure the disc thickness. SERVICE LIMIT: 2.6 mm (0.10 in} NOTE + Clutch discs and plates should be replaced as a set if any fre is beyond the service limit © CLUTCH PLATE Chack for plate warpage on a suriace plato, using a fealar gouge ‘SERVICE LIMIT: 0.3 mm (0.01 in) (2) PRESSURE PLATE © PRESSURE PLATE BEARING (1) BEARING, Turn the bearing inner rece wit your Fingor The bearing should turn smoothly and quietly. Also check that the outer race of the bearing fits tightly in the pressure plate Replace the beering with a navy one, if necessary.CLUTCH SSeS © CLUTCH CENTER (1) CLUTCH CENTER Cheek the teeth of the clutch cent cracks. fer wear, damage or (2) 7COTH © CLUTCH OUTER AND OUTER GUIDE Chesk the slats in the outer drum for nicks, cuts or indentations made by the fricton ciscs. Measure the I,D. of the olutch outer and the 0.0. of tho outor guide. SERVICE LIMITS: Cluteh outer 10+ 27.08 mm (1.085 in) Clutch outer guide 0.0: 26.91 mm (1.059 in} 1.D.: 22.05 mm (0.868 ind ‘Measure the mainshaft 0.D. at the clutch outer guide area. [SERVICE LINIT: 21.91 mm (0.863 in} Calculate the mainshafi-to-cluteh outer guide clearence. SERVICE LIMIT: 0.14 mm (0.006 int INSTALLATION gi) CLUTCH OUTER le iz clues ourer 8-5CLUTCH Install tho clutch lock nut and tighten it holding with curon F(1) CLUTCH CENTER 01 center holder. TORQUE: 110 Nem (11.0 kgm, 80 ft-1b) TOOL: Clutch center holder 077240050001 oF equivalent commarcialy available in U.S.A. ‘Stake the clutch lack nut with a punch: Inaort the clutch lifter rod through tho mainshatt Coot the 7 cisce ond 6 plates with clean engine cil and install them as shown, on CLUTCH PLATE (5 pieces) (2) DISC (7 pieces) Install the clutch push ro¢ tp into the mainshat B (2) CLUTCH DISC AND PLATESCLUTCH Install the pressure plate, clutch springs and clutch belts, and 11) CLUTCH SPRINGS 4 ‘tighten the bolts in a ciisscross pattern in two or mora steps. PRIMARY DRIVE GEAR REMOVAL Remove the pulse generator by removing the bolts and aromet. Romove the follewing componente: = Cluteh (page 8-2) — Oil pump page 2-5 ‘Temporarily install she clutch outer, then inetall the gear holder between the primary drive gear and driven gear as shown, TOOL: Goer holder Remove the primary drive gear nut, then remove the gear holder and clutch outer (2) PRIMARY DRIVE! SEAR NUT Famove the foloing JT Finan’ Baie oNreshor ioe = Gt ump drive gor ; — pulse generator rotor — primary drive ge 3) OL P DRIVE GEARCLUTCH INSTALLATION Install the primary crive gear over the crankshaft NoTE di Fs, . + the pulse generator rotor and oil pump ive gear wit only fe go on in one position because of the extra wide aligning f i spline ‘ é ‘ amt 4 ee i Install tha pulse generator rotor onto the crankshaft. (3) “OUT SIDE" MARK Inatall the oll pump drive goar and washar onto the crankcheft. NoTE Install the washer with the “OUT SDE" mark cing out. TT PRINARY DRIVE ‘Temporarily install the clutch outer, and set the gear holder be- Gran NUT s ‘tween the primary drive geer and driven gear as shown. Install and tighten the primary drive gear nut. TORQUE: 110 Nem (11.0 kg-m, 80 flo) ToL: Gear holder 07724—0010100 Not available in U.S.A. Remove the gear holder end clutch outer. Install the fellowing: = oil pump (page 2-11) — eluter (page 8-6) Install the pulse gonorator and secure it with two belte, and [AUT the gromet into the groove in the right crankcase, NOTE + Remove any metal chips that may be stuck to the pulse generator maanet ll ere _CLUTCH GEARSHIFT CAM REMOVAL Remove the following: = clutch ipage 8-2) — bolt, washer, stopper arm and spring — bolt and gearshift cam 15] WASHER INSTALLATION 71) HOLE 9 RR “Seon Install the gearshift cam on the shift drum, aligning the hole in ES ‘the cam with the dowel pin. Apply @ locking agent to the threads of the gearshift cam bolt, and tighten It to the specified torque. TOROUE: 12 Nem (1.2 ko-m. 9 ft1b) Install the spring, stopper arm, washer and bolt, holding the stepper arm with a screw driver. Tighten the stopper arm bolt. Install the clutch {page &-6) RIGHT CRANKCASE COVER INSTALLATION Instell the dowel pine and a now gasketCLUTCH Install the right orankcase cover, and install anc tighten the bolts and nuts in a crisscross pattern in two or mora steps. TORQUE: 12 Nem (1.2 kg-m, 9 feb} Insiall the following componentes: pipe (oage 6-20) — Brake pedal ipago 13.11) Fill the engine and of tank with recommended oil (page 2-2). Adjust the followings: = Clutch lever free play (page 3-12) Brako podal foo play {page 3-11) (17 3RARE PEDAL] SmALTERNATOR/STARTER CLUTCH 125 Nem (12.5 kgm, feb) 30 Nem (3.0 kgm, bb Pee 22 ft 12 Nem (1.2 kgm, 9 {tb9. ALTERNATOR/STARTER CLUTCH ‘SERVICE INFORMATION 91 STARTER CLUTCH 94 ‘TROUBLESHOOTING 9-1 FLYWHEELINSTALLATION 9.6 LEFT CRANKCASE COVER LEFT CRANKCASE COVER | REMOVAL 9-2 ASSEMBLY 97 | LEFT CRANKCASE COVER LEFT CRANKCASE COVER DISASSEMBLY 9-3. INSTALLATION a7 | FLYWHEEL REMOVAL 93 SERVICE INFORMATION GENERAL * This ccotion covore so-vicing of the atomnator and starter the frame, For alternator inspection and troubleshooting, refer to the seciton 16 and 17, SPECIFICATION [z ITEM clutch, These opotations can be accomplished with the engine in STANDARD SERVICE LIMIT 57.768 mm (2.2738 2.2743 in} 57.66 mm (2.270 in) Startor driven gear 0.0, TORQUE VALUES Starter clutch bolts 90 Nem [9.0 kg-m,22 feb} Apaly a locking ayent to the threads Flywneal bolt 125 Nem (1.2.6 kg-m, 90 ft-lb) Apply MoS? paste ipage 2-14} to the threacs Lett crankcase cover bolt 12 Nem |1.2 kg-m, 9 ft-lbh Starter gear cover 12 Nem (1.2 kg-m, 9 ft-lb) TOOLS Common Flywheel holder 077250940000 or equivalent commarcislly available in U.S.A, Rotor puler (07733 0920001 or 07933. 3290001 (U.S.A. enly) Torx bi (740) 07703—0910109 or equivalent commercially available in U.S.A, TROUBLESHOOTING Starter mowr tums, but engine does not crank: + Faulty starter clutch + Faulty starter idle gzars + Faulty etarcer criven gear Starter motor does not turn: + Faulty starter motor (section 18) + Faulty starting citcuit (section 18) + Bound idle gears 9-1ALTERNATOR/STARTER CLUTCH LEFT CRANKCASE COVER REMOVAL Remove the following: — five socket belts — sterter gear cover — cowel pins ~ gasket ~ shaft, reduction gaar and washers — chaft, idle goer and washers Check the idle gear anc reduction gear for excessive wear or damage. Remave the folowing: — gearshitt pedal crive sprocket cover [a seROCKET cove 4.) ee Disconnect the neutral ewitch wire fram the neutral switch, Flomove the belts and left crankcase cove NOTE + Loosen the bolts in a ciisscioss pattern in two or more steps.ALTERNATOR/STARTER CLUTCH Remove ihe folowing — dowel pins = gasket shaft, startor drive goar and wachers Check the sterter dnve gear for excessive wear or damage. LEFT CRANKCASE COVER DISASSEMBLY =) ures ARM Romove the followings: = Clutch lifter alece Clutch lifter arm = Spring Check the dust seal for damage or detericration, heck the nesdle bearing for wear ar damage. (4) NEEDLE BEARING, Remove the alternator wire holder and grommet. Fomove the three bolts and alternator startar. |4) HOLDER FLYWHEEL REMOVAL Remove the fiywheel boit while holding the flywheel with the ‘lywhee! holder. TooL: Flywheel holder 07725—0040000 (or equivalent commercially available in US.A,ALTERNATOR/STARTER CLUTCH Remove the flywheel using the ratar puller. TooL: Rotor puller 07733-0020001 or 07933—-3200001 (U.S.A, only) STARTER CLUTCH REMOVAL/DISASSEMBLY Fsmove the followings: — Ftywnee! {page 9-3} — Wesher and starter driven gear — Woodruf key Remove the needle bearing and washer, and check the needle beating for wear or damage. Install tha startor driven gear onte tho flywheel and inspect the starter clutch by turning the starter driven gear. The driven gear should 1m counter clockwise teely anc should not turn clockwise, if net so, replace the sterter clutch ‘Aiter inspection, remove the starter driven gear.ALTERNATOR/STARTER CLUTCH Loosen and remove the six torx bolts ina crisscross parttern in two or more steps, holding the fiywheel with the flywheel holder. (1) ToRX er ‘roots: Torx bit (140) 97703—0010100 or equivalent commercially available in U.S.A. Flywheel holder 077250040000 (or