Honda VT750C2 Manual PDF

HOWTO USETHISMANUAL
This service manual describes the service procedures for the

VT750C2IC2F.
Follow the Maintenance Schedule (Section 4) recommendations to
ensurethatthevehicleisinpeakoperatingconditionandtheemission
levelsarewiththestandards setbytheU.S. EnvironmentalProtection
Agency, California Air Resources Board (CARB) and Transport
Canada.
Performing the first scheduled maintenance is very important. It
compensates for the initial wear that occurs during the break-in
period.
CONTENTS
GENERALINFORMATION .
i==========

===FR=A=M=EIB==O=DY=PA=N=E=L=S=/E=X=H=A=U=S=T=S=Y=S=T=EM===_
r----i==M=A=IN=T=E=N=A=N=C=E===========_
Sections 1and 4apply tothe whole motorcycle. Section 3illustrates
procedures for removal/installation of components that may be
requiredtoperform servicedescribedIn thefollowing sections.
Section 5 through 21 describe parts of the motorcycle, grouped
accordingtolocation.
Find the section you want on this page, then turn to the table of
contentsonthefirstpageofthesection.
Most sections start with an assembly orsystem illustration, service
information and trOUbleshooting for the section. The subsequent
pagesgivedetailedprocedure.
If you don't know the source of the trouble, go to section 23
Troubleshooting.
Your safely, and the safely of others, is very important. To help
you make informed decisions we have provided safely
messages and other information throughout this manual. Of
course, it is not practical orpossible to warn you about all the
hazardsassociatedwithservicingthisvehicle.
You mustuseyourowngoodjudgement.
You will find important safely information in a variely of forms
including:
SafelyLabels- onthe vehicle
SafelyMessages- precededby asafelyalertsymbol&and
one of three signal words, DANGER, WARNING, or CAU-
TION.
Thesesignalwordsmean:
You WILL be KILLED or SERIOUSLY
HURTifyou don'tfollowinstructions.
You CAN be KILLED or SERIOUSLY
HURTifyou don'tfollowinstructions.
You CAN be HURT if you don't follow
instructions.
Instructions- howtoservicethisvehIclecorrectlyandsafely.
Asyoureadthismanual,youwillfindinformationthatisprecededbya
[NOm:EJ symbol. The purpose of this message is to help prevent
damagetoyourvehicle,otherproperty. ortheenvironment.
LUBRICATION SYSTEM
ALTERNATOR/STARTERCLUTCH
CRANKSHAFTrrRANSMISSION
COOLINGSYSTEM
CYLINDERJPISTON'
ENGINEREMOVAL/INSTALLATION
CYLINDERHEADNALVE
REARWHEELlBAAKElSUSPENSION
IGNITIONSYSTEM
WIRING DIAGRAMS
BATTERY/CHARGINGSYSTEM
FRONTWHEEL/SUSPENSIONISTEERING
CLUTCH/GEARSHIFTLINKAGE
FUELSYSTEM
FINALDRIVE
HYDRAULICBRAKE
ELECTRICSTARTER
LIGHTSIMETERSISWITCHES
z
:it
0:
...
W
>

C
C
z
<t
w
z
a
z
w
....I
<t
o

t;

W
TROUBLESHOOTING
INDEX
-
DateofIssue: September.2006
.. .. -
---_.---_.
SYMBOLS
" The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it would be explained specifically in the text without the use of the symbols.
..
IIiiiil'
Replace the part (s) with new one (s) before assembly.
Use recommended engine oil, unless otherwise specified.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1 : 1).
""""1
-,
....wM
Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent).
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent).
Example: Molykote BR-2 plus manufactured by Dow Corning U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent).
Example: Molykote G-n Paste manufactured by Dow Corning U.S.A.
Honda Moly 60 (US.A. only)
Rocol ASP manufactured by Rocol Limited, UK.
Rocol Paste manufactured by Sumico Lubricant, Japan
Use silicone grease.
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
,..
~
~
ew
~
Apply sealant.
Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.
Use Fork or Suspension Fluid.
I
..
1. GENERALINFORMATION
B
SERVICERULES.. 1-2
MODELIDENTIFICATION.. .... ..1-2
GENERALSPECIFICATIONS.......... 1-5
LUBRICATIONSYSTEM
SPECIFICATIONS...... ..........1-7
FUELSYSTEMSPECIFICATIONS.. 1-7
COOLINGSYSTEMSPECIFICATIONS1-7
CYLINDERHEAD/VALVE
SPECIFICATIONS.. .. :.......1-8
CYLINDER/PISTONSPECIFICATIONS1-8
SPECIFICATIONS 1-9
SPECIFICATIONS 1-9
CRANKSHAFT/TRANSMISSION
SPECiFiCATIONS 1-10
FINALDRIVESPECIFICATIONS....1-10
FRONTWHEEL/SUSPENSION/STEERING
SPECIFICATIONS.. ....1-11
REARWHEEUBRAKE/SUSPENSION
SPECIFICATIONS 1-11
HYDRAULICBRAKESPECIFICATIONS1-11
BATTERY/CHARGINGSYSTEM
SPECIFICATIONS.. .. .. ..........1-12
IGNITIONSYSTEMSPECIFICATIONS1-12
ELECTRICSTARTER
SPECIFICATIONS 1-12
LIGHTS/METERS/SWITCHES
SPECIFICATIONS 1-12
STANDARDTORQUEVALUES.. .. 1-13
ENGINE& FRAMETORQUEVALUES .. 113
LUBRICATION&SEALPOINTS.. 1-19
CABLE&HARNESSROUTING122
EMISSIONCONTROLSYSTEMS 139
1-1
------ . - --------- --------
GENERALINFORMATION
SERVICERULES
1. Use genuine Honda orHonda-recommended parts and lubricants ortheirequivalents. Partsthat don'tmeet Honda's
designspecificationsmaycausedamagetothemotorcycle.
2. Usethespecialtoolsdesignedforthisproducttoavoiddamageandincorrectassembly.
3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with
Englishfasteners.
4. Install newgaskets,a-rings,cotterpins,and lockplateswhen reassembling.
5. When tightening bolts ornuts, begin with the largerdiameterorinnerboltfirst. Then tighten tothe specified torque
diagonallyin incrementalstepsunlessaparticularsequenceisspecified.
6. Clean partsincleaningsolventupondisassembly.Lubricateanyslidingsurfacesbefore reassembly.
7. Afterreassembly,checkall partsforproperinstallationandoperation.
8. Routeallelectricalwiresas shownintheCableand HarnessRouting (page1-22).
ABBREVIAl"ION
Throughoutthismanual,thefollowingabbreviationsareusedtoidentifytherespective partsorsystems.
Abbrev.tenn Fulltenn
SE valve StartingEnrichmentvalve
TPsensor ThrottlePositionsensor
EOP switch EngineOil Pressureswitch
VS sensor VehicleSpeedsensor
ICM IgnitionControlModule
CAVcontrolvalve CarburetorAirVentcontrolvalve
PAIR PulsedSecondaryAirInjection
EVAP EvaporativeEmission
ECTsensor EngineCoolantTemperaturesensor
MODELIDENTIFICATION
1-2
GENERALINFORMATION
SERIALNUMBERS
The Vehicle Identification Number (VIN) is stamped on the right side of
the steering head.
The engine serial number is stamped on the right side of the
crankcase.
The carburetor identification number is stamped on the throttle
position sensor side ofthe c'arburetor body.
.........
CARBURETOR IDENTIFICATION NUMBER
.
LABELS
The Safety Certification Label is located on the right side of the frame
down tube.
1-3
GENERALINFORMATION
The color label is attachedtotheframe, behind ofthe leftside cover..
When orderingcolor-coded parts,alwaysspecifYthedesignatedcolor
code.
The Emission Control Information Label ('07 model) is located on the r-EM-IS-S-I-O-N-C-O-N-T-R-O-L---------..
rearfenderandframecrosspipeas shown.
INFORMATIONLABEL
(Canadatype)
EMISSIONCONTROL
INFORMATIONLABEL
(ExceptCanadatype)
TheEmissionControl InformationLabel (After'07)islocatedontheleft
sideoftheframedowntube.
z
, EMISSION CONTROL
"INFORMATIONLABEL
. (Canadatype)
,
. Revised:May2007.2007-2006Vf750C2
1.-4
GENERALINFORMATION
GENERALSPECIFICATIONS
ITEM SPECIFICATIONS
DIMENSION Overall length
Overall width
Overall height
Wheelbase
Seat height
Footpeg height
Ground clearance
Curb weight (49 states/Canada type)
(California type)
Maximum weight capacity
(49 states/California type)
(Canada type)
2,430 mm (95.7 in)
835 mm (32.9 in)
1,130 mm (44.5 in)
1,655 mm (65.2 in)
655 mm (25.8 in)
283 mm (11.1 in)
130 mm (5.1 in)
243 kg (536 Ibs)
246 kg (542 Ibs)
180 kg (397 Ibs)
184 kg (406 Ibs)
FRAME Frame type
Front suspension
Front axle travel
Rear suspension
Rear axle travel
Front tire size
Rear tire size
Tire brand Front
Rear
Front brake
Rear brake
Caster angle
Trail length
Fuel tank capacity
Double cradle
Telescopic fork
115 mm (4.5 in)
Swingarm
90 mm (3.5 in)
90/90-21 M/C 54S
160/80-15M/C 74S
EXEDRA G701 (BRIDGESTONE)
D404F (DUNLOP)
EXEDRA G702 (BRIDGESTONE)
D404 (DUNLOP)
Hydraulic single disc
Internal expanding shoe
3430'
158 mm (6.2 in)
14 liters (3.7 US gal, 3.1 Imp gal)
ENGINE Cylinder arrangement
Bore and stroke
Displacement
Compression ratio
Valve train
Intake valve opens
closes
Exhaust valve opens
closes
Lubrication system
Oil pump type
Cooling system
Air filtration
Engine dry weight
Firing order
Cylinder number
2 cylinders 52V transverse
79 x 76 mm (3.1 x 3.0 in)
745 cm
3
(45.4 cu-in)
9.6: 1
Silent cam chain driven, OHC
Front: 0BTDC (at 1 mm lift)
Rear: 5ATDC (at 1 mm lift)
25ABDC (at 1 mm lift)
35BBDC (at 1 mm lift)
Front: 0ATDC (at 1 mm lift)
Rear: 5BTDC (at 1 mm lift)
Forced pressure and wet sump
Trochoid
Liquid cooled
Viscous paper element
72.3 kg (159.4Ibs)
Front - 308- Rear - 412- Front
Front: #2/Rear: #1
CARBURETOR Type
Throttle bore
Constant velocity (CV)
34 mm (1.3 in)
'-5
--- ---- -----------
I
GENERALINFORMATION
ITEM SPECIFICATIONS
DRIVE TRAII;II Clutch system
Clutch operation system
Transmission
Primary reduction
Secondary reduction
Third reduction (Output drive reduction)
Final reduction
Gear ratio 1st
2nd
3rd
4th
5th
Gearshift pattern
Multi-plate, wet
Cable operating
Constant mesh, 5-speeds
1.763 (67/38)
0.891 (33/37)
1.058 (18117)
3.091 (34111)
2.400 (36/15)
1.550 (31/20)
1.174 (27/23)
0.960 (24/25)
0.852 (23/27)
Left foot operated return system,
1-N-2-3-4-5
ELECTRICAL Ignition system
Starting system
Charging system
Regu'lator/rectifier
Lighting system
Full transistorized ignition
Electric starter motor
Triple phase output alternator
SCR shortedltriple phase full-wave
rectification
Battery
1-6.
GENERALINFORMATION
LUBRICATIONSYSTEMSPECIFICATIONS
Unit mm (in)
ITEM STANDARD SERVICELIMIT
Engine oil capacity At draining 2.5 liters (2.6 US qt, 2.2 Imp qt) -
At oil filter change 2.6 liters (2.7 US qt, 2.3 Imp qt) -
At disassembly 3.2 liters (3.4 US qt, 2.8 Imp qt) -
Recommended engine oil Pro Honda GN44-stroke oil (U.S.A. and
Canada) or equivalent motor oil
API service classification: SG or higher -
JASO T 903 standard: MA
Viscosity: SAE 10W-30
Oil pressure at EOP switch 530 kPa (5.4 kgf/cm
2
, 77 psi)
-
at 5,000 rpm/(80C/176F)
Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008)
Body clearance 0.15 - 0.21 (0.006 - 0.008) 0.35 (0.014)
Side clearance 0.02 - 0.08 (0.001 - 0.003) 0.10 (0.004)
FUELSYSTEMSPECIFICATIONS
ITEM SPECIFICATIONS
Carburetor
identification number
49 states/Canada type VE5EA
California type VE5ES
Main jet Standard #122
High altitude #120
Slow jet #50
Pilot screw Initial/final opening See page 6-25
High altitude adjustment See page 6-26
Float level 18.5 mm (0.73 in)
Engine idle speed 1,200 100 rpm
Throttle grip freeplay 2 - 6 mm (1/16 -1/4 in)
COOLINGSYSTEMSPECIFICATIONS
ITEM SPECIFICATIONS
Coolant capacity Radiator and engine 1.58 liters (1.67 US qt, 1.39 Imp qt)
Reserve tank 0.38 liter (0.40 US qt, 0.33 Imp qt)
Radiator cap relief pressure 108 - 137 kPa (1.1 -1.4 kgf/cm
2
, 16 - 20 psi)
Thermostat Begin to open 80 - 84C (176 -183F)
Fully open 95C (203F)
Valve lift 8 mm (0.3 in) minimum at 95C (203F)
Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality
ethylene glycol antifreeze containing silicate-free corrosion
inhibitors
Standard coolant concentration 1 : 1 (mixture with distilled water)
1-7
1-8
GENERALINFORMATION
CYLINDERHEAD/VALVESPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cylinder compression at 400 rpm 1,373 98 kPa (14.0 1.0 kgf/cm<,
199 14 psi)
-
Valve clearance IN 0.15 0.02 (0.006 0.001) -
EX 0.20 0.02 (0.008 0.001) -
Cam chain tensioner wedge B length - 6 (0.2)
Camshaft Cam lobe height IN 37.188 - 37.348 (1.4641 - 1.4704) 37.16 (1.463)
EX 37.605 - 37.765 (1.4805 - 1.4868) 37.58 (1.480)
Runout IN/EX - 0.05 (0.002)
Journal 0.0. IN/EX 21.959 - 21.980 (0.8645 - 0.8654) 21.90 (0.862)
Oil clearance IN/EX 0.020 - 0.141 (0.0008 - 0.0056) 0.16 (0.006)
Rocker arm, Rocker arm shaft 0.0. IN/EX 11.966 - 11.984 (0.4711 - 0.4718) 11.83 (0.466)
rocker arm Rocker arm 1.0. IN/EX 12.000 - 12.018 (0.4724 - 0.4731) 12.05 (0.474)
shaft
Rocker arm-to-shaft clearance 0.016 - 0.052 (0.0006 - 0.0020) 0.07 (0.003)
Valve, valve Valve stem 0.0. IN 5.475 - 5.490 (0.2156 - 0.2161) 5.45 (0.215)
guide EX 5.455 - 5.470 (0.2148 - 0.2154) 5.41 (0.213)
Valve gUide 1.0. IN 5.500 - 5.510 (0.2165 - 0.2169) 5.56 (0.219)
EX 5.500 - 5.512 (0.2165 - 0.2170) 5.56 (0.219)
Stem-to-guide IN 0.010 - 0.035 (0.0004 - 0.0014) 0.10 (0.004)
clearance
EX 0.030 - 0.057 (0.0012 - 0.0022) 0.11 (0.004)
Valve guide projection IN 18.7 - 18.9 (0.736 - 0.744) -
above cylinder head EX 17.2 - 17.4 (0.68 - 0.69) -
Valve seat width IN/EX 0.90 - 1.10 (0.035 - 0.043) 1.5 (0.06)
Valve spring Free length IN 42.14(1.659) 40.58 (1.598)
EX 46.11 (1.815) 44.72 (1.761)
Cylinder head warpage - 0.10 (0.004)
CYLINDER/PISTONSPECIFICATIONS
Unit: mm (in)
Cylinder /.D. 79.000 - 79.015 (3.1102 - 3.1108) 79.10 (3.114)
Out-of-round - 0.06 (0.002)
Taper - 0.06 (0.002)
Warpage - 0.10 (0.004)
Piston, piston
pin, piston
Piston O.D. at 17 mm (0.7 in) from
the bottom
78.97 - 78.99 (3.109 - 3.110) 78.90 (3.106)
rings Piston pin bore 1.0. 18.002 - 18.008 (0.7087 - 0.7090) 18.05 (0.711)
Piston pin 0.0. 17.994 - 18.000 (0.7084 - 0.7087) 17.98 (0.708)
Piston-to-piston pin clearance 0.002 - 0.014 (0.0001 - 0.0006) 0.04 (0.002)
Piston ring end
gap
Top 0.15 - 0.25 (0.006 - 0.010) 0.4 (0.02)
Second 0.25 - 0.40 (0.010 - 0.016) 0.6 (0.02)
Oil (side rail) 0.20 - 0.80 (0.008 - 0.031) 1.0 (0.04)
Piston ring-to-
ring groove
clearance
Top 0.025 - 0.055 (0.0010 - 0.0022) 0.08 (0.003)
Second 0.015 - 0.045 (0.0006 - 0.0018) 0.07 (0.003)
Cylinder-to-piston clearance 0.010 - 0.045 (0.0004 - 0.0018) 0.10 (0.004)
Connecting rod small end I.D. 18.016 - 18.034 (0.7093 - 0.7100) 18.07 (0.711)
Connecting rod-to-piston pin clearance 0.016 - 0.040 (0.0006 - 0.0016) 0.06 (0.002)
Revised: September 2008. 2007-2009 VT750C2
---------- ---- ---------
GENERAL INfORMATION
CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS
Unit: mm (in)
Clutch lever freeplay 10 - 20 (3/8 -13/16) -
Clutch Spring free length 45.3 (1.78) 43.9 (1.73)
Disc thickness
I
Disc A 2.62 - 2.78 (0.103 - 0.109) 2.3 (0.09)
I
End disc 2.92 - 3.08 (0.115 - 0.121) 2.6 (0.10)
Plate warpage - 0.30 (0.012)
Clutch outer guide
I
I.D. 21.991 - 22.016 (0.8658 - 0.8668) 22.03 (0.867)
I
0.0. 31.959 - 31.975 (1.2582 -1.2589) 31.92 (1.257)
Mainshaft O.D. at clutch outer guide 21.967 - 21.980 (0.8648 - 0.8654) 21.95 (0.864)
Clutch outer guide-to-mainshaft clearance 0.011 - 0.049 (0.0004 - 0.0019) 0.08 (0.003)
Clutch outer I.D. 32.000 - 32.025 (1.2598 - 1.2608) 32.09 (1.263)
Clutch outer-to-outer guide clearance 0.025 - 0.066 (0.0010 - 0.0026) 0.18 (0.007)
Oil pump drive sprocket I.D. 32.025 - 32.145 (1.2608 1.2655) 32.16 (1.266)
Oil pump drive sprocket-to-c1utch outer guide
clearance
0.050 - 0.186 (0.0020 - 0.0073) 0.23 (0.009)
ALTERNATOR/STARTER CLUTCH SPECIFICATIONS
Unit: mm (in)
Starter driven gear
I
I
1.0.
0.0.
37.000 - 37.025 (1.4567 -1.4577)
57.749 - 57.768 (2.2736 - 2.2743)
37.10 (1.461)
57.73 (2.273)
Starter clutch outer I.D. 74.414 -74.440 (2.9297 - 2.9307) 74.46 (2.931)
1-9
GENERALINFORMATION
CRANKSHAFTITRANSMISSIONSPECIFICATIONS
Unit: mm (in)
Crankshaft Connecting rod big end side clearance 0.05 - 0.20 (0.002 - 0.008) 0.30 (0.012)
Crankpin bearing oil clearance 0.028 - 0.052 (0.0011 - 0.0020) 0.07 (0.003)
Main journal oil clearance 0.020 - 0.038 (0.0008 - 0.0015) 0.07 (0.003)
Crankshaft runout - 0.03 (0.001)
Main journal 0.0. 52.982 - 53.000 (2.0859 - 2.0866) 52.976 (2.0857)
I
Main journal 1.0. 58.010 - 58.022 (2.2839 - 2.2843) 58.070 (2.2862)
Shift fork, fork 1.0. 13.000 -13.018 (0.5118 - 0.5125) 13.03 (0.513)
shaft
Claw thickness 5.93 - 6.00 (0.233 - 0.236) 5.6 (0.22)
Fork shaft 0.0. 12.966 -12.984 (0.5105 - 0.5112) 12.90 (0.508)
Shift drum 0.0. at left end 11.966 -11.984 (0.4711 - 0.4718) 11.94 (0.470)
Shift drum journal 1.0. 12.000 - 12.018 (0.4724 - 0.4731) 12.05 (0.474)
Shift drum-to-shift drum journal clearance 0.016 - 0.052 (0.0006 - 0.0020) 0.09 (0.035)
Transmission Gear 1.0. M3,M5 28.000 - 28.021 (1.1024 - 1.1032) 28.04 (1.104)
C1,C4 31.000 - 31.025 (1.2205 - 1.2215) 31.05 (1.222)
C2 24.000 - 24.021 (0.9449 - 0.9457) 24.04 (0.946)
Gear busing 0.0. M3,M5 27.959 - 27.980 (1.1007 -1.1016) 27.94 (1.100)
C1, C4 30.950 - 30.975 (1.2185 -1.2195) 30.93 (1.218)
C2 23.959 - 23.980 (0.9433 - 0.9441 ) 23.94 (0.943)
Gear-to-bushing M3, M5, C2 0.020 - 0.062 (0.0008 - 0.0024) 0.10 (0.004)
clearance C1, C4 0.025 - 0.075 (0.0010 - 0.0030) 0.11 (0.004)
Gear bushing 1.0. M3 25.000 - 25.021 (0.9843 - 0.9851) 25.04 (0.986)
I C2 20.000 - 20.021 (0.7874 - 0.7882) 20.04 (0.789)
Mainshaft 0.0. at M3 bushing 24.959 - 24.980 (0.9826 - 0.9835) 24.94 (0.982)
CountershaftO.D. at C2 bushing 19.980 -19.993 (0.7866 - 0.7871) 19.96 (0.786)
Bushing-to-shaft M3 0.020 - 0.062 (0.0008 - 0.0024) 0.10 (0.004)
clearance C2 0.007 - 0.041 (0.0003 - 0.0016) 0.07 (0.003)
Output drive Output gear 1.0. 24.000 - 24.021 (0.9449 - 0.9457) 24.04 (0.946)
train Output gear 0.0. 23.959 - 23.980 (0.9433 - 0.9441) 23.70 (0.933)
bushing
1.0. 20.020 - 20.041 (0.7882 - 0.7890) 20.06 (0.790)
Output drive gear shaft 0.0. 19.979 - 20.000 (0.7866 - 0.7874) 19.97 (0.786)
Gear-to-bushing clearance 0.020 - 0.062 (0.0008 - 0.0024) 0.082 (0.0032)
Gear bushing-to-shaft clearance 0.020 - 0.042 (0.0008 - 0.0017) 0.08 (0.003)
Output gear damper spring free length 62.3 (2.45) 59 (2.3)
Output drive gear backlash 0.08 - 0.23 (0.003 - 0.009) 0.40 (0.016)
Backlash difference between
measurements
- 0.10 (0.004)
FINALDRIVESPECIFICATIONS
Unit mm (in)
Recommended final drive oil Hypoid gear oil, SAE #80 -
. Final drive oil capacity
I
At draining 160 ~ (5.4 US OZ, 5.6 Imp oz) -
I
At disassembly 170 cm
3
(5.7 US OZ, 6.0 Imp oz) -
Final drive gear backlash 0.05 - 0.15 (0.002 - 0.006) 0.30 (0.012)
Backlash difference between measurements - 0.10 (0.004)
Ring gear-to-stop pin clearance 0.30 - 0.60 (0.012 - 0.024) -
Final drive gear assembly pre-load 0.2 - 0.4 Nm (2 - 4 kgf'cm,
-
0.1 - 0.3 Ibfft)
1-10
GENERALINFORMATION
FRONTWHEEL/SUSPENSION/STEERINGSPECIFICATIONS
Unit mm (in)
Minimum tire tread depth - 1.5 (0.06)
Cold tire
pressure
Up to 90 kg (200 Ibs) load 200 kPa (2.00 kgf/cm
2
, 29 psi) -
Up to maximum weight capacity 200 kPa (2.00 kgf/cm
2
, 29 psi) -
Axle runout - 0.2 (0.01)
Wheel rim Radial - 2.0 (0.08)
runout Axial - 2.0 (0.08)
Wheel balance weight - 60 g max.
Fork Spring free length 371.8 (14.64) 364.4 (14.35)
Tube runout - 0.2 (0.01)
Recommended fork fluid Pro Honda Suspension Fluid SS-8
(10W)
-
Fluid level 100 (3.9) -
Fluid capacity 478 2.5 cm
3
(16.2 0.08 US OZ,
16.8 0.09 Imp oz)
-
Steering head bearing pre-load 8.5 -12.7 N (0.9 - 1.3 kgf) -
REAR WHEEL/BRAKE/SUSPENSIONSPECIFICATIONS
Unit: mm (in)
Minimum tire tread depth -
200 kPa (2.00 kgf/cm
2
, 29 psi)
2.0 (0.08)
Cold tire
I
Up to 90 kg (200 Ibs) load
pressure
I
Up to maximum weight capacity
Axle runout
Wheel rim
I
Radial
runout
I Axial
-
250 kPa (2.50 kgf/cm
2
, 36 psi) -
-
-
-
-
180.0 -180.3 (7.09 -7.10)
0.2 (0.01)
2.0 (0.08)
2.0 (0.08)
Wheel balance weight 70 g max.
Brake drum 1.0.
Brake pedal height
.
Brake pedal freeplay
181 (7.1)
75 mm (3.0 in) above the top of the
footpeg
20 - 30 (13/16 -1-3/16)
-
-
Shock absorber spring pre-load adjuster setting 2nd position -
HYDRAULICBRAKE SPECIFICATIONS
Unit: mm (in)
Recommended brake fluid 00T4 -
Front Brake disc thickness 5.8 - 6.2 (0.23 - 0.24) 5.0 (0.20)
Brake disc warpage - 0.30 (0.012)
Master cylinder 1.0. 11.000 - 11.043 (0.4331 - 0.4348) 11.05 (0.435)
Master piston 0.0. 10.957 - 10.984 (0.4314 - 0.4324) 10.945 (0.4309)
Caliper cylinder 1.0. 27.000 - 27.050 (1.0630 - 1.0650) 27.060 (1.0654)
Caliper piston 0.0. 26.935 - 26.968 (1.0604 -1.0617) 26.930 (1.0602)
1-11
- -- --
------------ -------
GENERALINFORMATION
BATTERY/CHARGINGSYSTEMSPECIFICATIONS
ITEM SPECIFICATIONS
Battery Capacity 12 V - 10 Ah or 12 V -11 Ah
Current leakage 1 mA max.
Voltage (20C/
68F)
Fully
charged
13.0 -13.2 V
Needs
charging
Below 12.4 V
Charging current Normal 1.1 Al5-10 h
Qui(::k 5.5 AltO h
Alternator Capacity 0.35 kW/5,000 rpm
Charging coil resistance (20C/68F) 0.1 -1.0 n
IGNITIONSYSTEMSPECIFICATIONS
ITEM SPECIFICATIONS
Spark plug
I
Standard
I
For extended high speed riding
Spark plug gap
Ignition coil primary peak voltage
DPR6EA-9 (NGK), X20EPR-U9 (DENSO)
DPR7EA-9 (NGK), X22EPR-U9 (DENSO)
0.8 - 0.9 mm (0.03 - 0.04 in)
100 V minimum
Ignition pulse generator peak voltage 0.7 V minimum
Ignition timing ("F"mark) 13BTDC at idle
TP sensor
I
Resistance (20C/68F)
I
Input voltage
4-6 kn
5V
ELECTRICSTARTERSPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICEUMIT
Starter motor brush length 12.5 (0.49) 6.5 (0.26)
LIGHTS/METERS/SWITCHESSPECIFICATIONS
ITEM SPECIFICATIONS
Bulbs Headlight 12 V -60/55 W
Brake/taillight 12 V - 21/5 W
License light 12V -5W
Front turn signal/position light 12 V - 21/5 W x 2
Rear turn signal light 12V-21Wx2
Instrument light LEDx6
Turn signal indicator LED
High beam indicator LED
Neutral indicator LED
Oil pressure indicator LED
Coolant temperature indicator LED
Fuse Main fuse 30A
Sub fuse 10 A x 5, 20 A x 1
ECT sensor
switch
Start to close (ON) 112 -118C (234 - 244F)
Stop to open (OFF) 108C (226F) minimum
Fan motor
switch
Start to close (ON) 103 -107C (217 - 225F)
Stop to open (OFF) 94 - 98C (201 - 208F)
1-12
GENERALINFORMATION
STANDARDTORQUEVALUES
FASTENER TYPE
TORQUE
Nm (kgfm, Ibfft)
FASTENER TYPE
TORQUE
Nm Ikgfm, Ibfft)
5 mm bolt and nut
6 mm bolt and nut
8 mm bolt and nut
10 mm bolt and nut
12 mm bolt and nut
5.2 (0.5, 3.8)
10 (1.0, 7)
22 (2.2,16)
34 (3.5, 25)
55 (5.6, 41)
5 mm screw
6 mm screw
6 mm flange bolt (8 mm head, small
flange)
6 mm flange bolt (8 mm head, large
flange)
6 mm flange bolt (10 mm head) and
nut
8 mm flange bolt and nut
10 mm flange bolt and nut
4.2 (0.4, 3.1)
9 (0.9, 6.6)
9 (0.9, 6.6)
12 (1.2, 9)
12 (1.2, 9)
27 (2.8, 20)
39(4.0,29)
ENGINE& FRAMETORQUEVALUES
Torque specifications listed below are for important fasteners.
Others should be tightened to standard torque values listed above.
ENGINE
FRAME/BODY PANELS/EXHAUST SYSTEM
ITEM Q'TY
THREAD
DlA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Left crankcase rear cover socket bolt
Exhaust pipe joint stud bolt
1
4
6
8
10 (1.0, 7)
- See page 3-11
MAINTENANCE
ITEM Q'TV
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Spark plug
Timing hole cap
Crankshaft hole cap
.
Valve adjusting screw lock nut
Engine oil filter cartridge
Oil filter boss (crankcase side)
Engine oil drain bolt
Alternator cover socket bolt
4
1
1
6
1
1
1
3
12
14
30
7
20
20
14
6
18 (1.8, 13)
10 (1.0, 7)
15 (1.5, 11)
23 (2.3, 17)
26 (2.7, 19)
18 (1.8, 13)
29 (3.0, 21)
10 (1.0, 7)
Apply grease to the threads
Apply grease to the threads
Apply engine oil to the
threads and seating surface
threads
Apply locking agent to the
threads
LUBRICATION SYSTEM
ITEM Q'TY
THREAD
DlA. (mm)
TORQUE
N'm (kgfm, Ibfft)
REMARKS
EQP switch
EOP switch terminal screw
Oil pump assembly bolt
1
1
3
PT118
4
6
1211.2,9)
1.9 (0.2, 1.4)
13(1.3, 10)
Apply sealant to the threads
P-,
i
1-13 I
GENERALINFORMATION
FUEL SYSTEM
ITEM Q'TY
THREAD
DIA. (mm)
TORQUE
Nm (kgf'm, Ibfft)
REMARKS
PAIR check valve cover bolt 4 5 7 (0.7, 5.2)
Vacuum chamber cover screw 4 4 2.1 (0.2, 1.5)
TP sensor torx screw 1 5 3.4 (0.3, 2.5)
Carburetor heater set plate screw 2 5 3.4 (0.3, 2.5)
Float chamber screw 4 4 2.1 (0.2, 1.5)
Accelerator pump cover screw 3 4 2.1 (0.2, 1.5)
Air cut-off valve cover screw 2 4 2.1 (0.2, 1.5)
Accelerator pump link mounting bolt 1 5 3.4 (0.3, 2.5)
Throttle cable stay mounting screw 2 5 3.4 (0.3, 2.5)
SE valve nut 1 12 2.3 (0.2, 1.7)
Carburetor drain screw 1 6 1.5 (0.2, 1.1)
Slow jet 1 6 1.8 (0.2, 1.3)
Needle jet holder 1 7 2.3 (0.2, 1.7)
Main jet 1 5 2.1 (0.2, 1.5)
COOLING SYSTEM
ITEM Q'TY
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Water pump cover bolt 5 6 13 (1.3, 10)
CYLINDER HEAD/VALVE
ITEM Q'TY
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Cylinder head cover bolt
Cylinder head bolt
Cylinder head nut
Cam sprocket bolt
Cam chain tensioner bolt
Camshaft holder bolt
Camshaft holder nut
Over head cover socket bolt
4
4
8
4
4
6
4
8
6
8
10
7
6
8
8
6
10 (to, 7)
23 (2.3, 17)
47 (4.8,35)
23 (2.3, 17)
10 (to, 7)
23 (2.3,17)
23 (2.3, 17)
10 (to, 7)
threads
See page 9-25
CYLINDER/PISTON
ITEM Q'TY
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Cylinder stud bolt
Cylinder stud bolt
Cylinder stud bolt
2
6
2
8
10
12
-
-
-
See page 10-8
See page 10-8
See page 10-8
CLUTCH/GEARSHIFT LINKAGE
ITEM Q'TY
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Clutch lifter plate bolt 4 6 12 (1.2,9)
Clutch center lock nut 1 18 128 (13.1,94) Lock nut; replace with a new
one and stake
Oil pump driven sprocket bolt 1 6 15 (1.5, 11) Apply locking agent to the
threads
Clutch cover socket bolt 5 6 10 (1.0, 7)
Primary drive gear bolt 1 12 88 (9.0,65) Apply engine oil to the
Gearshift spindle return spring pin
Gearshift spindle oil seal stopper
1 8 23 (2.3, 17)
plate bolt 1 6 13 (1.3, 10)
1-14
GENERALINFORMATION
ALTERNATOR/STARTER CLUTCH
ITEM Q'TY
THREAD
DIA. (mm)
TORQUE
N'm (kgfm, Ibfft)
REMARKS
Flywheel bolt
Stator socket bolt
Starter one-way clutch outer socket
bolt
Stator wire holder socket bolt
1
3
6
1
12
6
8
6
128 (13.1, 94)
12(1.2,9)
30 (3.1, 22)
12 (1.2, 9)
Left hand threads
threads
threads
threads
ITEM Q'TY
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Crankcase bolt 15 8 23 (2.3, 17)
Gearshift cam plate bolt 1 6 12 (1.2, 9) Apply locking agent to the
threads
Crankpin bearing cap nut 4 8 33 (3.4, 24) Apply engine oil to the
Output gear case mounting bolt
Output drive gear assembly
3 8 31 (3.2,23) Apply sealant to the threads
mounting bolt
Output driven gear assembly
2 8 31 (3.2,23) Apply engine oil to the
mounting socket bolt
Output drive gear bearing lock nut
4 8 3; (3.2,23) Apply engine oil to the
(inner) 1 30 73 (7.4, 54) Lock nut; replace with a new
one and stake
.
(outer)
Output driven gear bearing lock nut
1 64 98 (10.0, 72)
Lock nut; replace with a new
one and stake
(inner) 1 30 73 (7.4, 54) Lock nut; replace with a new
one and stake
(outer) 1 64 98 (10.0, 72) Lock nut; replace with a new.
one and stake
Output drive gear shaft bolt 1 10 49 (5.0, 36)
ELECTRIC STARTER
ITEM Q'TY
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Starter motor cable terminal nut
Starter motor assembly bolt
. Negative brush screw
1
2
1
6
5
5
10 (to, 7)
4.9 (0.5, 3.6)
3.7 (0.4, 2.7)
ITEM Q'TY
THREAD
DIA. (mm)
TORQUE
Nm lkgfm, Ibfft)
REMARKS
Neutral switch
VS sensor mounting bolt
1
1
10
6
12 (1.2, 9)
9.8 (1.0,7.2)
1-15
GENERAL INFORMATION
FRAME
FRAME/BODY PANELS/EXHAUST SYSTEM
ITEM Q'TV
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Seat mounting socket bolt
Grab rail mounting bolt
Fuel tank mounting bolt
Fuel valve nut
Fuel valve lever screw
Exhaust pipe joint nut
Muffler stay mounting bolt
Muffler mounting nut
Muffler bracket bolt
2
6
1
1
1
4
4
2
2
8
10
8
22
5
8
8
10
8
26 (2.7, 19)
64 (6.5,47)
27 (2.8,20)
34 (3.5, 25)
0.6 (0.1, 0.4)
25 (2.5, 18)
27 (2.8,20)
44 (4.5, 32)
34 (3.5,25)
ALOC screw; replace with a
new one
MAINTENANCE
ITEM Q'TV
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Air cleaner cover socket bolt
Final drive oil filler cap
Final drive oil drain bolt
5
1
1
5
30
8
1.5 (0.2, 1.1)
12 (1.2,9)
12 (1.2,9)
FUEL SYSTEM
ITEM Q'TV
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Air cleaner chamber stay mounting
screw
Air cleaner chamber connecting tube
band screw
1
1
5
4
1.1 (0.1, 0.8)
0.7 (0.1,0.5)
COOLING SYSTEM
ITEM Q'TV
THREAD
DIA. (mm)
TORQUE
Nm (kgf'm, Ibfft)
REMARKS
Fan motor mounting bolt
>
Cooling fan mounting nut
Radiator filler mounting bolt
Thermostat housing cover bolt
Water hose band screw
Fan motor assembly mounting bolt
3
1
2
2
6
3
5
5
6
6
-
6
5.1 (0.5,3.8)
2.7 (0.3,2.0)
10 (1.0,7)
10 (1.0,7)
-
8.4 (0.9, 6.2)
threads
See page 7-10
ENGINE REMOVAl/INSTALLATION
ITEM Q'TV
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Engine mounting nut
Engine hanger plate bolt
Main footpeg bracket mounting bolt
Main footpeg bracket mounting nut
Gearshift arm pinch bolt
4
8
3
1
1
10
8
10
10
6
54 (5.5, 40)
26 (2.7, 19)
39 (4.0,29)
39 (4.0,29)
12(1.2,9)
ITEM Q'TV
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Gearshift pedal pivot bolt 1 10 39 (4.0,29)
1-16
GENERALINFORMATION
FINAL DRIVE
ITEM Q'TV
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Pinion retainer 1 64 108 (11.0, 80)
Pinion retainer lock tab bolt 1 6 10 (1.0, 7)
Pinion joint nut 1 16 108 (11.0, 80) Apply locking agent to the
threads
Dust guard plate bolt 1 6 10 (1.0, 7)
Final gear case cover bolt 2 10 47 (4.8, 35) Apply locking agent to the
threads