equivalent commercially avaliable in U.S.A. INSPECTION Ingpect the starter driven gear for excessive wear or damege. ‘Measure the 0.D. of the starter driven gear hub. [SERVICE LIMIT: 57.66 mm {2.270 int Ingpect the one way chitch for wear or damage and replace if necessary. ASSEMBLY/INSTALLATION (1) CLUTCH | (2) ONE WAY OUTER cLuTcH Install the one way clutch onto the clutch outer so that the flange side faces flywheel (3) FLANGE, SIDE 9-5 SRALTERNATOR/STARTER CLUTCH Apply locking egont t9 the threads of the torx batts 11) FLYWHEEL HOLDER Tighten the 1orx bolts in a crisscross partern in two or more Steps while hoiding the flywheel with the flywheel holder. TORQUE: 20 Nem (3.0 kg-m, 22 felb) TooLs: ‘Torx bit (T40) 077030010100 or equivalent commercially available in U.S.A, Flyvihee! holder 07725—0040000 or equivalent commercially available in U.S.A, (2) TORX BIT Install the starter driven gear onto the one way clutch, With the flywheel, install the starter clutch assy, onto the crankshaft, FLYWHEEL INSTALLATION Wips all oil of the crankshaft and from within the tapered hole in the flywheel. Install the folowing: — woadruff key — washer jedlo boating Install the flywheel onto the crankshaft, aligning the woodrutt key with the keywey, (2) NEEDLE BEARING Apply MoS2 pasta to the threads of the flywheel bolt Install the bolt and washer, and tighton tho belt while halding tha flywheel. TORQUE: 125 Nem (12.5 kg-m, 90 feb) TooL: Flywheel holder 07728—0040000 oF equivalent commercially available in U.S.A. os)LEFT CRANKCASE COVER ASSEMBLY ALTERNATOR STATOR INSTALLATION Install tha stator onto the left ovankease cover and apply @ locking agent to the threads of the stator mounting bolts, Tighten the three bolts. Route the stator wire and install the wire grommet into the ‘groova of the caver as shown, CLUTCH LIFTER ARM INSTALLATION Install the spring onto the lifter arm. Incort the lifter arm and heok the pring to the loft cranksase Turn the lifter arm and install the lifter piece, aligning the groove on the lifter arm with the bottom of the lifter piece. LEFT CRANKCASE COVER INSTALLATION Install the following: — washer and shaft — starter crive gear NOTE Install the starter drive gear with the “OUT mark facing Install the dowel pins and a new gaskot 7 WASHER ALTERNATOR/STARTER CLUTCH 1) STATOR MOUNTING: BOLT [2) HOLDER \ 43) GROMMET he G 3 (LIFTER ARM (3) LIFTER PIECE oO SSi2) serine far Drive 8. 13h*0U EAR Sagi CASKET PALTERNATOR/STARTER CLUTCH Install the left crankcase cover and connect the neutral switch Put the neutral switch wire into the groove of the left crank: Instell the left crankcase cover with & clamp, ard tighten the left crankcase cover bolts In a crisscross pactern In two oF more steps. TORQUE: 12 Nim (1.2 kg-mn, 9 ft Ib) Install the drive sprocket caver and secure it with three bolts. Install the gearshift pecal. aligning the punch marks on the podal and goarchift spindl Secure the pedal with a bolt Install the shaft and idle gear with the washers. Install tho shaft and reduction gear with the wachALTERNATORI/STARTER CLUTCH Install the dowel pins end & new gasket Install the starter gear cover and secure it with the five boits. TORQUE: 12 Nem (1.2 kg-m, 9 fb)(CRANKSHAFT/BALANCER 10-010. CRANKSHAFT/BALANCER SERVICE INFORMATION 10-1 CRANKCASE BEARING ‘TROUBLESHOOTING 10-2 REPLACEMENT 10-6 GRANKSHAFT/BALANCER CRANKCASE SEPARATION 108 OA AON 10-10 BALANCER/CRANKSHAFT ROAR 10-4 CRANKCASE ASSEMBLY 10-11 ) SERVICE INFORMATION GENERAL Engine ‘Section 5 Ot! pamp Secton 2 Cylinder head Section 6 Cylinder/aiston Section 7 Clutch Section & Altemeter Section 9 SPECIFICATIONS rid rem STANDARD SERVICE LiMiT. Connecting rod big end side clearance (0.050—0.60 mm (0.0020-0.0256 in) 0.80 mm (0.081 in) Connecting red big end radial clearance 0.006 0.018 mm (0.0002-0.0007 in) | 0.05 mm (0.002 in) Crancshaft runout — [0.10 mm (0.004 in) TORQUE VALUE Cronkesse tot 12am 142 kgm, 8) roois Special Universal bearing cule 7821 ~9010000 Boring ie catch Oroat neo" 09 , Snoring remover 07930—MRSoIoo %eaivalent commercial femover ange 07936—Ke10100 Remover sng weight 07741 ~9010201 Need rece remover oree—-NiKse 100 Dawn remover shat o7748 a¢60%00 Palo son 07991-Meao0000r97891 -ME4G00A fssortly colar 7991 Kr00100 Ted adaptor 07931 400200 Attachment, 78 x 90 mm d7eab—s040101 Common Brver 0749-0010000 Pio. 96 mm o7r46 a0r0e00 ‘tachment 62 x 66 mn 97740-06t0s00 Pie, 28 mh 07748 -080600 btchmant, 42x 47 mm 07748 -o010300 Plot, 40 rm 07746 -oo40800 ‘tachment, 2 x 36 mm 87746 oot0v00 Attachrnen, 62 © 38 rn 877400010800 Astachinon, 36 mo 1.0. O76 —on0400 Attachment, 72x 75mm 077460010600 Plot. 20-0 77480040800 10-1 ——CRANKSHAFT/BALANCER TROUBLESHOOTING Excessive Noise rankaheft = Worn connecting rod bearings — Bent connecting rod — Worn crankshaft bearings nprope installation — Worn balancer beatings 10-2CRANKSHAFT/BALANCER CRANKCASE SEPARATION FERS ITA Ramave the following: bolt, collar and cam chain tensioner = carn chain = cam chain drive sprocket Inspect the cam chain tensioner for excessive wear or dam- 208 Loosen and remove the right crankease belts Loosen and remove the left crankease bolts in g crisscross pat- tein in two or more steps. 10-3CRANKSHAFT/BALANGER Remove the right crankcase from the left crankcase, (1) GasKeT NOTE * Separate the right and left crankcases from each othe: while tapping them at saveral locations with a soft hammer CAUTION ‘Do not pry the crankeases apart with a screwdriver. Remove the gasket and dowel pins. BALANCER/CRANKSHAFT REMOVAL |1) BALANCER Remove the transmission (nage 17-2). Insert a proper sized nail into the holes in the balancer, while prying the scissors gears with a screwdriver. Turn the balancer weight with the balancer weight out of she crank weight, and paint on the balancer drive gear end driven gear, Romove the balancer and pull out the nail. Using @ hydraulic press, press the crankshaft out of the left 11) CRANKSHAFT ‘cronkense, Remove the left crankshaft beating wth a bearing puller 1 ‘comes out with the crankshaft TooL: Universel bearing puler 07631—0010000 or equivalent commoretatly available in U.S.A. Bearing puller catch 07931—MK20100 valent commercially |3} PILOT 20. mm or EQUIVALENT Discard the bearing. CAUTION + Always replace the left bearing with a new one if t comes with the crankshaft. 10-4CRANKSHAFT/BALANCER CRANKSHAFT INSPECTION Sot the crankshaft on a ttuing stand or V blocks and measurs the runout using a dil indicator. SERVICE LIMIT: 0.10 mm (0.004 in} emm (0.24 in} Measure the side clearance of the connecting rod big end with 2 feoler gauge SERVICE LIMIT: 0.80 mm (0.031 In} ‘Measure the connecting rod big ond radicl cloarance. SERVICE LIMIT: 0.05 mm (0.002 in) BALANCER DISASSEMBLY/ASSEMBLY (1) WASHER ji Separate the outer driven gear from the inner driven gear by re- moving the snap ring and cone spring washer. Remove the four springs from the inner driven gear (3) SNAP RING 10-5CRANKSHAFT/BALANCER Check the gears and springs for weer, damage or fatigue, and (1) SPRINGS (2) OUTER DRIVEN GEAR replace If necessary. sii Ingtall the four epringe into the inner driven goar. Install the outer driven gear onto the inner driven gear NOTE + Position the punch mark on the outer gear hetwaen the punch marks on the inner got Install the cone spring washer and the snap ring soouroly, CRANKCASE BEARING REPLACEMENT INSPECTION Turn the inner reces with your finger. ‘The beerings should turn smoothly and quietiy. Algo check thst the outor raves of tha baaringe fit tightly in the crankcase, Replace the bearings if necessary. RIGHT CRANKCASE BEARING REPLACEMENT Romove the right balancer bearing using the following tools. TooLs: Bearing remover 07936—MK50100 oF oquivalont commorcilly available in U.S.A. Remover handle 07936—KC10100 or equivalent commercially available in U.S.A. 077410010207 oF equivalent commoretally available in U.S.A,CRANKSHAFT/BALANCER Bend down the tabs of the lock plete, and remove the bolt, lock plate and beating stopper plate Discard the lock plate. Romeve each boating cut of the right erankea Remove the oil seal and ciscard it after removing the éght crankshaft bearing, Apoly clean engine oil 10 the ip of the new right counter shaft cil seal and install it securely 2) ATTACH. Apply ell to each new bearings, and drive each bearing into the few fight crankease, NOTE Drive in the bearing perpendiculerly to the right crankoasa. Too.s: Crankshaft beating Driver 077490010000 Attachment, 72 x75mm 077460010600 Pilot, 35 mm. 07746-0040800 {ht mainshaft bearing Driver 077490010000 Attechment, 52x 55mm 077460010400 ‘ Pilot, 25 mm 077460040600 (1) BALANCER (2) MAINSHAFT. BEARING: BEARING Right countershaft bearing Driver 077490010000 Attachment, 42 x47 mm 07746—9010300 Puiot, 20 mm 077460040500 Right balancer bearing Driver 077490010000 Attachment, 42x47 mm 077460010300 (4) CRANKSHAFT! BEARING,CRANKSHAFT/BALANCER Install the bearing stopper plats and new lock plate, and secure them with a bolt. Berd up the tabs of the lock plate against the bolt LEFT CRANKCASE BEARING REPLACEMENT (1) REMOVER HANDLE’, os. (2) BEARING : ley iy REMOVER Romove the left belancer bearing using the following tools. TooLs: Bearing remover 07936—MK60100 or equivalent commarcially available in U.E.A. Remover handle 07936—Kc10100 wuivelent commarotally available in U.S.A. Remover sliding weight 07741—0010201 oF equivalent commercially available in U.S.A. Romove the needle bearing and check it for wear of damage, and replace if necessary. Remove the bolt and bearing race stopper. Remove the needle beating race from the right crankcase using the following touls. Toots: Needla raca remover 07GMe—MK50100 Booring remover shatt 077460060100 co atiaweeme ||) remover shar 10-8CRANKSHAFT/BALANCER Remove the le't countershaft bearing cil seal and discard it, i) COUNTERSHAFT Ol Be Check the gearshift spinde oil seal for wear, damage or fatigue, and replace it if necessary. Romove each bearing cut of the left crankoase. Replace the bearing plate if necessary. Apply oil to each new beering, and drive each bearing into the (1) DRIVER left crankease (2) ATTACH Nore + Drive in the bi rings perpendicularly to the left crankcase. Toots: Loft crankshaft beering Driver 07743—0010000 Attachment, 78x90 mm 07GAD—SD40101 Pilot, 40 mm 07746—0040900 Loft mainshaft bearing race Driver 07749-0010000 Attachment, 32x35 mm 07746—0010100 wo (0) COUNTERSHAET © “2) CRANKSHAFT BEARING, 3 BEARING Left countershaft booting Driver 07749-0010000 ttachment, 62x 68mm — 07746—0010500 lot, 25 mm 07746040800 Loft balancer bearing Driver 07748—0010000 Attachment, 42x47 mm 07746—0010300 10-9CRANKSHAFT/BALANCER Install a new countershaft cil seal in the left erankease, anc apply oil to the oll seal lp, Secure the bearing race stopper plate with the bolt Install the nescle bearing into the bearing race. CRANKSHAFT/BALANCER INSTALLATION Clean the crankcase mating surfacas hafora assembling and check for wear or damage. NOTE + IF thete ® minor roughness oF imegularities on the crankcase mating surfeces, dress them with an cil stone. + After cleaning, lubricate the crankshaft bearings and other contacting surfaces Install the special too! into the thread end of the crankshatt Positien tho orankehatt into the loft crankea Draw the crankshaft into the lett crankcase with the Following tools: NOTE + Draw in the crankshaft, making sure the connecting rad is not comprossed against the crankcase edge. TooLs: Puller shaft 97931—Me40000 Assembly collar 07931—KF00100 Thread adaptor 07931—KF00200 Attachment |.D. 35 mm 077460030400 Insert a proper sized nail into the hole in the balencer, while prying the scissors gears with a screw driver Install the balancer with the paint marks aligned, 10-10CRANKSHAFT/BALANCER ‘Turn the barencer, and meke sure the puntch marks on the ba (1) PUNCH MARKS ancer drive geer and driven gear are aligned. Draw the nail out of the balancer. Inetall the transmissicn (ssction 11}, CRANKCASE ASSEMBLY UIP SASKET Install the three dowel pins and a naw gesket Assemble the right and left crankcases being careful to align the dowel pins and snatts, CAUTION + Don't force the crankease halves together; if there is excessive force required, something is wrong, Remove the right crank ease and check for msatigned parts. Tighten the left crankcase bolts in a crisscross pattern in two or more steps. TORQUE: 12 Nem (1.2 kgm, 9 feb) Tighten the right crankcase bolts. TORQUE: 12.Nem (1.2 kgm, 8 tb)CRANKSHAFT/BALANCER Apply a locking egent to the threads of the tensioner bolt. ‘Secure che cam chain tensioner with the collar and bolt. Install the cam chein drive sprocket and cam chain, NOTE +The cam chain drive earackat will only go on ane position becauas of oxtr signing spline. Reinetall the romoved parte in the reverae order of removal (page 10-1), 10-12TRANSMISSION11. TRANSMISSION SERVICE INFORMATION 11-1 TRANSMISSION DISASSEMBLY 13 , TROUBLESHOOTING 11-2 TRANSMISSION ASSEMBLY 116 SERVICE INFORMATION GENERAL @ The crankcase must be separated to service the transmission '© The gosrshitt eam plate can be serviced with the engine ina:al in the frame (Section 8) SPECIFICATIONS ITEM STANDARD SERVICE LIMIT | Seerto. Wa, 68, C2 | 28020~78.941 mm (9.10311. 1080 hy | 2810 mm (106d [ms 28.000 ~ 28.021 mm (1.1024—1.1032 in) | 28.08 mm {1.106 ink ct _ 25.020—25.041 mm (0.9850—0.9859 in) | 25.10 mm (0.988 in} Gear bushing M6 0.0. 27.949 —27.980 mm (1.1004—1.1016 in) | 27.90 mm (1,098 in) crop 24.004 25.005 mer 10.8036 0.9044 in) _ 24.99 mm 0.961 in) cro. 70,020~20.081 men (0.7862—0.7660 in) | 20001 mm 0-788) Gear-to-bushing clearance | M5. 0,020—0.072 mm (0.0008—0.0028 int | _0.10 mm (0.004 in) | ct | 0.015-0.087 mn (0.0006—0.0022 in) | _0.10 mn 1.004 int 7 Ma, €3, C8 {0.020-0.062 mm (0,0008 0.0024 int | 0.110 men ©.004 in) | [ Mainshaf 0.0. M4, 24.872 24.983 mm (0.9831 0.9880 in) | 24.92 mm 0.981 in | ‘Countersheft 0.D. cr © 19.900— 19,999 mmm (0.7866—0.7071 in} | 19.94 mm (0.765 in) ro 24,972 24.983 mm (6.9831 —0.9840 in) | 24.92 mm (0.981 in) 3 | 24,959 24.980 mm (0.9826 0.9835 in) | 24.92 mm (0.981 in) Shoitto-gear Cecrence M4 0.027 0.068 mm (0.0011 0.0027 int | 0.10 mm 0.004 ind 2 “| 0.041—0.082 mm (0.0016—0.0032 in} | 0.15 mm (0.006 in) Shaft-to-bushing clearance C1 | 0.027—0.061 mm (0.0011—9.0026 in} [0.10 mm (0.004 in) ma,c2 £0.027--0.089 mm (0.0011 0.0027 int | _0.10 men 0.004 in) - 14,000— 14.018 mm (0.5512—9. 14.05 mm (0.653 in) ‘Shift fork claw thickness 4,938.00 mm (0.194—0.197 in) | 4.5 mm (0.18 in) [Shift fork shaft 0.0. 13.068 13.984 mm (0.6498—0.5506 in} | 13.90 mm (0.547 in) TORQUE VALUE Center shift fork bolt 18 Nn (1.8 kgm, 17 feb) 11-1TRANSMISSION TROUBLESHOOTING Hord to ohitt + Improper clutch agjustment; too much tree play + Shift forks bent + Shift fork shatt bent + Shift drum groove damaged ‘Transmission jumps out of gear + Gear dogs worn + Shft fork shaft bent + Shft drum stoppar broken + Shft forks! bontTRANSMISSION TRANSMISSION DISASSEMBLY (1) GeARSHIFT SPINDLE Separate tha crankcase (section 10). Pushtthe goarchatt plate in the direction the allow chews, ancl remove the gearshife spinds, Bend down the tabs of the lock washer, and remove the bolt and lock washer. Remove the following: ~ shift Fork shett (1) SHIFT FORKS: = Sit ts = Shit dum BOLT AND (Sek wai Remove te mainshatt and countersha as an assembly, (1) COUNTER: SHAFT TRANSMISSION GEAR/SHAFT INSPECTION Disassemble the mainshaft and countershaft, Inspect each gear fer wear or dameae. Check the gear teeth for wear or damage. Chock the engagement dogs of gears for wear or damege. (2) COUNTERSHAFTTRANSMISSION Check each gear for axcessive or abnormal weer. Inspect the I.D. of each year. SERVICE LIMITS: M4:28,10 mm (1.106 in) M9:28,08 mm (1.106 in) C1: 25.10 mm (0.988 in) C3: 28.10 mm (1-106 in) (€2: 28.10 mm {1.106 ind Measure the LD. and 0.0, of each azar bushing. SERVICE LIMITS: Ms, 0.0. 