. Final gear case assembly mounting
6 8 25 (2.5, 18)
nut 4 10 64 (6.5,47)
Final gear case stud bolt
Rear shock absorber lower mounting
4 10 - See page 14-22
bolt (left side) 1 8 22 (2.2, 16)
FRONT WHEEUSUSPENSION/STEERING
ITEM Q'TV
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Clutch lever pivot bolt 1 6 1 (0.1,0.7)
Clutch lever pivot nut 1 6 6 (0.6, 4.4)
Handlebar upper holder bolt 4 8 23 (2.3, 17)
Handlebar lower holder nut 2 8 23 (2.3,17)
Front brake disc bolt 6 8 42 (4.3,31) ALOC bolt; replace with a
new one
Spoke 52 BC4 4.2 (0.4, 3.1)
Front axle bolt 1 14 59 (6.0, 44)
Front axle pinch bolt 2 8 22 (2.2, 16)
Fork center socket bolt 2 10 29.5 (3.0, 22) Apply locking agent to the
threads
Fork cap 2 38 22.1 (2.3, 16)
Tire valve nut 1 8V1 4 (0.4, 3.0)
Fork top bridge pinch bolt . 2 8 22 (2.2, 16)
Fork bottom bridge pinch bolt 2 10 49 (5.0, 36)
Steering top thread 1 26 - See page 15-32
Steering top thread lock nut 1 26 - See page 15-32
Steering stem nut 1 24 103 (10.5, 76)
REAR WHEEUBRAKE/SUSPENSION
ITEM O'TV
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Spoke 52 BC4 4.2 (0.4, 3.1)
Tire valve nut 1 8V1 4 (0.4, 3.0)
Rear axle nut 1 18 88 (9.0, 65) U-nut
Rear axle pinch bolt 1 8 27 (2.8, 20)
Rear brake stopper arm nut 1 8 22 (2.2, 16)
Rear brake arm pinch bolt 1 8 26 (2.7, 19)
Rear shock absorber upper mounting
bolt 2 8 26 (2.7, 19)
Rear shock absorber lower mounting
bolt (right side) 1 10 34 (3.5, 25)
Stopper plate bolt 5 6 20 (2.0, 15) ALOC bolt; replace with a
new one
Swingarm left pivot bolt 1 30 103 (10.5, 76)
Swingarm right pivot bolt 1 30 - See page 16-26
Swingarm right pivot bolt lock nut 1 30 103 (10.5, 76)
1-17
GENERALINFORMATION
HYDRAULIC BRAKE
ITEM Q'TV
THREAD
DIA.(mm)
TORQUE
N'm (kgfm, Ibfft)
REMARKS
Brake caliper bleed valve 1 8 5.5 (0.6,4.1)
Front master cylinder reservoir cap
screw 2 4 1.5 (0.2, 1.1)
Brake pad pin 1 10 18 (1.8, 13)
Brake pad pin plug 1 10 2.5 (0.3, 1.8)
Brake hose oil bolt 2 10 34 (3.5, 25)
Brake lever pivot bolt 1 6 1 (0.1,0.7)
Brake lever pivot nut 1 6 6 (0.6, 4.4)
Front brake light switch screw 1 4 1.2 (0.1, 0.9)
Front master cylinder holder bolt 2 6 12 (1.2,9)
Front brake caliper bracket pin 1 8 12 (1.2, 9) Apply locking agent to the
threads
Front brake caliper pin 1 8 27 (2.8,20) Apply locking agent to the
threads
Front brake caliper mounting bolt 2 8 30(3.1,22) ALOC bolt; replace with a
new one
BATTERY/CHARGING SYSTEM
ITEM Q'TV
THREAD
DIA.(mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Battery case cover screw 1 6 1 (0.1,0.7)
ITEM Q'TV
THREAD
DIA.(mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Headlight unit mounting bolt
Brakeltail light mounting nut
Speedometer mounting socket bolt
Ignition switch mounting bolt
Ignition switch cover screw
Fan motor switch
.
Sidestand switch bolt
ECT sensor switch
Horn mounting bolt
2
3
2
2
1
1
1
1
1
5
6
6
6
4
16
6
PT 1/8
8
4.1 (0.4,3.0)
6.3 (0.6, 4.6)
10 (1.0, 7)
12 (1.2, 9)
1 (0.1,0.7)
18 (1.8,13)
10 (1.0,7)
7 (0.7, 5.2)
21 (2.1,15)
ALOC bolt; replace with a
new one
Apply sealant to the threads
OTHERS
ITEM Q'TV
THREAD
DIA.(mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Sidestand pivot bolt
Sidestand pivot lock nut
Sidestand bracket bolt
Tool box screw
1
1
2
2
10
10
10
4
9 (0.9, 6.6)
30 (3.1, 22)
49 (5.0, 36)
2 (0.2, 1.5)
Apply grease to the sliding
surface
1-18
GENERALINFORMATION
LUBRICATION&SEALPOINTS
ENGINE
MATERIAL LOCATION REMARKS
Molybdenum disulfide
oil (a mixture of 1/2
engine oil and 1/2
molybdenum disulfide
grease)
Camshaft lobes and journal surface
Valve stem (valve guide sliding surface)
Rocker arm slipper surface
Rocker arm shaft outer surface
Crankpin bearing thrust surface
Crankshaft main journals
Clutch outer guide outer surface
Transmission gear shift fork groove
Transmission bushing sliding surface
Connecting rod small end inner surface
Engine oil Piston outer surface
Piston ring outer surface
Piston pin outer surface
Primary drive gear bolt threads and seating surface
Flywheel bolt threads and seating surface
Starter one-way clutch sprag
Starter idle and reduction gear shaft outer surface
Clutch center lock nut threads and seating surface
Clutch lifter arm sliding surface of the right crankcase cover
Clutch lifter arm sliding surface and slit
Clutch discs and plates
Cylinder wall
Cylinder stud bolt threads
Valve adjusting screw lock nut threads and seating surface
Shift fork shaft whole surface
Crankpin bearing cap nut threads and seating surface
Output drive gear assembly mounting bolt threads and seating
surface
> Output driven gear assembly mounting socket bolt threads
and seating surface
Output drive gear bearing lock nut (inner/outer) threads and
seating surface
Output driven gear bearing lock nut (inner/outer) threads and
seating surface
Cylinder head bolt/nut threads and seating surface
Transmission gear tooth
Engine oil filter cartridge threads
Crankshaft main journal bearing surface
Oil pipe seal
Each bearings rotating area
Each O-rings
Multi-purpose grease Crankshaft hole cap threads
Timing hole cap threads
Each oil seal lips
Sealant EOP switch threads
Right and left crankcase mating surface
Right crankcase cover mating surface
Left crankcase cover mating surface
Output gear case mounting bolt threads
Do not apply to the
sealant to the head
3-4 mm (0.1-0.2 in)
1-19
GENERALINFORMA1"ION
Locking agent Cam sprocket bolt threads
Starter one-way clutch outer socket bolt threads
Oil pump driven sprocket bolt threads
Final gear case stud bolt threads (gear case side)
Stator wire holder socket bolt threads
Gearshift cam plate bolt threads
Transmission bearing setting plate bolt threads
Cam chain tensioner setting plate bolt threads
Stator socket bolt threads
Oil filter boss crankcase side threads
Left crankcase cover bolt threads (marked "8')
Coating width:
6.5 1 mm
(0.26 0.04 in)
Coating width:
6.5 1 mm
(0.26 0.04 in)
Coating width:
6.5 1 mm
(0.26 0.04 in)
Coating width:
6.5 1 mm
(0.26 0.04 in)
Coating width:
6.5 1 mm
(0.26 0.04 in)
Coating width:
6.5 1 mm
(0.26 0.04 in)
Pro Honda Hondabond
HT or equivalent
Cylinder head cover-to-gasket groove
1-20
GENERALINFORMATION
FRAME
Sealant Final gear case cover mating surface
ECT sensor switch threads Do not apply to the
thread head
Multi-purpose grease Sidestand pivot Apply 1 g
Main step sliding area
Pillion step sliding area
Throttle pipe flange groove and sliding surface Spreading 0.2 - 0.3 g
Clutch lever pivot bolt sliding surface
Gearshift spindle oil seal lips
Gear shift pedal dust seal lips
Front axle sliding surface
Shock absorber mount inner surface
Rear brake middle rod joint pivot and dust seal lips
Rear brake cam sliding surface Spreading 0.5 - 1.0 g
Brake shoe-to-anchor pin sliding surface Spreading 0.5 - 1.0 g
Brake pedal pivot sliding surface
Brake pedal dust seal lips
Rear brake joint pins
Front wheel dust seal lips
Final gear case O-ring
Final gear case oil seal lips
Urea based multi- Steering head bearings Apply 3 - 5 g for each
purpose grease with bearing
extreme pressure Steering head bearing dust seal lips
(example: EXCELITE
EP2 manufactured by
KYODO YUSHI, Japan)
or equivalent
Swingarm pivot bearing needle rollers
Swingarm pivot dust seal lips
Apply 1.0 - 1.5 g for
each bearing
Molybdenum disulfide Output drive gear and damper cam splines Apply 1 g
grease Final drive shaft oil seal lip Apply 0.5 g
Final drive shaft splines (universal joint side) Apply 1 g
Final drive pinion joint splines Apply 2 g
Molybdenum disulfide Final driven flange (rear wheel hub mating surface) Apply 0.5 - 1.0 g
paste Final driven flange O-ring
Final gear case O-ring guide and driven flange joint surface Apply 4- 5 g
Thrust washer and rear wheel hub end (final driven flange Apply 2- 3 g
side)
Cable lubricant Throttle cable outer inside
Clutch cable outer inside
Choke cable outer inside
Pro Honda Handgrip Handlebar grip inside
Cement or equivalent Handlebar and throttle pipe outer surface (grip rubber
contacting area)
I
Engine oil Steering top threads
Rear brake cam felt seal
Silicone grease Brake lever pivot bolt sliding surface Apply 0.1 g
Brake lever-to-master piston contacting area Apply 0.1 g
Brake caliper and bracket pin boot inside Apply 0.4 g
Brake caliper dust seal
DOT 4 brake fluid Brake master piston and cups
Brake caliper piston and piston seals
Pro Honda Suspension Fork dust seal and oil seal lips
Fluid SS-8 (10W)
Fork cap O-ring
Locking agent Pinion joint nut threads
Final gear case cover 10 mm bolt threads
Fork center socket bolt threads
Front brake caliper bracket pin threads
Front brake caliper pin threads
Final gear case stud bolt threads
Steering stem cover bolt threads
Cooling fan mounting nut threads
1-21
GENERALINFORMATION
CABLE& HARNESSROUTING
THROTrLE CABLES
RIGHT HANDLEBAR
SWITCH WIRE
FRONT BRAKE HOSE CLUTCH CABLE
FRONT TURN SIGNAL LIGHT WIRES
FOG LIGHT 3P LEFT HANDLEBAR SWITCH RIGHT HANDLEBAR SWITCH
CONNECTOR (Option) 6P (BLACK) CONNECTOR 6P (RED) COI\INECTOR
LEFT HANDLEBAR SWITCH
6P (BLUE) CONNECTOR
HEADLIGHT 3P CONNECTOR
1-22
--------
GENERALINFORMATION
RIGHTHANDLEBAR SWITCHWIRE
Up
t
~ '-'-1~ t side
~ .J. 30 5
1-23
0 __-
GENERALINFORMATION
CLUTCH CABLE
~ 4
-------------------
GENERALINFORMATION
FUEL TANK
FUEL TANK BREATHER HOSE
BREATHER HOSE
(Except California type)
FUEL TANK BREATHER HOSE
WATER HOSE
FUEL VALVE
Revised: May 2007, 2007-2008 VT750C2
-,""",,
1-25
- - ---------
-------
GENERALINFORMATION
. (1) SIDESTANDSWITCHWIRE
(2) GROUNDCABLE
(3) STARTER MOTORCABLE
(4) ALTERNATORWIR.E
(5) NEUTRAUOILPRESSURESWITCHWIRE
(6) VS SENSORWIRE
(7) IGNITIONSWITCHWIRE
IGNITION SWITCHWIRE
(1) (5)
(4)
STARTER MOTORCABLE
(1)
(1)
NEUTRAUOILPRESSURE
SWITCHWIRE
SIDESTANDSWITCHWIRE.
1-26
GENERAL INFORMATION
FUEL TANK BREATHER (California type: EVAP CANISTER) HOSE
to fuel tank
CARBURETOR AIR VENT
RADIATOR RESERVE
TANK BREATHER HOSE
SIPHON HOSE
HOSE (Except California type)
1-27
~ ~ ~ _ ~ --------
GENERALINFORMATION
SUB AIR CLEANERS
/
STARTER MOTOR CABLE
GROUND CABLE
1-28
GENERALINFORMATION
INSIDE BOOT CONNECTORS:
IGNITION PULSE GENERATOR 2P (RED) CONNECTOR
FAN MOTOR 2P (NATURAL) CONNECTOR
REAR BRAKE LIGHT SWITCH 3P (LIGHT GRAY) CONNECTOR
PAIR COI\JTROL VALVE VACUUM HOSE
MAIN WIRE HARNESS
THROTTLE CABLES
FUEL TANK BREATHER (California type:
EVAP CANISTER) HOSE
Left side
CARBURETORAIR VENT HOSE
(Except calif6riJia type)
IGNITION PULSE GENERATOR WIRE
1-29
GENERALINFORMATION
PAIR CONTROL VALVE VACUUM HOSE
t Up
~ ~ ~ 4 5 0 ~ ~ !
1 ~ ~ _--.
. Left side
i
Revised: May 2007,2007-2008 VT750C2
1-30
GENERALINFORMATION
PAIR CONTROL VALVE
PAIR CONTROL VALVE VACUUM HOSES
SUB AIR CLEANERS
1-31
GENERALINFORMATION
FUEL TANK BREATHER
(California type: EVAP CANISTER)
HOSE
LEFT REAR SPARK PLUG WIRE
BRAKEITAIULICENSE
LIGHT WIRE
RIGHT REAR SPARK PLUG WIRE
REAR TURN SIGNAL
REGULATOR/RECTIFIER
LIGHT WIRES
TURN SIGNAL RELAY
STARTER RELAY SWITCH
BATTERY POSITIVE (+) CABLE
PRIMARY WIRES
1-32
GENERALINFORMATION
INSIDE BOOT CONNECTORS:
RIGHT REAR TURN SIGNAL LIGHT 2P (LIGHT BLUE) CONNECTOR
LEFT REAR TURN SIGNAL LIGHT 2P (ORANGE) CONNECTOR
rCM 22P CONNECTOR
BRAKEfTAIULICENSE LIGHT 3P ~ A T U R A L CONNECTOR
INSIDE BOOT CONNECTORS: ICM
. IGNITION SWITCH 2P (BLACK) AND 1P (NATURAL) CONNECTOR
SIDESTAND SWITCH 2P (GREEN) CONNECTOR
VS SENSOR 3P (NATURAL) CONNECTOR
ALTERNATOR 3P (NATURAL) CONNECTOR
NEUTRAUEOP SWITCH 2P (BLACK) CONNECTOR
1-33
GEI\lERALINFO .
RMATION
LEFT REAR TUR
SIGNAL LIGHT R
BRAKEfT
LIGHT AIULICENSE
WIRE
1-34
GENERAL INFORMATION
EVAP CONTROL SYSTEM (California type only)
EVAPCAV
CONTROLVALVE
VACUUMHOSE
FUELCUT-OFFSOLENOID MAINWIRE HARNESS
VALVEVACUUM HOSE
SECONDARYAIR
SUPPLYHOSE
EVAP CAVCONTROL.
EAVAPPURGECONTROL
VALVE HOSE (tofuel
VALVE HOSE(tocanister)
SIPHON HOSE
cut-offsolenoidvalve)
EVAP PURGE CONTROL
VALVE HOSE(tothrottlebore)
EVAPCAVCONTROL
VALVEHOSE(tocanister)
FUELHOSE
Revised:May2007,2007-2008VT750C2
1-35
GENERAL INFORMATION
RADIATOR RESERVE
TANK BREATHER
HOSE
EVAP CAN ISTER HOSE
(to fuel tank)
Revised: May 2007. 2007-2008 VT750C2
1-36
GENERALINFORMATION
EVAP CAV CONTROL
VALVE VACUUM HOSE
EVAP CAV CONTROL VALVE HOSE
(to fuel cut-off solenoid valve)
EVAP PURGE CONTROL
VALVE HOSE (to <.:anister)
FUEL CUT-OFF
SOLENOID VALVE
VACUUM HOSE
to rear PAIR check valve
EVAPPURGECONTROL
VALVE HOSE (to throttle bore)
EVAP CAN ISTER
HOSE
EVAPCAVCONTROL VALVE
HOSE (to sub air cleaner)
EVAP CAV CONTROL
VALVE HOSE (to canister)
FUEL CUT-OFF SOLENOID
VALVE HOSE (to float chamber)
EVAP PURGE CONTROL VALVE
VACUUM HOSE
FUEL HOSE
Revised: May 2007, ~ 7 2 8 VT750C2
-------- -_.. -- ---
1-37
GENERALINFORMATION
FUEL CUT-OFF
SOLENOID VALVE WIRE
EVAPCAVCONTROL VALVE HOSE
(to fuel cut-off solenoid valve)
FUEL CUT-OFF SOLENOID
VALVE VACUUM HOSE
EVAP CAV CONTROL VALVE
HOSE (to sub air cleaner)
EVAP CAV CONTROL
VALVE HOSE (to canister)
EVAPPURGECONTROL
VALVE VACUUM HOSE
EVAP CAV CONTROL
VALVE VACUUM HOSE
May 2007, 2007 VT750C2
1":38
GENERALINFORMATION
EMISSIONCONTROLSYSTEMS
EXHAUSTEMISSIONREQUIREMENT
The U.S. Environmental Protection Agency (EPA), California Air Resources Board (CARB) and Transport Canada require
manufacturers to certify that their motorcycles comply with applicable exhaust emissions standards during their useful
life, when operated and maintained according to the instructions provided.
NOISEEMISSIONREQUIREMENT
The EPA also required that motorcycles built after January 1, 1983 comply with applicable noise emission standards for
one year or 6,000 km (3,730 miles) after the time of sale to the ultimate purchaser, when operated and maintained
according to the instructions provided.
WARRANTYCOMPLIANCE,
Compliance whhthe terms'of}be Dil?tributor's Limited Warranty for Honda Motorcycle Emission Control Systems is
necessary in order to keep the emissions system warranty in effect.
SOURCEOFEMIS'SIONS
The combustion process produces carbon monoxide (CO), oxides of nitrogen (NOx) and hydrocarbons (HC). Control of
carbon monoxide, oxides of nitrogen and hydrocarbons is very important because, under certain conditions, they react to
form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but is toxic.
Honda Motor Co., ltd. utilizes appropriate carburetor settings as well as other systems, to reduce carbon monoxide, and
hydrocarbons.
CRANKCASEEMISSIONCONTROLSYSTEM
The engine is equipped with ~ l o s e d crankcase system to prevent discharging crankcase emissions into the atmosphere.
Blow-by gas is returned to the combustion chamber through the air cleaner and carburetor. .
AIR CLEANER
; FRESH AIR
~ BLOW-BY GAS
'..39
GENERALINFORMATION
EXHAUSTEMISSIONCONTROLSYSTEM
Theexhaustemissioncontrolsystem iscomposedofapulsesecondaryairsupplysystemandleancarburetorsettings.
No adjustmentshould be madeexceptidlespeed adjustmentwiththethrottlestopscrew.Theexhaust emissioncontrol
systemis separatefromthecrankcaseemissioncontrolsystem.
SECONDARYAIRSUPPLYSYSTEM
Thepulsesecondaryairsupplysystemintroducesfilteredairintotheexhaustgasesintheexhaustport.Fresh airisdrawn
intotheexhaustportbythefunctionofthePAIR (PulseSecondaryAirInjection)controlvalve.
This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of
hydrocarbonsandcarbonmonoxideintorelativelyharmlesscarbondioxideandwatervapor.
Thereedvalvepreventsreverseairflowthroughthesystem.ThePAIRcontrolvalvereactstohighintakemanifoldvacuum
andwillcutoffthesupplyoffresh airduringengine therebypreventingafterburnintheexhaustsystem.
No adjustmentstothe secondary airsupplysystem should be made, although periodicinspection ofthe components is
recommended.
FRESHAIR
..EXHAUSTGAS
-41.'11 NEGATIVE PRESSURE
OXIDATIONCATALYTICCONVERTER(Californiatypeonly)
Thismotorcycleisequippedwithan oxidationcatalyticconverter.
The oxidation catalytic converter is in the exhaust system. Through chemical reactions, itconverts HC and CO in the
engine'sexhausttocarbondioxide(C02) and watervapor.
FUELPERMEATIONEMISSIONCONTROLSYSTEM
This motorcycle complies with the Fuel Permeation Emission regulations ofthe U.S. Environmental Protection Agency
(EPA), California Air Resources Board (CARB), and Environment Canada (ECl.The fuel tank, fuel hoses, and fuel vapor
chargehosesusedonthismotorcycleincorporatefuel permeationcontroltechnologies.Tamperingwiththefueltank,fuel
hoses,orfuelvaporchargehosestoreduceordefeattheeffectivenessofthefuel permeationtechnologiesisprohibitedby
federal regulations.
Revised:May2007.2007-2008VT750C2
1-40

GENERALINFORMATION
EVAPORATIVEEMISSIONCONTROLSYSTEM(Californiatypeonly)
This model complies with CARB evaporative emission requirements. Fuel vapor from the fuel tank is routed into the
evaporative emission (EVAP) canister where it is absorbed and stored whilethe engine is stopped. When the engine is
running and the EVAP purge control solenoid valve is open, fuel vapor in the EVAP canister is drawn intothe engine
throughthecarburetor.
EVAPPURGECONTROLVALVE
EVAPCAVCONTROLVALVE
(ATENGINESTOP)

EVAPCAVCONTROL
VALVE
(ATENGINE RUNNING)
<-
FUELVAPOR
(ATENGINESTOP)
..
FUELVAPOR
FUELTANK
(ATENGINE RUNNING)
NEGATIVE PRESSURE
EVAPCANISTER
I\lOISEEMISSIONCONTROLSYSTEM
TAMPERINGWITH THE NOISE CONTROLSYSTEM IS PROHIBITED: U.S.Federal lawprohibits,orCanadian provincial law
mayprohibitthefollowingactsorthecausingthereof:(1)Theremoval orrendering inoperativebyanyperson,otherthan
forpurposesofmaintenance,repairorreplacement,ofanydeviceorelementofdesign incorporated intoanyvehicle for
the purpose ofnoisecontrol priorto itssale ordeliverytotheultimatecustomerorwhileitis in use; (2) the use ofthe
vehicleaftersuchdeviceorelementofdesignhas been removed orrendered inoperativebyanyperson.
AMONGTHOSE ACTS PRESUMEDTO CONSTITUTETAMPERINGARETHEACTSLISTED BELOW:
1. Removal of,orpuncturingofthemuffler,baffles, headerpipesoranyothercomponentwhichconductsexhaustgases.
2. Removal of,orpuncturingofanypartoftheintakesystem.
3. Lackofpropermaintenance.
4. Replacing any moving parts of the vehicle, or parts ofthe exhaust or intake system, with parts other than those
specified bythemanufacturer.
1-41
MEMO
--------------,----
2. TECHNICALFEATURE

OXIDATION CATALYTIC CONVERTER
PROTECTION FROM UNBURNED
GASOLINE (California type only) 2-2
2-1
TECHNICALFEATURE
OXIDATION CATALYTIC CONVERTER PROTECTION FROM
UNBURNEDGASOLINE(Californiatypeonly)
OUTLINE
Thismotorcycleisequippedwith heat-tubeenhancedoxidationcatalyticconverters.Throughthechemical reactions,they
convertHC and CO intheengine'sexhausttocarbon dioxide(C02) and watervapor. Ifthe unburned (raw) gasolinefrom
thecombustionchamberflowsintothe catalyticconverter, itwill damagethecatalyticconverterthrough excessivetem-
peratures.A damagedcatalyticconvertercannotbeeffectiveforexhaustemissionscontrol.
Thefuelcut-off solenoidvalveand heat-tubeprotecttheoxidationcatalyticconverterfromdamagebyrawgasoline.
FUELCUT-OFFSOLENOIDVALVE
CONSTRUCTION
Rawgasolinecanenterthecatalyticconverterunderthefollowingconditions:
- Theenginestopswitchisturnedto suddenlywhiletheengineisrunning.
- Ignitioncutsystem(revlimiter)operateswhentheengineisoverrewed.
The fuel cut-offsolenoidvalve is controlled bythe ICM, andthefloatchamberairventpassage ischanged according to
abovedescribedconditions.
Thefuelcut-offsolenoidvalveconsistsofacoilandvalve,and3passages.
1. Connectiontosubaircleaner(atmosphere)
2. Connectiontothrottlebore
3. Connectiontofloatchamberairvent
Thefuel cut-offsolenoidvalveopenspassages 1to3passagewhenthereis nooperationvoltage.
OPERATION
NormalOperation(Whenthefuelcut-offsolenoidvalvedoesnotoperate):
1. NooperationvoltagefromtheICM.
2. Thefloatchamberairventisopentoatmosphere.
3. Thefloatchamberpressure(surfaceofthegasolineinthefloatchamber)isatmosphere.
4. Thecarburetoroperatesnormally.
FuelCutOperation(Whenthefuelcut-offsolenoidvalveoperates):
1. Theoperationvoltagecomesfrom'theICM.
2. Thefloatchamberairventpassage isclosedtoatmosphere.
3. Thefloatchamberairventisopenedtothethrottlebore.
4. Thefloatchamberpressure(surfaceofthegasolineinthefloatchamber) becomesnegative.
5. Thefloatchamberpressurewill besameasthrottleborepressure.
6. Thecarburetorstopsfuel supply.
VALVE TOTHROTTLE BORE
FUELCUT-OFF
TOATMOSPHERE
t
OPERATION
VOLTAGE
SOLENOIDVALVE
CARBURETOR
/l------, FUELCUT-OFFSOLENOID
VALVE DOES NOT
OPERATE:
..FUELCUT-OFFSOLENOID
VALVE OPERATES:
2-2.
TECHNICALFEATURE
HEAT-TUBE
Rawgasolinecan enterthecatalyticconverterunderthefollowingconditions:
- Theenginestopswitchisturnedto suddenlywhiletheengineis running.
- The engine stopswitch isturnedto suddenlywhiletheengine is running and thethrottle is snapped open (addi-
tionalfuelisdischargedfromtheacceleratorpump).
The heat-tubeis installed upstream oftheoxidationcatalyticconvertertoprotectthecatalyticconverterfromdamageby
chemical reactions.
ACCELERATOR PUMP
OXIDATIONCATALYTICCONVERTER
2-3
MEMO
--- --------- ---
3. FRAME/BODYPANELS/EXHAUSTSYSTEM
-
SERVICEINFORMATION 3-2
TROUBLESHOOTING 3-2
SEAT ..33
SIDECOVER 3-3
FUELTANK 3-4
STEERINGSIDECOVER 3-5
LEFTCRANKCASEREARCOVER 3-5
FRONTFENDER 3-6
REAR FENDER 3-6
EXHAUSTSYSTEM 3-8
~ ...~
3-1
FRAME/BODYPANELS/EXHAUSTSYSTEM
SERVICEINFORMATION
GENERAL
Thissectioncoversremoval andinstallationofthebodypanels,fueltankand exhaustsystem.
Seriousburnsmayresultiftheexhaustsystem is notallowedtocool beforecomponentsare removedorserviced.
Alwaysreplacetheexhaustsystemgasketswithnewonesafterremovingtheexhaustsystemfromtheengine.
Wheninstallingtheexhaustsystem,looselyinstallall oftheexhaustpipefasteners.Alwaystightentheexhaustclamps
first,thentightenthemountingfasteners.
Alwaysinspecttheexhaustsystemforleaksafterinstallation.
TORQUEVALUES
Seatmountingsocket8mmbolt 26Nm (2.7 kgfm,19lbfft)
Grabrail mountingbolt 64N'm(6.5 kgfm,47 Ibfft)
Fueltankmountingbolt 27 Nm(2.8 kgfm,20 Ibfft)
Fuelvalvenut 34N'm(3.5 kgf'm,25 Ibfft)
Leftcrankcase rearcoversocketbolt 10N'm(1.0kgfm,7Ibfft)
Exhaustpipejointnut 25 Nm(2.5 kgfm,18Ibfft)
Mufflerstaymountingbolt 27 Nm (2.8 kgfm,20 Ibfft)
Mufflermountingnut 44Nm(4.5 kgfm,32 Ibfft)
Mufflerbracketbolt 34Nm(3.5 kgfm,25 Ibfft)
Exhaustpipejointstud bolt See page3-11
TROUBLESHOOTING
Excessiveexhaustnoise
Brokenexhaustsystem
Exhaustgasleak
Poorperformance
Deformedexhaustsystem
Exhaustgasleaks
Cloggedmuffler
3-2
SEAT
REMOVAL
Remove the 8 mm socket bolts, 6 mm bolt, washer
and seat by moving it rearward.
INSTALLATION
Install the seat by inserting its prong under the
raised lip of the frame.
Install the washer, 6 mm bolt and tighten the 6 mm
bolt securely.
Install and tighten the 8 mm socket bolts to the
specified torque.
TORQUE:26Nm(2.7 kgfm, 19Ibf.ft)
SIDECOVER
REMOVALIINSTALLATION
Be careful not to Remove the side cover by releasing its bosses from
damage the side the frame grommets.
cover bosses.
Install the side cover by inserting its bosses into the
frame grommets.
SIDE COVER
3-3
FUELTANK
REMOVAL
Removethefollowing:
- Speedometerassembly(page21-10)
- Seat(page3-3)
TurnthefuelvalvetoOFF.
Disconnectthefuel andvacuumhosesfromthefuel
valve.
Disconnectthebreatherhose(Californiatype: EVAP
canisterhose)fromthefueltank.
Removethemountingbolt,washerandcollar.
Removethefueltankbymovingitrearward.
INSTALLATION
Installthefueltankbyinsertingitsgroovesoverthe
mountingrubbers.
Install the collar and washer with the flat of the
washerfacing rearward.
Installandtightenthemountingbolttothespecified
torque.
TORQUE:27Nm(2.8kgfm,20Ibf.ft)
Route thehoses Install the removed parts in the reverse order of
properly removal.
(page 1-22).
DISASSEMBLY
Removethefueltank(page3-4).
FUELVALVE
Drain the fuel from the fuel tank into an approved
gasolinecontainer.
Loosenthenutand removethefuelvalve.
WASHER
BREATHER (EVAPCANISTER) HOSE
Removethefuel strainerscreenandO-ring.
Wash the fuel strainer screen in high flash-point
cleaningsolvent.
Check the fuel strainer screen for clog or damage,
replaceitifnecessary.
ASSEMBLY
Install a newO-ring and fuel strainer screen to the
fuelvalve.
STRAINERSCREEN
O-RING S!I
3-4.
Installthefuelvalveintothefueltank.
Tighten the nuttothe specified torque while hold-
ingthefuelvalve.
TORQUE:34Nm(3.5kgfm,25Ibftt)
Installthefueltank(page3-4).
FUELVALVE
STEERINGSIDECOVER
REMOVAL/INSTALLATION
Removethespeedometerassembly(page21-10).
STEERING SIDE COVERS CLIP
Removethebolts.
Removetheretainingclipbyslidingitrearward.
Be carefulnotto Remove the steering side covers by releasing the
damage theboss leftcoverbossfromtherightcoverslot.
andslot.
Installationisinthereverseorderofremoval.
NOTE:
After installation, check that the wire harness and
cablesdonotinterferewithhandlebarrotation.
f

LEFTCRANKCASEREARCOVER
REMOVALIINSTALLATION
RemovetheB-clipandwasher.
Remove the socket bolt and left crankcase rear
coverbyreleasing itsbossesfromthegrommets.
Check the B-clip forfatigue ordamage, replace itif
necessCiry
InlrtallatiQnisinthereverseorderofremoval.
TORQU.E:
socketbolt:
10Nm(1;()kQ"m,7IbHI:)
SOCKETBOLT WASHER
I B-CLIP
LEFTCRANKCASE REAR COVER
3-5
FRONTFENDER
REMOVAUINSTALLATID1\1
Removethefollowing:
GROMMETS/COLLARS
- Nuts
- Collars
- Frontfenderbrace
- Frontfender
- Grommets
- Bolts
BRACE
REAR FENDER
REAR FENDERASSEMBLY
REMOVAL
Removetheseat(page3-3).
Disconnect the brakeltail/license light 3P and rear
turnsignallight2P connectors.
3-6.
-- ---
Removethefollowing:
GRABRAILS
- Bolts
- Washers
- Grabrails
- Rearfenderassembly
NOTE:
When removing the rear fender assembly, be care-
ful nottodamagethewires.
INSTALLATION
Route the wires Installationisinthereverseorderofremoval.
properly
(page 1-22). TORQUE:
Grabrailmountingbolt:
64Nm(6.5kgfm,47Ibf.ft)
REAR FENDER
ASSEMBLY
REAR FRAME/REARFENDERA
REMOVAL
Removetherearfenderassembly(page3-6).
Releasetherearframe bosses fromthe rear fender
holes,then removetherearframe/rearfenderA.
NOTE:
When removing the rear frame/rear fender A, be
carefulnottodamagethewires.
RemovetherubberfromtherearfenderA.
Removethegrommetfromtherearfender.
HOLES
~ E R
~ ._-
3-7
DISASSEMBLYI ASSEMBLY
Removethefollowing:
- Rearturnsignal lights(page21-7)
GROMMETS
- Brake/taillight(page21-8)
- Licenselight(page21-8)
Remove the mounting bolt, collars, grommets and
rearfenderA.
Removethenutand reflector.
Assemblyisinthereverseorderofdisassembly.
INSTALLATION
Routethewires Installationisinthereverseorderofremoval.
properly
(page 1-22).
COLLAR
BOLT
EXHAUSTSYSTEM
REMOVAL
Removetheexhaustpipejointnuts.
Remove the nuts, bolts, washers, collars and muf-
flerassembly.
REAR FENDER A
3-8.
Removethefrontandreargaskets.
FLANGE
Removetheexhaustpipejointcollarsandflanges.
JOINTCOLLAR
DISASSEMBLY
Rear muffler only: Drivetherearexhaustpipeprotectorusingaplastic
PLASTICHAMMER
hammerand breakthe locktab (reverse side ofthe
protector)andremoveit.
NOTE:
The rearexhaustpipe protectorcan be removed
wit/:loutremovingthe exhaust system from the
n g i r i ~
[)onofreusE! theremovedprotector.
Loosenthemufflerjointbandbolt.
Removethemounting bolts, mufflerstayandsepa-
ratethemufflers.
STAY MOUNTING BOLTS
3-9
ASSEMBLY
."REAR EXHAUST REAR MUFFLER
IIIiiiijjlII PIPE PROTECTOR
Installanewgasketontothefrontmufflerjointpipe.
Assemblethefrontmufflerand rearmuffler.
Install the mufflerstay, mounting bolts and tighten
themountingboltstothespecifiedtorque.
TORQUE:27 Nm(2.8kgfm,20Ibf.ft)
Tightenthemufflerjointbandboltsecurely.
Rear muffler only: Installanewrearexhaustpipeprotector.
PROTECTOR
IIIiiiijjlII
3-10
------------
INSTALLATION
MUFFLER ASSEMBLY
If the exhaust pipejoint stud bolts are loose, tighten
them. Be s.ure tb verify the distance from the top of 40.0-40.2 mm
the stud to the cylinder head as shown.
(1.57 -1.58 in)
Install the flanges and exhaust pipe joint collars.
FLANGE
JOINT COLLAR
3-11
Installnewgaskets.
Installthemufflerassembly.
NOTE:
Inserting the rear exhaust pipeto the rear exhaust
portfirst, then insertthe front exhaust pipe to the
frontexhaustport.
Temporarilyinstalltheallfasteners.
Tightentheexhaust pipejointnutstothespecified
torque.
TORQUE:25Nm(2.5kgfm,18Ibfft)
Tighten the mufflermounting nuts to the specified
torque.
NOTE:
Always inspect the exhaust system for leaks after
installation.
3-12
4. MAINTENANCE
SERVICE INFORMATION ......4-2
MAINTENANCE SCHEDULE 4-4
FUEL LINE .. 4-5
THROTTLE OPERATION 4-5
CHOKE OPERATION 4-6
AIR CLEANER .................... .. .... .. .. 4-7
SUB AIR CLEANER 4-8
CRANKCASE BREATHER 4-8
SPARK PLUG 4-9
VALVE CLEARANCE 4-10
ENGINE OIL .. .... .. ........ .. ............ 4-12
ENGINE OIL FILTER 4-13
ENGINE IDLE SPEED 4-15
RADIATOR COOLANT 4-15
COOLING SySTEM 4-15

SECONDARY AIR SUPPLY SYSTEM ...... 4-16
EVAPCONTROLSYSTEM
(California type only) 4-17
FINAL DRIVE OIL 4-18
BRAKE FLUID 4-19
BRAKE SHOES/PADS WEAR 4-20
BRAKE SYSTEM 4-20
BRAKE LIGHT SWITCH 4-22
HEADLIGHT AIM 4-22
CLUTCH SYSTEM 4-22
SIDESTAND .. .. ......................4-23
SUSPENSiON ...... .............. ...... 4-24
NUTS, BOLTS, FASTEI\lERS 4-24
WHEELS/TIRES 4-25
STEERING HEAD BEARINGS 4-26
4-1
~ ~ ~ ~ _ ~ ~ ~ --------- ~
MAINTENANCE
SERVICEINFORMATION
GENERAL
Placethemotorcycleon levelgroundbeforestartinganywork.
Gasolineis extremelyflammableandisexplosiveundercertainconditions.
Workin awell ventilated area. Smoking orallowing flames orsparks in theworkarea orwherethegasolineisstored
cancauseafireorexplosion.
Theexhaustcontainspoisonouscarbonmonoxidegasthatmaycause lossofconsciousnessand mayleadtodeath.
Runtheengineinandopenarea orwithan exhaustevacuationsysteminan enclosedarea.
SPECIFICATIONS
ITEM SPECIFICATIONS
Throttlegripfreeplay 2- 6mm(1/16- 1/4in)
Sparkplug Standard DPR6EA-9(NGK),X20EPR-U9(DENSO)
Forextendedhighspeed riding DPR7EA-9(NGK),X22EPR-U9 (DENSO)
Sparkpluggap 0.8- 0.9mm(0.03- 0.04in)
Valveclearance IN 0.150.02 mm(0.0060.001 in)
EX 0.200.02mm(0.0080.001 in)
Recommendedengineoil Pro HondaGN44-strokeoil (U.S.A.andCanada)orequiva-
lentmotoroil
API serviceclassification:SG orhigher
JASOT903 standard:MA
Viscosity:SAE 10W-30
Engineoil Atdraining 2.5liters(2.6USqt,2.2Impqt)
capacity Atoilfilterchange 2.6liters(2.7 USqt,2.3Impqt)
Atdisassembly 3.2 liters(3.4USqt,2.8Impqt)
Engineidlespeed 1,200100rpm
Recommendedantifreeze ProHondaHPcoolantoran equivalenthighqualityethyl-
eneglycolantifreezecontainingsilicate-freecorrosion
inhibitors
Recommendedfinaldriveoil Hypoidgearoil,SAE #80
Final driveoil Atdraining 160cm
3
(5.4USoz,5.6Impoz)
capacity Atdisassembly 170cm
3
(5.7 USoz,6.0Impoz)
Recommendedbrakefluid DOT4
Brake pedal height 75mm(3.0in)abovethetopofthefootpeg
Brakepedalfreeplay 20-30mm(13/16-1-3/16in)
Clutch leverfreeplay 10- 20 mm(3/8-13/16in)
Coldtirepressure Upto90kg(200Ibs) Front 200kPa (2.00kgf/cm
2
, 29 psi)
load
Rear 200kPa (2.00kgf/cm
2
, 29 psi)
Uptomaximum Front 200kPa (2.00kgf/cm
2
, 29 psi)
weightcapacity
Rear 250kPa (2.50kgf/cm
2
, 36psi)
Tiresize Front 90/90-21M/C545
Rear 160/80-15M/C74S
Tirebrand BRIDGESTONE Front EXEDRAG701
Rear EXEDRAG702
DUNLOP Front D404F
Rear D404
Minimumtiretreaddepth Front 1.5 mm(0.06in)
Rear 2.0mm(0.08in)
4-2.
MAINTENANCE
TORQUEVALUES
Sparkplug
Valve adjustingscrewlocknut
Timing holecap
Engineoilfiltercartridge
Engineoildrainbolt
Final driveoilfillercap
Finaldriveoildrainbolt
Frontmastercylinderreservoircapscrew
Aircleanercoversocketbolt
Crankshaftholecap
Alternatorcoversocketbolt
Spoke
SEvalvenut
TOOLS
18 N'm(1.8 kgfm,13Ibfft)
23 N'm(2.3 kgf'm,17 Ibfft)
10 Nm(1.0 kgf'm,7Ibfft)
26 Nm(2.7 kgf'm,19 Ibfft)
29 N'm(3.0 kgf'm,21 Ibfft
12 Nm(1.2 kgfm,9Ibfft)
1.5 N'm(0.2 kgfm,1.1 Ibfft)
1.5 N'm(0.2 kgf'm,1.1 Ibfft)
15N'm(1.5 kgfm,11 Ibfft)
4.2 N'm(0.4kgfm,3.1 Ibfft)
2.3 Nm(0.2 kgfm,1.7 Ibfft)
Applyengineoiltothethreadsand
seating surface
. Applygreasetothethreads
Applyengineoiltothethreads
Applygreasetothethreads
Valve adjustingwrench Oil filterwrench Spokewrench
07908-KE90000 07HAA-PJ70101
or07908-KE90100(U.S.A.only)with or07HAA-PJ70100(U.S.A.only)
10-mmoffsetboxwrench . or07HAA-PLCA100(U.S.A. only)
4-3
---------------
MAINTENANCE
MAINTENANCE SCHEDULE
PerformthePre-rideinspectionintheOwner'sManualateach scheduled maintenanceperiod.
I: Inspectandclean,adjust,lubricateorreplace ifnecessary.C: Clean. R: Replace.A: Adjust. L: Lubricate.
The following itemsrequire some mechanical knowledge.Certain items(particularlythose marked *and **) mayrequire
moretechnical informationandtools.ConsultyourHondadealer.
FREQUENCY WHICHEVER
COMESFIRST ODOMETERREADING (NOTE 1)

REFERTO
PAGE
X1,000mi 12 16 0.6 4 20 24
ITEMS
8
NOTE X1,000km to 6.4 12.8 19.2 25.6 32.0 38.4
*
FUEL LINE I I I 4-5
*
THROTTLE OPERATION I I I 4-5
*
CHOKE OPERATION I I I 4-6
en
AIR CLEANER NOTE2 4-7 R R

SUBAIR CLEANER R R 4-8 LU *
t::
CRANKCASE BREATHER NOTE3 C C C C 4-8 C C
Cl
SPARK PLUG I R R I R 4-9 I
LU
VALVE CLEARANCE I I I 4-10 I
*
....J
ENGINE OIL INITIAL=600mi(1,000km) or1month:R
LU
II:
REGULAR =Every8,000mi(12,800 km) or12 4-12
z
months:R
0
ENGINEOILFILTER . R R R R 4-13 til
en
ENGINE IDLE SPEED I I I I I I I 4-15
*

RADIATOR COOLANT NOTE4 I I R 4-15
*
LU
COOLING SYSTEM I 4-15
*
I I
SECONDARYAIR SUPPLYSYSTEM I 4-16
*
I I
EVAPCONTROLSYSTEM NOTE5 I 4-17 I
(f)
FINALDRIVE OIL 4-18 R
::2:
BRAKE FLUID NOTE4 I R R I 4-19 w
!::
BRAKE SHOES/PADSWEAR I I I I 4-20
Cl
w
BRAKE SYSTEM I I 4-20
BRAKE LIGHTSWITCH I 4-22
* -
w
HEADLIGHTAIM I 4-22
* II:
z CLUTCH SYSTEM I I 4-22 I I I
0
SIDESTAND 4-23 I (ij
(f)
SUSPENSION 4-24 I
*

NUTS,BOLTS,FASTENERS I 4-24
Z
I w
*
WHEELSmRES I I I I I 4-25
**
0
z STEERING HEAD BEARINGS I I 4-26
**
* Shouldbeserviced byyourdealer,unlesstheownerhaspropertoolsand servicedataand ismechanicallyquali-
fied
** Intheinterestofsafety,werecommendtheseitemsbeservicedonlybyyourHondadealer
NOTES:
1. Athigherodometerreading,repeatatthefrequencyintervalestablishedhere.
2. Service morefrequentlywhen ridinginunusuallywetordustyareas.
3. Servicemorefrequentlywhenridinginrain oratfullthrottle.
4. Replaceevery2years,oratindicatedodometerinterval,whichevercomesfirst.Replacementrequiresmechanicalskill.
5. Californiatypeonly.
4-4.
MAINTENANCE
FUELLINE
Check the fuel line for deterioration, damage or
leakage.
Replacethefuel lineifnecessary.
Alsocheckthefuelvalvevacuumhosefordamage.
Replacethevacuum hoseifnecessary.
THRorrLEOPERATION
foranydeterjorationordamagetothethrot-
'tIecables. Checldhethr6ttlegripforsmooth opera-
tion.Checkthatthethrottleopensandautomatically
steeringpositions.
Ifthethrottlegripdoesnotreturnproperly,lubricate
the throttle cables and overhaul and lubricate the
throttlegriphousing.
If the throttle grip still does not return properly,
replacethethrottlecables.
With the engine idling, turn the handlebar all the
wayto the right and left to ensure that the idle
speed does not change. If idle speed increases,
checkthethrottlegripfreeplayandthethrottlecable
connection.
MeasuretQethrottlegripfreeplayatthethrottlegrip
flange.
FREEPLAY: 2- 6mm(1116- 1/4in)
Throttlegripfreeplaycan be adjusted ateither end
ofthethrottlecable.
Minoradjustmentismadewiththeupperadjuster.
Loosenthelocknut,turntheadjusteras required.
Tightenthelocknutwhileholdingtheadjuster.
4-5
MAINTENANCE
Majoradjustmentis madewiththe loweradjuster.
Removetheaircleanerhousing(page6-6).
Loosenthelocknut,turntheadjusteras required.
Tightenthelocknutwhileholdingtheadjuster.
Recheck the throttle operation and install the air
cleanerhousing(page6-7).
CHOKEOPERATION
Thismodel'schokesystemusesafuel enrichingcir-
cuitcontrolled byaSE valve.
The SE yalveopenstheenrichingcircuitvia acable
whenthechoke knobontheleftsideoftheframeis
pulled out.
CheckforsmoothoperationoftheSE valveknob.
Check for any deterioration or damage to the SE
valvecable.
Iftheoperationis!'lotsmooth,lubricatetheSE valve
cableandSEvalveknobslidingsurfacewithacom-
mercially available cable lubricantora lightweight
oil.
To adjust the friction, pull the rubber cover away
andturn theadjuster.
Starting enrichment system operation can be
checked bythewaytheenginestartstoruns:
Difficulty in starting before the engine is warm
up (easy once itis warmed up): SE valve is not
completelyopened.
Idle speed is erratic even after warm-up (imper-
fect combustion): SE valve is not completely
closed.
When the above symptoms occur, inspect the SE
valveusingthefollowingprocedure.
Removethecarburetor(page6-7).
LoosentheSE valvenutand removeitfromthecar-
buretor.
RUBBER COVER
ADJUSTER
4-6.
MAINTENANCE
Pull the SE valve knob all thewayouttofullyopen
positionand recheckforsmoothoperationoftheSE
valveknob.
Thereshouldbe nofreeplay.
CheckvalveseatontheSE valvefordamage.
Reinstall the SE valve in the reverse order of
removal.
TORQUE:
SEvalvenut: 2.3Nm(0.2kgfm,1.7Ibf.ft)
AIR CLEANER
NOTE:
The viscous paper elementtype air cleaner can
not be cleaned because the element contains a
dustadhesive.
Ifthe motorcycleis used in usuallywetordusty
areas,morefrequentinspectionsare required.
Removethesocketboltsandaircleanercover.
Removetheaircleanerelementfromtheaircleaner
housing.
Makesurethatthe isinstalledin positionand
isingoodcondition,'andreplaceitwithanewoneif