27.90 mm (1.098 In) 61, 0.0: 24.93 mm (0.981 in} cn. 1 20.01 mm (0.788 in) Ma, C3, C2, 0..: 27.93 mm (1.100 in) M4, C3, C2, 1.D.: 25.10 mm (0.988 in) Calculate the clearance between the gear and sushing. SERVICE LIMITS: M5, Ct: 0.10 em (0.004 in} M4, C3, C2; 0.11 mm (0.004 in} Measure the mainshaft 0.0. SERVICE LIMIT: Mia; 24.92 mm (0.981 in} Calculate the clearance between the mainshaft and M4. bush- ing SERVICE LIMIT: 0.10 mm (0.004 in) Measur> the countershafi 0.0. SERVICE LIMITS: C1: 19.94 mm (0.785 in) (C2, C3: 24.92 mm (0.981 in} Calculate the clearance between the geer ar bushings and countershatt. SERVICE LIMITS: C1 bushing: 0.10 mm {0.004 in) 62 bushing: 0.10 mm (0.004 in) €3 gear: 0.15 mm (0.006 in) 11-4TRANSMISSION SHIFT FORK/SHIFT FORK SHAFT INSPECTION Measure the LD. of the right and left shift fork. [SERVICE LIMIT: 14.05 mm (0.553 in} Measure the thickness of each shift fork claw. SERVICE LIMIT: 4.5 mm (0.18 int Measure the 0.D. of the shift ferk shatt at the surfaces sliding with the right and left shift forks. SERVICE LIMIT: 13.90 mm (0.647 in} SHIFT DRUM INSPECTION (1) SHIFT DRUM BEARING Turn the outer rave of che shift drum bearing with your finger, ‘The bearing should turn smoothly ané quietly. Also check that the inner race of the bearing fits tiahtly onto the shitt deur Replace the beeting if necessary. Inspect the shift drum crooves for weer or damage, and r- place it if necessary. (2) SHIFT DRUM GEARSHIFT SPINDLE |NSPECTION/DISASSEMBLY (1) RESET SPRING [2 SPINDLE _— Check the spincle for bends, excessive wear or other damage, (Check the return spring anc reset spring for fatigue or damage. (4) SNAP RING Remove the return spring. snap ring and reset spring, (3) RETURN SPRING GEARSHIFT SPINDLE ASSEMBLY [1 SNAP RING (2) Rest Install the snap ring, return spring and reset spring. ‘SPRING (3) RETURN SPRINGTRANSMISSION TRANSMISSION ASSEMBLY (1) SNAP FING Apply clean engine oil to the sliding and rotating surfaces of the gears, bushings and shafts. Assemble the mainshaft andl counter shaft. NOTE + Install he snap rings aligning thelr end gaps between the shaft teeth as shown, + Make sure the sep rings are seated securely in the grooves S of the ahafte (2) SHAFT. (3) M3 GEAR (20T1 (2) MS GEAR (25T} (4) M4 GEAR (23T! 5) yy GEAR (127) (1) M2 GEAR (167) 4 MAINSHAFT. aooats 00 | ae GF « cogr a © (7) MB GEAR BUSHING (6) M4 GEAR BUSHING (10) C5 Gear (217) (12) C4 GEAR (13).C1 GEAR (8) C2 GEAR (287) ‘inca Gear ist) (237) (G27) |9) COUNTERSHAFT ates ) Q) Oy ® o@ (0 Lm econdys (16) C2. GEAR (15) C3 GEAR (14) C1 GEAR BUSHING. BUSHING. BUSHING. Align the hole in the MS gear bushing with the hole in the main i (1) HOLES shaft when installing " After assembly, check the gears for smooth rotation and slid- ing on the shaftTRANSMISSION Install the mainshaft and countershaft into the leit crankease (1) MAINSHAFT togethor is \ ' (2) COUNTERSHAFT ) cach eit fork hae an dentifietion mark; "RC leentan 11) IDENTIFICATION MARKS fee Install each shift fark to the correct position. Apply clean engine oil to the sliding and rotating surfsces of (1) SHIFT FORKS the shift forks ena shirt fork shaft, and the groove of the shift drum. Install the shi! drum, then install the shift forks wits their identification marks feoing up. Insert the shift fork shaft through the shift forks, and align the bolt holes in the center fork and shaft, Install and tighten the center shift fork bolt with a new lock washer. TORQUE: 16 Nem (1.5 kgm, 111 ftb) Bend up the tabs of the lack washer against the center shift fork bolt.TRANSMISSION Align the return sping with the pin belt and install the gear shift spindle while pushing the gearshitt plate in the direction the arrow shows. Assombie tho erankease (Section 10) Install the gearshift cam, stopper arm (page 8-9} and gearshift: pedal, and check the transmission for srmaoth cperation B82) RETURN SPRING AND | PIN BOLTFRONT WHELL/SUSPENSION/STEERING 24 Nem (2.4 kgm, 17 Feld) 100 Nem (19.9 kgm, 72 Feb) 28 Nem {2.8 kg-m, 20 feb) 33 Nem {3.3 kg-m, 24 feb) 65 Nun 16.5 kgm, 47 telby 32.Nem (1.2 kgm, 9 feb) 27 Nem (2.7 kgm, 20 Feb12, FRONT WHEEL/SUSPENSION/STEERING ‘SERVICE INFORMATION 12-1 FRONT WHEEL 125 TROUBLESHOOTING 12-2 FORK 12-40 HANDLEBARS 12-3. STEERING STEM 1247 SERVICE INFROMATION GENERAL © A box or work stand is required to support the motorcyle. iN Brake dust may contain asbestos. + Inkailed asbestos fibers have been found 10 cause respiratory disease and cancer. Never use an cir hose or dry brush (a clean brake assemblies. + In the United States, ust an OSHA approved vacuum cleaner or eternate method approved by OSHA designed to minimice the hazard caused by airborne asbestos fibers. SPECIFICATIONS vera ‘STANDARD SERVICE LIMIT ‘Axle runout Front wheel rim runout — 0.2 mm 10.0% in) Radial — 2.0 mm 10.08 in) Axial — 2.0 mm (0.08 in) Fork spring free length Fork tube runout 999.3 mm (23.59 in| 893.3 mm [23.36 In) — 0.2 mm (0.01 in) Front fork oil capacity 592 cc (20.0 US oz, 20.8 Imp 02) = Fork oil level 120 rn (4.7 in) — TORQUE VALUES Handiotare upper holder Handletars lower holder Front hub cover screw Brake disc bok Front axle Front axle holder nut Fork slider socket bolt Lower fork pinch bolt Fork cao bolt Upper fork pinch bolt Brake calizer bracket bolt Steering adjustment nut Steering stem nut TOOLS Special Fork seal driver Fork seal driver attachment Steoring stem socket Stearing stom driver Boll race remover Ball race remover attachment = Driver handle Adjustable pin spanner Stoorng booring attachmart 24 Nem (2.4 kgm, 17 Fell) 26 Nem (2.4 kgom, 17 feb) 1.5 Nem (0.15 kgm, 1.1 ft-lb) 15 Nem (1.5 kgom, 11 feb) 56 Nem (6.5 kgm, 47 feb) 12 Nem (1.2 kgran, 9 feeb) 20 Nem {2.0 kg-m, 14 ft-lb) Apply locking agent to the threads 33 Nem {3.3 ko-m, 24 feb) 23 Nem (2.3 gyn, 17 Ftlb) 24 Nem (2.4 kgm, 17 fttbh 26 Nem {2.5 kgm, 18 [Clb 5 Nem 10.5 kg-m, 3.6 fb) 100 N-m {10.0 kg-m, 72 fib) 97947—KA5O100 97947—«FO0100 07916—KA50100 97946—4300101 or 07946—Msco000 97953—MJ10000 or 07853—MJI000A (U.S.A, only) 07953—MJ10100 97953—MJ10200 077020020001 GN HTS4 {U.S.8. only) 12-1FRONT WHELL/SUSPENSION/STEERING Common Bearing remover head, 15mm 07746-08040 Bering remover shaft 0774600501002" sa valent commercaly Driver 077480010000 *vallable in U.S. ‘tachment, 92 «36 mm 077460010109 Pict, 19 mir 077460049300 Look nut merch, 80 x 32 mm 077160920409. Extension bar 07716 -o020500-1 9% eauvatent commercially Attachment, 42 x 47 mm 977460010300 Svallat “ Hard Stosing + "Storing scfustment to tight + Faulty steering stem bearings + Insufficient air in front tire ‘Staars to One Side ot Does Not Track Straight Bent fork + Bent front axle, whee! installed Incorrectly + Unequal oil quantity in fork tubes Front Whee! Web! + Distorted rim Worn front whee! bearings Loose or broken spckes Faulty tire Asle or axle holder not tightened properly Soft Suspansion + Weak fork springs + Insufficient fluid in fork leas Hard Suspension + Fork all level too nigh + Fork tubets) bent or fork siideris} damaged Front Sueponsion Noioe + Fork slider binding + Insuffient fluid in fork legs + Loss fork fasteners 12-2FRONT WHEEL/SUSPENSION/STEERING HANDLEBARS (1) LETHANDLEBARS (2) MASTEN SWITCH CYLINDER ) REMovaL : aE (3) THROTTLE Femave the following parts: eRe — Wire bands = Left handlabars ewitch Clutch/choko lover ho'dor — Front brake master cylinder ) —Sotorengne sey saan — Throttle grip (6) CLUTCH CHOKE LEVER 314) STARTER! remove to upper hls sn hadobr ESI on Remove the lower holders it necessary. INSTALLATION Install the washers, lower holders and nuts i removed. Placo the handlabars on the lower holders by aligning the punch merks on the hendlebers with the upper surface of the lower holder. Install the upper holders with the punch marks facing forward Tighten the forward bolts firsts then the rearward. TORQUE: 24 Nem (2.4 kgm, 17 fb} Tighten the lower holder nuts 10 the specified torque. TORQUE: 24 Nem (2.4 kg-m, 17 ft-lb) instal tne stertniengine stop switch by elgniag he pin with (1) STASTERIENGINE the hole n the handlebars stor switcy Tighten the forward screw first. than tighten the rearward. % (asin MERRIS) HOLE, (2) SCREWSFRONT WHELL/SUSPENSION/STEERING the grips were removed, apply Honda Bond A or Honde Grip Cement (U.S.A. oniy} to the inside surfaces of the arins and to the clean surface of the left handlebar and throttia arin pipe, Wait 3-6 minutoo and install the grips. Rotate the grips fo: even application of the adhesive. NOTE ‘Allow the adhesive to dry for an four detore using, Apply grease to the throtle giip siding surface and cable guide. Apply grease to the throttle cable ends, and connect the throt- tle cable encs to the throttle crip Apply giezse to the throttle cable slider, and install the slider a8 shown, Assemble the throttle housing halves, and align the mating surface of the halves with the punch mark an the hendlebers, Tighten the upper screw first, then the lower one. Install the master cylinder and position the master cylinder holder with “up'" mark facing up, end loosely instell the holder bolts Align the edge of the maste- cylinder with the punch merk on the nenglebers and tighten the upper bolt fist, then the lower bolt. Connect the frant stop switch wires to the ewicch terminals, Install the left hanclebors switch by aligning the pin with the hole in the handisbars, and tighten the forward screw first, ‘then the rearward screw. 