in accordance with
4-4) oranytimeit
9!:r:tY ordamaged.
InstaU:the remqved parts in the reverse order of
removal. '
TORQUE:
Ail' cleaner cover socket bolt:
1.5N:11l (0.2kgf;m,1.1 Ibfft)
SEVALVE
VALVE SEAT
4-7
------- --
MAINTENAI\lCE
SUBAIRCLEANER
Removetheleftsidecover(page3-3).
Disconnect the air suction hoses and remove the
subaircleaners.
SUBAIR CLEANER
Replacethesub aircleaners inaccordancewiththe
maintenanceschedule(page4-4).
Installthesubaircleaners withthearrowmarkfac-
ingdown (PAIR control valveside) and connectthe
airsuctionhoses.
Installtheleftsidecover(page3-3).
ARROWMARK
CRANKCASE BREATH'ER
NOTE:
Service morefreqllentlywhen ridden in rain, atfull
throttle, orafterthe moforcycle is washed orover-
turned. Service ifthe deposit level can be seen in
thedrainplug.
Removethedrainplugfromtheaircleanerhousing
anddrl!inthe deposits into a suitable container,
then"rernstallthedrainplugsecurely.
4-8.
MAINTENANCE
SPARKPLUG
REMOVAL
Disconnect the spark plug caps and clean around
thesparkplugbases.
NOTE:
Clean aroundthesparkplugbaseswithcompressed
air before removing the spark plugs, and be sure
thatno debrisis allowedto enterintothe combus-
tionchamber.
RemovethesparkplllgS.
INSPECTION
Check the"insulator for cracks or damage, and the
electrodesforwear,foulingordiscoloration.
Replaceeach spark ifnecessary.
RECOMMENDEDSPAFlKPLUG:
Standard:
DPR6EA9(r,lgl),
...
EPR-U9(DENSO)
For !fding:
(N!i!<l, (DENSO)
Check the spark plug gap between the center and
sideelectrodeswithafeelergauge.
SPARKPLUGGAP: 0.8- 0.9mm(0.03- 0.04in)
Ifnecessary, adjustthe spark plug gap by bending
thesideelectrodecarefully.
....--
CENTER ELECTRODE
INSULATOR SIDEELECTRODE
4-9
MAINTENANCE
INSTALLATION
Install and handtightenthespark plug tothe cylin-
der head, then tighten the spark plug tothe speci-
fiedtorque.
TORQUE: 18Nm(1.8kgf'm,13IbHt)
Connectthesparkplugcaps.
VALVE CLEARANCE
INDEXNOTCH
"FT"MARK
Inspect and adjust
the valve clearance
while the engine is
cold (below 35"C/
95Fj.
INSPECTION
Remove;thecylinderheadcover(page9-6).
Removethesocketboltsandalternatorcover.
Removethetiming.andcrankshaftholecaps.
FRONT
Rotate the crankshaft counterclockwise and align
the "FT" markonthe flywheel with the index notch
ontheleftcrankcasecover.
MakesurethepistonisatTDC (TopDeadCenter)on
thecompressionstroke.
This position can be obtained by confirming that
thereisslackintherockerarms. Ifthereisnoslack,
rotatethecrankshaftcounterclockwiseonefullturn
andalignthe"FT" markwiththeindexnotchagain.
4-10
MAII\lTENANCE
When checking the
valve clearance,
slide the feeler
gauge from the
center toward the
outside.
Apply engine oil to
the valve adjusting
screw lock nut
threads and seating
surface.
When checking the
valve clearance,
slide the feeler
gauge from the
center toward the
outside.
Check the valve clearances by inserting a feeler
gauge between the valve adjusting screw and valve
stem.
VALVE CLEARANCES:
IN: 0.15 0.02 mm (0.006 0.001 in)
EX: 0.20 0.02 mm (0.008 0.001 in)
Adjust by loosening the valve adjusting screw lock
nut and turning the adjusting screw until there is a
slight drag on the feeler gauge.
TOOL:
Valve adjusting wrench 07908-KE90000 or
07908-KE90100
(U.S.A. only) with
10-mm offset box
wrench
Hold the valve adjusting screw and tighten the valve
aqjusting screw lock nut to the specified torque.
TORQUE: 23 Nm (2.3 kgf'm, 17 Ibf.ft)
After tightening the valve adjusting screw lock nut,
recheck the valve clearance.
REAR
Rotate the crankshaft counterclockwise and align
the "RT" mark on the flywheel with the index notch
on the left crankcase cover.
Make sure the piston is at TDC (Top Dead Center) on
the compression stroke.
Check the valve clearances by inserting a feeler
gauge between the valve adjusting screw and valve
stem.
VALVE CLEARANCES:
IN: 0.15 0.02 mm (0.006 0.001 in)
EX: 0.20 0.02 mm (0.008 0.001 in)
INDEX NOTCH
"RT" MARK
4-11
MAINTENANCE
Adjust byloosening the valve adjusting screw lock
nutand turning the adjusting screw untilthere is a
slightdragonthefeelergauge.
TOOL:
Valveadjustingwrench 07908-KE90000or
07908KE90100
(U.S.A.only)with
10-mmoffsetbox
wrench
Apply engine oil to Holdthevalveadjustingscrewandtightenthevalve
the valve adjusting adjustingscrewlocknuttothespecifiedtorque.
screw lock nut
TORQUE:23 Nm(2.3 kgfm,17Ibfft)
threads and seating
surface.
Aftertightening thevalve adjusting screw locknut,
recheckthevalveclearance.
Coat new O-rings with engine oil and install them
into thetimingandcrankshaftholecap grooves.
Applygreasetothetiming andcrankshaft holecap
threads;
Installthetimingholecap andtightenittothespec-
ifiedtorque.
TORQUE: 10N'm(1.0kgfm,7Ibfft)
Install the crankshaft hole cap and tighten itto the
specifiedtorque.
TORQUE: 15Nm(1.5kgfm,11 Ibfft)
Install the alternator cover and tighten the socket
boltstothespecifiedtorque.
TORQUE: 10Nm ~ O kgfm,7Ibfft)
Installthecylinderheadcover(page9-31I.
ENGINEOIL
OILLEVELCHECK
Starttheengine,and letitidlefor3- 5minutes.
Stoptheengineandwait2- 3minutes.
Holdthemotorcycleinanuprightposition.
Remove the oil filler cap/dipstick and wipe the oil
fromthedipstickwithacleancloth.
Insertthedipstickwithoutscrewing itin, remove it
andchecktheoillevel.
4-12
MAINTENANCE
Ifthe oil level is belowornearthelowerlevel mark
on the dipstick, add the recommended oil to the
upperlevelmark.
RECOMMENDEDENGINEOIL:
ProHondaGN44-strokeoil(U.S.A.andCanada)or
equivalent motoroil
API serviceclassification:SG orhigher
JASO MA
Viscosity:SAI:10W-30
NOTE:
Other viscosities shown in the chart may be used
whentheaveragetemperatureinyourriding area is
withintheindicatedrange.
ifnecessary.
CoattheO-ringwithengineoilandinstallit.
Reinstalltheoilfillercap/dipstick.
Forengineoilchange(page4-13).
ENGINEOILFILTER
NOTE:
Changethe oil with enginewarm and the motorcy-
cle on its sidestand to assure complete and rapid
draining.
Starttheengine,warmitupandstopit.
Removetheoilfillercap/dipstick(page4-12).
Removetheoildrainbolt,sealingwasherand drain
theoil.
UPPER LEVEL
LOWER LEVEL ---il.aI
OILVISCOSITIES
-30 -20 -10 o 10 20 30 40 50C
[ I I I I j I I
-20 0 20 40 60 80 100 120F
CheckthattheO-ring isingoodcondition,replaceit l\""'-.....""'""'..................
4-13
MAINTENANCE
4-14
Removetheoilfiltercartridgeusingthespecialtool
and lettheremainingoildrainout.
TOOL:
Oilfilterwrench 07HAA-PJ70101 or
07HAA-PJ70100
(U.S.A.only)or
07HAA-PLCA100
(U.S.A.only)
CoatanewO-ring with engineoil and install itto a
newoilfiltercartridge.
Applyengineoiltothethreadsofanewoilfiltercar-
tridge.
Install the oil filter cartridge and tighten it to the
specifiedtorque.
TOOL:
Oilfilterwrench 07HAA-PJ70101 or
07HAA-PJ70100
(U.S.A.only)or
07HAA-PLCA100
(U.S.A.only)
TORQUE:26Nm(2.7kgfm,191bHt)
Install the oil drain boltwith a newsealing washer
andtightenittothespecifiedtorque.
TORQUE:29Nm(3.0kgf'm,21 Ibfft)
Fillthecrankcasewiththerecommended engineoil
(page4-13).
OILCAPACITY:
2.5Ii,ers(2.6USqt, 2.2Impqt) atdraining
2,6liters(2.7USqt, 2.3Impqt)atoilfilterchange
3.2liters(3.4USqt, 2.8Impqt) at disassembly
Checktheengineoil level(page4-12).
Installtheoilfillercap/dipstick(page4-13).
Makesuretherearenooilleaks.
, a-RING
!
til OIL FILTER
MAINTENANCE
ENGINEIDLESPEED
NOTE:
Inspect and adjustthe idle speed after all other
engine maintenanceitemshave been performed
andare withinspecifications.
Theenginemustbewarmforaccurateidlespeed
inspectionand adjustment.
Connect a tachometer according to its manufac-
ture'sinstructions.
Warm up the engine, shift the transmission into
neutral and hold the motorcyclein an uprightposi-
tion.
Checktheidlespeed.
IDLESPEED: 1,200100rpm
Iftheadjustmentis necessary,turnthethrottlestop
screwknobas required.
RADIATORCOOLANT
Checkthecoolantlevelofthereservetank.
The level shouldbe between the "UPPER" and
"LOWER" level lines with the motorcycle in an
uprightposition.
Ifthelevel is low,removethereservetankcap, and
fillthetanktothe"UPPER" level linewitha1:1mix-
tureofdistilledwaterandantifreeze(coo'lantprepa-
ration: page7-6).
RECOMMENDEDANTIFREEZE:
ProHondaHP coolantoranequivalenthighqual-
ityethyleneglycolantifreezecontainingsilicate-
freecorrosioninhibitors.
Checktoseeifthereareanycoolantleakswhenthe
coolantleveldecreasesveryrapidly.
Ifthereservetankbecomescompletelyempty,there
isapossibilityofairgettingintothecoolingsystem.
Be sureto remove anyairfrom thecooling system
(page7-7),
COOLINGSYSTEM
Checktheradiatorairpassageforclogsordamage.
.._- - -------
4-15
MAINTENANCE
Straighten bentfins with a small, flat blade screw-
driver and remove insects, mud or other obstruc-
tionswithcompressedairorlowpressurewater.
Replacethe radiatorifthe airflowis restricted over
morethan20% oftheradiatingsurface.
Forradiatorreplacement(page7-11l.
Remove thesteeringsidecovers (page3-5).
Checkforanycoolantleakagefromthewaterpump,
waterhosesand hosejoints.
Checktheradiatorhosesforcracks ordeterioration
andreplaceifnecessary.
Checkthatallwaterhosebandsaretight
(page7-10).
Thismodel isequippedwithabuilt-insecondary
airsupplysystem.The pulsesecondary airsup-
plysystem is located on the cylinder head cov-
ers.
The secondary air supply system introduces fil-
teredairintoexhaustgasesintheexhaustport.
Thesecondaryairis drawnintotheexhaustport
wheneverthereisnegativepressurepulsein the
exhaustsystem.Thischargedsecondaryairpro-
motes burning ofthe unburned exhaust gases
andchangesaconsiderableamountofhydrocar-
bonsandcarbon monoxideinto relatively harm-
lesscarbondioxideandwater.
.
PAIRCHECKVALVE
EXHAUSTPORT
4-16
MAINTENANCE
If the hoses show
any signs of heat
damage, inspect
the PAIR check
valves in the
cylinder head
covers for damage
(page 6-29).
Check the PAIR (pulse secondary air injection) air
supply hoses between the PAIR control valve and
cylinder head cover for deterioration, damage or
looseconnections. Makesurethatthehosesarenot
cracked.
Check the air suction hose between the sub air
cleaner and PAIR control valve for deterioration,
damageorlooseconnections.
Makesurethatthehosesarenotkinked,pinched or
cracked.
Californiatypeshown:
EVAPCONTROLSYSTEMlCalifornia
typeonly}
ChecktheEVAPcanisterforcracksordamage.
Removethefollowing:
- Steeringsidecovers(page3-5)
- Fueltank(page3-4)
Checkthehoses betweenthefueltank, EVAP canis-
ter, EVAP purge control valve, EVAP CAY control
valVE:! and carburetorfordeterioration, damage or
looseconnections.Alsocheckthatthehosesarenot
'kinkedorpinched. .
Removetheboltandpullthesubaircleanerboxout
withthestay.
Removethesubaircleanercoverandcheckthesub
aircleanerfilterforcontaminationordamage.
Replacethesubaircleanerfilterifnecessary.
Install the removed parts in the reverse order of
removal.
....--
4-17
- ---- - ._-----
MAINTENANCE
FINALDRIVEOIL
OILLEVELCHECK
Placethemotorcycleon itssidestandonalevelsur-
face.
Removetheoilfillercapfromthefinal gearcase.
Checkthattheoil levelisuptotheloweredgeofthe
oilfillerhole.
Checkforleaks iftheoil level is low.Filltherecom-
mendedfinaldriveoilthroughtheoilfillerholeuntil
itreachestheloweredgeofthehole.
RECOMMENDEDFINALDRIVEOIL:
Hypoidgearoil,SAE#80
Coata newO-ringwithoil and install itontothe oil
fillercap.
Install and tighten the oil filler cap to the specified
torque.
TORQUE: 12N'm(1.2kgfm,9Ibf.ft)
OILCHANGE
Supportthe motor"cycle securelyand raise the rear
wheel;off
Remove the oil filler cap, drain bolt and sealing
washerfromthefinalgearcase,slowlyturntherear
Wheel anddrainthe;()il.. .
After-thE!oil is completelydralned, install thedrain
boltwithanewsealingwasherandtighten ittothe
specified .
TORQUE: 12N'm(1.2kgfm,9Ibfft)
Fill thefinal gearcase withthe recommended final
driveoiltothecorrectlevel (page4-18).
OILCAPACITY:
160em
3
(5.4USoz,5.6Impoz)atdraining
170em
3
(5.7U$OZ, 6.0Impoz)atdisassembly
...- ......_--
4-18
MAINTENANCE
BRAKE FLUID
I NOTICE
Spilled fluid can damage painted, plastic or rubber
parts. Place a rag over these parts whenever the
system is serviced.
Do not mix differenttypes offluid, as they are
notcompatiblewitheach other.
Do notallowforeignmaterialtoenterthesystem
whenfillingthereservoir.
NOTE:
Whenthefluid level is low,checkthebrake pads
forwear(page4-20).
A lowfluidlevel maybeduetowearofthebrake
pads. Ifthe brake pads are worn and thecaliper
pistons are pushed out, this accounts for a low
reservoir level. Ifthe brake pads are not worn
andthefluid level is low,checktheentiresystem
forleaks(page4-20).
Turnthehandlebartotheleftsidesothereservoiris
level and checkthefront brake reservoirfluid level
throughthesightglass.
If the fluid level is near the "LOWER" level mark,
removethescrews, reservoircap,setplateand dia-
phragm.
Fill the reservoir with DOT 4 brake fluid from a
sealedcontainertothecasting ledge.
Install the diaphragm, set plate and reservoir cap,
thentightenthecapscrewstothespecifiedtorque.
TORQUE: 1.5N,m(0.2kgfm,1.1 Ibfft)
4-19
SCREWS
CAP
MAINTENANCE
BRAKE SHOES/PADSWEAR
FRONTBRAKE PADS
Checkthebrakepadforwear.
Always replace the Replace the brake pads ifeither pad is worn to the
brake pads asaset wearlimitgroove.
to assure even disc
Forbrakepad replacement(page17-7).
pressure,
REAR BRAKESHOES
Check the indicator plate position when the brake
pedal applied.
Ifthe arrow on the indicator plate aligns with the
"f':,," mark,inspectthebrakedrum(page16-14).
If the brake drum 1.0. is within the service limit,
replacethebrakeshoes(page16-15).
NOTE:
Ifno adjustmentremains beforethe wearindicator
limit is reached, this indicates excessive wear and
thebrakeshoesneedtobereplaced.
BRAKESYSTEM
Firmly applythe brake lever, and check that no air
hasenteredthesystem.
If the lever feels soft or spongy when operated,
bleedtheairfromthesystem.
Forairbleeding procedures(page17-5).
Inspectthebrakehoseandfittingsfordeterioration,
cracks,damageorsignsofleakage.
Tightenanyloosefittings.
Replacethehoseandfittingsas required.
BRAKE PADS
I
WEARLIMITGROOVES
4-20
MAINTENANCE
BRAKE PEDALHEIGHT
Checkthebrakepedal height.
BRAKEPEDALHEIGHT:
75mm(3.0in)abovethetopofthefootpeg
Make sure the cut-
out on the adjusting
nut is seated on the
joint pin.
Toadjust:
Loosen the lock nut and turn the stopper bolt as
required.
IT"igl'1tenthelock'nutsecurely.
Afteradjustingthebrakepedalheight,checkthefol-
lowing:
- Brakepedalfreeplay(page4-21)
- Rearbrakelightswitchoperation(page4-22)
BRAKEPEDALFREEPLAV
NOTE:
Perform brake pedal freeplay adjustment after
adjustingbrakepedal height.
Cl'1eckthebrakepedalfreeplay.
FREEPLAY: 20- 30mm(13/16- 1-3/16in)
Ifnecessary,adjustthebrakepedalfreeplaybyturn-
ingtheadjustingnut.
NOTE:
After adjusting the brake pedal freeplay, check the
rearbrakelightswitchoperation(page4-22).
4-21
MAl NTENAI\JCE
BRAKE LIGHTSWITCH
NOTE:
The brake lightswitch onthe frontbrake master
cylinder cannot be adjusted. If the front brake
lightswitch actuation and brakeengagementare
not synchronized, either replace the switch unit
orthemalfunctioning partsofthesystem.
Make the rear brake light switch adjustments
afterthe brake pedal heightadjustment and the
brake pedal freeplay adjustment have been
made.
Checkthatthebrake lightcomesonjustpriortothe
brakeactuallybeingengaged.
If the light fails to come on, adjust the rear brake
lightswitchso thatthelightcomesonatthe proper
time.
Do not turn the Hold the rear brake light switch body and turn the
switch body while adjustingnutasrequired.
turning the Recheck'the rearbrake lightswitchoperation.
adjusting nut.
HEADLIGHTAIM
Holdthemotorcycleinan uprightposition.
Adjust the headlight Adjust vertically by turning the vertical adjusting
beam as specified screw.
by local laws and Adjusthorizontallybyturningthe horizontaladjust-
regulations. ingscrew.
HORIZONTALADJUSTING SCREW
CLUTCHSYSTEM
Inspect the clutch cable for kinks or damage, and
lubricatethecableifnecessary.
Measurethe clutch leverfreeplay at theend ofthe
lever.
FREEPLAY: 10 -20 mm(3/8 -13/16 in)
VERTICALADJUSTING SCREW
10 -20 mm (318 -13/16 in)
4-22
MAINTENANCE
The adjuster may Minoradjustment is made with the upper adjuster
be damaged if it is attheclutch lever.
positioned too far Loosen the lock nut and turn the adjuster as
out, leaving minimal required.
thread Tightenthelocknutwhileholdingtheadjuster.
engagement.
Iftheadjusteristhreaded outnearits limitand the
correct freeplay cannot be obtained, turn the
adjusterallthewayinandbackoutoneturn.
Tighten the lock nut and make major adjustment
(page4-23).
Majoradjgstrnent is madewiththe loweradjusting
nutatthee,ngirie.
Loosenthe lock nut and turn the adjusting nut as
required.
After adjustment is complete, tighten the lock nut
whileholdingtheadjustingnut.
Checktheclutchoperation.
Ifthefreeplaycannotbeobtained,ortheclutchslips
during the test ride, disassemble and inspect the
clutch(page11-7).
SIDESTAN0 ,
an uprightposition.
Checkthe for damage or loss of
tension. ,",-
Check assemblyforfreedomofmove-
sidestand pivotifnecessary.
cut-offsystem:
and raise the side-
'.. '
.situ inneutral,
thl{n shifftbe- transTission into gear, while
squeezing
- Fullylowerthe'$ioestand;
- The as thesidestand is low-
ered.
Ifthereis.a problElI11....,iththesystem,checktheside-
standsl!lfitch
LOCKNUT
ADJUSTER
SIDESTAND
4-23
MAINTENANCE
SUSPENSION
FRONTSUSPENSIONINSPECTION
Check the action oftheforks by applying thefront
brakes and compressing the front suspension sev-
eraltimes.
Check the entire assembly for leaks, damage or
loosefasteners.
Replace damaged components which cannot be
repaired.
Tighten all nutsand bolts.
Forforkservice(page15-19).
REAR_SUSPENSIONINSPECTION
Check the actionof the shock absorbers by com-
pressingthemseveraltimes.
Checktheentireshockabsorberassemblyforleaks,
damageorloosefasteners.
Replace damaged components which cannot be
repaired.
Tightenall nutsand bolts.
Forshockabsorberservice(page16-21).
Supportthe motorcyclesecurely and raise the rear
wheelofftheground.
Checkforwornswingarm bearings bygrabbingthe
rearwheel and attemptingto movethe wheel side
toside.
Replacethebearingsifanyloosenessisnoted
(page16-22).
NUTS, BOLTS, FASTENERS
Checkthatall chassisnutsand boltsaretightenedto
theircorrecttorquevalues(page1-13).
Check thatall cotterpins, safetyclips, hose clamps
andcablestaysareinplaceandproperlysecured.
4-24
--------------- ._-- ._-- --- ------- ---- --------
MAINTENANCE
WHEELS/TIRES
Tap on the spokes
and be sure that the
same clear metallic
sound can be heard
on all spokes.
Supportthe motorcyclesecurelyand raisethefront
wheelofftheground.
Hold the front fork leg and move the front wheel
sidewaysforcefullytosee ifthewheel bearings are
worn.
Forfrontwheel service(page15-13).
wheel offtheground.
Hold the swingarm and movethe rear wheel side-
wayswiththeforcetosee ifthewheel bearingsare
worn.
Forrearwheelservice(page16-6).
Inspect the spokes for looseness by tapping them
withascrewdriver.
Ifaspokedoesnotsound clearly,orifitsoundsdif-
ferentfromtheotherspokes,tighten ittothespeci-
fiedtorque. .
TOOL:
07JMAMR60100
'TORQUE:4.2N'm(0.4kgfm,3.1 Ibfft)
Check the tire pressure with atire pressure gauge
whenthetiresarecold.
RECOMMENDEDTIREPRESSURE:
Upto90kg (200Ibs)load:
Front:200kPa (2.00kgf/cm
2
, 29psi)
Rear:200kPa (2.00kgflcm
2
, 29psi)
Uptomaximumweightcapacity:
Front:200kPa (2.00kgf/cm
2
, 29psi)
Rear: 250kPa (2.50kgf/cm
2
, 36psi)
4-25
MAINTENANCE
Check the tires for cuts, embedded nails, or other
damage.
Checkthefrontand rearwheelsfortrueness.
Measurethetreaddepthatthecenterofthetires.
Replacethetires whenthetread depth reachesthe
followinglimits.
MINIMUMTIRETREADDEPTH:
Front: 1.5mm(0.06in)
Rear: 2.0mm(0.08in)
STEERINGHEADBEARINGS
Supportthemotorcyclesecurelyand raisethefront
wheelofftheground. .
Checkt ~ t t h handlebarmovesfreelyfromsideto
side. Mcikesurethe control cables do not interfere
withthehandlebarrotation.
Check for steering stem bearings by grabbing the
forklegsandattemptingtomovethefrontforkside
toside.
Ifthehandlebarmovesunevenly,binds,orhasver-
tical movement,inspectthe steering head bearings
(page15-28).
4-26
5. LUBRICATIONSYSTEM
LUBRICATIONSYSTEMDIAGRAM.. 52
OILPRESSUREINSPECTION 5-5
SERVICEINFORMATION 53
OILPUMP 5-6
TROUBLESHOOTING 54
5-1
LUBRICATIONSYSTEM
LUBRICATIONSYSTEMDIAGRAM
CAMSHAFT
MAINSHAFT
COUNTERSHAFT
OIL PUMP
OIL FILTER PRESSURE RELIEF VALVE
5-2
LUBRICATIONSYSTEM
SERVICEINFORMATION
GENERAL
ACAUTION
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is
unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and
water as soon as possible after handling used oil.
The crankcase must be separated to service the oil pump.
When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine.
If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly.
After the oil pump has been installed, check that oil pressure is correct.
For engine oil level check (page 4-12).
For engine oil and filter change (page 4-13).
For oil pressure indicator inspection (page 21-15).
SPECIFICATIONS
Unit: mm (in)
Engine oil capacity At draining 2.5 liters (2.6 US qt, 2.2 Imp qt) -
At oil filter change 2.6 liters (2.7 US qt, 2.3 Imp qt) -
At disassembly 3.2 liters (3.4 US qt, 2.8 Imp qt) -
Recommended engine oil Pro Honda GN4 4-stroke oil (U.S.A. and
Canada) or equivalent motor oil
API service classification: SG or higher -
JASO T 903 standard: MA
Viscosity: SAE 10W-30
Oil pressure at EOP switch 530 kPa (5.4 kgf/cm
z
, 77 psi)
-
at 5,000 rpm/(80C/176F)
Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008)
Body clearance 0.15 - 0.21 (0.006 - 0.008) 0.35 (0.014)
Side clearance 0.02 - 0.08 (0.001 - 0.003) 0.10 (0.004)
TORQUEVALUES
EOP switch 12 N'm (1.2 kgfm, 9 Ibfft) Apply sealant to the threads
EOP switch terminal screw 1.9 N'm (0.2 kgf'm, 1.4 Ibfft)
Oil pump assembly bolt 13 N'm (1.3 kgfm, 10 Ibfft)
5-3
LUBRICATIONSYSTEM
TOOLS
Oil pressure gauge set
07506-3000001
or equivalent commercially avail-
able in U.S.A. (Gauge set MT37A)
Oil pressure gauge attachment
07510-4220100
able in U.S.A. (Adaptor AT77AH)
TROUBLESHOOTING
Oil leveltoolow
Oil consumption
External oil leak
Worn piston rings
Improperly installed piston rings
Worn cylinders
Worn stem seals
Worn valve guide
Lowoilpressure
Oil level low
Clogged oil strainer
Faulty oil pump
Internal oil leak
Incorrect oil being used
Nooilpressure
Oil level too low
Oil pressure relief valve stuck open
Broken oil pump drive chain
Broken oil pump drive and/or driven sprocket
Damaged oil pump
Internal oil leak
Highoil pressure
Oil pressure relief valve stuck closed
Clogged oil gallery or metering orifice
Incorrect oil being used
Oilcontamination
Oil or filter not changed often enough
Worn piston rings
Oil emulsification
Blown cylinder head gasket
Leaky coolant passage
Entry of water
5-4
LUBRICATIONSYSTEM
OILPRESSUREINSPECTION
Removetheleftcrankcaserearcover(page3-5).
Ifthe engine is cold, the pressure reading will be
abnormally high. Warm up the engine to normal
operatingtemperature beforestartingthistest.
Stoptheengine.
Remove the rubber cap and disconnect the EOP
switchwirebyremovingtheterminalscrew.
RemovetheEOP switchandconnectan oilpressure
gauge attachment and gauge to the EOP switch
hole.
TOOLS:
Oilpressuregaugeset 07506-3000001
Oilpressuregaugeattachment 07510-4220100
(orequivalentcommerciallyavailableinU.S.A.,
gaugesetMT37AandadaptorAT77AH)
Check the oil level and add the recommended
engineoilifnecessary(page4-12).
Starttheengineand check theoil pressureat5,000
rpm.
OILPRESSURE:
530kPa (5.4kgf/cm
2
, n psi)at5,000rpm
(80C/176F)
Stoptheetlgine.
Do not apply Apply sealant to the EOP switch threads as shown
sealant to the andtightenittothespecifiedtorque.
thread head 3 - 4
mm(0.1- 0.2 in). TORQUE: 12Nm(1.2kgfm,9Ibfft)
ConnecttheEOP switchwireandtightenthetermi-
nal screwtothespecifiedtorque.
TORQUE: 1.9Nm(0.2kgfm,1.4Ibfft)
Installtherubbercap.
Starttheengine.
Checkthattheoilpressureindicatorturnsoffafter1
or2seconds. Ifthe oil pressure indicatorstays on,
stop the engine immediately and determine the
cause(page21-15).
3-4mm(0.1-0.2in)
5-5
LUBRICATIONSYSTEM
OILPUMP
REMOVAL
Separatethecrankcase(page 13-9).
Removethe boltsand oil pumpassemblyfrom the
leftcrankcase.
RemoveJhedowelpin,collarsand O-rings.
DISASSEMBLY
OILPUMPBODY .
Removetheoil pipe,oil pipeseal and O-ring.
Removethepressurereliefvalveand O-ring.
5-6.
LUBRICATIONSYSTEM
Removetheoilstrainerand gasket.
Remove the assembly bolts and pump body from
thepumpcover.
Removethedowelpins.
Removethewasher,driveshaft,drivepin,innerand
outerrotors.
PRESSUREREblEFVALVE
operation ofthe pressure reliefvalve by
SNAPRING
pushingQnthepiston.
The snapring is spring and piston
under spring fromWpressu-rereliefvalvebody.
pressure. Use care
when removjng it
and wear eye and
face protection. Be
careful not to lose
the disassembled
parts.
OUTER ROTOR DOWELPINS
5-7
LUBRICATIQNSYSTEM
Checkthepistonforwear,stickingordamage.
Checkthevalvespringforwearorfatigue.
Checkthereliefvalvebodyforcloggingordamage.
Clean all parts and assemble the reliefvalve in the
reverseorderofdisassembly.
NOTE:
Install the snap ring with the chamfered edge
facingthethrustloadside.
Do not reuse worn snap ring which could easily
spininthegroove.
Checkthatthesnapringisseated inthegroove.
INSPECTION
NOTE:
Measure each clearance at several points and use
thel r g ~ s t readingtocomparetheservicelimit.
BODYCLEARANCE
Temporarily assemble the inner rotor, outer rotor,
drivepinandpumpshaftintothepumpbody.
Measurethebodyclearance.
SERVICEI.IMIT: 0.35mm(0.014in)
TIPCLEARANCE
Measurethetipclearance.
PISTON RELIEFVALVE BODY
~
SPRING
?,
SNAPRING WASHER
BODYCLERARANCE:
TIPCLEARANCE:
5-8.
LUBRICATIONSYSTEM
SIDECLEARANCE
Measurethesideclearance.
SIDE CLEARANCE:
SERVICELIMIT: 0.10 mm (0.004 in)
OILPUMPASSEMBLY
Dipall partsinclean engineoil.
13Nm(1.3 kgfm,10IbHt)
DRIVE PIN ~ , -
OILPUMPBODY
SNAPRING
~ ~ ~ - - - : 7 DOWELPINS
DRIVE SHAFT
II\JI\JER ROTOR
OIL PIPE
WASHER
-, "
~
PIPE SEAL
OILPUMPCOVER
Installthe'outerandinnerrotorstothepumpbody.
OILSTRAINER
INNER ROTOR
GROOVE
NOTE:
Install the inner rotor with the groove side facing
thepumpcover'.
OUTER ROTOR
5..9
LUBRICATIONSYSTEM
Install the drive shaftand drive pin byaligning the
DRIVE PIN DOWELPINS
drivepinwiththegroovesintheinnerrotor.
Placethewasherintotheinnerrotorgroove.
Installthedowelpinstothepumpbody.
Installthepumpcoveronthepumpbody.
Install and tighten the assemblybolts tothe speci-
fiedtorque.
TORQUE: 13N'm(1.3 kgfm,10IbHt)
Cleantheoilstrainer.
Coat a newgasket with engine oil and install itto
thepumpbody.
Installtheoilstrainertothepumpcoverbyaligning
itssideendwith ~ grooveonthepumpcover.
Coat a newO-ring with engine oil and install itto
thepressurereliefvalve.
Installthepressurereliefvalveintothepumpcover.
,
,,,O-RING
5-10
Coatanewoil pipeseal andnewO-ringwithengine
oil,then installthemtotheoil pipe.
NOTE:
Install an O-ringwithitstaperedsidefacingout.
Installtheoilpipetothepumpcover securely.
PIPE SEAL ..
----
"71
INSTALLATION
et
--:71 O-RING OILPIPE
LUBRICATIONSYSTEM
Installthedowelpin andcollars.
CoatnewO-ringswithengineoiland installthem.
Install the oil pump assembly into the crankcase
securely.
Installandtightentheboltssecurely.
Assemblethecrankcase(page13-49).
Checktheoilpressure(page5-5).
5-11
----------- --------------------
MEMO
6. FUELSYSTEM
COMPONENTLOCATION 6-2
SERVICEINFORMATION6-3
TROUBLESHOOTING 6-4
AIRCLEANERHOUSII\lG 6-6
CARBURETORREMOVAL.. .. 6-7
CARBURETORDISASSEMBLYI
INSPECTION 6-9
CARBURETORASSEMBLy6-15
..
CARBURETORINSTALLATION6-21
INTAKEMANIFOLD 6-23
PILOTSCREWADJUSTMENT 6-25
HIGHALTITUDEADJUSTMENT 6-26
SECONDARYAIRSUPPLYSYSTEM 6-28
EVAPCONTROLSYSTEM
(Californiatypeonly) 6-30
6-1
FUEL SYSTEM
COMPONENT LOCATION
27 Nm (2.8 kgfm, 20 IbHt)
6-2
FUELSYSTEM
SERVICE INFORMATION
GENERAL
Workin awellventilated area. Smokingorallowingflamesorsparksintheworkarea orwheregasoline isstored can
cause afireorexplosion.
Bending ortwistingthecontrolcablewillimpairsmoothoperationand couldcausethecabletostickorbind,resulting
in lossofvehiclecontrol.
Forfueltankremovalandinstallation(page3-4).
Beforedisassemblingthecarburetor, placean approvedfuel containerunderthefloatchamber, loosenthedrainscrew
anddrainthefloatchamber.
Afterremovingtheintakemanifold,covertheintakeportsofthecylinderheadswithshoptowelstopreventanyforeign
materialfromdroppingintotheengine.
Be suretoremovethediaphragmsbeforecleaning airandfuel passageswithcompressedair.Thediaphragmmightbe
damaged.
Whendisassemblingthefuelsystem parts,notethelocationsoftheO-rings.Replacethemwithnewoneson reassem-
bly.
Ifthevehicleistobestoredformorethan1month,drainthefloatchamber. Fuelleftinthefloatchambermayclogjets,
resultinginhardstartingorpoordriveability.
ForTPsensorinspection(page19-10).
SPECIFICATIONS
ITEM SPECIFICATIONS
Carburetoridentifica-
tion number
49states/Canadatype VE5EA
Californiatype VE5EB
Mainjet Standard #122
Highaltitude #120
Slowjet #50
Pilotscrew Initial/finalopening See page6-25
Highaltitudeadjustment Seepage6-26
Floatlevel 18.5mm(0.73 in)
Engineidlespeed 1,200100rpm
Throttlegripfreeplay 2- 6mm(1/16-1/4in)
TORQUE VALUES
Aircleanerchamberconnectingtubebandscrew
Aircleanercoversocketbolt
PAIR checkvalvecoverbolt
Aircleanerchamberstaymountingscrew
Vacuumchambercoverscrew
TPsensortorxscrew
Carburetorheatersetplatescrew
Floatchamberscrew
Acceleratorpumpcoverscrew
Aircut-offvalvecoverscrew
Acceleratorpumplinkmountingbolt
SEvalvenut
Carburetordrainscrew
Slowjet
Needlejetholder
Mainjet
0.7 N'm(0.1 kgfm,0.5Ibfft)
1.5 N'm(0.2 kgf'm,1.1 lbfft)
7Nm(0.7 kgf'm,5.2 lbfft)
1.1 N'm(0.1 kgf'm,0.8Ibfft)
2.1 N'm(0.2 kgf'm,1.5 lbfft)
3.4N'm(0.3kgfm,2.5Ibfft)
3.4Nm(0.3kgf'm,2.5Ibfft)
2.1 N'm(0.2 kgf'm,1.5Ibfft)
2.1 Nm(0.2 kgfm,1.5 lbfft)
2.1 N'm(0.2 kgf'm,1.5 lbfft)
3.4 N'm(0.3kgfm,2.5 lbfft)
2.3 Nm(0.2 kgf'm,1.7 lbfft)
1.5 N'm(0.2 kgf'm,1.1 lbfft)
1.8Nm(0.2 kgfm,1.3 lbfft)
2.3 N'm(0.2 kgf'm,1.7 lbfft)
2.1 Nm (0.2 kgfm,1.5 lbfft)
6-3
FUELSVSTEM
TOOLS
Carburetorfloatlevelgauge Pilotscrewwrench Pilotscrewelbowguide
07401-0010000 07KMA-MS60102 07PMA-MZ20110
or07MMA-MT3010B(U.S.A. only) or07PMA-MZ2011A(U.S.A.only)
TROUBLESHOOTING
Enginecranksbutwon'tstart
Nofuelintank
Nofueltocarburetor
- Cloggedfuel strainer
- Cloggedfuel line
- Cloggedfueltankbreatherhose
Toomuchfuelgettingtotheengine
- Cloggedaircleaner
- Floodedcarburetor
Intakeairleak
Contaminated/deterioratedfuel
CloggedSE valvecircuit
ImproperSE valveoperation
Improperthrottleoperation
Nosparkatplug(faultyignitions ~ s t - page19-5)
leanmixture
Cloggedfueljets
Faultyfloatvalve
Floatleveltoolow
Restrictedfuel line
Cloggedcarburetorairventhose
Restrictedfueltankbreatherhose
Intakeairleak
Faultyvacuumpiston
FaultyEVAPcontrolsystem(Californiatypeonly)
- FaultyEVAPCAVcontrolvalve
- Clogged hoseoftheEVAPCAVsystem
Rich mixture
SE valveopen(ON)
Cloggedairjets
Faultyfloatvalve
Floatleveltoohigh
Dirtyaircleaner
Wornjetneedleorneedlejet
Faultyvacuum piston
- FaultyEVAPpurgecontrolvalve
- Clogged hoseoftheEVAP purgesystem
6-4.
FUELSYSTEM
Enginestalls,hardtostart,roughidling
Restrictedfuel line
Fuel mixturetoolean/rich
Contaminated/deterioratedfuel
Intakeairleak
Misadjustedidlespeed
Misadjustedpilotscrew
Misadjustedfloatlevel
Restrictedfueltankbreatherhose
Cloggedaircleaner
Cloggedslowcircuit
CloggedSEvCllvecircuit
FaultyEVAPcontrolsystem (Californiatypeonly)
- FaultyEVAPpurgecontrolvalve
- CloggedhoseoftheEVAPcontrolsystem
Faultyignitionsystem(page19-5)
Afterburnwhenenginebrakingisused
Lean mixtureinstowcircuit
Faultyaircut-offvalve
FaultyPAIR sy$fem
- FaultyPAIRcontrolvalve
ImproperPAIR controlvalveforhighaltituderiding(page6-26)
Backfiringormisfiringduringacceleration
Lean mixture
Faultyignitionsystem (page19-5)
Faultyacceleratorpump
Poorperformance(driveability)andpoorfueleconomy
Cloggedfuel system
- CloggedhoseoftheEVAPCAV system
6-5
FUELSYSTEM
AIRCLEANERHOUSING
REMOVAL
Remove the throttle stop screw knob from the air
cleanerhousingstay.
Removetheaircleanerhousingmountingboltsand
collars.
Disconnectthecrankcase breatherhosefromtheair ..-----
cleanerhousing.
Loosen the air cleaner housing connecting tube
band screw.
Removetheaircleanerhousing.
DISASSEMBLYI ASSEMBLY
1.1 N'm(0.1 kgf'm,0.8IbHt)
AIR CLEANERCHAMBER
0.7 N'm(0.1 kgfm,0.5IbHtl
AIR CLEANERCHAMBER
CONNECTINGTUBE
1.5N'm(0.2kgf'm,1.1 IbHt)
a-RING
COVER
6-6.
FUELSYSTEM
INSTALLA"nON
Connect the crankcase breather hose to the air
cleanerhousing.
Connecttheconnectingtubetothecarburetor.
Tighten the air cleaner housing connecting tube
bandscrewsecurely.
Install the collars, air cleaner housing mounting
bolts,andtightenthemountingboltssecurely.
Jnstall the throttle stop screw knob onto the air
"cleanerhousingstay.
CARBURETOR REMOVAL
Removethefollowing:
- FueltaAk(page.3-4)
- Aire1eanerhoiisIng(page6-6)
Disconnect the PAIR control valve vacuum hose
fromthe?-wayjgint.
DisconnecttheTPsensor3Pconnector.
Connect thefloatchamber.
and drain the
gasolinetotheapprovedgasolinecontainer.
the carburetor drain screw to the speci-

TORfiUE:1.5Nm(0.2kgfm,1.1 Ibfft)
Disconnectthedrainhose.
Except california Release the carburetor air vent hose from the
type: clamp.
Californiatypeshown:
6-7
FUELSYSTEM
Loosen the insulator band screw (carburetor side!
SCREW
anddisconnectthecarburetorfromtheinsulator.
Loosenthelocknutsalltheway.
Disconnect the throttle cables from the throttle
drumandcablestays.
Disconnectthe carburetorairvent (California type:
fuel cut-offsolenoid valve) hose from the carbure-
tor.
California typeonly: Disconnect the EVAP purge control valve hose (to
throttlebore).
Clampthewaterhosesanddisconnectthem.
California typeonly: Disconnect the EVAP purge control valve vacuum
hose.
Removethecarburetor.
6-8
FUELSVSTEM
CARBURETORDISASSEMBLVI
INSPECTION
Remove the PAIR control valve vacuum hoses and
VACUUM HOSES
fuel hose from the carburetor.
SEVALVE
Loosen the SE valve nut and remove the SE valve
fromthe carburetor.
CARBURETORFUELSTRAINER
Remove the fuel strainer from the carburetor.
Check the strainer for clog or damage.
Replace the strainer if necessary.
6-9
FUELSYSTEM
TPSENSOR
ReleasetheTP sensorwirefromtheclamp.
Removethetorxscrew,TPsensoranda-ring.
NOTE:
Do notremovetheTP sensorunless itis necessary
to replaceitordisassemblethecarburetor. Forsen-
sorinspection(page19-10).
AIRCUT-OFFVALVE
The aircut-offvalve Remove the screws while holding the air cut-off
coveris under valvecover.
springpressure. Do
notlose thespring
andscrews.
Remove the air cut-off valve cover, spring and air
cut-offvalve/diaphragmfromthecarburetorbody.
Checkthediaphragmforpin holes,deteriorationor
otherdamage.
Checktheaircut-offvalvefor wearordamageatthe
tip.. . ..'
Checkthe otificein the air' cl.!t-off valve cover and
carburet9!bod'}lforclog
Airlivill;[eaRgufof thevacuLitn chamber ifthe dia-
phragmisdamagedinanyway,evenwithjustapin
hole.
SPRING
ACCELERATORPUMP
The accelerator Remove the screws while holding the accelerator
SCREWS
pumpcoveris pumpcover.
underspring
pressure. Donot
lose thespringand
screws.

COVER
6-10
FUELSYSTEM
Remove the accelerator pump cover, spring and
DIAPHRAGM/ROD
diaphragm/rodfromthecarburetorbody.
Checkthe diaphragmforpin holes, deterioration or
otherdamage.
Checktherodforwearordamageatthetip.
Checktheorifice intheacceleratorpumpcoverand
carburetorbodyforclogorrestriction.
Airwill leak outofthevacuum chamber ifthe dia-
hole.
SPRING COVER
Checkthepump rod bootfordeterioration ordam-
age.
CARBURETORHEATER
Removethescrewsandsetplate.
Remove the carburetor heater from the carburetor
body.
Removethea-ringsfromthecarburetorheater.
6-11
FUELSYSTEM
VACUUM CHAMBER
Remove the screws while holding the vacuum
chambercover.
COMPRESSION SPRING

!I
'DIAPI-IRAGMNACUUMPISTON
Remove the vacuum chamber cover, compression
spring and diaphragm/vacuum pistonfromthecar-
buretorbody.
Be careful not to Turnthejetneedleholdercounterclockwiseusinga
damage the screwdriver while pressing it in and release the
diaphragm. holderflangefromthevacuumpiston.
Removethejetneedleholder,springandjetneedle.
DIAPHRAGMNACUUMPISTON
Checkthejet needleforsteppedwear.
Checkthevacuumpistonforwearordamage.
Checkthe vacuum piston forsmooth operation up
anddowninthe.carburetorbody.
Check diaphragmforpin holes,deteriorationor
otherdamage. . .'
Airwill leakQut ofthe vacuu"m chamberifthe dia-
hole.
SPRING
JETNEEDLE HOLDER
6-12
-----------'_.,----' ------------------
FUELSYSTEM
JETSANDFLOAT
Removethefollowing:
- Acceleratorpumplinkmountingbolt
Plasticwasher
Collar
Plainwashers
Springwasher
Cotterpin
Acceleratorpumplink
Removethescrews,floatchamberandO-ring.
Removethefloatpin,floatandfloatvalve.
Checkthefloatfordamageorfuel inthefloat.
Check the float valve and valve seat for scoring,
scratches,clogsordamage.
Checkthetipofthefloatvalvewhereitcontactsthe
valveseat,forsteppedwearorcontamination.
Checktheoperationofthefloatvalve.
6-13
FUELSVSTEM
Handle all jets with
care. They can
easily be scored or
scratched.
Damage to the pilot
screw seat will
occur if the pilot
screw is tightened
against the seat.
Cleaning the air and
fuel passages with
a piece of wire will
damage the
carburetor body.
Removethefollowing:
- Mainjet
- Needlejetholder
- Needlejet
- Slowjet
Turnthe pilotscrewin and carefullycountthe num-
berofturnsuntil itseats lightly. Makea note ofthis
to use as a reference when reinstalling the pilot
screw.
TOOL:
Pilotscrewwrench 07KMA-MS60102or
07MMA-MT3010B
(U.S.A.only)
Removethe pilotscrew,spring,washerand O-ring.
Checkeach jetforwearordamage.
Checkthepilotscrewforwearordamage.
Cleanth,ejetswithcleaning solvent.
CARBURETORCLEANING
Blowopen all ah and fuel passages in the carbure-
torbodyandfloatchamberwith compressed air.
-
MAINJET SLOWJET PILOTSCREW
NEEDLEJET
I
NEEDLEJET
HOLDER
-:iMAINJET
O-RING ~ ~
WASHER~ ~ SLOWJET
SPRING PILOTSCREW
-
6-14
-- --- ------------
FUELSYSTEM
CARBURETOR ASSEMBLY
JETNEEDLE HOLDER
VACUUMCHAMBERCOVER
JETNEEDLE
DIAPHRAGMNACUUM PISTON
PLASTICWASHER
ACCELERATOR
PUMPLINK
COMPRESSION SPRING
ACCELERATOR PUMPCOVER
6-15
FUELSYSTEM
JETSANDFLOAT
-
Damage to the pilot
screw seat will
occur if the pilot
screw is tightened
against the seat.
Handle all jets with
care. They can
easily be scored or
scratched.
Set the float level
gauge soit is
perpendicular to the
float chamber face
at the highest point
ofthe floa t.
Installthepilotscrewwiththespring,washerand a
newO-ringuntilitseatslightly. Return ittoitsorigi-
nal positionas notedduringremoval.
TOOL:
Pilotscrewwrench 07KMA-MS60102or
07MMA-MT3010B
(U.S.A.only)
Perform the pilot screw adjustment if a new pilot
screwisinstalled(page6-25).
Installtheneedlejet,needlejetholder,mainjetand
slowjet.
TORQUE:
Needlejetholder:2.3Nm(0.2kgfm,1.7Ibf.ft)
Mainjet: 2.1 Nm(0.2kgfm,1.5Ibf.ft)
Slowjet: 1.8Nm(0.2kgfm,1.3Ibf.ft)
Hangthefloatvalveontothefloatarmlip.
Install the float with the float valve and insert the
floatpin.
FLOATLEVELINSfECTION
NOTE:
Check the float level afterchecking the float valve,
valveseatandfloat.
With the float valve seated and the float arm just
touchingthevalve, measurethefloatlevel withthe
floatlevelgauge.
TOOL:
Carburetorfloatlevelgauge 07401-0010000
Floatlevel: 18.5mm(0.73in)
Thefloatcannotbeadjusted.
Replacethefloatifthefloatlevel isoutofspecifica-
tion.
MAINJET SLOWJET PILOTSCREW
FUELSYSTEM
Install a new a-ring intothe floatchamber groove
properly.
Installthefloatchamberandtightenthefloatcham-
berscrewstothespecifiedtorque.
TORQUE:2.1 N'm(0.2kgfm,1.5Ibfft)
Installthefollowing:
- Springwasher
-
- CoJlat"'-
pumplink
- Plasticwasher
- Newcotterpin
Tightentheacceleratorpumplinkmountingboltto
thespecifiedtorque.
TOR9UE:3.4 (0.3kgfm,2.5Ibfft)
.VACUUM CHAMBER
Insenthe jetneedle into tl)e vacuumpiston.
Install int<:Uhe holderand set
thejet piston.
Turn whilepressing
ituntilitlocks.

. SPRING .
JETNEEDLE HOLDER
6-17
FUELSYSTEM
Installthediaphragm/vacuumpistonintothecarbu-
COMPRESSION SPRING
retorbodybeing careful nottodamagethejetnee-
dle.
Liftthe bottom ofthe pistonwithyourfingertoset
the diaphragm rib intothegrooveinthecarburetor
body.
Be careful not to Install the compression spring and vacuum cham-
pinch the bercoverwhile liftingthepiston in place. Alignthe
diaphragm. bossesofthecoverwiththegroovesofthecarbure-
tor body and secure the cover with at least two
screws beforereleasingthevacuum piston.
Install and tighten the vacuum chamber cover
screwstothespecifiedtorque.
TORQUE:2.1 Nm(0.2kgfm,1.5Ibfft)
CARBURETOR HEATER
Coat new O-rings with engine oil and install them
ontothecarburetorheater.
Install the carburetor heater into the carburetor
body.
Installthesetplateontothecarburetorheater.
Install and tighten the carburetor heater set plate
screwstothespecifiedtorque.
TORQUE:3.4N'
11l
(0.3kgfm,2.5Ibfft)
RIB

DIAPHRAGMNACUUMPISTON
FUELSVSTEM
ACCELERATORPUMP
Be careful not to Install the diaphragm/rod, spring and cover to the
pinch the floatchambercover.
diaphragm.
SPRING COVER
Install and tighten the accelerator pump cover
screws to the specified torque while holding the
cover.
tORQUE:.2.1 Nm(0.2kgfm,1.5Ibfft)
DIAPHRAGMIROD
~
AIRCUT-OFFVALVE
Be careful not to Install the air cut-off valve/diaphragm, spring and
pinch the coverontothecarburetorbody.
diaphragm.
SPRING COVER
Installthealrcut-off"(l:Ilye coverscrews whilehold-
ingtheair u t ~ o vl:l!\/e cover,and tighten ittothe
speCifiedtorque.
6-19
FUELSVSTEM
TPSENSOR
ApplyengineoiltoanewO-ring and installittothe
TPsensorgroove.
InstalltheTP sensorbyaligning itsslotwiththeflat
ofthethrottleshaft.
Measure the resistance (A) between the Blue and
Black wire terminals at the TP sensor connector
(page19-10).
Resistance(A):
STANDARD: 4- 6kO. (20C/68F)
Measuretheresistance (B) betweentheYellowand
Blackwireterminal,then adjusttheTP sensorinitial
positionsothattheresistance(B) iswithinthestan-
dardvalue.
Resistance (8) =Resistance (AI x (0.09to 0.11 I
e.g:
When the resistance (A) is 5 kn, the resistance (B)
should be 450- 550Q.
Tighten the TP sensor torx screw to the specified
torqueattheinitialposition.
TORQUE:3.4NmJO.3kgfm,2.5Ibf.ftl
ClamptheTP sensorwire.
CARBURETORFUELSTRAINER
Installthefuelstrainerintothecarburetorbody.
6-20
FUELSYSTEM
SEVALVE
Install theSE valve andtightenthe SE valve nutto
thespecifiedtorque.
TORQUE:2.3Nm(0.2kgfm,1.7Ibfft)
Connect the fuel and PAIR control valve vacuum
hoses.
CARBURETORI,NSTALLATION
Connect the water hoses to the carburetor heater
and theclamps.
Californiatypeonly: ConnecttheEVAPpurgecontrolvalvevacuumhose
tothecarburetor.
GonnEl
ct
thecarPLJretorairvent(Californiatype:fuel
hosetothecarburetor.
'-C'__' .;:.. _;---,- ,.- ',' __ __. - -
Californiatypeonly:' Connect- 'the EVAP purge control valve hose (to
bore).
------
AIRVENT(SOLENOIDVALVE)
HOSE
....
6-21
FUELSYSTEM
Connectthethrottlecablestothethrottledrumand
installthemontothecablestays.
Connectthecarburetortothe insulatorwhilealign-
ingitslugwiththeinsulatorgroove.
Tightentheinsulatorband screwsecurely.
Except california Connecttheairventhosetotheclamp.
type:
ConnecttheTPsensor3Pconnector.
ConnectthePAIR.controlvalvevacuum hosetothe
3-wayjoint.
- Aircleanerhousing(page6-7)
- Fueltank(page3-4)
Performthefollowinginspectionsandadjustments:
Engineidlespeed (page4-15)
- Throttleoperation(page4-5)
- Pilotscrewifitwasreplaced (page6-25)
6-22
FUELSYSTEM
INTAKEMANIFOLD
REMOVAL
Drainthecoolantfromthecoolingsystem
(page7-6).
Removethecarburetor(page6-7).
Loosen the insulator band screw and remove the
insulatorfromtheintakemanifold.
Disconnect the water hose from the rear cylinder
head.
Removetheboltsandchokecablestay.
Removethebolts,intakemanifoldand a-rings.
Sealtheintakeportsofthecylinderheadswithtape
orclean clothstokeepdirtand debrisfromentering
theengine.
INSTALLATION
Install newa-ringsontotheintakemanifold.
STAY BOLTS
6-23
FUELSYSTEM
Installtheint
Installthe man.ifoldontoth .
sandtightenthem. ecylinderheads.
thechoke
Tightenthebolt cablestayand b I
ssecurely. 0 ts.
Installthe'
c b msulato'
ar uretorsid withthe"CA "
manifold. e, ahgnlng ;'S m.a'kfadngthe
Ightentheinsulato eWith the lug on
Installth rbandscrew
Filland Ipage6-211 s""urely.
oolmgsystem'(page7-7).
6-24
FUELSYSTEM
PILOT SCREW ADJUSTMENT
IDLE DROP PROCEDURE
NOTE:
The pilotscrewis factory pre-set and no'adjust-
ment is necessary unless the pilot screw is
replaced.
Use atachometerwith graduations of50 rpm or
smaller that will accurately indicate 50 rpm
change,
Damage to thepilot 1. Turn the pilot screw clockwise until it seats
screwseatwill lightly, then back it out to specification given.
occurifthepilot This is an initial setting prior to the final pilot
screwis tightened screwadjustment.
againsttheseat.
TOOL:
Pilotscrewwrench 07KMA-MS60102
Pilotscrewelbowguide 07PMA-MZ20110
or
Pilotscrewwrench 07MMA-MT3010B
(U.S.A.only)
Pilotscrewelbowguide 07PMA-MZ2011A
(U.S.A.only)
INITIALOPENING:
49states/Canadatype: 2turnsout
Californiatype: 2-1/8turnsout
2. Warm up the engine to operating temperature.
Ride the motorcycle for approximately 10 min-
utes.
3. Stop the engine and connect a tachometer
accordingtoitsmanufacturer'sinstructions.
4. Remove thefuel tank (page 3-4) and disconnect
the PA'IR control valve vacuum hose and plug it
tokeepairfromentering,thenconnectavacuum
pump to the PAIR control valve vacuum hose
joint.
5. Applymorethanspecifiedvacuum(page6-28)to
the PAIR control valve vacuum hose and install
thefueltank(page3-4).
6. Start the engine and adjust the idle speed with
thethrottlestopscrewknob.
TEMPORARYIDLESPEED: 1,200100rpm
7. Turnthepilotscrewinoroutslowlytoobtainthe
highestenginespeed.
8. Lightlyopenthethrottle2or3times,thenadjust
theidlespeedwiththethrottlestopscrewknob.
9. Turnthepilotscrewin graduallyuntiltheengine
speeddropsby50rpm.
10.Turn the pilotscrewoutthe final opening from
thepositionobtainedinstep9. .
FINALOPENING:1/4turnsout
6-25
-_._-----
FUELSYSTEM
11.Removethefueltank(page3-4).
VACUUMPUMP
Remove the plug from the vacuum hose, then
disconnect the vacuum pump and connect the
vacuum hose tothe PAIR control valve vacuum
PAIRCONTROLVALVE VACUUM HOSE
hosejoint.Installthefueltank(page3-4).
12.Readjust the idle speed with the throttle stop
screwknob.
13.Disconnectthetachometer.
\ .
PLUG
HIGHALTITUDEADJUSTMENT
This adjustment Whenthevehicle tobe operatedcontinuouslyabove6,500feet(2,000m),thecarburetorsetting
mustbemadeat mustbechangedas described belowtoimprovedriveabilityanddecreaseexhaustemissions.
highaltitudeto
ensureproperhigh
altitudeoperation.
STANDARDSETIING HIGHALTITUDE SETIING
Below5,000ft(1,500m) Above6,500ft(2,000 m)
Mainjet #122 #120
Pilot 49states/Canada Factorypreset 3/4turninfromfactorypreset
screw type (2turnsout) (1-1/4turnsout)
opening Californiatype Factorypreset 3/4turninfromfactorypreset
(2-1/8turnsout) (1-3/8 turnsout)
PAIR controlvalve
.
PIN: 18650-MFE-671 PIN: 18650-MFE-801
*Ifafterburnappearswhensnappingthethrottlegripclosed,duringenginebraking,itisnecessaryto
replacethePAIR controlvalve(page6-29)forhighaltituderidinginadditiontochangingthecarbure-
torsetting.
Remove the carburetor (page 6-7) and the float
chamber.
Replacethestandardmainjetwiththehighaltitude
type.
HIGHALTITUDEMAINJET: #120
Check that the O-ring on the float chamber is in
goodcondition,replaceitifnecessary.
Installthefloatchamberandcarburetor(page6-21).
6-26
FUELSYSTEM
6-27
Do not attach the
label to any part
that can be easily
removed from the
vehicle.
This adjustment
must be made at
low altitude to
ensure proper low
altitude operation.
Warmuptheenginetooperatingtemperature. Ride
themotorcycleforapproximately10 minutes.
Turnthepilotscrewintothespecificationgiven.
TOOL:
Pilotscrewwrench 07KMA-MS60102
Pilotscrewelbowguide 07PMA-MZ20110
or
Pilotscrewwrench 07MMA-MT3010B
(U.S.A.only)
Pilotscrewelbowguide 07PMA-MZ2011A
(U.S.A.only)
HIGHALTITUDEPILOTSCREWOPENING:
3/4tum itlfromthefaetOiy presetposition
Adjust the idle speedwith the throttle stop screw
knob.
Attach the Vehicle Emission Control Information
Updatelabelontherearfenderneartheframecross
pipeas shown.
See Service Letter No. 132 for information on
obtaining.the label.
I NOTICE I
Sustained operation at an altitude lower than 5,000
feet (1,500 m)with the parts replaced and adjusted
for high altitude settings may cause the engine to
idle roughly and stall in traffic. It may also cause
engine damage due to overheating.
When the vehicle is to be operated continuously
below5,000feet(1,500 m),replaceand readjustthe
partsasfollows:
Replace main jet with the standard main jet, and
screwoutthepilotscrewtothespecified numberof
turnsfromthehighaltitudesetting.
STANDARDMAINJET: #122
LOWALTITUDEPILOTSCREWOPENING:
3/4tumoutfromthehighaltitudesetting
Replace the PAIR control valve with the standard
type.
Warm up the engine and adjust the idle speed at
lowaltitudewiththethrottlestopscrew.
PILOTSCREW
\
\

UPDATELABEL:
VEHICLE EMISSION CONTROL INFORMATION UPDATE
-HONDA MOTOR CO. ,LTD. fI
THIS VEHICLE HAS BEEN ADJUSTED TO
IMPROVE EMISSION CONTROL PERFORMANCE
WHEN OPERATED AT HIGH ALTITUDE.
ALTITUDE PERFORMANCE ADJUSTMENT INSTRUCTIONS
ARE AVAILABLE AT YOUR AUTHORIZED HONDA DEALER.
FUELSYSTEM
SYSTEMINSPECTION
Warmuptheenginetooperatingtemperature.
Removethefuel tank(page3-4).
Checkthatthesecondaryairsupplyhosesareclean
andfreeofcarbondeposits.
CheckthePAIR checkvalvesifthehosesarecarbon
fouled(page6-29).
Disconne,ctthePAIRcontrolvalvevacuumhoseand
plugthevacuumhose.
ConnectavacuumpumptothePAIR controlvalve.
Installthefuel tank(page3-4).
Starttheengineand openthethrottleslightlyto be
certain that air is sucked in through the airsuction
hose.
Iftheairisnotdrawnin,checktheairsuctionhoses
forclogs.
Withtheenginerunning,graduallyapplyvacuumto
thePAIRcontrolvalvevacuumhose.
Check thatthe air suction hose stops drawing air,
andthatthevacuumdoesnotbleed. .
SPECIFIEDVACUUM:
STANDARDSETTING:65kPa (485mmHg)
HIGHALTITUDESETrlNG:57kPa (425mmHg)
Ifthe air is drawn in, orifthe specified vacuum is
notmaintained,installanewPAIRcontrolvalve.
Ifafterburn occurs on deceleration, even when the
secondaryairsupplysystemisnormal,checktheair
cut-offvalve.
VACUUMPUMP
PLUG AIR SUCTION HOSE
6-28
FUELSYSTEM
PAIRCONTROLVALVEREMOVALI
INSTALLATION
Route the hoses
properly
(page 1-22).
Disconnectthe vacuum, airsupply, and airsuction
hoses.
RemovethePAIR controlvalve.
PAIRCHECKVALVEINSPECTION
RemovetheboltsandPAIR checkvalvecover.
Remove the PAIR check valve from the cylinder
headcoveF.
Check the reed for damage or fatigue. Replace if
necessary.
Replace the PAIR check valve ifthe rubber seat is
cracked, deteriorated or damaged, or if there is
clearancebetweenthereed andseat.
Install the PAIR check valve in the reverse orderof
removal.
TORQUE:7Nm(0.7kgfm,5.2Ibfft)
"-,,",,,n","'D",'.'\H\',,,OO<,, ""
...--
REED RUBBER SEAT
6-29
FUELSVSTEM
EVAPCONTROLSYSTEM(California
typeonly)
EVAPCANISTERREMOVALI
INSTALLATION
Disconnectthefollowing hosesfrom theEVAPcan- ,---------------------,
ister: CANISTER HOSE
- EVAPcanisterhose
- EVAPcanisterhose(tofueltank)
- EVAPcanisterairventhose
- EVAPcanisterdrainhose
Removethebolt,collarand EVAP canisterfromthe
bracket.
Route the hoses
properly
(page 1-35).
Install the EVAP canister in the
removal.
reverse order of
(TO FUELTANK)
EVAPPURGECONTROLVALVE
REMOVAUINSTALLATION
DisconnecttheEVAPpurgecontrolvalvehosesand
EVAPpurgecontrolvalvevacuumhose(page 1-35).
RemovetheEVAP purgecontrolvalve.
Route the hoses Installationisinthereverseorderofremoval.
properly
(page 1-35),
INSPECTION
NOTE:
TheEVAPpurgecontrolvalveshouldbeinspectedif
hotrestartisdifficult.
RemovetheEVAPpurgecontrolvalve(page6-30).
Connectavacuum pumptothethrottleboreport.
ApplythespecifiedvacuumtotheEVAPpurgecon-
trolvalve.
SPECIFIEDVACUUM: 50mm Hg(2.0in Hg)
Thespecifiedvacuumshouldmaintained.
Replace the EVAP purge control valve ifvacuum is
notmaintained.
EVAPCANISTER PORT
-........
-........ VACUUMPORT
6-30
FUELSVSTEM
Damage to the
EVAP purge control
valve may result
from use of a high
pressure air source.
Use a hand-
operated air pump
only.
Remove the vacuum pump and connect it to the
vacuum port.
ApplythespecifiedvacuumtotheEVAP purgecon-
trolvalve.
SPECIFIEDVACUUM: 250mmHg(9.8inHg)
Thespecifiedvacuumshouldmaintained.
Replace the EVAP purgecontrol valve ifvacuum is
notmaintained.
ConnectapressurepumptotheEVAPcanisterport.
Whileapplyingthespecifiedvacuumtothevacuum
port,pumpairthroughtheEVAPcanisterport.
SPECIFIEDVACUUM: 25mmHg(1.0inHg)
Air should flow through the EVAP purge control
valveandoutthethrottleboreport.
ReplacetheEVAPpurgecontrolvalveifairdoesnot
flowout.
Removethepumpsand installtheEVAP purgecon-
trolvalve(page6-30).
EVAPCAVCONTROLVALVE
REMOVAUINSTALLAnON
Disconnectthe EVAP CAV control valve hoses and
vacuum hose(page 1-35).
RemovetheEVAPCAVcontrolvalvefromthestay.
VACUUMPUMP
PRESSURE PUMP
VACUUM PUMP
6-31
FUELSYSTEM
INSPECTION
NOTE:
The EVAPCAV control valveshould be inspected if r--------------------,
hotrestartisdifficult. SUBAIRCLEANER PORT
RemovetheEVAPCAVcontrolvalve(page6-31).
t
Connectavacuum pumptothevacuumport.
EVAPCANISTER
Applythe specified vacuum tothe EVAP CAV con-
PORT
trolvalve.
/' .........
SPECIFIEDVACUUM: 500mmHg(19.7 inHg)
Thespecifiedvacuumshouldbemaintained.
Replace the EVAP CAV control valve ifvacuum is
notmaintained. FUELCUT-OFF
SOLENOIDVALVE
PORT
Removethevacuumpumpandconnectittothesub
aircleanerport.
Applyvacuum tothe EVAP CAV control valve. The
vacuumshouldholdsteady.
Replace the EVAP CAV control valve if vacuum
leaks.
VACUUM PUMP
Removethevacuum pump and reconnect ittothe
vacuumport.
Connect a pressure pump to the sub air cleaner
port.
Damage tothe While applying vacuum tothevacuum port, pump
EVAP CAV control airthroughthesubaircleanerport.
valve may result AirshouldflolN ~ o l l h theEVAPCAVcontrolvalve
from use of ahigh andout the fuel cl..It"off solenoid valve port.
Use ahand-
operated air pump
only.
Plugthefuelcut-offsolenoidvalveport.
While applying vacuum tothevacuum port, pump
airthroughthesubaircleanerport.
Itshouldholdsteady.
Replace the EVAP CAV control valve ifpressure is
notretained.
Remove the pumps and install the EVAP CAV con-
trolvalve(page6-31).
VACUUM PUMP
6-32
FUELSVSTEM
Removethefollowing:
- Fueltank(page3-4)
Release thewire band and disconnectthe fuel cut-
offsolenoidvalve2Pconnector.
Disconnect the fuel cut-off solenoid valve hose,
EVAP CAV control valve hose and vacuum hose
(page 1-35).
Remove the fuel cut-off solenoid valve from the
stay.
Route the solenoid Installationisinthereverse orderofremoval.
valve hosesand
wireproperly
(page 1-35).
INSPECTION
Removethefuelcut-offsolenoidvalve(page6-33).
Damage to the fuel Connectavacuum pumptothevacuumport.Apply
cut-offsolenoid the specified vacuum to the fuel cut-off solenoid
valve mayresult valve.
from useof a high
TOOL:
pressureairsource.
Vacuumpump Commerciallyavailable
Usea hand-
operatedairpump
SPECIFIEDVACUUM: 250mmHg
only.
Thespecifiedvacuumshouldbe maintained.
Replace the fuel cut-offsolenoid valve ifvacuum is
notmaintained.
Removethevacuumpump.
Connect the pressure pump to the float chamber
port.
PumpairthroughtheEVAPCAVcontrolvalveport.
VACUUM PORT
VACUUM PUMP
FLOATCHAMBER PORT
PRESSURE PUMP
6-33
FUELSVSTEM
Damage to the fuel
cut-off solenoid
valve may result
from use of a high
Use a hand-
operated air pump
only.
Remove the pressure pump and connect it to the
FUELCUT-OFF FLOATCHAMBER PORT
EVAPCAVcontrolvalveport.
Pumpairthroughthefloatchamberport.
Connectthe12Vbatterytothefuel cut-offsolenoid
valve2P connectorterminals.
Connect avacuum pumptothe EVAP CAV control
valve port. Applythe specified vacuum to the fuel
cut-off valve.
SPECIFIEDVACUUM: 250mmHg
Thespecifiedvacuumshouldbe maintained.
Replace thefuel cut-offsolenoid valve ifvacuum is
notmaintained.
SOLENOIDVALVE

PRESSURE PUMP
Remove the pressure pump and connect itto the
vacuumport.
Pumpairthroughthefloatchamberport.
Replacethefuelcut-offsolenoidvalveifnecessary.
Removethe pressurepumpand installthefuel cut-
offsolenoid valve in the reverse order ofremoval
(page6-33).
VACUUM PORT
PRESSURE PUMP
2PCONNECTOR BATTERY

6-34
7. COOLINGSYSTEM
SYSTEM FLOWPATTERN 7-2
TROUBLESHOOTING 7-4
SYSTEMTESTING;7-5
COOLANTREPLACEMENT7-6
THERMOSTAT .. 7-8 _
THERMOSTATHOUSiNG ... 7-9
RADIATOR/COOLING FAN7-11
WATER PUMP 7-16
RADIATOR RESERVETANK7-17
7-1
--
COOLINGSYSTEM
SYSTEMFLOWPATTERN
CARBURETOR
THERMOSTAT
\
RESERVE TANK
7-2.
COOLINGSYSTEM
SERVICEINFORMATION
GENERAL
Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding you.
Always let the engine and radiator cool down before removing the radiator cap.
I NOTICE I
Using coolant with silicate corrosion inhibitors may cause premature wear of water pump seals or blockage of radiator
passages. Using tap water may cause engine damage.
Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system.
All cooling system service can be done with the engine in the frame.
Avoid spilling coolant on painted surfaces.
After servicing the system, check for leaks with a coaling system tester.
For the ECT sensor switch (coolant temperature indicator) inspection (page 21-12).
For fan motor switch inspection (page 21-14).
SPECIFICATIONS
ITEM SPECIFICATIONS
Coolant capacity Radiator and engine 1.58 liters (1.67 US qt, 1.39 Imp qt)
Reserve tank 0.38 liter (0.40 US qt, 0.33 Imp qt)
Radiator cap relief pressure 108 - 137 kPa (1.1 - 1.4 kgf/cm
2
, 16 - 20 psi)
Thermostat Begin to open 80 - 84C (176 -183F)
Fully open 95C (203F)
Valve lift 8 mm (0.3 in) minimum at 95C (203F)
Recommended antifreeze
Standard coolant concentration
Pro Honda HP Coolant or an equivalent high quality ethyl-
ene glycol antifreeze containing silicate-free corrosion
inhibitors
1 : 1 (mixture with distilled water)
TORQUEVALUES
Radiator filler mounting bolt
Thermostat housing cover bolt
Fan motor mounting bolt
Cooling fan mounting nut
Water pump cover bolt
Fan motor assembly mounting bolt
Water hose band screw
10 N'm (1.0 kgf'm, 7 Ibfft)
10 Nm (1.0 kgf'm, 7 Ibfft)
5.1 Nm (0.5 kgf'm, 3.8 Ibf.ft)
2.7 Nm (0.3 kgfm, 2.0 Ibf.ft)
13 Nm (1.3 kgfm, 10 Ibfft)
8.4 Nm (0.9 kgfm, 6.2 Ibf.ft)
See page 7-10
Apply locking agent to the threads
7-3
COOLINGSYSTEM
TROUBLESHOOTING
Engine temperature too high
Faulty coolant temperature indicator or EeT sensor switch
Thermostat stuck closed
Faulty radiator cap
Insufficient coolant .
Passages blocked in radiator, hoses or water jacket
Air in system
Faulty fan motor
Faulty fan motor switch
Faulty water pump
Engine temperature too low
Thermostat stuck open
Faulty fan motor switch
Coolant leaks
Faulty water pump mechanical seal
Deteriorated O-rings
Faulty radiator cap
Damaged or deteriorated cylinder head gasket
Loose hose connection or band
Damaged or deteriorated hoses
7-4.
-_.. ~
COOLINGSYS"rEM
SYSTEMTESTING
COOLANT(HYDROMETER"rEST)
Remove the fuel tank (page 3-41.
Remove the radiator cap.
Test the coolant specific gravity using a hydrome-
ter,
Look for contamination and replace the coolant if
necessary.
COOLANTGRAVITYCHART
CoolanttemperatureC (OH
0 5 10 15 20 25 30 35 40 45 50
(32) (41) (50) (59) (68) (77) (86) (95) (104) (113) (122)
"*
0
'';:::;
ell
...
....
c:
.!!!
0
0
u
5 1.009 1.009 1.008 1.008 1.007 1.006 1.005 1.003 1.001 0.999 0.997
10 1.018 1.017 1.017 1.016 1.015 1.014 1.013 1.011 1.009 1.007 1.005
15 1.028 1.027 1.026 1.025 1.024 1.022 1.020 1.018 1.016 1.014 1.012
20 1.036 1.035 1.034 1.033 1.031 1.029 1.027 1.025 1.023 1.021 1.019
25 1.045 1.044 1.043 1.042 1.040 1.038 1.036 1.034 1.031 1.028 1.025
30 1.053 1.052 1.051 1.049 1.047 1.045 1.043 1.041 1.038 1.035 1.032
35 1.063 1.062 1.060 1.058 1.056 1.054 1.052 1.049 1.046 1.043 1.040
40 1.072 1.070 1.068 1.066 1.064 1.062 1.059 1.056 1.053 1.050 1.047
45 1.080 1.078 1.076 1.074 1.072 1.069 1.066 1.063 1.060 1.057 1.054
50 1.086 1.084 1.082 1.080 1.077 1;074 1.071 1.068 1.065 1.062 1.059
55 1.095 1.093 1.091 1.088 1.085 1.082 1.079 1.076 1.073 1.070 1.067
60 1.100 1.098 1.095 1.092 1.089 1.086 1.083 1.080 1.077 1.074 1.071
7-5
-- ...- --------
--
COOLINGSYSTEM
RADIATORCAP/SYSTEMPRESSURE
INSPECTION
Removethe radiatorcap (page7-5).
Wetthesealing surfaces ofthecap, then install the
cap ontothetester.
TOOLS:
Coolingsystempressuretester SVTS4AH
Coolingsystemadaptor OTCJ33984A
Pressurizeitheradiatorcap usingthetester. Replace
the radiator cap ifitdoes not hold pressure, or if
relief pressure istoo highortoo low. It must hold
thespecified preSSiJrefbr,atleast6seconds.
RADIATORCAPREUEF
108 137!cPa (1.1 - t4kgf/Cin
2
, 16 - 20 psi)
Pressurizethe radiator, engine and hoses using the
tester,andcheckforleaks.
I NOTICE I
Excessive pressure can damage the cooling system
components. Do not exceed 137kPa (1.4kgf/crrr, 20
psi).
Repairorreplacecomponentsifthesystemwill not
holdthespecifiedpressureforatleast6seconds.
Removethetesterand installtheradiatorcap.
COOLANTREPLACEMENT
PREPARATION
NOTE:'
The effectiveness of coolant decreases with the
accumulationofrustorifthereisachangeinthe
mixing proportion during usage. Therefore, for
best performance change the coolant regularly
as specifiedinthemaintenanceschedule.
Mixonlydistilled,lowmineralwaterwiththerec-
ommendedantifreeze.
RECOMMENDEDANTIFREEZE:
ProHondaJiPCo()lantoran equivalenthighqual-
ityethyleneglycolantifreezecontainingsilicate-
freecorrosioninhibitors
STANDARDCOOLANTCONCENTRATION:'
1:1(mixturewithdistilledwater)
7-6.
ANTIFREEZE
SOLUTION
(ETHYLENE
GLYCOLBASE
LOWMINERAL
SOLUTION)
OR DISTILLED
WATER
COOLANT
COOLINGSYSTEM
REPLACEMENTI AIRBLEEDING
NOTE:
When filling the system or reserve tank with cool-
ant,orcheckingthecoolantlevel,holdthemotorcy-
cleinan uprightposition.
Removetheradiatorcap.
Drainthecoolantfromthesystem by removing the
,drainboltandsealingwasher.
Reinstall the drain boltwith a new sealing washer
andtightenittothespecifiedtorque.
TORQUE: 13Nm(1.3kgfm,10Ibf.ft)
Removetheleftcrankcase rearcover(page3-5).
Disconnect the siphon hose from the reserve tank
anddrainthecoolant.
Empty the coolantby removing the reserve tank
(page 7-17) and r s ~ the inside ofthe reserve tank
withwater.
Reservetank(page7-17)
- Leftcrankcase rearcover(page3-5)
Fill the system with the recommended coolant
throughthefilleropeninguptothefillerneck.
Installthefueltank(page3-41.
Bleedairfromthesystemasfollows:
1. Shiftthetransmissionintoneutral.
Starttheengineandletitidlefor2- 3minutes.
2. Snapthethrottlethreetofourtimestobleed air
fromthesystem.
3. Stoptheengine, removethefuel tank(page3-4)
andaddthecoolantuptothefillerneck.
4. Installtheradiatorcap.
7-7
--
COOLINGSYSTEM
Removethereservetankcap.
Fill the reserve tank to the upper level line and
installthetankcap.
THERMOSTAT
REMOVAL
Drainthecoolantfromthesystem (page7-7).
Removethesteeringsidecovers(page3-5).
Place ashoptowelunderthethermostathousing.
DisconnecttheECTsensorswitchconnector.
Removethethermostathousingcoverbolts.
Pull outthethermostat housing and removethe0-
ringandthermostat.
THERMOSTATINSPECTION
Visuallyinspectthethermostatfordamage.
Replace the thermostat ifthe valve stays open at
roomtemperature.
Wearinsulated Heat a container ofwater with an electric heating
glovesand elementfor5minutes.
adequateeye Suspend the thermostat in the heated water to
protection. checkitsoperation.
Keep flammable
THERMOSTATBEGINTOOPEN:
materialsaway
80 - 84C (176 - 183F)
from theelectric
heatingelement.
VALVELIFT:
Do notletthe
8 mm (0.3in) minimum at 95C(203F)
thermostator
thermometertouch
Replace thethermostatifthevalve opensatatem-
thepan, oryou will
peratureotherthanthosespecified.
getfalse readings.
"LOWER" LEVEL
THERMOMETER
COOLINGSYSTEM
INSTALLATION
Installthethermostatbyaligning itsflangewiththe
thermostathousingslot.
Install a new O-ring into the thermostat housing
groove.
Install the thermostat housing to the cover and
tightentheboltstothespecifiedtorque.
TORQUE: 10Nm(1.0kgfm,7Ibfft)
ConnecttheECTsensorswitchconnector.
Fillandbleedthecoolingsystem(page7-7).
Installthesteeringsidecovers(page3-5).
THERMOSTATHOUSING
Drainthecoolantfromthesystem(page7-71.
Loosenthewaterhoseband screwsanddisconnect
thew&terhoses.
Disconnectthesiphon o s ~
Removetheboltandthermostathousingassembly.
7-9
COOLINGSYSTEM
Route the hoses Install the thermostat housing assembly in the
and wires properly reverseorderofremoval.
(page 1-22).NOTE:
Tightenthewaterhosebandscrewstothespecified
rangeas shown.
0-1 mm(0 - 0.04 in)
DISASSEMBLY
Removethefollowing:
a-RING
Thermostathousing(page7-9)
- TherJTIostat(page7-8)
- ECTsensorswitch(page21-13)
Removetheboltsanda-ring.
I
I
__1. .
I
I
I
--'
BOLTS
ASSEMBLY
Installanewa-ringtotheradiatorfiller.
RADIATOR FILLER COVER
Assemblether i ~ t o r fillerandthermostathousing
cover.
Installandtightentheboltstothespecifiedtorque.
- ECTsensorswitch(page21-13)
Thermostat(page7-9)
- Thermostathousing(page7-9)
7-10
COOLINGSYSTEM
RADIATOR/COOLING FAN
REMOVAL
Be careful not to Drain the coolant from the system (page 7-7).
damage the radiator Remove the steering side covers (page 3-5).
fins while servicing
Remove the wire band and disconnect the fan
the radiator and fan
motor switch 2P (Natural) connector.
motor.
Loosen the water hose band screw and disconnect
the radiator upper water hose.
the radiatC?r lower water hose.
7-11
COOLINGSYSTEM
Removethe boltand collar.
Release the rear brake light switch and ignition
pulsegeneratorwiresfromthe radiatorgrill.
Release the fan motor wire from the clamp and
removetheradiator.
FAN MOTORWIRE
BRAKEL1GHTSWITCH/PULSE
GENERATORWIRES
DISASSEMBLY
For fan motor Releasethefanmotorwiresfromtheradiatorgrill.
RADIATOR GRILL
switch inspection Removetheradiatormounting rubbersandradiator
(page 21-14). grill. .
Disconnect the fan motor switch connector and
releasethewiresfromtheclamp.
Remove the bolts, ground terminal and fan motor
assembly.
MOUNTINGRUBBERS
7-12
COOLINGSYSTEM
Remove the nut and cooling fan.
Remove the bolts and fan motor from the shroud.
ASSEMBLY
RADIATOR GRILL RADIATOR
FAN MOTOR
SHROUD
8.4 N'm (0.9 kgf'm, 6.2 IbHt)
7
O-RING
MOUNTING RUBBER
7-13
- -- ---- -- ---------------j
COOLINGSYSTEM
Install the fan motor on the shroud in the direction
as shown and tighten the bolts to the specified
torque.
TORQUE: 5.1 Nm (0.5 kgfm, 3.8 Ibftt)
Install the cooling fan onto the motor shaft, aligning
the flat surfaces.
Clean and apply locking agent to the nut threads.
Tighten the nut to the specified torque.
Install the fan motor assembly on the radiator and
tighten the bolts with the ground terminal as
shown.
Clamp the wires:
7-14
COOLINGSYS"rEM
Installtheradiatoronthegrill.
RADIATORGRILL
Installthemountingrubbers.
Routethefan motorwiresthroughtheshroud.
WIRES
INSTALLATION
Installtheradiatorbyinsertingitsmountingrubbers
intotheholderoftheframe.
UPPER HOSE
Routethe rearbrake lightswitch and ignitionpulse
generatorwiresthroughtheradiatorgrill
(page 1-22).
Connectthefan motorswitchwiretotheclamp.
Installthecollar,boltandtightenthebolt.
Connect the radiator upperand lowerwater hoses
(page1-22).
Tightenthewaterhosebandscrewstothespecified
range(page7-10).
FAN MOTORWIRE
BRAKELIGHTSWITCH/PULSE
GENERATORWIRES
Route the wire Connectthe fan motorswitch 2P (Natural) connec-
properly torandinstallthewireband.
(page 1-22).
Fill and bleedthecoolingsystem(page7-7).
....
7-15
COOLINGSYSTEM
WATER PUMP
MECHANICALSEALINSPECTION
Inspectthetelltaleholeforsignsofcoolantleakage.
Ifthere is leakage,thewaterpump mechanical seal
isdefectiveandthewaterpumpshouldbereplaced.
C
,.
REMOVAL
Drainthecoolantfromthesystem (page7-7).
thewaterhose.
Remove the bolts, sealing washer and water pump
cover.
Disconnectthewaterhose.
RemovetheO-ringsandwaterpump.
INSTALLATION
CoatanewO-ringwitbengineoiland install itonto
thesteppedsectionofthewaterpump.
Install the water pump while aligning its groove
withtheprojectionoftheoilpumpshaft.
7-16
-----------------
COOLINGSYSTEM
Connectthewaterhose(page1-22).
Tightenthewaterhose band screwtothespecified
range (page7-10).
Install a new O-ring into the groove in the water
pump.
Align the bolt holes in the pump and crankcase,
theninstallthewaterpumpcoverwiththeboltsand
anewsealingwasher.
Tighten the bolts tothe specifiedtorque in a criss-
crosspattern inseveralsteps.
TORQUE: 13Nm(1.3 kgfm,10Ibfft)
Connectthewaterhose(page 1-22) andtightenthe
waterhosebandscrewtothespecified range
(page7-10).
....
lIiIiiiI'
SEALINGWASHER
RADIATORRESERVETANK
REMOVAL/lNSlALLAliON
Disconnect the siphon hose from the reserve tank
RESERVETANK
anddrainthecoolant.
Removetheboltandreservetank.
Route the hoses Installationis inthereverse orderofremoval.
properlv
(page 1-22).
SIPHON HOSE BOLT
7-17
MEMO
8. ENGINEREMOVAL/INSTALLATION
8-4
SERVICEINFORMATION.. .. 8-3 ENGINEINSTALLATION 8-7 -
COMPONENTLOCATION 8-2 ENGINEREMOVAL
8-1
COMPONENT LOCATION
26 N'm (2.7 kgfm, 19 IbHt)
10 N'm (1.0 kgfm, 7lbHt)
12 N'm (1.2 kgf'm, 91bHt)
-
1.9 N'm (0.2 kgf'm, 1.4IbHt)
39 N'm (4.0 kgfm, 29 IbHt)
26 N'm (2.7 kgfm, 19 IbHt)
54 Nm {5.5 kgfm, 40 Ibfftj
54 N'm (5.5 kgf'm, 40 Ibfft)
8-2.
SERVICEINFORMATION
GENERAL
A hoistorequivalentisrequiredtosupportthemotorcyclewhen removingand installingtheengine.
Afloorjackorotheradjustablesupportisrequiredtosupportand maneuvertheengine.
When installing theengine, be suretotighten the engine mountingfastenerstothespecified torque in thespecified
sequence. Ifyou make a mistakewiththetightening torque orsequence, loosen all mounting fasteners, then tighten
themagaintothespecifiedtorqueinthecorrectsequence.
Do notsupporttheengineusingtheengineoilfilteroritwill bedamaged.
Whenremoving/installingtheengine,tapetheframearoundtheenginebeforehandforframeprotection.
Thefollowingcomponents requireengineremovalforservicing.
- Cylinderhead (page9-14)
- Cylinder/piston (page 10-4)
- Crankshaft(page13-10)
- Transmission(Includinggearshiftdrum/shiftfork: page 13-20)
- Outputgearcase (page 13-28)
- Oil pump(page5-6)
Thefollowingcomponentscan be servicedwiththeengineintheframe.
- Camshaft(page9-8)
- Carburetor(page6-7)
- Waterpump(page7-16)
- Clutch/gearshiftlinkage(page 11-3)
- Alternator/starterclutch (page 12-3)
- Startermotor(page20-6)
SPECIFICATIONS
ITEM SPECIFICATIONS
Enginedry weight 72.3kg (159.4Ibs)
Engineoilcapacityatdisassembly 3.2 liters(3.4USqt,2.8Impqt)
Coolalltcapadty(radiatorandengine) 1.58liters(1.67 USqt,1.39Impqt)
'<,
TORQUEVALVES
EngJn$lmquntingI1Yt
Enginehanger
Startermotorcableterrninalnut
. .