12-4 SN (1) MASTER CYLINDER (1) HOLE SA. 2IN (2) PUNCH MARK (2) LEFT HANDLEBARS SWITCH (3) SCREWSFRONT WHEEL/SUSPENSION/STEERING Install the chatch/choke lever holders and loosely install the |1| HOLDERS holder bolts 21 MATING SURFACE AND PUNCH MARK ‘Agn the mating surface of ihe clutch/choks laver holder with ‘the punch mark on the handlebars and tighten the forward screw first, then tighten the rearward screw. Connect the clutch ewitch wires to the awitch torminale, Route the switch wires and secure them with the wire bands (page 1-12) Adjuat the following: (3) CLUTCH SWITCH — throttle gtip free play (page 3-4) GL SCREWS. WIRES clutch over fee play (oag6 3-12) Ti) SPEEDOMETER FRONT WHEEL CABLE REMOVAL, Raize ths front wheel off the ground by placing @ box or work stand under the engine. Disconnect the speedometer cable from the speedometer gearbox a: the front wheel. Loosen the axla holder nuts and then wemave the frant axle Femove the front wheel INSPECTION FRONT AXLE ‘Sot the axle in V blocks and measure the runout. ‘The actual runout is 1/2 of tha total reading, SERVICE LIMIT: 0.2 mm (0.01 in) WHEEL BEARINGS. Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quiaty. ‘Alco chock thet the boaring outor race fits tightly in tho hub. Remove end discerd the bestings if the races do not tur smoothly, quietly, or if they fit loosely in the hub, NOTE + Replace wheel bearings in pairs. For bearings replacement, see page 12-7.FRONT WHELL/SUSPENSION/STEERING WHEEL RIM RUNOUT Check the rim runout by placing the wheel on a truina stand. ‘Thon epin the wheal by hand, and read the runout using a dial indicator. SERVICE LIMITS: RADIAL: 2.0 mm (0.08 int AXIAL: 2.0 mm (0.08 in} WHEEL BALANCING CAUTION + Wheel balance directly affects the stability, handling ond over alt safety of the motorcycle, Always check balance when tie tire are removed from the rim. ‘optimum balance, the tire balance mark {e paint det on the sldewell) must be located next to the valve stem. Mount the front wheel in a ingpection stand. Spin te wheel, allow It 10 stop, and merk the lowest [heaviest part of the wheal with chalk. Do this two or three times to verify the heaviest area If the wheel ig bslanced, it will not stop consistently in the same position. To balance the wheel, instell wheel weights on the highest side of the rim, the sice opposite te the chalk marks. Add just, enough weight so the whes! does not stop in the same positian when it ie spun. De not add more than 60 grame 12-6FRONT WHEEL/SUSPENSION/STEERING DISASSEMBLY (1) GEAR BOX (2) DUST SEAL Remove the spaedemator gearaox from the right side of wheel hub. Remove the dust seal and soesdometer gear retainer } Remove the side collar, front brake dise, dust seal and the hub (3) DUST | SEAL Remove tho wheol bearings and distance caller. 07746—0050400 or equivalent commarcially available in U.S.A, Bearing remover shat: 07746—0050100 or equivalent commercially available in U.S.A. NOTE + Replace the wheel bearing with a now one, whenever the ), Baeting ie removed + Replace the wheel bearings in pale. (2) BEARING REMOVER HEAD] 12-7FRONT WHELL/SUSPENSION/STEERING ASSEMBLY + Do not get grease on the brake dise or stopping power will be reduced. (1) SPEEDOMETER GEARBOX So sm (2) SPEEDOMETER GEAR 43) pusT seat cay weaning ofl Placa the rim on the work bench. Place the hub with the dise sida down and begin lacing with new spokes. ‘Adjust the hub position so thet the distance from the disc out side surface to the side of rim is 22.25 mm (0.876 ini es shown, Tightan tho spokes in 2 or 3 progroscive steps. TORQUE: 4 Nom (0.4 Kg-m, 3 feb} Tool: SPOKE WRENCH C, 6.8 x 8.1 mm 07701 —0020200 or equivalent commorcially available in U.S.A, Pack new wheel bearings with greese, Drive in tho right bearing firat until it costs completely, Install the distance collar and drive in the left bearing. NOTE install the bearngs with their sealed ends facing outside. + Drive the bearings in perpendiculaiy. 07749-0010000 077460010100 07746—0040300 Attachment, 32 x 35. mm. Pilot, 15 mm Check the whos! uncut (page 12-6). Install the rm lock, rim bang, tube and tire NOTE + Install the tre with its directional arrow gcinting in the di rection of normal rotation for fowaird motion. 12-8 (6) DISTANCE COLLAR (6) BEARING (2) DUST SEAL (@) SIDE COLLAR, (9) HUB BEARING (19) Disc __ | 22.26 mm (0.878 in) (2) ATTACHMENT ‘AND PILOT. iy DpWERFRONT WHEEL/SUSPENSION/STEERING Apply alocking agent to the threads of the hub cover sciews, 11) BRAKE (21 BOLT. (3) SIDE COLLAR, and secure the hub cover with the screws, DISC f Install the brake disc yrith the stemped side facing out, and secure the dise with four bolts TORQUE: 15 Nem (1.5 kgem, 11 feb) ‘Apply grease to the dust seal lips and install It Install the left side collar. (6) HUB ios COVER (5) SCREW ta) DUST SEAL Inatall the shims inta the speedomater gearbox Apply grease to the inside surface of the goarbox and goar ‘teeth, anc install the gear Into the gearbox. (1) SPEEDOMETER, San i GEAR Install the specdoreter gear retainer, aligning tabs of the re tainer with the grooves in the veel hub. Apply grease 10 the dust seal bub. Install the speedometer gearbox onto the dust seal. engaging the tebe of the gear retainer with the bosses of th: ter gear cach other. and install it into the whealFRONT WHELL/SUSPENSION/STEERING INSTALLATION Place the front wheel between the fork legs. Fit the ealizer over the brake disc, teking care not to damage {the brake pads. Clean the axle and helder Inetall tho axle through the speedometer goerbox and wheel ub. Set the speedometer gearbox tab against the behind of the tang on the fork slider UP" MARK If you removed the axle holder, instal it with “UP mark, fecing up. Install the axle holder nuts locsely. ‘Tighten the front axle to the specified torgue. TORQUE: 86 Nem (6.5 kgm, 47 fb) Connect the spe with the screw. jomerer cable te the gearbox, and secure it With the front brake applied, pump the front suspension up and down severe! times to seat the axlo. Tighten the front axla holder nuts, the upper nuts first, then the lower nuts in 2—3 steps, TORQUE: 12 Nem (1.2 kgm, 9 ft-lb) FORK REMOVAL (1) FRONT FENDER (2) FORK Remove the following parts. BRACE: Front wheel (page 12-5) Front fender — Fork brace — Retlectors In) REFLECTORS: = Speedometer cable clam. — Brake hose clamp — Brake caliper Ipags 14-9) NOTE Se S (2) BRAKE q + ris no: necessary to hore. ae (a) SPEEDOMETER caale clamp 12-10FRONT WHEEL/SUSPENSION/STEERING Loosen the upper ‘ork pinch bolts first, then the fork cap bolts. Holding the fork legs, loosen the lower fork pinch bolts, then romove the fork lege. '3| UPPER FORK PINCH BOLTS DISASSEMBLY £1) FORK BOOT Loosen the boot band screws and remove the fork boot and boot bands. Romove the fork cap bol. + The cap bolts are under spring pressure. Use eare when remov- ing and weur eye and jace protection. (1) SPRING (a1 FORK Remove the spacer, spring seat and fork spring. Drain the fork fluid by pumping the ‘ork tube in and out several times. Check the spacer and spring scat for wear or damage.FRONT WHELL/SUSPENSION/STEERING Hold the fork slider in 2 vise with soft jaws or @ shop rowel Remove the fork slider socket bot. CAUTION + Do not distor: the fork slider in a vise Remove the fork piston anc rebound soring. Remove the dust caal and circlip. CAUTION + Be careful not to damage the fork