GearspJft:a.fmRinchbolf ..
54N'm(5.5 kgf'm,40 IbHt)
26 N'm(2.7 kgf'm,19 IbHt)
10 Nm(1.0 kgfm,7IbHt)
1.9 Nm(0.2 kgfm, 1.4IbHt)
39N'm(4.0 kgf'm,29 IbHt)
39Nm(4.0 kgf'm,29 IbHt)
12 N'm(1.2 kgfm,9IbHt)
ENGINE REMOVAL/INSTALLATION
ENGINEREMOVAL
Draintheengineoil(page4-13).
Drainthecoolantfromthecoolingsystem
(page7-7).
Removethefollowing:
- Fuel tank(page3-4)
- Sparkplugcaps (page4-9)
- Rearbrakelightswitch(page21-18)
- Brake pedal (page16-17)
- Leftcrankcaserearcover(page3-5)
- Exhaustsystem(page3-8)
- Radiator(page7-11)
- Overheadcovers(page9-6)
- Clutchcover(page11-5)
- Alternatorcover(page4-10)
NOTE:
Wraptheintakemanifold portwith a shoptowelor
coverthem with a piece oftapeto prevent anyfor-
eign materialfromdroppingintotheengine. .
Disconnectthefollowingconnectors:
Ignitionswitch2P (Black) and 1P(Natural)
- VSsensor3P (Natural)
- Alternator3P (Natural)
Disconnect the ignition pulse generator 2P (Red)
connector.
8-4.
Releasethewiresfromtheclampsandwirebands.
Disconnecttheneutralswitchconnector.
Disconnect the EOP switch wire by removing the
terminalscrew.
Removethepinch boltand gearshiftarm.
Disconnectthesecondaryairsupplyhosesfromthe
PAIRcheckvalvecovers.
RElmove the clutch cable holder by removing the
boltand disconnectthe clutch cable end from the
,clutch lifterarm.
-----
8-5
----- -------- --
------------------------ ------ --- ----
ENGINE REMOVAL/lNSlALLAliON
Open the terminal cover and remove the starter
motorterminalnut.
Disconnectthestartermotorcable.
Removetheboltand disconnectthegroundcable.
Removethebolts,nut,rightmainfootpegand brake
pedal bracketsfromtheframe.
FOOTPEG BRACKET BOLTS NUT
The jack height Place afloorjackorotheradjustablesupportunder
must be continually theengine.
adjusted to relieve
Removetherearenginemountingnuts.
stress for bolt
Remove the bolts and right rear engine hanger
removal.
plates.
Removetherearenginemountingbolts.
Removetheboltsandleftrearenginehangerplate.
8-6.
Removethefrontenginemountingnuts.
Removetheboltsandfrontenginehangerplate.
Removetheenginemounting boltsandcollar.
OUTPUTSHAFT
Releasethejointbootfromtheoutputgearcase.
Duringengine Move the engine forward and release the output
removal, holdthe shaftfromtheuniversaljointintheswingarm.
enginesecurelyand maneuvertheengineand removeitoutof
becarefulnot frametotheright.
damage theframe '
andengine.
ENGINEINSTAL-LAtJON
NOTE:
iDEl hangerbolts.
gbolts and nuts loosely
instalh"the." ,.
tbebolts and nuts to the
"specifiedsequence.
BestC-
. mountingfasteners
tot' tilespecifiedsequence.
ltv ththetighteningtorque
ors atnountingfasteners,then
o.,tljespecifiedtorqueinthe
correct
Routet

Duringengine Ul:;ingaflo()rjackor adjustablesupport,care-
instal/ation, holdthe- fullypiagetheengineintothe-frameand maneuver
enginesecurelyarid iqntoplace.
becarefulhot to'.. i-'.,
damage:the
aridengine:
8-7
Carefully align the Apply 1 g of molybdenum disulfide paste to the out-
mounting points. put shaft splines (universal joint side). Engage the
output shaft with the universal joint.
Loosely install all engine hanger plates, mounting
fasteners and collar.
Tighten the front lower, then front upper engine
mounting nuts to the specified torque.
TORQUE: 54 Nm (5.5 kgfm, 40 Ibfft)
Tighten the rear lower, then rear upper engine
mounting nuts to the specified torque.
TORQUE: 54 Nm (5.5 kgfm, 40 Ibfft)
Tighten the front e,ngine hanger plate bolts to the ..
specified torque. .
TORQUE: 26 N'm(2:lkgfm;19 Ibfft)
,'t)- -
UNIVERSAL JOINT
----- -------_. ----
8-8
---------- -
Tighten the right rear lower engine hanger plate
TORQUE:26Nm(2.7 kgfm,19Ibf.ft)
Tightenthele.ftrearupper enginehangerplatebolts
tothespecifiedtorque.
Tighten the right rear upper engine hanger plate
TORQUE: Ibfft)
FBRAK'E PEDAL
' '
...
...
rightrnainfootpegandbrakepedal
etsandtlghtelJ the, bolts,and nut to the specIfIed
c; '. ," . ,

moulllingbolt/nut:
39Nht(4.0"kgf.m,29Ibf.ft)
FOOTPEG BRACKET BOLTS NUT
8-9
Connectthestartermotorcable andtightentheter-
minalnuttothespecifiedtorque.
Connect the ground cable and tighten the bolt
securely.
Closetheterminalcoversecurely.
Connecttheclutchcableendtotheclutch lifterarm.
Installtheclutchcableholderandbolt.
Tightenthebolt,securely.
ConnectthesecondaryairsupplyhosestothePAIR
checkvalvecovers.
Install the gearshift arm to the gearshift spindle,
aligningwiththepunch marks.
Tightenthegearshiftarm pinchbolttothespecified
torque. .
...--_.....
...--
8-10
Clampand bindthewireswiththeclamps and wire
bands.
Connecttheneutralswitchconnector.
Connectthe EOP switch wire bytightening theter-
minalscrewtothespecifiedtorque.
TORQUE: 1.9N'm(0.2kgf'm,1.4Ibfft)
Connectthe ignition pulse generator 2P (Red) con-
nector.
Connectthefollowingconnectors:
- Ignitionswitch2P(Black) and 1P(Natural)
- VS sensor3P (Natural)
- Alternator3P (Natural)
Installthejollowing:
- Radiator(page7-15)
- Exhaustsystem(page3-11)
- Sparkplugcaps(page4-10)
- Brakepedal(page16-19)
- Overheadcovers(page9-31)
- Clutch cover(page 11-22)
- Alternatorcover(page4-12)
- Fuel tank(page3-4)
Fillthecrankcasewithengineoil(page4-13).
Checktheengineoillevel(page4-12).
8-11
MEMO
--------- - -
9. CYLINDERHEAD/VALVE
COMPONENT LOCATION 9-2
SERVICE INFORMATION .. 9-3
TROUBLESHOOTING 9-5
CYLINDER COMPRESSION .. .. 9-6
CYLINDER HEAD COVER REMOVAL 9-6
CAMSHAFT REMOVAL .. 9-8
CYLINDER HEAD REMOVAL 9-14
CYLINDER HEAD DiSASSEMBLy 9-15
VALVE GUIDE REPLACEMENT 9-18
_:
VALVE SEAT
INSPECTION/REFACING 9-19,
CYLINDER HEAD ASSEMBLy 9-22
CYLINDER HEAD INSTALLATION.. 9-24
CAMSHAFT INSTALLATION 9-26
CYI.INDER HEAD COVER
INSTALLATION .. .. 9-31
9-1
CYLINDERHEAD/VALVE
COMPONENT LOCATION
10 N'm (1.0 kgfm, 7 IbHt)
- - - - - - - . ~
10 N'm (1.0 kgf'm, 7 IbHt)
~
,
~ ~
~ ~
23 N'm (2.3 kgf'm, 17Ibfft)
47 N'm (4.8 kgfm, 35 Ibfft)
-----"'0
@
~ 10 Nm 11.0 kglm. 71bHt)
23 Nm (2.3 kgf'm, 17 Ibfft)
9-2.
CYLINDER HEAD/VALVE
SERVICEINFORMATION
GENERAL
Thissectioncoversserviceoftherockerarm,camshaft,cylinderheadandvalve.
The rockerarm and camshaftservicescan be donewiththeengineinstalledintheframe.Thecylinderhead and valve
servicerequiresengineremoval.
Becareful nottodamagethematingsurfaceswhen removingthecylinderheadcoverand cylinderhead. Do notstrike
thecylinderheadcoverandcylinderheadtoohardduringremoval.
When disassembling, markand storethedisassembled partstoensurethattheyare reinstalled in theiroriginal loca-
tions.
Clean all disassembled parts with cleaning solvent and drythem by blowing them offwith compressed air before
inspection.
Camshaftand rockerarmlubricatingoil isfedthroughoil passagesinthecylinderheadandcamshaftholder.Cleanthe
oilpassagesbeforeassemblingthecylinderheadandcover.
SPECIFICATIONS
Unit'mm(in)
Cylindercompressionat400 rpm 1,37398kPa (14.01.0kgf/cm' ,
-
19914psi)
Valveclearance IN 0.150.02 (0.0060.001) -
EX 0.200.02(0.0080.001) -
CamchaintensionerwedgeBlength - 6(0.2)
Camshaft Camlobeheight IN 37.188- 37.348(1.4641 - 1.4704) 37.16 (1.463)
EX 37.605- 37.765(1.4805- 1.4868) 37.58 (1.480)
Runout IN/EX - 0.05 (0.002)
JournaIO.D. IN/EX 21.959- 21.980(0.8645- 0.8654) 21.90(0.862)
Oilclearance IN/EX 0.020- 0.141 (0.0008- 0.0056) 0.16(0.006)
Rocker arm, RockerarmshaftO.D. IN/EX 11.966- 11.984(0.4711 - 0.4718) 11.83(0.466)
rockerarm RockerarmI.D. IN/EX 12.000- 12.018(0.4724- 0.4731) 12.05(0.474)
shaft
Rockerarm-to-shaftclearance 0.016- 0.052(0.0006- 0.0020) 0.07 (0.003)
Valve,valve ValvestemO.D. IN 5.475- 5.490(0.2156- 0.2161) 5.45 (0.215)
guide
EX 5.455- 5.470(0.2148- 0.2154) 5.41 (0.213)
ValveguideI.D. IN 5.500- 5.510(0.2165- 0.2169) 5.56 (0.219)
EX 5.500- 5.512(0.2165- 0.2170) 5.56(0.219)
Stem-to-guidec1ear- IN 0.010- 0.035(0.0004- 0.0014) 0.10(0.004)
ance
EX 0.030- 0.057(0.0012- 0.0022) 0.11 (0.004)
Valveguideprojection IN 18.7- 18.9(0.736'- 0.744) -
abovecylinderhead
EX 17.2- 17.4(0.68- 0.69) -
Valveseatwidth IN/EX 0.90- 1.10 (0.035- 0.043) 1.5 (0.06)
Valvespring Freelength IN 42.14(1.659) 40.58(1.598)
EX 46.11 (1.815) 44.72(1.761)
Cylinderheadwarpage - 0.10 (0.004)
TORQUEVALUES
Cylinderheadcoverbolt
Cylinderhead 10mmnut
Cylinderhead8mmbolt
Camsprocketbolt
Camchaintensionerbolt
Camshaftholderbolt
Camshaftholdernut
Overheadcoversocketbolt
Rear PAIR checkvalvecover
bolt
23N'm(2.3 kgfm,17Ibfft)
23Nm(2.3 kgf'm,17Ibfft)
23 N'm(2.3 kgfm, 17Ibfft)
7N'm(0.7kgf'm,5.2 Ibfft)
Applyengineoiltothethreadsandseatingsurface
Applyengineoiltothethreadsandseatingsurface
Applylockingagenttothethreads
Seepage9-25
Revised: September2008,2007-2009VT750C2
9-3
CYLINDERHEAD/VALVE
TOOLS
Valve spring compressor
07757-0010000
Valve guide reamer, 5.510 mm
07984-2000001
or 07984-200000D (U.S.A. only)
Valve guide driver, 5.5 mm
07742-0010100
Seat cutter, 27.5 mm (45
0
IN)
07780-0010200
or e'quivalent commercially avail-
able in U.S.A.
Seat cutter, 35 mm (45
0
EX)
07780-0010400
able in U.S.A.
Flat cutter, 28 mm (32
0
IN)
07780-0012100
able in U.S.A.
Flat cutter, 35 mm (32
0
EX)
07780-0012300
able in U.S.A.
Interior cutter, 30 mm (60
0
IN)
07780-0014000
able in U.S.A.
Interior cutter, 37.5 mm (60
0
EX)
07780-0014100
able in U.S.A.
Cutter holder, 5.5 mm
07781-0010101
able in U.S.A.
Valve guide driver
07743-0020000
Not available in U.S.A.
9-4
CYLINDERHEAD/VALVE
TROUBLESHOOTING
Enginetop-end problemsusuallyaffectengineperformance.Thesecan be diagnosedbyacompressiontest,orbytracing
top-endnoisewithasoundingrodorstethoscope.
Compressiontoolow,hardstartingorpoorperformanceatlowspeed
Valves
- Incorrectvalveadjustment
- Burnedorbentvalves
- Incorrectvalvetiming
- Brokenvalvespring
- Unevenvalveseating
- Valvestuckopen
Cylinderhead
- Leaking ordamagedcylinderheadgasket
- Warpedorcrackedcylinderhead
- Loosesparkphig
Cylinder/piston problem(page 10-3)
Compr'lfsiontoohigh
Excessive build-uponpistonheadorcombustionchamber

Worn.valv:estemorvalveguide
Damagedstemseal
Cylinder/pistonproblem(page10-3)
Excessivenoise
Incorrectvalveclearance
Stickingvalveorbrokenvalvespring
Excessivewornvalveseat
Wornordamagedcamshaft
Wornordamagedrockerarmand/orshaft
Worn rockerarmfollowerorvalvestemend
Worncamsprocketteeth
Worncamchain
Wornordamagedcam chaintensioner
Cylinder/pistonproblem(page10-3)
Rough idle
Lowcylindercompression
9-5
CYLINDERHEAD/VALVE
CYLINDERCOMPRESSION
To measure the
cylinder
compression of
each cylinder,
remove only one
plug at atime.
To avoid discharging
the battery, do not
operate the starter
motor for more
than seven
seconds.
NOTE:
If the engine must be running to do some work,
makesurethearea iswell-ventilated. l\Ieverrun the
engineinan enclosedarea.
Warm upthe engineto normal operating tempera-
ture.
Stoptheengine,disconnectthesparkplugcapsand
removeonesparkplug atatime.
Shiftthetransmissionintoneutral.
Install a compression gauge into the spark plug
hole.
Open thethrottle all the way and crank the engine
withthestartermotoruntilthegaugereading stops
rising.
The maximumreading isusuallyreachedwithin4-
7seconds.
Compressionpressure:
1,37398kPa (14.0 1.0kgf/cm
2
, 19914psi)
at400rpm
Lowcompressioncan becaused by:
- Blowncylinderheadgasket
- Impropervalveadjustment
- Valve leakage
- Wornpistonring orcylinder
Highcompressioncan becaused by:
- Carbon deposits in combustion chamber or on
piston head
CYLINDERHEADCOVERREMOVAL
FRONT
Disconnectthesparkplugcap.
Removetheboltsandfrontrightoverhead cover.
9-6
CYLINDER HEAD/VALVE
Remove the socket bolts and front left over head
cover.
Disconnecttheairsupplyhose.
Removethecylinderheadcoverbolts,washersand
rubberseals.
Be careful not to Removethecylinderheadcoverand gasket.
damage the wire
harness and mating
surfaces when
removing the
cylinder head cover.
REAR
Remove the socket bolts and rear right over head
cover.
9-7
CYLlI\lDERHEAD/VALVE
PAIRCHECKVALVE
. Removethebolts,coverand rearPAIRcheckvalve.
BOLTS
Removetheboltsand rearleftoverheadcover.
Oisconnect the crankcase breather hose from the
cylinderheadcover.
Removethecylinderhead coverbolts,washers and
rubberseals.
Be careful not to Removethecylinderheadcoverandgasket.
damage the wire
harness and mating
surfaces when
removing the
cylinder head cover.
CAMSHAFTREMOVAL
NOTE:
The camshaft can be serviced with the engine
installedinthe.frame.
Tilefrontcamshaftusesthesameserviceproce-
dureastherearcamshaft.
Remove cover(page9-7).
9-8.
CYLINDER HEAD/VALVE
Remove the crankshaft and timing hole caps from
theleftcrankcasecover.
Turn the crankshaft counterclockwise and align the
INDEXNOTCH
"RT'mark(frol"ltc;ylinder: "FT" mark)withtheindex
notchonthe-leffhrankcasecover.
MakesurethepistonisatTDC(TopDead Center)on
stroke so the piston is at TDC on the
-compression stroke when removing the camshaft
holder.
MeasurethecamchaintensionerwedgeBlengthas
shown.
SERVICE L1MIT:..
"RT"MARK
WEDGE B
WEDGEA
9-9
CYLINDERHEAD/VALVE
Be careful not to let Remove the cam sprocket bolt, turn the crankshaft
the cam sprocket counterclockwise one full turn (360) and remove
bolts fall into the theothercamsprocketbolt.
crankcase.
Attach a piece of Removethecam sprocketfromthecamshaftflange ::::!:===
wire to the cam surface.
chain to prevent it
from falling into the
crankcase.
Makesurethepiston is atTDC(TopDeadCenter)on
thecompression stroke.
Loosen the bolts and nuts in a crisscross pattern in
several steps, then remove them and camshaft
holderassembly.
Removethecamshaft.
9-10
CYLINDERHEAD/VALVE
INSPECTION
CAMSHAFTRUNOUT
Support both end journals ofthe camshaftwith V-
blocks and check the camshaft runout with a dial
MEASUREMENTPOINT
indicator.
Actual runoutis1/2thetotal indicatorreading.
SERVICE LIMIT: 0.05mm (0.002in)
CAMLOBEHEIGHT
Checkthecam lobesurfacesforscoringorevidence
ofinsufficient lubrication.
Measureeach cam lobeheight.
SERVICEI.IMITS: IN: 37.16mm(1.463 in)
EX: 37.58mm(1.480 in)
NOTE:
Check the rocker arm ifthe cam lobe is worn or
damaged.
CAMSHAFTJOURNAL
.
Che9kthe camshaft journal surfaces for scoring or
evidenceoMnsLifficientlubrication.
.Measure ca.mshaftjournal.
SERVICELlIVIIT:21.9()mm(0.862in)
NOTE: .
Check the oil passages and camshaft holder for
weaxor damage ifthe journal surface is worn or
damaged.
CAMSpaOCKET
Checkthecamsprocketforwearordamage.
9-11
CYLINDERHEAD/VALVE
CYLINDERHEAD
Check the camshaft journal surfaces of cylinder
JOURNALSURFACES
head for scoring, scratches or evidence of insuffi-
cientlubrication.
CAMSHAFTOILCLEARANCE
Clean offanyoil from the journals ofthe camshaft
holders,cylinderheadand camshaft.
Put the camshaft onto the cylinder head and lay a
strip of plastigauge lengthwise on each camshaft
journal.
NOTE:
Do not block any oil passages with the
plastigauge.
Donotrotatethecamshaftduringinspection.
Carefullyinstallthecamshaftholderandtightenthe
camshaft holder bolts and nuts to the specified
torqueinacrisscrQss pattern inseveralsteps.
TORQUE:23Nm(2.3kgf'm,17Ibf.ft)
Remove the camshaft holder and measure the
widthofeach plastigauge.
Thewidestthicknessdeterminestheoilclearance.
SERVICELIMIT: 0.16mm(0.006in)
Whentheservicelimitisexceeded,replacethecam-
shaftandrechecktheoilclearance.
Replace the cylinder head and camshaft holder if
theoilclearancestillexceedstheservicelimit.
.....----
...-------
9-12
CYLINDERHEAD/VALVE
CAMSHAFTHOLDERDISASSEMBLY
NOTE:
The frontand rearcylindercamshaftholderservice
proceduresarethesame.
Remove the rocker arm shafts, intake and exhaust
rockerarms.
ROCKERARMINSPECTION
Check the sliding surface of the rocker arms for
wear ordamage where they contactthe camshaft,
orforcloggedoil holes.
Check the contact surface of the valve adjusting
screwforwearordamage.
Measurethe1.0.ofeach rockerarm.
SERVICE LIMIT: 12.05 mm (0.474 in)
ROCKERARMSHAFTINSPECTION
Checkthe'rockerarmshaftsforwearordamage.
Measureeach rockerarm shaft0.0.
Calculatethe rockerarm-to-shaftclearance.
Replacetherockerarmand/orshaftifnecessary.
CAMSHAFTHOLDERINSPECTION
Check the camshaft journal surfaces of each cam-
shaft holder for scoring, scratches or evidence of
insufficientlubrication.
EXHAUSTROCKER ARM
INTAKEROCKER ARMS SHAFTS
JOURNALS
9-13
CYLINDERHEAD/VALVE
CYLINDERHEAD REMOVAL
NOTE:
The engine must be removed from the frame
beforeservicingthecylinderhead.
The front and rear cylinder head service proce-
duresarethesame.
Removethefollowing:
- Engine(page8-4)
Cylinderhead cover(page9-6)
- Camshaft(page9-8)
- Intakemanifold(page6-23)
Removethe boltand water hosejointfromthe cyl-
inder.
Rear cylinder head Disconnectthevacuumhose.
only:
Remove the cam chain tensioner bolts and sealing
washers.

Removethecamchaintensioner.
CAMCHAINTENSIONER
Loosen the bolts
and nuts in a
crisscross pattern
in several steps.
Removethefollowingcylinderhead boltsand nuts:
- 6mmbolt
- 8mmbolts
- 10 mmnuts/washers
Be careful not to
damage the mating
surface when
Removethecylinderhead.
removing the
cylinder head.
9-14
CYLINDERHEAD/VALVE
Removethegasketanddowelpins.
Removethecam chain guide.
CYLINDERHEADDISASSEMBLY
Mark all parts Removethesparkplugs(page4-9).
.-
SPRING COMPRESSOR
during disassembly
Removethecottersusingaspecialtool.
so they can be
placed back in their
TOOL:
original position.
Valvespring compressor 07757-0010000
NOTE:
Compressingthevalvespring morethan necessary
willcause lossofvalvespringtension.
Do not reuse the Removethevalvespring compressor,then remove
removed stem seal. theretainer, springandvalve.
Removethestem seal andspringseat.
STEM SEAL
9-15
CYLINDERHEAD/VALVE
Remove the carbon deposits from the combustion
chamberandcleanoffthehead gasketsurface.
Check the spark plug hole and valve areas for
cracks.
INSPECTION
CYLINDERHEAD
Checkthecylinderhead forwarpagewithastraight
edgeangf ~ e l e r gauge.
VALVESPRING
Checkthevalvesp!ingforfatigueordamage.
Measurethefree lengthofeachvalvespring.
SERVICE LIMITS: IN: 40.58mm(1.598in)
EX: 44.72mm(1.761 in)
VALVESTEM
Checkeach valveforbending,burning,scratchesor
abnormalwear.
Insertthevalvesintheiroriginalpositionsinthecyl-
inder head. Check that each valve moves up and
downsmoothlywithoutbinding.
Measureeachvalvestema.D.and recordit.
SERVICELIMITS: IN: 5.45mm(0.215in)
EX: 5.41 mm(0.213in)
~ f
9-16
CYLINDERHEAD/VALVE
VALVEGUIDE
Ream thevalve guideto remove any carbon build-
upbeforemeasuringtheguideI.D.
NOTE:
Take care not to tilt or lean the reamer in the
guide while reaming. Otherwise, the valves
maybe installed slanted, causing oil leakage
fromthestemseal and impropervalveseatcon-
tact.Thismaypreventvalveseatrefacing.
Insertthe reamerfromthe combustion chamber
side of the head and always rotate the reamer
clockwise.
TOOLS:
Valveguidereamer
5.510 mm(IN/EX) 07984-2000001 or
07984-2000000
(U.S.A.only)
MeasureeachvalveguideI.D.and record it.
EX: 5.56mm(0.219in)
Subtracteachvalvestem O.D. fromthecorrespond-
ingguideI.D.toobtainthestem-to-guideclearance.
EX: 0.11 mm(0.004in)
Ifthe stem-to-guide clearance exceeds the service
limit, determine if a new guide with standard
dimensionswould bring the clearance within toler-
ance.
Ifso, replace any guides as necessary and ream to
fit.
If the stem-to-guide clearance exceeds the service
limitwithanewguide,alsoreplacethevalve.
1IIt:
NOTE:
Inspect and reface the valve seats whenever the
valveguidesarereplaced (page9-19).
CAMCHAINGUIDE
Checkthecam chainguideforwearordamage.
CAM CHAIN GUIDE
Replacethecam chainguideifnecessary.
9-17
CYLINDERHEAD/VALVE
CAMCHAINTENSIONER
Checkthecamchaintensionerforwearordamage.
CAM CHAINTENSIONER
Replacethecamchaintensionerifnecessary.
\
VALVEGUIDEREPLACEMENT
NOTE:
Refinish the valve seats whenever thevalveguides
are replacedtopreventunevenseating.
Chill newvalveguides inthefreezersection ofa
refrigeratorforaboutan hour.
Donotuseatorch Heatthecylinderhead to 130- 140C (266- 284F)
toheatthecylinder with a hot plate or oven. Do not heat the cylinder
head;itmaycause headbeyond150C(302F). Usetemperatureindica-
warping. torsticks, available from welding supply stores, to
be sure the cylinder head is heated to the proper
temperature.
To avoid burns, wear insulated gloves when han-
dlingtheheatedcylinderhead.
Becarefulnotto Support the cylinder head and drive out the old
damagethe guides from the combustion chamber side of the
cylinderhead. head.
TOOL:
Valveguidedriver
5.5mm(IN/EX) 07742-0010100
Adjust the valve guide driver to the valve guide
height.
TOOL:
Valveguidedriver 07743-0020000
Notavailablein
U.S.A.
I
VALVEGUIDEPROJECTIONABOVECYLINDER
HEAD:
IN: 18.7- 18.9mm(0.736- 0.744in)
EX: 17.2- 17.4mm(0.68- 0.69in)
Drive newguides in from thecamshaft sideofthe
cylinder head to the valve guide height while the
cylinderheadisstill heated.
Revised:Sectember2008.2007-2009VT750C2
9-18
CYUNDERHEAD/VALVE
Let the cylinder head cool to room temperature,
then ream newvalveguides.
TOOLS:
Valveguidereamer
5.510mm(IN/EX) 07984-2000001 or
07984-2000000
(U.S.A.only)
NOTE:
Take care not to tilt or lean the reamer in the
guide while reaming. Otherwise, the valves
maybe installed slanted, causing oil leakage
fromthestemseal and impropervalveseatcon-
tact.Thismaypreventvalveseatrefacing.
Insertthe reamerfromthecombustion chamber
side ofthe head and always rotate the reamer
clockwise.
Clean the cylinder head thoroughlyto remove any
metalparticlesafterreaming.
Refacethevalveseat(page9-20).
VALVESEATINSPECTION/REFACING
INSPECTION
Clean all intake and exhaust valves thoroughly to
removecarbondeposits.
Apply a thin coat of Prussian Blue to each valve
face.
Tap the valve against the valve seat several times
using a hand-lapping tool withoutrotating valveto
makeaclearpattern.
Removethevalveandinspectthevalveseatface.
NOTE:
The valve cannot be ground. If the valve face is
burned or badly worn or if it contacts the seat
unevenly,replacethevalve.
Inspectthevalveseatfacefor:
Damagedface:
- Replacethevalveandrefacethevalveseat.
Unevenseatwidth:
- Replacethevalveandrefacethevalveseat.
DAMAGEDFACE UNEVENSEAT
WIDTH
9 ~ 9
---- ~ ~ _ ... _._-- -----
CYLINDERHEAD/VALVE
Contactarea (too high ortoolowarea):
- Refacethevalveseat.
TOO LOW TOO HIGH
Inspectthewidthofthevalveseat.
The valve seat contact should be withinthe speci-
fiedwidthand evenall aroundthecircumference.
STANDARD: 0.90- 1.10mm(0.035- 0.043in)
Ifthe valve seat width is not within specification,
refacethevalveseat.
VALVESEATREFACING
NOTE:
VALVE SEAT
CONTACTWIDTH
FolioVI' the refacing manufacturer's operating
instructions.
RefaceAhe valve seat wheneverthevalve guide
replaced.
Be"careful nottogrindtheseatmorethanneces-
sary.
Ifthecontactarea istoo high on thevalve,theseat
mustbeloweredusinga32flatcutter.
Ifthe contactarea istoo Iowanthevalve,the seat
mustberaised usinga60interiorcutter.
\ b
45
"
I", 32" \ 73:"
--------- -----
CYLINDERHEAD/VALVE
Usinga45
0
cutter,removeanyroughnessorirregu-
laritiesfromtheseat.
TOOLS:
Seatcutter,27.5 mm(IN)
Seatcutter,35mm(EX)
Cutterholder,5.5mm
07780-0010200
07780-0010400
07781-0010101
orequivalentcommerciallyavailableinU.S.A.
ROUGHNESS
Using a32
0
cutter, remove thetop 1/4 ofthe exist-
ingvalveseatmaterial.
TOOLS:
Flatcutter,28mm(IN) 07780-0012100
Flatcutter,35mm(EX) 07780-0012300
Cutterholder,5.5mm 07781-0010101
Usinga60
0
cutter,removethebottom1/4oftheold
seat.
TOOLS:
Interiorcutter,30mm(IN) 07780-0014000
Interiorcutter,37.5 mm(EX) 7 7 8 ~ 4
Cutterholder,5.5mm 07781-0010101
Using a 45 seat cutter, cut the seat to the proper
width.
Make sure that all pitting and irregularities are
removed.
OLDSEATWIDTH
OLDSEATWIDTH
\
60
D
9-21
CYLINDERHEAD/VALVE
After cutting the seat, apply lapping compound to
the valve face, and lap the valve using light pres-
sure.
Excessive lapping pressure maydeformordam-
agetheseat.
Change the angle of lapping tool frequently to
preventunevenseatwear.
Lappingcompoundcan causedamageifitenters
betweenthevalvestemand guide.
After lapping, wash any residual compound offthe
cylinderhead andvalve.
Rechecktheseatcontactafterlapping.
CYLINDER..lEADASSEMBLY
INTAKEVALVES

e
()

VALVE SPRING
SPRING SEAT
STEM SEAL:fI
VALVE GUIDE
EXHAUSTVALVE
Blowoutall oftheoil passages inthecylinderhead
withcompressedair.
Exhaust stem seal Installthespringseatand newstemseal.
has stopper rings.
IN: EX:

9-22
- ------ -----------
-
CYLINDERHEAD/VALVE
Lubricatethemolybdenumdisulfideoiltothevalve
guideslidingsurfaceofthevalvestem.
Installthevalveintothevalveguide.
NOTE:
Exhaust valve spring has a larger 0.0. than
intakevalvespring.
Toavoiddamagetothestem seal,turnthevalve
slowlywheninstallingthevalve.
Install thevalvespringwithtightlywoundcoilsfac-
ingthecombustionchamber.
Installtilespringretainer.
:--".
Grease the cotters thecottersusingaspecialtool.
SPRINGCOMPRESSOR
to ease , ,.,;', ','
spring 07757-0010000
;iN()i[E:
springs more than neces-
sarywillcause lossQfvaIvespringtension.
head so the valve heads will
nqtcontacl.anythingandpossiblygetdamaged.
gently with two plastic ham-
. firmlyas shown.
(page4-10).
9..23
CYLINDERHEADNALVE
CYLINDERHEADINSTALLATION
NOTE:
The front cylinder head uses the same service
procedureastherearcylinderhead.
Be careful not to damage the mating surfaces
whencleaningthecylinderheadmatingsurface.
Whencleaningthecylinderhead matingsurface,
placetheshoptoweloverthecylinderopeningto
preventdustordirtfromenteringtheengine.
Cleanthegasketmatingsurfacesofthecylinderand
cylinderheadthoroughly,beingcareful nottodam-
agethem.
Install the cam chain guide by aligning the guide
endwiththegrooveinthecrankcaseandthebosses
withthegrooveinthecylinder.
Installthedowel pinsandanewgasket.
Thecylinderheadsare identified bymarksontheir
oilpockts.
"F": Frontcylinderhead
"R": Rearcylinderhead
9-24
..... <,.4''''''''
CYLINDERHEAD/VALVE
Installthecylinderheadtothecylinder.
Applyengineoiltothecylinderhead each boltsand
nutsthreadsand seating surfaces.
Install andtightenthecylinderhead 8mmbolts, 10
mmnutsandwashertothespecifiedtorque.
TORQUE:
10mmnut: 47Nm(4.8kgfm,35Ibfft)
8mmbolt: 23Nm(2.3kgfm,17IbHt)
Installandtightenthe6mmboltsecurely.
NOTE:
Tighten all to hand-tight, then torque the larger
fastenersbeforetighteningthesmallerfasteners.
Tightentheboltsand nutsinacrisscross pattern
inseveralsteps.
Installthecam chaintensioner,aligningitsendwith
thegrooveinthecrankcase.
Tightenthetensionerboltsas follow:
BOLTS/SEALINGWASHER
1. Temporarilyinstall the tensionerbolts with new
sealing.washers. fI,

2. Tighten the cylinder head side cam chain
tensionerbolttothespecifiedtorque.
3. Tighten the cylinder side cam chain tensioner
bolttothespecifiedtorque.
Installanewa-ringtothewaterhosejoint.
9-25
CYLINDERHEAD/VALVE
Installthewaterhosejointbyaligningtheboltholes
inthestopperplateandcylinderhead.
Installandtightentheboltsecurely.
Rear cylinder head Connectthevacuum hose.
only:
Installtheengineintotheframe(page8-7).
- Camshaft(page9-26)
- Cylinderhead~ v r (page9-31)
CAMSHAFTINSTALLATION
CAMSHAFTHOLDERASSEMBLY
EXHAUSTROCKERARM SHAFT
-,
INTAKEROCKERARMSHAFT
,
EXHAUSTROCKERARM
VALVEADJUSTINGSCREW
~ LOCKNUT
~
I
CAMSHAFTHOLDER
When Apply engine oitto the valve adjusting screw lock
disassembling the nutthreadsandseating surface.
valve adjusting lock Installthevalveadjustingscrewandlocknut.
nut and adjusting
screw.
ADJUSTINGSCREW
~ LOCKNUT
CYLINDERHEAD/VALVE
NOTE:
The exhaust rocker arm has larger slipper face
thantheintakerockerarm.
The intake rocker arm shaft has two holes on
each end.
The exhaust rocker arm shaft has two grooves
oneachend.
Apply molybdenum disulfide oil solution to the
rockerarmshaftoutersurface.
Installtherockerarmsandshafts.
Align the intake rocker arm shaft holes with the
HOLES
camshaftholderholes.
Aligntheexhaustrockerarmshaftgrooveswiththe
camshaftholderholes.
CAMSHAFTTIMINGPROCEDURE
NOTE:
The camshafts are identified by the stamped
marks:
"F": Frontcylindercamshaft
"R": Rearcylindercamshaft
Ifboth (front and rear) camshafts are removed,
install the front cylinder camshaft first, then
installtherearcylindercamshaft.
Ifthe rear cylinder head is notserviced, remove
the rear cylinder head cover to check the cam-
shaftposition.
Ifthefrontcylinderhead isnotserviced,remove
the front cylinder head coverto check the cam-
shaftposition.
HOLES
9-27
CYLINDERHEAD/VALVE
If the rear cylinder
has not been
serviced, begin
here.
If both camshafts
have been serviced,
begin installation of
the front camshaft.
FRONTCYLINDERTDCSETTING
Remove the rear cylinder head cover (page 9-7) and
check the rear cylinder camshaft position as follows:
Turn the crankshaft counterclockwise and align the
"RT" mark on the flywheel with the index notch on
the left crankcase cover, then check the identifica-
tion mark "R" on the rear camshaft.
- If the "R" mark faces up, turn the crankshaft
counterclockwise 1-1n (412) turn (align the "FT"
mark on the flywheel with the index notch) and
begin installation of the front camshaft.
- If the "R" mark faces down (cannot be seen), turn
the crankshaft counterclockwise 1n (52) turn
(align the "FT" mark with the index notch) and
begin installation of the front camshaft.
Install the front camshaft (page 9-29).
BOTHCYLINDERTDCSETTING
Align the "FT" mark on the flywheel with the index
notch on the left crankcase cover.
Install the front camshaft (page 9-29).
Set the rear cylinder at TDC (page 9-29).
Install the rear camshaft (page 9-29).
INDEX NOTCH
"RT" MARK
"R" MARK
INDEX NOTCH
"FT" MARK
9-28
CYUNDERHEAD/VALVE
REARCYLINDERTDCSETIING
Ifthefrontcylinder Remove the front cylinder head cover (page 9-6)
INDEXNOTCH
hasnotbeen and check the front cylinder camshaft position as
serviced, begin follows:
here.
Turn the crankshaftcounterclockwise and align the
"FT" mark on theflywheel with the index notch on
the left crankcase cover, then check the identifica-
tionmark"F" onthefrontcamshaft.
- Ifthe"F"markfacesup,turnthecrankshaftcoun-
turn (align the "RT" mark
onthe W}ththeindexnotch) and begin
installationoftherearcamshaft.
Ifthe""F" (cannotbe seen),turn
otHe l-Sn (668) turn (align
the "RT" mark with the index notch) and begin
installationoftherearcamshaft.
Installthe reatcan1shaftlJsing thefollowing proce-
"F" MARK
dure.
TION
NOTE: 0 0 .. 00 . 0
TIMING PRO-
. thecamshaft.
The frontandrear journal surfaces ...----
camshaftsare
installedwiththe .Jpstall thecamshaftwith1h8ccamshaftidentification
sameprocedure. mark(R: rearcams;haft,F:fr,qntcamshaft)facingup.
9-29
with
CYLINDER HEAD/VALVE
Lubricate each rocker arm slipper surface
molybdenumdisulfideoil.
NOTE:
Before camshaft holder installation, loosen
valveadjustingscrewand locknutfully.
Installthecamshaftholderassembly.
Installthecamshaftholderboltsandnuts.
Tightentheboltsandnutstothespecifiedtorquein
acrisscrosspattern inseveral steps.
TORQUE:
Camsllaft holder bolt: 23 N'm (2.3 kgfm, 17 Ibfftl
Camshaft holder nut: 23 Nm (2.3 kgfm, 17 Ibfftl
Install the cam sprocket to the cam chain with the
"IN" markfacing inside.
Installthecarn sprocketon.thecamshaftflange and
check that thetirning-marks align with the upper
surfaceofthecylibderhead.
9..30
Be careful not tolet
the cam sprocket
bolts fall into the
crankcase.
Cleanand applyalockingagenttothecamsprocket
boltthreads.
Align the cam sprocket bolt holes in the cam
sprocketandcamshaft.
Temporarilyinstallthecam sprocketbolt.
Turn the crankshaft counterclockwise 360
0
and
tighten the other sprocket bolt to the specified
torque.
TORQUE:23Nm(2.3 kgfm,17Ibfft)
Turn the crankshaft counterclockwise 360
0
and
tighten the other sprocket bolt to the specified
torque.
Remove anO.D.2mmpinwhileholdingcam chain
tensionerwedgeAandpushingdownthewedgeB.
NOTE:
Becarefulnottoletan 0.0.2mmpinfallintothe
crankcase.
Donotforgettoremovean0.0.2mmpinbefore
installingthecylinderhead cover.
Fill the oil pockets inthecylinder head with engine
oil.
Adjustthevalveclearance(page4-10).
CYLINDERHEAD/VALVE
CYLINDE'R"cRIiAD, COVER
INSTAtLATI'OIl,
" head mating

replace it if
'"
ApplY'P'fg' a.""Q,ndabond HT or equivalent to
thegasket.g}iOftheCYlinderheadcover.
Installthe
ProHondaHondabondHT
o
o
CYLINDER HEADCOVER
9-31
------
CYLINDERHEAD/VALVE
FRONT
Clean thecylinderhead covermatingsurface ofthe
cylinderhead.
Installthefrontcylinderheadcoveronthefrontcyl-
inderhead.
Checkthe condition ofthe rubber seals, replace
themifnecessary.
Installtl)erubbersealsontothecylinderhead cover
inthedrtectionas shown.
RUBBERSEAL
Installthewashers.
InstaUand tighten the cyljnder head cover bolts to
thespecifiedtorque.
TORpUE:lONm(1.0 kgfm, 7Ibf.ft)
Connecftheairsupplyhose.
Installthefrontleftoverhead coverandtightenthe- ...
socketboltstothespecifiedtorque.
TORQUE:10 Nm (1.0 kgfm, 7Ibf.ft)
Connectthesparkplugcap.
9-32
CYLINDERHEAD/VALVE
Install the front right over head cover and tighten
thesocketboltstothespecifiedtorque.
.---
REAR
Clean thecylinderhead covermatingsurfaceofthe
cylinderhead.
Installtherearcylinderheadcoverontherearcylin-
derhead.
Installtherubberseals(page9-32).
Installthewashers.
Install and tighten the cylinder head cover boltsto
thes p e i f i ~ torque.
Connectthecrankcasebreatherhose.
Install the rear leftoverhead coverand tighten the ::======:::::
InstalltherearPAIR checkvalveand cover.
Install and tightenthe rear PAIR check valve cover
TORQUE:7Nm(0.7 kgfm,5.2IbHt)
9-33
- ----- ------
CYLINDERHEAD/VALVE
Installtherearrightoverheadcoverandtightenthe
9-34
10.CYLINDER/PISTON
COMPONENTLOCATION.. .. 10-2 CYLINDER/PISTON REMOVAL10-4
SERVICEINFORMATION.. ...... ..10-3 CYLINDER/PISTONINSTALLATION10-9
TROUBLESHOOTING 10-3
-
10-1

CYUNDER/PISTON
COMPONENTLOCATION
10-2
CYUNDER/PISTON
SERVICEINFORMATION
GENERAL
This section covers service ofthe piston and cylinder. To service these parts, the engine must be removed from the
frame.
Take carenottodamagethecylinderwallsand pistons.
Be careful nottodamagethemating surfaces when removingthecylinder. Do notstrikethecylindertoo hard during
removal.
When disassembling, markand storethe disassembled partsto ensurethatthey are reinstalled intheiroriginal loca-
tions.
Clean all disassembled parts with cleaning solvent and dry them by blowing them offwith compressed air before
inspection.
Camshaftandrockerarmlubricatingoilisfedthroughoil passagesinthecylinder.Cleantheoilpassagesbeforeinstall-
ingthecylinder.
SPECIFICATIONS
Unit:mm(in)
Cylinder 1.0. 79.000- 79.015(3.1102- 3.1108) 79.10(3.114)
Out-of-round - 0.06(0.002)
Taper - 0.06(0.002)
Warpage - 0.10 (0.004)
Piston,piston
pin,piston
Piston0.0.at17 mm(0.7 in)from
thebottom
78.97- 78.99(3.109- 3.110) 78.90(3.106)
rings Piston pinbore1.0. 18.002-18.008(0.7087- 0.7090) 18.05(0.711)
Pistonpin0.0. 17.994- 18.000(0.7084- 0.7087) 17.98(0.708)
Piston-to-piston pinclearance 0.002- 0.014(0.0001 - 0.0006) 0.04(0.002)
Pistonring end Top 0.15- 0.25(0.006- 0.010) 0.4(0.02)
gap
Second 0.25- 0.40(0.010- 0.016) 0.6(0.02)
Oil(siderail) 0.20- 0.80(0.008- 0.031) 1.0 (0.04)
Piston ring-to- Top 0.025- 0.055(0.0010- 0.0022) 0.08(0.003)
ring grooveclear-
ance
.
Second 0.015- 0.045(0.0006- 0.0018) 0.07 (0.003)
Cylinder-to-pistonclearance 0.010- 0.045(0.0004- 0.0018) 0.10 (0.004)
Connecting rodsmallend1.0. 18.016-18.034(0.7093- 0.7100) 18.07(0.711)
Connectingrod-to-pistonpinclearance 0.D16 - 0.040(0.0006- 0.0016) 0.06(0.002)
TORQUEVALUES
Cylinderstud bolt(8 mm) See page10-8
Cylinderstudbolt(10 mm) See page10-8
Cylinderstudbolt(12 mm) See page10-8
l'ROUBLESHOOTING
Compressiontoolow,hardstartingorpoorperformanceatlowspeed
Leaking cylinderheadgasket
Worn,stuckorbrokenpiston ring
Wornordamagedcylinderand piston
Compressiontoohigh,overheatingorknocking
Excessivecarbonbuilt-uponpistonheadot combustionchamber
Excessivesmoke
Worncylinder,pistonorpiston rings
Improperinstallationofpistonrings
Scoredorscratchedpistonorcylinderwall
Abnormalnoise
Wornpistonpinorpistonpinbore
Worncylinder,pistonorpiston rings
Wornconnectingrodsmallend
CYLINDER/PISTON
CYLINDER/PISTONREMOVAL
CYLINDERREMOVAL
NOTE:
Thefrontcylinderusesthe same service procedure
astherearcylinder.
Removethecylinderhead(page9-14).
Front cylinder only: Removethebolts,waterhosejointand O-ring.
Removetheretaining clips.
Slidethecylinderjointcollartowardeitherthefront
orrearcylinder.
Liftthe cylinderan'd remove it, being careful notto
damagethepistonwiththestudbolts.
NOTE:
Attach a piece ofwire to the cam chain to pre-
ventitfromfallingintothecrankcase.
Do not strike the cylinder too hard and do not
damagethematingsurfacewithascrewdriver.
Removethejointcollarfromthecylinder.
RemovetheO-rings.
10-4
CYLINDER/PISTON
Removethegasketand dowel pins.
Be careful not to Clean offanygasketmaterialfromthecylindermat-
damage the gasket ingsurface.
surface.
PISTONREMOVAL
Place a clean shop Removethepiston pin clipswith pliers.
towel over the Pushthepiston pinoutofthepiston andconnecting
crankcase to rod,and removethepiston.
prevent the piston
pin clips from falling
into the crankcase.
Do not damage the Spread each piston ring and remove it by lifting up
piston ring by apointoppositethegap.
spreading the ends
too far.
Never use a wire Clean carbon depo.sits frol1) thering grooveswith a
brush; it will scratch usedpiston ringthatwill bediscarded.
the groove.
10-5
CYLINDER/PISTON
INSPECTION
PISTON/PISTONRING
Always replace the Inspect the piston rings for smooth movement by
piston rings as a rotating them.The rings should be able to move in
set. theirgrooveswithoutcatching.
Push the ring until the outer surface ofthe piston
ring is nearlyflush withthepiston and measurethe
ring-to-ringgrooveclearance.
SERVICEI.IMITS:
Top: 0;08mm(0.003in)
Second: O:07mm(0.003in)
Insertthepistonringintothebottomofthecylinder
squarely!Cusingthepistoncrown.
Measure-thepistonringendgap.
SERVICELIMITS:
Top: 0.4mm(0.02in)
Second: 0.6mm(0.02in)
Oil(siderail): 1.0mm(0.04in)
Measure the piston0.0. at a point 17 mm (O.7 in)
fromthebottornand90 tothepistonpin hole.
SERVICELIMIT:. 78.90mm (3.106in)
Compare this measurement against the maximum
cylinder 1.0. measurernentand calculate the cylin-
der-to-pistoncfearance(pagei0-7).
SERViCE; I.IMIT: 0.10mm(0.004in)
17 mm(O.7 in)
Measurethepistonpin0.0. atthreepoints.
10-6
CYLINDER/PISTON
Measurethepiston pin bore1.0.
SERVICE LIMIT: 18.05mm(0.711 in)
Calculatethe piston-to-pistonpinclearance.
SERVICEUMIT: 0.04mm(0.002in)
CONNECTINGROD
Measuretheconnectingrodsmallend 1.0.
SERVICELIMIT: 18.07mm(0.711 in)
Calculate the connecting rod-to-piston pin clear-
ance.
SERVICE LIMIT: 0.06mm(0.002in)
CYLINDER
Check thetop ofthe cylinder for warpage with a
straight edge and feeler gaiJge across the stud
holes.
SERVICELIMIT: 0.10 mm(0.004in)
Checkthecylinderwallforscratchesorwear.
Measure the cylinder 1.0. afthree levels on the X
and Y axes. Take the maximum reading to deter-
minethecylinderwear.
Calculatethecylinder-to-pistonclearance.
SERVICELIMIT: 0.10 mm(0.004in)
CYLINDER/PISTON
Calculate the cylinder taper and out-of-round at
threelevelsontheXandYaxes.Takethemaximum
readingtodeterminethetaperandout-of-round.
SERVICELIMITS:
Taper: 0.06mm(0.002in)
Out-of-round: 0.06mm(0.002in)
MIDDLE
tonfittediftheservicelimitsareexceeded.
The cylinder must be rebored and an oversize pis-
Thefollowingoversizepistonsareavailable:
BOTTOM 0.25mm(0.010in)
0.50mm(0.020in)
Thepistontocylinderclearancefortheoversizepis- L ---=::::::==::::....-...
tonmustbe:0.010- 0.045mm(0.0004- 0.0018in).
CYLINDERS"rUDBOLT
REPU\OEMENI
Thread nutsCohto the stud and tighten them
STUD BOLTS
together,anduseawrenchonthemtoturnthestud
boltout.
Applyengineoilto"the10\Verthreadsofanewstud
boltandinstaUjt.
NOTE:
Ii'lsfallthe8mmcand 10 mm stud boltswith itstab
sidefacingthecyllttderheadside.
c'-....... ...--./
-'-" .-.......
./ .."",..-.. _.. .._.. _.........,.
Be suretoverifythestud heightfromthecrankcase r---8-m-m-ST-U-D-------------,
surface. 12 mm
BOLT: 10mm
Adjusttheheightifnecessary. STUDBOLT:
E'!:

.... 0
+1 -H
CDr-.
co'
....
... _
,--..
,
,

--- - -----------
CYLINDER/PISTON
CYLINDER/PISTONINSTALLATION
PISTONRING INSTALLATION
Applyengineoil tothe piston and piston ring outer ,----------------------,
surface.
Be careful not to Carefullyinstallthepiston rings intothe piston ring
damage the piston grooveswiththemarkingsfacingup.
and rings.
NOTE:
Do notconfusethetopandsecond rings.
Toinstalltheoilring,installthespacerfirst,then
installthesiderails.
Stllgger the piston ring end gaps 120
0
apart from
eacnother.
Staggerthesiderail endgapsasshown.
SECOND
RING iii
SPACER "71
20mm(0.8in)
OR MORE
-:71 TOP RING
SIDE
RAILS
PISTONINSTALLATION
Apply molybdenum dis.lHfideoil to the connecting
rodsmallend innersurface.
Place aclean shopt()weloverthecrankcaseto pre-
ventthe,clipfr()mfallirlgintothecrankcase.
-. _ 0'--,' _
Apply oiltothepistonpinoutersurface.
InstaIIJJ;iepiston.
through the piston and con-
nectillg:rq<:kL' ....
10-9
CYLINDER/PISTON
Install new piston pin clips intothe grooves in the
pistonpin hole.
NOTE:
Make sure the piston pin clips are seated
securely.
Do notaligntheclipendgapwiththepistoncut-
out.
CYLINDERINSTALLATION
Cleanthegasketsurfaces ofthecylinderand crank-
casethoroughly,beingcareful nottodamagethem.
InstallnewO-ringstothejointcollar.
Installthejointcollartothecylinder.
Installthedowel pinsandanewgasket.
Apply engine oil to the cylinderwall, piston outer
surfaceand pistonrings.
Routethecamchainthroughthecylinderandinstall
thecylinder overthepiston whilecompressing the
pistonringswithyourfingers.
The front cylinder
uses the same
service procedure
as the rear cylinder.
Be careful not to
damage the piston
rings and cylinder
wall.
10-10
CYLINDER/PISTON
Slidethejointcollarintotheholeinthecylinderand
connectit.
Install the retaining clips into the joint collar
grooves.
Frontcylinderonly: Install a new O-ring into the water hose joint
groove.
Installandtightenthehosejointboltssecurely.
Installthecylinderhead (page9-24),
10-11
MEMO
11.CLUTCH/GEARSHIFTLINKAGE
COMPONENTLOCATION........ .. 11-2
SERVICEINFORMATION.. .. .... 11-3
TROUBLESHOOTING.. ...... .... ..11-4
RIGHTCRANKCASECOVER
REMOVAL...... ...... ............ 11-5
CLUTCH REMOVAL...... .. .. ....11-7
PRIMARYDRIVEGEAR.. 11-12
GEARSHIFTLINKAGE...... .... 11-14
CLUTCH INSTALLATION ........ .. ....11-18
RIGHTCRANKCASECOVER
INSTALLATION 11-21
-
11-1
COMPONENTLOCATION
23 N'm (2.3 kgfm, 17 IbHt)
Q ~
15 N'm (1.5 kgf'm, 11 IbHt)
t X \ ~ ~
12 N'm (1.2 kgf'm, 9 IbHt)
~
~ /
/
10 Nm (1.0 kgf'm, 7 IbHt)
11-2
SERVICEINFORMATION
GENERAL
Theclutch andgearshiftlinkagecan be servicedwiththeengineintheframe.
Engineoilviscosity,oil level and the use ofoil additives have an effecton clutch disengagement. Oil additives ofany
kind are specificallynotrecommended. When theclutch does notdisengage orthe motorcycle creepswiththe clutch
disengaged,inspecttheengineoilandoil level beforeservicingtheclutch system.
SPECIFICATIONS
Unit:mm(in)
Clutch leverfreeplay 10- 20(3/8- 13/16) -
Springfree length 45.3(1.78) Clutch 43.9 (1.73)
Discthickness
I
DiscA 2.62- 2.78(0.103- 0.109) 2.3(0.09)
End disc 2.92-3.08(0.115-0.121) 2.6(0.10)
I
Platewarpage 0.30(0.012) -
Clutch outerguide
I
1.0. 21.991 - 22.016(0.8658- 0.8668) 22.03(0.867)
31.959- 31.975 (1.2582-1.2589) 31.92 (1.257)
I
0.0.
21.95 (0.864) 21.967- 21.980 (0.8648- 0.8654) Mainshaft0.0. atclutchouterguide
0.08(0.003) 0.011 - 0.049(0.0004- 0.0019) Clutch outerguide-to-mainshaftclearance
32.000- 32.025 (1.2598- 1.2608) 32.09(1.263) Clutch outer 1.0.
Clutch outer-to-outerguideclearance 0.025- 0.066(0.0010- 0.0026) 0.18(0.007)
32.025- 32.145(1.2608- 1.2655) 32.16(1.266) Oil pumpdrivesprocket1.0.
Oil pumpdrivesprocket-to-c1utch outerguidec1ear-
0.050- 0.186(0.0020- 0.0073) 0.23 (0.009)
ance
TORQUEVALUES
Clutch lifterplatebolt
Clutch centerlocknut
Clutchcoversocketbolt
Primarydrivegearbolt
Gearshiftarmpinch bolt
Oil pumpdrivensprocketbolt
Gearshiftpedal pivotbolt
Gearshiftspindlereturnspringpin
Gearshiftspindleoilseal stopper
platebolt
TOOLS
128N'm(13.1 kgf'm,94Ibfft)
88 Nm(9.0kgf'm,65Ibfft)
15Nm(1.5 kgf'm,11 Ibfft)
39 N'm(4.0kgf'm,29 Ibfft)
23 N'm(2.3kgfm,17Ibfft)
Locknut;replacewithanewoneand stake
Applyengineoiltothethreadsandseating
surface
Applyengineoiltothethreadsandseating
surface
Clutch centerholder Gearholder,2.5
07JMB-MN50301 07724-0010100
or07HGB-001010B (plate)and or07724-001A100(U.S.A.only)
07HGB-001020B (collar)(U.S.A.
only)
11-3
-------------- --------
TROUBLESHOOTING
Clutch lever too hard to pull in
Damaged, kinked or dirty clutch cable
Improperly routed clutch cable
Damaged clutch lifter mechanism
Faulty clutch lifter bearing
Clutch will not disengage or motorcycle creeps with clutch disengaged
Too much clutch lever freeplay
Warped clutch plates
Loose clutch center lock nut
Engine oil level too high, improper oil viscosity or oil additive used
Clutch slips
No clutch lever freeplay
Worn clutch discs
Weak clutch springs
Clutch lifter sticking
Engine oil level too low or oil additive used
Hard to shift
Improper clutch operation
Incorrect engine oil viscosity
Incorrect clutch adjustment
Bent or damaged gearshift spindle
Damaged gearshift cam
Bent fork shaft or damaged shift forks and shift drum (page 13-21)
Transmission jumps out of gear
Broken shift drum stopper arm
Weak or broken gearshift spindle return springs
Worn or damaged gearshift cam
Bent fork shaft or worn shift forks and shift drum (page 13-21)
Worn gear dogs or dog holes (page 13-21)
11-4
----------- ----- ---- --- ---- - ------------
RIGHTCRANKCASECOVERREMOVAL
Draintheengineoil(page4-13).
Removethebolts,clutchcoverand oilseal rubber.
Remove thepolts in a crisscross pattern in several
steps.
;Removetheclutch cable holderand disconnectthe
clutch cable.
Removetherightcrankcasecover.
Be careful not to Remove the dowel pins and clean off the sealant
damage the mating fromthematingsurface.
surface.
DISASSEMBLY
Remove the clutch lifter piece while turning the
clutch lifterarmclockwise.
11-5
Remove the snap ring and return spring from the
clutch lifterarm.
Remove the clutch lifter arm from the right crank-
casecover.
INSPECTION
Checktheoilsealforfatigueordamage.
Check the lifter arm sliding surface of the right
crankcasecoverforwear,damageorloosefit.
Replacethesepartsifnecessary.
NOTE:
Iftheoil seal replacementisrequired, install theoil
seal flashwiththecasesurface.
Check the clutch lifter arm for wear, damage or
bending.
Checkthespringforfatigueordamage.
Replacethesepartsifnecessary.
....-------...
LIFTER ARM
11-6
CLUTCH REMOVAL
Removetherightcrankcasecover(page 11-5).
If the oil pump driven sprocket will be removed,
loosen the driven sprocket bolt while the clutch is
stillinstalled.
Loosen the clutch lifter plate bolts in a crisscross .----"""
patterninseveralsteps.
,Removethelifterplate/bearingandclutchsprings.
Be careful not to Unstaketheclutchcenterlocknut.
damage the
mainshaft threads.
HOld the clutch using a special tool and
loosenthec.lutchcenter Jocknut.
- ..-
TOOL:.
Cilltch holder' 07JMB-MN50301 or
07HGB-001010B(plate)
and
07HGB-001020B(collar)
(U.S.A.only)
Removethespecialtoolandclutchcenterlocknut.
11-7
Remove the spring washer and thrust washer.
11-IJ
Remove the following:
- Clutch center
Pressure plate
End clutch disc
ClutcD plates
Clutch disc A
Judder spring
Spring seat
Remove the thrust washer and clutch outer.
Remove the oil pump driven sprocket bolt and
washer.
Remove the oil pump drive sprocket, driven
sprocket and drive chain as a set.
Remove the clutch outer guide.
INSPECTION
CLUTCH LIFTER BEARING
Turn the inner race of the bearing with your finger.
The bearings should turn smoothly and quietly.
Also h ~ that the bearing outer race fits tightly in
the lifter plate.
Remove and discard the bearing if the races do not
turn smoothly and quietly, or if they fit loosely in the
lifter plate.
CLUTCH SPRING
Replace the clutch Check the clutch spring free length.
springs as a set.
11-9
CLUTCHDISC
Replace the clutch Replace theclutch discsforsigns ofscoring ordis-
discs and plates as coloration.
aset. Measuretheclutchdiscthickness.
SERVICELIMITS:DiscA: 2.3 mm(0.09in)
End disc: 2.6mm(0.10in)
CLUTCHPLATE
Replace the clutch Checktheclutchplatefordiscoloration.
discs and plates as
Check tl)e clutch plate warpage on a surface plate
aset. usingafeelergauge..
-:
CLUTCHCENTER
Check the clutch center for nicks, indentations or
abnormalwearcausedbytheclutchplates.
CLUTCHOUTER
Checktheslotin theclutch outerfornicks, indenta-
tionsorabnormalwearcaused bytheclutchdiscs.
MeasuretheclutchouterI.D.
11-10
CLUTCH OUTERGUIDE
Check the clutch outerguidefordamageorabnor-
mal wear.
Measuretheclutch outerguide1.0.
Measuretheclutch outerguide0.0.
Calculatetheclutchouter-to-outerguideclearance.
OILPUMPDRIVESPROCKET
Checktheoilpumpdrivesprocketforwearordam-
age.
Measurethe1.0. ofthedrivesprocket.
Calculate the oil pump drive sprocket-to-clutch
outerguideclearance.
MAINSHAFT
Measure the mainshaft 0.0. at the clutch outer
guideslidingsurface.
Calculatethe clutch outerguide-to-mainshaftclear-
ance.
JUDDERSPRING/SPRINGSEAT
Checkthe spring seat and judderspring for distor-
tion,wearordamage.
..
SPRING SEAT JUOOERSPRING
11-11
...................--.....----
CLUTCH/GEARSHIFTUNKAGE
OILPUMPDRIVENSPROCKET
Check the oil pump driven sprocket for wear or
damage.
PRIMARYDRIVEGEAR
REMOVAL
Removetheclutch(page 11-7).
Remove the ignition pulse generator mounting
bolts.
Remove the ignition pulse generator and grom-
mets.
Temporarilyinstall-theclutch outerguide, oil pump r-'-----
drive sprocket and clutch outerontothe mainshaft
(page11-18).
Holdtheprimarydrivegearusing aspecialtooland
removetheprimarydrivegearboltandwasher.
TOOL:
Gearholder,2.5 07724-0010100or
07724-001A100
(U.S.A.only)
Remove the gear holder and temporarily installed
parts.
Remove the ignition pulse generator rotor and pri-
marydrivegear..
11-12
INSPECTION
Checktheignitionpulsegeneratorrotorforwearor
damage.
Checktheprimarydrivegearforwearordamage.
INSTALLA"rlON
Installtheprimarydrivegearonthecrankshaft.
NOTE:
Install the primary drive gear, aligning its wide
groovewiththewidetoothofthecrankshaft.
Installtheprimarydrivegearwithits"OUT"mark
facingout.
Installtheignitionpulsegeneratorrotor,aligningits
widegroovewiththewidetoothofthecrankshaft.
...---------
11-13
-------------- ------
Temporarilyinstalltheclutch outerguide,oil pump
drivesprocketandclutch outerontothemainshaft.
Apply engine oil to the primary drive gear bolt
threadsandseatingsurface.
Installthewasherandprimarydrivegearbolt.
Holdtheprimarydrivegearusingaspecialtool.
TOOL:
Gearholder,2.5 077240010100or
07724-001A100
(U.S.A.only)
Tightenthebolttothespecifiedtorque.
Remove the gear holder and temporarily installed
parts.
Install the ignition pulse generator, wire grommets
andtightenthebolts.
Installtheclutch (page11-18).
GEARSHIFTLINKAGE
REMOVAL
Removethefollowing:
- Clutch (page11-7)
Remove the pinch bolt and gearshiftarm from the
spindle.
Cleanthegearshiftspindle.
Removethepivotbolt,washerandgearshiftpedal.
11-14
Remove the pivot collar and dust seals from the
gearshiftpedal.
Checkthedustsealsforwearordamage.
B . ..
Replacethedustseal ifnecessary.
..
"
.
""-
'
/
/'
PIVOTCOLLAR
Removethefollowing:
Bolt
- Washer
- Stopperarm
- Collar
- Returnspring
Remove the gearshift spindle from the crankcase
whileunhookingthe shifterarm fromthe gearshift
cam plate.
DUSTSEALS
INSPECTION
Removetheboltandstopperplate.
Apply grease to the Checkthegearshiftspindleoilseal fordeterioration
oil seal lips. ordamage,replaceitifnecessary.
NOTE:
Installtheoilseal withitsmarkedsidefacingout.
Install the stopper plate and tighten the boltto the
specifiedtorque.
TORQUE: 13Nm(1.3kgfm,10Ibf.ft)
11-15
- - ----------------
Checkthegearshiftspindleforbend, wear ordam- RETURN SPRINGS
age.
Checkthereturnspringsforfatigueordamage.
GEARSHIFTSPINDLE
Check the gearshift pedal rod fordamage or loose
locknuts.
Replacetherod ifnecessary.
LOCKNUTS
INSTALLATIOI\l
Install the gearshift spindle, aligning the return
spring endswiththegearshiftspindlereturn spring
pininthecrankcase.
Hooktheshifterarmtothegearshiftcam plate.
- Collar
- Returnspring
- Stopperarm
- Washer
- Bolt
11-.16
Hold the stopper arm with the screwdriver, and
tightentheboltsecurelyas shown.
ApplygreasetqthedustSeal lips.
Installthedustsealsandpivotcollartothegearshift
pedal.