tube, (2rciRCLIP Pull the fork tubo out until it stope. Then move it in and out, ‘tapping the bushing lightly until the fork tube separates from ‘he fork slider. The slider bushing will be forced out by the fork tube bushing. Remove the oil lock piace from the Fork alid Remove the oll seal, back-up ring and slider bushing from the ‘ork tube, PIECE Do net remove the fork tube bushing until inspection determi is nacessary (page 12-13). g BUSHING. (5) SLIDER. BUSHING. (4) O1L SEAL 12-12os -( S- FRONT WHEEL/SUSPENSION/STEERING INSPECTION Measure the fork 5 free length, ‘SERVICE LIMIT: 593.3 mm (23.36 In) Chack the oil lock piece. rebound spring and fork tube piston ring for damage er wear Replace if necessan Chack tha fork slider, fork tube and fork piston for scering scratches, deformation or excessive weer. Replace any camponents which ara worn or camaged. Sot the fork tube on V blocks and measure the runout, ‘The actual runout is 1/2 of the total indicator reading, SERVICE LIMIT: 0.2 mm (0.01 ind (1) OL LOCK PIECE (3) REBOUND SPRING ©: (2) FORK SLIDER (2) PISTON RING 12-13FRONT WHELL/SUSPENSION/STEERING Visually Inspact the slider an fork tube bushings. Replace the bushings if there is excessive scoring or scratch- ing. or ifthe teflon is worn so that the copper surface anpears ‘on more than 3/4 of she entire surface. (1) BUSHING (2) BACK-UP RING Check the back-up ring; replace It if there 1s any distortion at ‘the ocints shown. (3) CHECK POINTS ASSEMBLY (a) SPACER 2) WASHER, (WOUSTSEAL 12) FORK Boor ne cRcur ~e "roma | Lo FORK TUBE (17) OW SEAL, tis) aac aed AING © & a = P (9 Fone SPRING a |onaror7 RING gj ineom—i! ey Sa PISTON Sa 113) FORK TUBE A j BUSHING. Flee u 3 (g) REBOUND 7S 4 serine 0 Jay FORK SUIGER ——_(@) OIL Lack. lece ; (1) OL, LOCK (2) FORK a) StibER Insert the fork giston with the rebound spring and with its ore eB 8 SER piston ring side facing up. Apply ATF to a new oil seal lia, Install the slider busking, back-up ring and new cil seal onto ‘the fork tube. NOTE Install tre oll seal with the Sot the oll tock piece onto the end of the fork piston, then ig) FORK (6) BACKUP. Insert the fork tube Into the fork slider. SLIDER RING (4) OIL SEAL SS 12-14 eee errr er eTETTTE ES TT eTFRONT WHEEL/SUSPENSION/STEERING ‘Temporary install the ‘ork spring, spring seat, spacer, washer (1) SockeT BOLT ‘and fork cap bolt into the fork tube, Place the fork slider in @ vise with soft jaws or a shop towel. ‘Apply a locking agent to tie socket bol: threads and torque the fork slider socket boit. TORQUE: 20 Nem (2.0 kegem, 14 ft-lb} Drive the oll seal inte place using a fork seal driver end ettach- (1) FORK SEAL DRIVER | i ment. ‘oous: Fotk seal driver 07947—KA50100 Fork seal driver attachment —-_-07947—KFO0100 Install the circlip and dust coal (2) DUST SEAL Note + Be careful net to damage the fork tube sliding surface. + Make sure the circiip Is seated securely in the fork sider groove. Remove the fork cap bolt, washer, spzcer, spring seat and fork spring. Pour in the specified emount of ATF. ‘SPECIFIED FLUID: ATF CAPACITY: 592 cc (20.0 US oz, 20.8 Imp 021 Slowly compress the fotk leg up and down about five times, then megsure the ol level from the top of the tube with he ‘ork leg fully compressed. NOTE + Make sure the oil level is the same in both fork tubes, STANDARD OIL LEVEL: 120 mm (4.7 in} 12-15FRONT WHELL/SUSPENSION/STEERING Wipe any ail off the fork spring Install the fork spring into the fork tube with its nallow pitch end facing down, end install the spring seat and spacer. (1) FORK CAP (2) O RING BOLT sins Apply ATF to « new O-ting end instal it onto the Fork cap bolt. Put the wasiter onto the fork cag bolt, and screwr the cap bolt in-the fork tube. (31 WASHER Install the fork boot with the breather holes facing the rear. HT FORK BOOT !2)!.50042) BREATHER HOLES Install the lower band with the screw head facing eur, and : tighten it Loosely install the upper band with the screw head facing out. INSTALLATION Install the fork legs through the steering stem and steering top brioge. Align the tops of the fork tube and steering top bridge and tiahten the lower fork pinch bolts, TORQUE: 33 Nom (3.3 kg-m, 24 feb) Tighton the fork cap belts to the specified zorque. TORQUE: 34 Nem (2.3 kg-mn, 17 feb) Tighten the upper fork pinch bolts to the specified toraue. TORQUE: 28 Nem (2.8 kg-m, 20 ft-lb) 12-16FRONT WHEEL/SUSPENSION/STEERING Install the brake caliyer and calipar bracket onto the lett fork (1) REFLECTORS slider, and secure the bracket with the boits. TORQUE: 25 Nem (2.5 keg-m, 18 feb} Secure the brako hose with the brace hose clamp. Secure the speedometer with the speedometer clamp. Install the reflectors as shown. : (a secéoomerer" CABLE CLAMP ) Pl the fork boots up to the steering bottom bridge, and tight- (1) 8907. ‘an tha boot band screws, Banos ——— Install the fork brace and front fender anto the fork legs and |1) FRONT FENDER. s0oure thom with the four bolts Instell the front wheel (page 12-10) (3) FORK BRACE STEERING STEM REMOVAL Romave the follawing: — handlebars (page 12-31 — ignition switch {page 19-6) — front wheel (page 12-5) stom nut cap — brake hose clampFRONT WHELL/SUSPENSION/STEERING Fomeve the air guide piate and brake pipe attaching bolts. Remove the steering stam nut (1) EXTENSION BAR Toots: Lock nut wrench, 30 x 32 mm 077160020400 (or equivalent commercially availaale in U.S.A, Extonsion bar 077160020500 ‘r equivalent commercially available in U.S.A. Loosen the upper Tork pinch balts and ramove the steering top bridge. Remove the fork lege. Hold the stearing stem to prevent it from felling. Fomove the stecring adjustment nut rooLs: Steering stem socket 07916—KA50100 Extension bar ‘Adjustable pin spanner move the Fellow (0) DUST (2) UPPER WNC YR STH SETI eusteed Seat |” Race Sev — upoer bearing inn = upper bearing steering stem Check the dust sesl, inner race, upper and lower besrings and outer races for wear or damage. Replace if necessary. Remove the lower bearing from the steering stem, (5) UPPER BEARING 12-18FRONT WHEEL/SUSPENSION/STEERING BEARING REPLACEMENT NOTE + Always replace the bearing and rece as a set. emove the bearing inner race and dust seal from the steering stem, NOTE + Temporarily install the steering stem nut onto the steering stom te prevent the stom threade from being demagac when removing lower inner race. Install a new dust seal onto the steering stem and press the lower bearing inner race anto the stem with the special soo! Toots: Steeting stem driver 97946—4300101 or Not available in U.S.A. Stosring stem driver 97946—Ma00000 with Steering bearing attachment GN HTS¢ (U.S.A. only) Remove the upner and lower outer races using special tool Toots: W race remover 97953-10000 Not available in U.S.A, — Ball race remover 97953—MJ10100 attachment Not available in U.S.A, = Driver hana 97953—MJ10200 or Not available in U.S.A, Ball race remover 07953—MJ1000A, IUSA. only) Diivo now outer racea inta the etsering head. 97749-0010000 Attachment, 42 x 47 mm 07746—0010300 (1) DUST SEAL (2) INNER RACEFRONT WHELL/SUSPENSION/STEERING INSTALLATION MIT LOWER BEAAING BAM (2) bust x SEAL Pack a new bearing cavities with grease. Inetall the lowor toaring onto the stooring atom, then insert the steering stam through the steering head. Install the upper bearing end beering inner race. Apply grease to the dust se: head and install it onto the stearing 11) STEERING STENT SOCKET Install and tighten the steering adjustment nut to the specified torque. TORQUE: 5 N-m (0.5 kg-m, 3.6 fb) stem socket 07916—KA50100 oF Adjustable pin spannsr 077020020001 Extension bar 07716—0020500 or equivalent commercially available in U.S.A. Turn the stooring stom lock to lock 56 timse to.ceat the bear ings, and check the sieering stem for up-and-down move ment. Tighten the adjustment nut-to the specified torque again. (1) TOP BRIDGE Install the staering top bridge and steering stem nut, ‘Ternporarity install the ‘ork legs. Tighten the steering stem nut to the specified torque: TORQUE: 100 Num (10.0 kg-m, 72 fe-10) Toots: Lock nut wrench, 30 x32 mm —07716—0020400 for equivalent commercially avalable in U.S.A, Extension bar 07716-0020500 or eauivalent commercially avalable in U.S.A, ‘Secure the brake pipe to the steering bottom bridge with twa bolts. Install the air guide plate with twe bola, 12-20FRONT WHEEL/SUSPENSION/STEERING {Install tie following components: Fork legs page 12-16 — Brake hose lamp Stom nis cap. — Ignition switch (page 19-7) Handlebars ‘page 12-3) — Front wheel (page 12-10) [2) STEM NUT_CAP| 12-21REAR WHEEL/BRAKE/SUSPENSION 75 Nem (7.5 kgan, 54 feb) 45 Nem (4.5 kam, Feb) 95 Nem (8.5 kg-m, 69 tab) 45 Nem 14/6 kom, 32 fel) 45 Nem (4.5 kom, 32 flbp 13-013, REAR WHEEL/BRAKE/SUSPENSION SERVICEINFORMATION 13-1 SHOCK ABSORBER 13-12 TROUBLESHOOTING 13-2 SHOCK LINKAGE 13-15 REAR WHEEL 13-3. SWING ARM 13-18 REAR BRAKE 13-9 SERVICE INFORMATION GENERAL © A box or work stand is required to support the motorcycle. 4 Use genuine suspension linkage and shock absorber pivotimount bolts. Note installation cirection of the bolts, The shock absorber contains nitrogen under high pressure. Do not allow fire or heat near the shock absorber. Refore disposal of the shock absorber, release the nitrogen (ee page 13-14). + Inhated asbestos fibers have been found to cause resplraiory disease and cancer. Never use an cir hose ar dry brush to clean brake assemblies. + Inthe United States, use an OSHA-approved vacuum cleaner or alternate method approved by OSHA designed to minimize the hazard caused by airborne asbestos fibers SPECIFICATION Te STANDARD SERVICE UMAT Rear wheel runout Radial 2 mm (0.08 in) ___ Axl 2.0 mm (0.08 It) Rear brake drum LD. 130.0 mm 6.12 | 181.0 mm (5.16 in) Fear bre shoe wioknese 40mm0.18 i) 2.0 nm 0.08 I Shock aboother spring foe nah 297.8 mm (8.96 in) 796.1 ym (8.28 in [ear susoonsion damper conoresson 39 ka (72.8 28 ka (61.7 b) TORQUE VALUES, Driven eprockat nut 46 Nem [4.6 kg-m, 33 ft-lb) Apply ol ro the threads Rear axle nut 95 Nemn (9.5 kur, 58 fib) Brake erm nut 10 Nem 11.0 kgm, 7 fb) Shock absorber spring lock nut 90 Nem {8.0 kg-m, BS Fb) Shock absorber upper maunt nut 75 Nem 17.5 ka-m, 54 fib) Shock absorbor lower mount bolt 48 Nem 5 kgm, 32 fb) Shock arm-to-shock link nut 45 Nem 14.5 korm, 32 fb) ‘Shock link-o-swing arm nut 45 Nem 14.5 kg-m, 32 frib) Shack arm-to-frame nut 45 Nam (4.5 kg-m, 32 fb} Swing arm pivot nut 110 Nem {11.0 ka-m, 80 ft-b) TOOLS Special Driver shatt (07946—MJ00100. Neodlo bearing romever (07637 MA7co001 NOt avaliadle in U.S.A. Bearing remover, 20 mm 078303710000 Remover handle 07936-3710100 Remover sliding weight 079363710200 13-1REAR WHEEL/BRAKE/SUSPENSION Common Boaring remover head, 17 mm Bearing remiover shaft Driver Attachment, 37 x 40 mm Pilot, 17 mm Attachment, 42 x 47 mm Attachment, 24 x 26 mm Pit, 20 mm Pilot, 22 mm TROUBLESHOOTING Wobble or vibration in motorcycle + Bent rim + Loose wheel bearingts) Loose or bent spokes. Damaged tire Axle net tightened properly Swing arm pivot bearing worn Chain adjusters not acjusted equally Soft suspension Weak spring + Improper shock absorber spring preoad Hard suspension + Improper shock absorber spring preload Bent damper rod + Swing arm pivot bearings damaged + Bent frame or siving arm ‘Suspension ncise + Faulty damper + Loose fasteners + Worn suspension linkage pivot bearingist Poor brake performance + Improper brake adjustment + Worn brake shoes + Brake linings oily, greasy or dirty + Worn brake cam + Worn brake drum + Brake erm serrations improperly engaged + Brake shoes worn at car contact erea 13-2 077460050500 07746—0050100— 077490010000 07746 9010200 077460040400 07746—0010300 077460010700 07746—0040500 07746 9041000 - or equivalent commercially availabe In U.S.A.REAR WHEEL/BRAKE/SUSPENSION REAR WHEEL REMOVAL Raise the rear wheel off the ground by placing a box or work stand under the engine. Ramove the adjustar from the brake rod. Disconnect the brake rod from the brake arm. Remove the axle nut and loosen the drive chain adjuster lock rut and adjusting nut. Move the rear wheel forward all the way and detach the drive chain from the ¢riven sprocket Remove the rear axle and rear wheel. Remove the rear brake panal from the rear wheel INSPECTION S91 the axle on V blocks and measure the runout, ‘The actual runout is 1/2 of the total indiceter reading. ‘SERVICE LIMIT: 0.2 mm (0.01 int Turn the inner race of each bearing with your finger. ‘The bearings should turn sincothly and quietly. Also check that the bearing outer race fits tightly in the hub. Remove and discard the bearines if the races do not tuin ‘smoothly. quietly, ar if they fit loosely in the hub. NoTE + Replace wheel bearinge in p For baaring roplacoment, see page 13-6. (1) WHEEL BEARING 13-3REAR WHEEL/BRAKE/SUSPENSION Check the rim junout by placing the whee! on a truing stand. Turn the wheel by hand and measure the runout using ¢ dali dicator. SERVICE LIBITS: RADIAL: 2.0 mm (0.08 in} AXIAL: 2.0 mm {0.08 in} is -— Check the condition of the final driven sprocket teath.. | Roplace a worn or damaged sprocket. (1) Good (2) REPLACE NOTE + The crive chain and drive eprokot must sleo be inspoctod if ‘the driven aprokot is worn er damagec.. Never install @ new drive chain on worn sprockets or a worn chain on neve sprockets. Both chain and sprocket must be in good condi tion or the new replacement chain or sprockets will waar a rapidly WHEEL BALANCING Fifer to page 12-6. Do not dd the whee! weight more than 60 grams. (1) WHEEL WEIGHT DISASSEMBLY Pe COLLAR ES Remove the axle collar and dust seal P ‘ Romove the final driven flange. NOTE + When removing the driven sprocket, loosen the sprocket bolt with the driven flange installed 13-4REAR WHEEL/BRAKE/SUSPENSION I the criven flange fits tightly in the hub, drive i out by tapping several locations. UP cOLLaR ‘When replacing the driven ‘lange bearing, remove the collar from the bearing, Drive out the driven flange bearing, if necessary. Romove the driven epreckot from tho driven flango, if nocos- sary. Remove the damper rubbers. Replace the damper rubbers if they are damaged or deteriorat- ed. Remave the O-ring,REAR WHEEL/BRAKE/SUSPENSION Drive out the wheel bearings and the distance coll (1) REMOVER HEAD NOTE + IW the bearings are removed, they shoukd be replaced with TooLs: Bearing remover head, 17 mm 077480060500 or equivalent commercially available in U.S.A. Booring remover shaft 07746—0050100 cr equivalent commercially available in U.S.A. ASSEMBLY (2) DAMPER. (4) DRIVEN. RUBBER FLANGE i () DUST (6) DRIVEN SEAL SPROCKET o “ shee COLLAR (7) SIDE COLLAR monn O-RING 13-6REAR WHEEL/BRAKE/SUSPENSION Place the rim and tire on the work bench. Adjust the pesition so that the distance from the right end sur face of the hub to the side of rim is @ mm {0.9 in} as shown, Tighten the spokes in 2 or 3 progressive steps. TORQUE: 4 Nem 10.4 kg-m, 3 fb) TooL: ‘Spoke wrench C, 5.8.x 6.1mm 07701—0020300 oF equivalent commercially able in U.S.A. Install the rim band, rim lock, cube and the tre with its direc: tional arrow mark pointing in the direction of normal rotation for forward mation, Tighten tha tim lock TORQUE: 13 Nem (1.3 kgm, 9.4 ft-lb) Check the wheel rim runout as shown on page 13-4, end adjust as required Pack the bearing cevities with grease, Drive in the right bearing with te sealed side of the bearing facing out away fram the center of the hub. Be careful not to tilt the bearing while driving it into the hub ‘and make gure that it i fully coated Install the distence collar in the hub, then dive io the left bear Ing with its sealed side facing out, em + Grease on the brake drum reduces stopping power. Keep grease Off the brake dru, TooL Driv 077490010000 Attachment, 37 x 40 mm 077460010200 Pilot, 17 mm 077460040400 Pack a new driven flange bearing with graase, then drive i into the driven flange with kes sealed end facing out. Toots: Driver 07748 -0010000 Attachment, 4247 mm (077460010300 Pilot, 20 mm 077460040500 Install the collar onto the driven flange bearing, If the driven sprocket wee removed, install it with the teath umber facing out. Apply ol to the threads af the driven sprocket bolts and tight fen the sprocket nuts to the specified torque. TORQUE: 46 Nem (4.8 kg-m, 33 ftlb) [8 mm 0-3ini t (2) ATTACHMENTREAR WHEEL/BRAKE/SUSPENSION Install the demper tubbers. (0) DAMPER (2) DRIVEN FLANGE Apply grease to a new O-ring and install it onto the groove of RUBBER eye the wheel hub, P Inatall the driven flange. ‘Apply grease to the cust seal ip and install it. Install the axle collar INSTALLATION Install the brake pnel on the wheel hub. Prace the tear wheel between the swing arm and ral the ariva chain over the drivan sprocket. Lift the rear wheel and insert the tang on the swing arm into ‘the slot in the oraks panel, then insert the reer axle from right side through swing arr, Loosely install the axle nut. Adjust the drive chain (pege 9-6). Tighten the rear axle nut, TORQUE: 90 Nem (9.0 kam, 65 ft1h) 13-8REAR WHEEL/BRAKE/SUSPENSION Connect the brake rod to the breke arm and install the adjust ing nut Adjust the rear brake pedal free play (page 2-11) REAR BRAKE INSPECTION Remove the rear wheel (page 13-2). Ramove the rear brake panel Measure tho roar brake drum 1.0. SERVICE LIMIT: 131 mm (5.16 in} Maacure the rear brake lining shiokne SERVICE LIMIT: 2.0 mm (0.08 in} Replace the brake shoes if thinner than the service limit. DISASSEMBLY Remove the brake shoes and springs from the brake panel. NOTE + Mark the shoas to indicata thai original positions before moving thom,REAR WHEEL/BRAKE/SUSPENSION Remove the following parts from the brake panel: = Bott nut, and brake arm — Indicator plate Brake cam. = Thrust plate — Dust seals Clean all parts throughly. (5) BRAKE, ASSEMBLY (2) DUST SEALS 3) THRUST (4) BRAKE CAM. {1) INDICATOR PLATE (5) BRAKE ‘SHOES (7) BRAKE PANEL (8) BRAKE ARM. Apply greaso to tho dust seals, and install therm inte the brake pane. Install the thrust plate by aligning the pin on the brake panel with tha slot in the plate. 13-10REAR WHEEL/BRAKE/SUSPENSION Apply grease to the brake cam and installit Apply areese to the anchor pin and thrust plate =a + Grease on the brake linings will rechuce stepping power. Keep grease off the brake linings, Wipe excess grease off the came and chor pin. Install the indicator plate onto the brake cam, aligning its tab with cutout on the brake cam. Install the brake arm by aligning the punch marks. Install the belt and tighten the nut te the specified toraue. TORQUE: 10.N-m (1.0 kgm, 7 ft-1b} Position the brake shoes in their original positions snd install (4) graKe the springs. SHOE: Check the rear brake assembly for smooth operation by moving the breke arm EA (2) SPRINGS. torres 1 fT GRake Licht s SWITCH SPRING BRAKE PEDAL REMOVAL/INSTALLATION Remove the following parts: — Brake adjustor — Brake red from the brake arm Brake rod spring — Brake pedal return spring — Brake light switch spring — Beta pin, nut and wash Brake pedal 14) BETA PIN NUT (3) ROD (5) RETURN SPRING AND WASHER SPRING 13-11REAR WHEEL/BRAKE/SUSPENSION eo" Si abvusren (4) spAING (1) BRAKE PEDAL sen (6) Nur o “Apply graase to the dust seal ips and brake pedal pivot, and in stall the breke pecal Install she fallowing parts: — Washer, nut and beta pin — Brake licht switch spring — Brake pedal return spring Brake rod spring — Brake rod to the brake arm — Brake adjuster Acjust the braka padal free play (page 3-11) SHOCK ABSORBER REMOVAL Rise the rear wheel off the ground by placing a box or work stand under the engine, Remove the shock arm bolt (shock link side] and shack absorb: ‘or lowar mount bolt. Flemove the right side cover (page 15:2) and shock absorber Upper mount bolt 5) BETA PIN TH BRAKE LIGHT ITCH SPRING [ : Z. adiwaster, NuT (31 ROD (RETURN SPRING" RipceTa pin SPRING in) LOWER MOUNT (2) UPPER MOUNT 13) SHOCK ARM 3OLT (SHOCK LINK SIDE) 13-12REAR WHEEL/BRAKE/SUSPENSION DISASSEMBLY (1) LOCK NUT, Hold the check upper mount Towel Remove the lock nut and adjusting nut. Remove the shock spring. 18 viee with soft jawe ar a chos Sis (2) ADJUSTING NUT, 4 Check the spring fer damage, and meseure the spring ‘ree length. ‘SERVICE Lim ‘+ The damper unitis filed with nitrogen gas under high pressure, do not try to disascennble, +: 235.1 mm (9.26 in) camper rod for trusness. BUSHING (2) DAMPER FUBGER ‘Check the camper unit for oll leaks oF other damage and the {" UPPER MOUNT Check the spring seat stopper, spring seat, spring guide and camper rubber far wear or damage. |S) STOPPER ‘Check the upper mount bushing for wear or demage. 4) DAMPER ROD Mark the 10 mm position as shown of the damper rod. Place the damper rod on a scale and measure the force re- ‘quired to compress the damper 10 mm (0.4 inl. COMPRESSION FORCE: 33 kg (72.8 Ib} If the force required is less than 28 kg |61.7 Ib), gas is leaking. Examine the damper rod and reniace the damper unit if itis bent or ecarad.REAR WHEELIBRAKE/SUSPENSION SHOCK ABSORBER DISPOSAL PROCEDURE Contor punch the damper case to mark the dtiling point, ap- | proximazely 16,0 mm (0.63 in} trom the top surface. ‘Wrap the damper unit inside @ plastic bag 1H) PLASTIC BAG Support the demaer unit upright in a vise as shown, (2) DRILL BIT Woy 16.0 mv (0.83 in) Through the open ond of the bag, insert a drill motor with a sharp 2—3 mr (6/64—1/8 in) dil i ow + Domot use a dull dri bit which could causea build-up of exees- ‘sive heat and pressure inside the damper, leading (0 explosion and severe personal injury. + The shoek absorber contains nitrogen gas and oil under high pressure. Da not drill any farther down the damper case than the measurement given above, or you may dill into the off ‘chamber; oi escaping under High pressure may cause serious personal injury. + Always wear eve protection to avoid getting metel shavings in ‘your eyes when the gas pressure is releared. The plastie bag is ‘only intended to shield you from the escaping gas. Hold the bag around the drill moter and briefly run tho dri ‘moot Inside the beg; this will inflate the bag with air from the (3) DAMPER UNIT ‘motor end help keep the bag from getting caught in the bt when you start. ASSEMBLY (2) Lock, (3) SPAING NUT SEAT (1 Agustin (4) DAMPER UNIT NU en sfine (5) SPRING GUIDE 13-14REAR WHEEL/BRAKE/SUSPENSION Install the spring, adjusting nut and lock nut [ Turn the spring acjusting nut until the spring length is as speci- (2) LOCK NUT fied. ‘A: DECREASE THE SPRING LENGTH B: INCREASE THE SPRING LENGTH STANDARD SPRING LENGTH: 237.5 mm (9.35 in) MAXIMUM LENGTI 239.9 mm (9.44 in) MINIMUM LENGTH 235.1 mm (9.26 in) NOTE (One turn of the adjusting nut changes tho epring longth by 1.5 min, Hold the shock absorber upper mount in @ vice with soft jaws. for a shop towel Using pin spanners, tighten the lock aut while holding tho ad justing nut. TORQUE: 90 Nem (9.0 ka-m, 65 fb) Install the breather tube to the scat stepper. Install the shack absorber te the frame with the bresther tube toward the rear Install and tighten the shock absorber upper mount bolt and rut. (a) Lowel mount BOLT iy UPPEn MOUNT BOLT TORQUE: 75 Nem (7.5 kom. 54 ftib) Install and tighten the shock absorber lower mount belt TORQUE: 45 Nem (4.5 kgm, 32 feb) Inctall and tighten the thock arm-to-shock fine holt TORQUE: 45 N-m (4.5 kgm, 32 fib) (3) SHOCK ARIV-TO: Install the right side cover (page 15-2) ‘ pear ~_SHOCK LINK BOLT ‘Cheok the operation of the shack abscrber ipage 3-14) SHOCK LINKAGE REMOVAL TAP SHOCK ARMTTO: FRAME BOLT (2) LoweR MOUNT] Raise the rear whee! of! the ground by placing a work stend or box ungar the angina Femove the following components: — Shook arm-to-shack tink bolt = Shook link-to-swing arm bolt = Shock ink (5) SHOCK ARM-TO- ck abeorber lowor mount bolt SHOCK LINK BOLT — Shock arm-to-frame bolt 8 ee NY BO = Shack arm RMB) stock Lyk Swing ARM BOLT,REAR WHEEL/BRAKE/SUSPENSION (1FCOLLAR (2) NEEDLE BEARINGS (3) DUST. SEALS __-SSHOCK ARM NEEDLE BEARING REPLACEMENT Drive the needle beatings out of the shock arm and ehack link. TooLs: Driver sheft 07946—NJ00100 or Not available in U.S.A Driver 077490070000 Pilot, 22 mm 077450041000 SHOCK ABSORBER LOWER MOUNT BOLT PIVOT AND. SHOCK ARM-TO-SHOCK LINK BOLT PIVOT (1) DRIVER Pack a new needle bearings with multi purpose creas Prose tha neecle bearings into the shock atm until the bearing outer ends are on a level with the shock aim inner edges. NOTE + Press the needle bearing on the stamped ena, Toots: Driver 077490010000 Attachment, 24 x 26 mm 077460010700 (3) NEEDLE BEARINGS 13-16