/'''r
PIVOTCOLLAR DUSTSEALS
Installthegearshiftpedal,washerandpivotbolt.
Tightenthepivotbolttothespecifiedtorque.
TORQUE:39N'm(4.0kgfm,29Ibf.ft)
Installthegearshiftarmtothespindle,aligningwith
thepunchmarks.
9 Ibfft)
11-17
- -- ---------
CLUTCH INSTALLATION
Apply molybdenum disulfideoiltotheclutch outer
guideoutersurface.
Installtheclutchouterguidetothemainshaft.
Install the oil pumpdrive chain, drive sprocket and
drivensprocketas aset.
NOTE:
Installtheoil pumpdrivensprocketwiththe"0"
markssidefacing inside.
Aligntheflatsurfacesofthedrivensprockethole
and oil pumpshaftend.
AppIYl()(::kingageIlttothe oil pumpdrivensprocket
boltthreads'andInstallthewasherand bolt.
NOTE:
.,-; - -
Tighten the dtj\/en sprocket bolt to the specified
torqueafterinstilJlingtheclutch.
.................-.......
11-18
Installtheclutch outerontothemainshaft.
NOTE:
AUgn the grooves in the clutch outer with the
bossesontheoilpumpdrivesprocketwhileturning
the sprocketwith the chain and pushing the clutch
outerontothemainshaft.
Installthethrustwasherontothemainshaft.
Coattheclutch discsand plateswithengineoil.
Install the sprIng seat and judder spring to the
clutchcenterasshown.
End clutch disc haslt\Stalltheeridclutchdisc.
alarger /.D. than Intall th,e"seven clutch plates and seven discs A,
JUDDERSPRING
disc A. theclutchplste."
Il1stallflie.pressureplate.

-:71 ENDCLUTCH DISC
11-19

Installtheclutch assemblyintotheclutchouter.
Install the end clutch disc intothe shallowslots of
theclutchouter.
Installthethrustwasher.
Install the spring washer with its "OUTSIDE" mark
facing out.
Applyengineoiltothethreads and seating surface
ofanewclutchcenterlocknutand installitontothe
mainshaft.
Hold the clutch center using a special tool
tightenthelocknuttothespecifiedtorque.
TOOL:
Clutchcenterholder 07JMB-MN50301 or
07HGB001010B(plate)
and
07HGB-001020B(collar)
(U.S.A.only)
TORQUE:128N'm(13.1 kgfm,94Ibfft)
1120
Be careful not to Stake theclutch center lock nutintothe mainshaft
damage the groove.
mainshaft threads.
Install the clutch springs, lifter plate/bearing and ...11111111!"'........
bolts.
Tignten the bolts inacrisscross pattern in several
stepstothespecifiedtorque.
iTORQUE.-12Nm(1.2kgfm,9Ibfft)
Ifthe oil pumpdrivensprocketis removed, tighten
the oilpump drivensprocket bolt to the specified
torqlJi:l:" .. ...
TORQUE: 15Nm(1.5,kgqn,11 Ibfft)
Install therightcrankcasecover(page11-21).
RIGHT CRANKCASE COVER
INSTALLATION
. .""
qiltotheclutch lifterarm sliding sur-
cover.
Apply totheoilseal lips.
11-21
----------"-----
CLUTCH/GEARSHIFT LlI\lKAGE
Apply engine oil to the clutch lifter arm sliding sur-
face and slit. .
Install the clutch lifter arm.
Install the return spring by inserting its short end
into the clutch lifter arm groove.
Install the snap ring to the clutch lifter arm groove
securely.
Hook the long spring end to the cover tab.
Install the clutch lifter piece, aligning the piece end
with the groove in the clutch lifter arm by turning
the clutch lifter arm clockwise.
INSTALLATION
Install the dowel pins.
2 ~
Be careful not to Clean the mating surfaces of the right crankcase and
damage the mating cover.
surfaces.
Apply liquid sealant to the right crankcase cover
mating surface.
Connect the clutch cable.
Install the right crankcase cover, clutch cable holder
and tighten the bolts in a crisscross pattern in sev-
eral steps.
Install the oil seal rubber to the clutch cover with its
smail flange side facing up.
Install the clutch cover and tighten the bolts to the
specified torque.
TORQUE:-10Nm(1.0kgfm,7Ibfft)
Fill the .crankcase with the recommended engine oil
(page 4-12).
~
---
11-23
---------
MEMO
12. ALTERNATOR/STARTERCLUTCH
12-4
SERVICEINFORMATION 12-3 FLYWHEEL/STARTERCLUTCH ..12-5
TROUBLESHOOTING 12-3 STATORINSTALLATION .. 12-11
COMPONENTLOCATION.. .. 12-2
STATORREMOVAL
EI
12-1
ALTERNATORISTARTERCLUTCH
COMPONENTLOCATION
12 N'm (1.2 kgfm, 9 IbHt)
128 N'm (13.1 kgfm, 94 IbHt)
12-2
SERVICEINFORMATION
GENERAL
Thissection coversserviceofthealternatorstatorandflywheel.All servicecan bedonewiththeengineinstalled inthe
frame.
Foralternatorinspection(page18-9).
Forstartermotorservice(page20-6).
SPECIFICATIONS
Unit:mm(in)
Starterdrivengear
I
I
1.0.
0.0.
37.000- 37.025 (1.4567- 1.4577)
57.749- 57.768(2.2736- 2.2743)
37.10 (1.461)
57.73 (2.273)
Starterclutch outer1.0. - 74.414- 74.440(2.9297- 2.9307) 74.46(2.931)
TORQUEVALUES
Statorsocketbolf
Flywheel bolt
Statorwireholdersocketbolt
Starterone-wayclutchoutersocketbolt
TOOLS
Flywheel holder
07725-0040001
orequivalentcommerciallyavail-
ableinU.S.A.
128Nm(13.1 kgfm,94Ibfft)
30N'm(3.1 kgf'm,22 Ibfft)
Rotorpuller
07733-0020001
or97933-3290001 (U.S.A. only)
seating surface
Lefthandthreads
Starter motortqdjs, but engine does not turn
Faultystarterclutch
Damaged reductiongE;lar
Damagedstarteridlegear
12..3
STATORREMOVAL
Removethefollowing:
- Seat(page3-3)
- Leftsidecover(page3-3)
Disconnectthealternator3P (Natural)connector.
Releasethewiresfromtheclampsandwirebands.
Place a container under the leftcrankcase coverto
catchtheengineoil.
Loosen the bolts in Removethebolts.clampsand leftcrankcasecover.
a crisscross pattern
NOTE:
in several steps.
The leftcrankcase cover (stator) is magnetically
attached to the flywheel, be careful during
removal.
Be careful nottodamagethealternatorcover.
Be careful not to Remove the dowel pins and clean offthe sealant
damage the mating fromthematingsurface.
surface.
124
Remove the bolt and stator wire holder from the left
crankcase cover.
Remove the wire grommet.
Remove the bolts and stator from the left crankcase
cover.
FLVWHEEL/STARTERCLUTCH
FLYWHEELREMOVAL
For alternator Remove the left crankcase cover (page 12-4).
charging coil
inspection
(page 18-9).
Remove the starter reduction gear and shaft.
Remove the starter idle gear and shaft.
The flvwheel bolt Remove the flywheel bolt and washer while holding
has left hand the flywheel using a special tool.
threads.
TOOL:
Flywheel holder 071250040001 or
equivalent com-
mercially avail-
able in U.S.A.
12-5
.
ALTERNATOR/STARTER CLUTCH
Removetheflywheelusingaspecialtool.
TOOL:
Rotorpuller 07733-0020001 or
07933-3290001
(U.S.A.only)
Remove thewasher, needle bearing and woodruff !! WOODRUFFKEY
keyfromthecrankshaft.
NOTE:
Durtng woodruff key removal, be careful not to
damagethekeygrooveandcrankshaft.
Do notlosethewoodruffkey.
STARTER IDLE/REDUCrION GEAR
INSPECTION
STARTERIDLEGEAR/SHAFT
Check the starter idle gear and shaft for wear or
IDLE GEAR
damage.
STARTERREDUCTIONGEAR/SHAFT
Checkthe starter reduction gearand shaftforwear
REDUCTION GEAR
ordamage.
SHAFT
STARTERDRIVENGEAR/STARTER
CLUTCH REMOVAL
Checktheoperation ofthe one-wayclutch byturn-
ingthestarterdrivengear.
You shouldbe abletoturnthedrivengearcounter-
clockwise smoothly, but the gear should not turn
clockwise.
Remove the starter driven gear from the flywheel
whileturningthedrivengearcounterclockwise.
Removethesocketboltswhileholdingtheflywheel
usingaspecialtool.
TOOL:
Flywheelholder 07725-0040001 or
equivalentcom-
merciallyavail-
ableinU.S.A.
Remove the starter clutch outer/one-way clutch
fromtheflywheel.
STAFrrERCLUTCHINSPEC1"ION
NEEDLE BEARING
c:fieck the needle bearing for abnormal wear or
damage..
DRIVEN GEAR
FLYWHEEL CLUTCH OUTER
NEEDLE BEARING
12-7
----------- ._- -- -
---------------
ONE-WAYCLUTCH/STARTERCLUTCHOUTER
Checktheone-wayclutch spragforabnormalwear,
damageorirregularmovement.
NOTE:
Do not remove the one-way clutch from the
sr:
clutch outer, unless it is necessary to replace
SPRING
withanewone.
Ifthespringisremovedfromtheone-wayclutch
groove, replace the one-way clutch assembly
withanewone.
Checkthestarterclutch outerinnercontact surface
forwearordamage.
Measurethestarterclutchouter1.0.
ONE-WAYCLUTCH
SERVICELIMIT: 74.46mm (2.931 in)
STARTERDRIVENGEAR
Checktheone-wayclutch sprag contactsurfacefor
wearordamage.
e a s u ~ l e thestarterdrivengear0.0.
Measurethestarterdrivengear1.0.
CLUTCHOUTER
STARTERDRIVENGEARISTAR"rER
CLUTCHINSTALLATION
ew
30 Nm(3.1 kgfm,22 Ibf.ft)
-,ONE-WAYCLUTCH
FLYWHEEL
12-8
~ ~
Cleantheone-wayclutchandapplyengineoiltothe
sprag.
Install the one-way clutch into the starter clutch
outerwithitsflangesidefacingtheflywheel.
NOTE:
Ifthe spring is removed from the one-way clutch
groove,replacetheone-wayclutchassemblywitha
newone.
Installthestarterclutch outer/one-wayclutchtothe
flywheel.
Holdtheflywheelusingaspecialtool.
TOOL:
Flywheelho.lder 07725-0040001 or
equivalentcom
merciallyavail-
ableinU.S.A.
Clean and apply a locking agenttothe socket bolt
threads; .
Install and tighten the socket boltstothe specified
torque.,
TORQUE:30Nm(3.1 kgfm,22lbfft)
Install the starter driven geartotheflywheel while
turningthedrivengearcounterclockwise.
Rechecktheone-wayclutch operation(page12-7).
\
CLUTCH OUTER
ONE-WAYCLUTCH
DRIVEN GEAR
12-9
FLYWHEELINSTALLATION
During woodruff
key installation, be
careful not to
damage the key
groove or
crankshaft.
The flywheel bolt
has left hand
threads.
Install the woodruff key to the key groove of the
crankshaft.
Applyengineoiltotheneedle bearing and install it
tothecrankshaft.
Installthewashertothecrankshaft.
Wipe any oil offthe mating surface ofthe crank-
shaft.
Wipeanyoiloffthematingsurfaceoftheflywheel.
Install the flywheel to the crankshaft, aligning the
keygrooveoftheflywheel withthewoodruffkeyon
thecrankshaft.
Holdtheflywheelusingaspecialtool.
TOOL:
Flywheelholder 07725-0040001 or
equivalentcom-
merciallyavail-
ableinU.S.A.
Apply engine oil to the flywheel bolt threads and
seatingsurface. .
n s t l l ~ d tightentheflywheel boltwiththewasher
TORQUE:128N'm(13.1 kgfm,94lbfft)
Apply engine oil to the starter reduction gear and
starteridlegearshaftoutersurface.
Install the starter reduction gear, idle gear and
shaftstotheleftcrankcaseas an assembly.
NOTE:
Installthesta.rterreductiongearwithits"OUT"mark
facingout.
Installthestatorand leftcrankcasecover
(page12-11).
12-10
STATORINSTALLATION
LEFTCRANKCASECOVER
WIRE HOLDER
ew
J kgf'm,9Ibfftl
ew
12 Nm(1.2 kgf'm,9IbHt)
Installthestatortotheleftcrankcasecover.
Clean and applya locking agenttothe boltthreads
(page1-19).
Install and tighten the stator socket bolts to the
specifiedtorque.
TORQUE: 12Nm(1.2kgfm,9lbf-tt)
Install the grommet into the grooves in the left
crankcasecover. .
Clean and applyalockingagenttotheboltthreads
(page1-19).
Installthewireholdertotheleftcrankcasecover.
Installandtightenthebolttothespecifiedtorque.
TORQUE: 12Nm(1.2kgfm,9Ibftt)
12-11
Clean offthe sealant from the left crankcase cover r--------------------,
mating surface.
Do not wipe off the Applyliquid sealanttothe leftcrankcasecovermat-
excessive sealant ing surface.
by using the organic
solvent.
Installthedowel pins.
The left crankcase Installthe leftcrankcasecover.
cover (stator) is
Apply locking agentto the one left crankcase cover
magnetically
bolt(marked "8') threadsas shown.
attracted to the
flywheel. be careful In$tallthec1amp$ andleftcrankcasecoverbolts.
during installation. Tightentheleftcrankcase coverbolts in acrisscross
pattern inseveralsteps.
12-12
------------- ---- ------------
Route the wires Clamp and bind the wires with clamps and wire
properly bands.
(page 1-22).
Connect the alternator 3P (Natural) connector.
Install the following:
- Left crankcase rear cover (page 3-5)
- Left side cover (page 3-3)
- Seat (page 3-3) .
Check the engine oil level (page 4-12).
12-13
-- _ ~
MEMO
13.CRANKSHAFT/TRANSMISSION
COMPONENTLOCATION.. 13-2
SERVICEINFORMATION..13-3
TROUBLESHOOTING.. ..13-8
CRANKCASESEPARATION.. 13-9
CRANKSHAFT/CONNECTINGROD13-10
CRANKPINBEARING.. ...... ....13-13
MAINJOURNALBEARING .. .. .. 13-16
TRANSMiSSiON .. .. .. .. 13-20
OUTPUTGEAR.. .. 13-28
CRANKCASEBEARING
REPLACEMENT 13-47
CRANKCASEASSEMBLy .. 13-49
13-1
I
CRANKSHAFTITRANSMISSION
COMPONENT LOCATION
23 Nm (2.3 kgf'm, 17 Ibf.ft)

I'
33 Nm (3.4 kgf'm, 24 Ibf.ft)
CRANKCASE SOLT: 23 N'm (2.3 kgf'm, 17 Ibf.ft)
13-2
SERVICEINFORMATION
GENERAL
Thecrankcasemustbe separatedtoservicethefollowing:
- Oil pump
- Crankshaft/connecting rod
- Outputgear
- Transmission
Thefollowing partsmustberemoved beforeseparatingthecrankcase:
- Oilfiltercartridge(page4-13)
- Waterpump(page7-16)
- Cylinderhead(page9-14)
- Cylinder(page10-4),piston (page10-5)
- Clutch (page11-7).gearshiftlinkage(page11-14)and primarydrivegear(page11-12)
- Flywheel(page12-5)
- Startermotor(page20-6)
- VS sensor(page21-11)
- Neutralswitch(page21-19)
- EOP switch(page5-5)
Becareful nott6 damagethecrankcasematingsurfaceswhenservicing.
Markand storetheconnecting rods, bearing capsand bearing insertsto be sureoftheircorrectlocationsforreassem-
bly. .
Thecrankpinand mainjournal bearinginsertsareselectfitandareidentified bycolorcodes. Selectreplacementbear-
ings from the code tables. After selecting new bearings, recheckthe oil clearance. Incorrectoil clearance can cause
majorenginedamage.
Priortoassemblingthecrankcasehalves,applysealanttotheirmatingsurfaces.Wipeoffexcesssealantthoroughly.
Wheneveryou replace theoutputdriven/drivegears, bearings, bearing holderorgearcase, performthe gearcontact
pattern and backlash inspection and adjusttheshim. Theextension linesfrom the gearengagementsurfaces should
intersectatonepoint.
Whenusingthelocknutwrenchfortheoutputgearcase, useadeflectingbeamtypetorquewrench20incheslong.The
locknutwrenchincreasesthetorquewrench'sleverage,sothetorquewrench readingwillbelessthanthetorqueactu-
allyappliedtothe locknut.The specification given isthe actual torqueappliedtothe locknut, notthereading onthe
torquewrench. Do notovertightenthelocknuts.Thespecificationlaterinthetextgivesbothactualandindicated.
Protecttheoutputgearcasewitha shoptowelorsoftjawswhileholdingitinvise. Do notclampittootightlyasitcould
damagethegearcase.
13-3
SPECIFICATIONS
Unit: mm (in)
Crankshaft Connecting rod big end side clearance 0.05 - 0.20 (0.002 - 0.0081 0.30 (0.012)
Crankpin bearing oil clearance 0.028 - 0.052 (0.0011 - 0.0020) 0.07 (0.003)
Main journal oil clearance 0.020 - 0.038 (0.0008 - 0.0015) 0.07 (0.003)
Crankshaft runout - 0.03 (0.001)
Main journal 0.0. 52.982 - 53.000 (2.0859 - 2.0866) 52.976 (2.0857)
Main journal 1.0. 58.010 - 58.022 (2.2839 - 2.2843) 58.070 (2.2862)
Shiftfork, fork 1.0. 13.000 -13.018 (0.5118 - 0.5125) 13.03 (0.513)
shaft Claw thickness 5.93 - 6.00 (0.233 - 0.236) 5.6 (0.22)
Fork shaft 0.0. 12.966 - 12.984 (0.5105 - 0.5112) 12.90 (0.508)
Shift drum 0.0. at left end 11.966 -11.984 (0.4711 - 0.4718) 11.94 (0;470)
Shift drum journal 1.0. 12.000 -12.018 (0.4724 - 0.4731) 12.05(0.474)
Shift drum-to-shift drum journal clearance 0.016 - 0.052 (0.0006 - 0.0020) 0.09 (0.035)
Transmission Gear 1.0. M3, M5 28.000 - 28.021 (1.1024 -1.1032) 28.04 (1.104)
C1, C4 31.000 - 31.025 (1.2205 -1.2215) 31.05 (1.222)
C2 24.000 - 24.021 (0.9449 - 0.9457) 24.04 (0.946)
Gear busing 0.0. M3, M5 27.959 - 27.980 (1.1007.,.. 1.1016) 27.S4 (1.100)
C1, C4 30.950 - 30.975 (1.2185 -1.2195) 30.93 (1.218)
C2 23.959 - 23.980 (0.9433 - 0.9441 ) 23.94 (0.943)
Gear-to-bushing M3, M5, C2 0.020 - 0.062 (0.0008 - 0.0024) 0.10 (0.004)
clearance
C1, C4 0.025 - 0.075 (0.0010 - 0.0030) 0.11 (0.004)
Gear bushing 1.0. M3 25.000 - 25.021 (0.9843 - 0.9851) 25.04 (0.986)
C2 20.000 - 20.021 (0.7874 - 0.7882) 20.04 (0.789)
Mainshaft 0.0. at M3 bushing 24.959 - 24.980 (0.9826 - 0.9835) 24.94 (0.982)
Countershaft 0.0. at C2 bushing 19.980 - 19.993 (0.7866 - 0.7871) 19.96 (0.786)
Bushing-to-shaft M3 0.020 - 0.062 (0.0008 - 0.0024) 0.10 (0.004)
clearance
C2 0.007 - 0.041 (0.0003.,.. 0.0016) 0.07 (0.003)
Output drive Output gear 1.0. 24.000 - 24.021 (0.9449 - 0.9457) 24.04 (0.946)
train Output gear bush- 0.0. 23.959 - 23.980 (0.9433 - 0.9441) 23.70 (0.933)
ing
1.0. 20.020 - 20.041 (0.7882 - 0.7890) 20.06 (0.790)
Output drive gear shaft 0.0. 19.979 - 20.000 (0.7866 - 0.7874) 19.97 (0.786)
Gear-to-bushing'clearance 0.020 - 0.062 (0.0008 - 0.0024) 0.082 (0.0032)
Gear bushing-to-shaft clearance 0.020 - 0.042 (0.0008 - 0.0017) 0.08 (0.003)
Output gear damper spring free length 62.3 (2.45) 59 (2.3)
Output drive gear backlash 0.08 - 0.23 (0.003 - 0.009) 0.40 (0.016)
Backlash difference between
measurements
- 0.10 (0.004)
13-4
TOEQUEVALUES
Crankcase bolt(8mm)
Crankpin bearingcap nut
Gearshiftcam platebolt
Outputgearcase mountingbolt
Outputdrivegearassemblymountingbolt
Outputdrivengearassemblymounting
socketbolt
Outputdrivegearbearing locknut
(inner)
(outer)
Outputdrivengearbearinglocknut
(inner)
(outer)
Outputdrivengearshaftbolt
23 l\Im (2.3 kgfm,17 Ibfft)
33 Nm(3.4kgfm,24Ibfft)
31 Nm (3.2 kgfm,23 Ibfft)
98 Nm(10.0 kgfm,72 Ibfft)
73Nm(7.4 kgf'm,54Ibfft)
98 Nm(10.0kgf'm,72 Ibfft)
seatingsurface
Applysealanttothethreads
seatingsurface
seatingsurface
Locknut;replacewithanewoneand
stake
seatingsurface
stake
seatingsurface
stake
seatingsurface
stake
seatingsurface
13-5
TOOLS
Driver
07749-0010000
Attachment, 62 X 68 mm
07746-0010500
Pilot, 20 mm
07746-0040500
Bearing remover set, 20 mm
07936-3710600
Attachment, 42 x 47 mm
07746-0010300
Pilot, 22 mm
07746-0041000
Pilot, 30 mm
07746-0040700
Remover weight
07741-0010201
or 07936-371020A or 07936-3710200
(U.S.A. only)
07746-0010400
Pilot, 17 mm
07746-0040400
Remover handle
07936-3710100
Driver, 57 mm
070MF-MEG0100
13..6
Metal installer set
070MF-MEG0200

Damper spring compressor
07964-ME90000
Shaft holder A
07PAB-001 01 00
or 07923-6890101 (U.S.A. only)
Holder handle
07PAB-0010400
Lock nut wrench, 36 x 47.8 mm
07916-MB00002
Differential inspection tool
07KMK-HC50101
or 07KMK-HC5010A (U.S.A. only)
Bearing remover set, 17 mm
07936-3710300
Oil seal driver
07965-KE80200
Driver, 40 mm 1.0.
07746-0030100
Attachment, 30 mm 1.0.
07746-0030300
Assembly bolt
07965-1660200
Assemb1y collar
07965-1660302
or 07965-166030A
13-7
Threaded adaptor
07965-KA30000
Snap ring pliers
07914-5670101
not available in U.S.A. or
07914-5670100
Compressor seat
07967-9690200
TROUBLESHOOTING
Excessiveenginenoise
Worn main journal bearings
Worn crankpin bearings
Worn or damaged transmission gear
Worn or damaged transmission bearings
Excessivenoiseinsidegear
Worn or damaged output shaft and final drive shaft gears
Worn or damaged output gear case bearing
Incorrect adjusted shim
Hardtoshift
Improper clutch operation (page 11-9)
Incorrect engine oil viscosity
Bent shift forks
Bent shift fork shaft
Bent shift fork claw
Damaged shift drum cam grooves
Bent gearshift spindle
Transmissionjumpsoutofgear
Worn gear dogs or holes
Worn gear shifter groove
Bent shift fork shaft
Broken shift drum stopper arm
Worn or bent shift forks
Broken drum stopper arm spring
Broken gearshift spindle return spring
13-8
CRANKCASESEPARATION
Removetheenginefromtheframe(page8-4).
RefertoServiceInformation(page13-3)forremoval
ofnecessarypartsbeforeseparatingthecrankcase.
Remove the bolts and cam chain tensioner setting
plates.
Removethecam chains.
SHAFTHOLDERA BOLTIWASHER
Hold the outputdriven gearshaftusing thespecial
tools, loosen the output drive gear shaft bolt and
removeitwiththewasher.
TOOLS:
ShaftholderA 07PAB-0010100or
07923-6890101
(U.S.A.only)
Holderhandle 07PAB-0010400
Removetheboltsand bearingsettingplate.
Loosen and removethe 6mm and 8 mm boltsin a
crisscrosspatterninseveral steps.
13-9
Loosen and removethe 6 mmand8 mmboltswith
washerinacrisscrosspatterninseveralsteps.
Turntheshiftdrumuntilthe positionas shown.
Place the crankcase with the left crankcase down
andremovetherightcrankcase.
NOTE:
Separatethe rightcrankcase from the leftcrank-
casewhilepryingatthepointsas shown.
Separatethe rightcrankcase fromthe leftcrank-
casewhiletappingthematseveral locationswith
asofthammer.
Removethedowelpinsandpipeseal.
Clean offthe sealant from the left and right crank-
case matingsurfaces.
PIPE SEAL
CRANKSHAFT/CONNECTINGROD
CRANKSHAFTREMOVAL
Separatethecrankcase(page13-9).
Duringcrankshaft Removethecrankshaft/connecting rod fromthe left
andconnectingrod crankcase.
service, becareful
notto damagethe
mainjournalor
crankpinbearing
inserts.
13-10
SIDECLEARANCEINSPECTION
Before removingtheconnecting rods, checkthe big
FEELER GAUGE
endsideclearance.
Measure the side clearance by inserting the feeler
gauge between the crankshaft and connecting rod
bigend.
CONNEC"rlNG ROD REMOVAL
Tap the side of the Removethecrankpin bearingcapnutsandthebear-
CAPS
cap lightly if bearing ingcaps.
cap is hard to
remove.
Mark the rods, bearingsand caps as you remove
themtoindicatetheGorrectcylinderandpositionon
thecrankpinsforreassembly.
Forthe o n n ~ t i n rod smallendinspection
(page10-7).
13-11
CRANKSHAFTINSPECTION
Check the crankshaft journal surfaces for damage,
discolorationorscratch.
CRANKSHAFTRUNOUT
Placethecrankshafton astandorV-blocks.
Setadialindicatoronthemainjournals.
Rotatethecrankshafttwo revolutions and read the
runout.
10 mm(0.4in)
....1..-
40 mm(1.6in)
I......'
MEASUREMENTPOINT
CONNECTINGROD INSTALLATION
INOTICE I '
Do not interchange the bearing inserts. They must
be installed in their original locations or the correct
bearing oil clearance may not be obtained, resulting
in engine damage.
Wipeanyoirfrol11theconnecting rod,capand bear-
ingil}serts('-> Align
..;j9serts on the connecting rods
tabwiththegroove.
Apply molybdenum disulfide oil to the thrust sur-
face ofthecrankpin bearings.
Installtherods and capsonthecrankshaftbyalign-
ing the I.D. code on the rod and cap. Be sure each
partisinstalledinitsoriginalposition,asnoteddur-
ingremoval.
NOTE:
Facetheoiljetoffrontcylinderconnecting rodto
rearward(intakeside)ofthecylinder. Oil JET
Face theoiljetofrearcylinderconnecting rodto
rearward(exhaustside)ofthecylinder.
Applyengineoiltothe bearingcap nutthreadsand
seating surface, then tighten them in several steps
alternately.
Aftertighteningthenuts, checkthattheconnecting
rodsmovefreelywithoutbinding.
13-12
CRANKSHAFTINSTALLATION
Apply molybdenum disulfide oil to the crankshaft
mainjournalsand installthecrankshaft intothe left
crankcase.
Assemblethecrankcase(page 13-49).

_,
CJonoirf,terchlIhgetlJe inserts. They must
be or the correct
bearing maynot be obtained, resulting
in engine damage,
Rernovethe rod (page 13-11).
-. _ . _. _.c.,' :" : " "-.' '. - _. - ". - ",
CheckthCe unusualwear,damage
BEARINGS
orpeelinganareplacethem ifnecessary.
Selectthereplacementbearing(page 13-14).
OILCLEARANCEINSPECTION
Clean offanyoilfromthebearing insertsandcrank-
pins.
Put.a strip of plastigauge lengthwise on each
cranl<pinavQidingtheoil hole.
. connecting rods and bearing
cal#orrttie' correct
. - "'.0.'
13-13
Do not rotate the Applyengineoiltothethreadsandseatingsurfaces
crankshaft during ofthebearingcap nuts.
inspection. Installthenutsandtightenthemevenly.
Remove the bearing caps and measure the com-
pressed plastigauge at its widest point on each
crankpintodeterminetheoilclearance.
Iftheclearance exceeds theservice limit,selectthe
correctreplacementbearingsasfollows.
BEARINGSELECTION
Recordtheconnecting rod 1.0.codenumber.
NOTE:
Number3or4ontheconnecting rod isthecodefor
theconnecting rod1.0.
Recordthecrankpin0.0.codeletter.
NOTE:
Let!ersA orBon each crankweight isthe code for
thecrankpin0.0.
Cross, reference the connecting rod and crankpin
codes todetermine the replacement bearing color
code. .
CONNECTING ROD 1.0.CODE NUMBER
13-14
CRANKPIN BEARING SELECTIONTABLE:
CONNECTING ROD J.D. CODE
3 4
43.000-43.008mm 43.008- 43.016mm
(1.6929- 1.6932in) (1.6932- 1.6935in)
CRANKPIN0.0.
CODE
A
39.982- 39.990mm
(1.5741 -1.5744in)
C
(Pink)
B
(Yellow)
B
39.974- 39.982mm
(1.5738-1.5741 in)
B
(Yellow)
A
(Green)
BEARINGTHICKNESS:
IDENTIFICATIONCOLOR
A (Green): Thick
B(YeJlow): t
C Thin
INE>TII; I
Afterse.Je 'ng new bearings, recheck the clearance
vyith a
2
ql a.l)ge. Incorrect clearance can cause
evereJi, .
CONNECTINGROD SELECTION
Analphabeticalweightcodeisstampedonthecap.
rod requires replacement, you
a rod with the same weight code as
.tllg'ofigll"la'L
unavailable, you may use one ofthe
s' inthefollowingchart.
RC1>DWEIGHTCOMBINATION
-1 table indicated thatmatch-
ingis. thecrossedcodes.
WEIGHTCODE
WEIGHT
A 398- 4039(14.0- 14.2oz)
B 403- 408 9(14.2- 14.4oz)
C 408-413g(14.4-14.6oz)
REARWEIGHTCODE
B C
I- A 0 0
I- :r:W f---j------I------+---------1
BOO 0
a: W U f---j------I------+---------1
i.C 0 0
.

- Cdnrtecting ro.p(page13-12)
- Crankshaft(p:age:J3-13)
13-15
CRANKSHAFT{TRANSMISSION
MAINJOURNALBEARING
INOTICE I
Do not interchange the bearing inserts. They must
be installed in their original locations or the correct
bearing oil clearance may not be obtained, resulting
in engine damage.
Removethecrankshaft(page 13-10).
BEARINGINSPECTION
Clean offanyoilfromthebearings.
Check the bearings for unusual wear, damage or
peelingand replacethemifnecessary.
Measure the main journal bearing 1.0. at between
the bearing groove and crankcase outside end of
thebearing,and 90 degreestotheindexmark.
Cleanoffanyoilfromthecrankshaftjournals.
Measure and record the crankshaft main journal
0.0.
CalculatElthemainjournaloilclearance.
$ERVICELIMIT: 0.07mm(0.003in)
Iftheclearance e)(ceeds theservice limit,selectthe
bearing.
BEARINGSELECTION
Setaspecialtooland hydraulicpressontheoutside
ofthecrankcase.
TOOL:
Driver/57mm 070MF-MEG0100
13-16
Pressthemainjournalbearingstowardtheinsideof
thecrankcase.
DRIVER
BEARING
Measureand recordthecrankcase mainjournal1.0.
at between the main journal groove and crankcase
outsideend,and90 degreestotheindexmark.
Depending upon the results ofthe
ments there are four possible scenarios for mam
journalbearingselection:
Crankshaftandcrankcasearereplaced
Crankcaseonlyisreplaced
Crankshaftonlyis replaced
Mainjournalbearingsonlyarereplaced
Carefully refer to the following instructions and
tablesformainjournalbearingselection.
Record,the bearingsupport1.0. codeletter.
NOTE:
LettersA orBon each crankcase isthecodeforthe
crankcase1.0. L ----:---'
Recordthemainjournal0.0.codenumber.
NOTE:
Letters1,2or3oneachcrankweightisthecodefor
crankshaftjournal0.0.
Cross-referencethecrankshaftandcrankcasecodes
todeterminethereplacementbearingcolor.
13-17
In case the crankshaft and crankcase are replaced:
<
58.016 - 58.022 mm BEARING
A
(2.2841 - 2.2843 in) SUPPORT
I.D. CODE 58.010 - 58.016 mm
B
(2.2839 - 2.2841 in)
In case the crankcase only is replaced:
1
52.994- 53.000 mm
(2.0864 - 2.0866 in)
C
(Brown)
D
(Green)
MAIN JOURNAL O.D. CODE
2 3
52.988 - 52.994 mm 52.982 - 52.988 mm
(2.0861 - 2.0864 in) (2.0859 - 2.0861 in)
B A
(Black) (Blue)
C B
(Brown) (Black)
MAIN JOURNAL O.D.
52.994 - 53.000 mm 52.988 - 52.994 mm 52.982 - 52.988 mm 52.976 - 52.982 mm
12.0864 - 2.0866 in) (2.0861 - 2.0864 in) (2.0859 - 2.0861 in) (2.0857 - 2.0859 in)
BEARING
A
58.016 - 58.022 mm
SUPPORT (2.2841 - 2.2843 in)
C
(Brown)
B A
(Black) (Blue)
A
(Blue)
I.D. CODE
B
58.010 - 58.016 mm
(2.2839 - 2.2841 in)
D
(Green)
C B
(Brown) (Black)
A
(Blue)
In case the crankshaft onlyjs replaced:
MAIN JOURNAL O.D. CODE
1 2 3
52.994-53.000 mm 52.988 - 52.994 mm 52.982 - 52.988 mm
(2.0864 - 2.0866 in) (2.0861 - 2.0864 in) (2.0859 - 2.0861 in)
MAIN JOURNAL 58.010 - 58.016 mm D C B
I.D. (2.2839 - 2.2841 in) (Green) (Brown) (Black)
58.016 - 58.022 mm C B A
(2.2841 - 2.2843 in) (Brown) (Black) (Blue)
58.022 - 58.034 mm B A A
(2.2843 - 2.2848 in) (Black) (Blue) (Blue)
58.034 - 58.046 mm A O.S.G O.S.G
(2.2848 - 2.2853 in) (Blue) (Red) (Red)
58.046 - 58.058 mm O.S.G 0.5. F 0.5. F
(2.2853 - 2.2857 in) (Red) (Pink) (Pink)
58.058-58.070 mm 0.5. F 0.5. E 0.5. E
(2.2857 - 2.2862 in) (Pink) (Yellow) (Yellow)
In case of main bearing replacement only:
MAIN JOURNAL O.D.
52.994 - 53.000 mm
(2.0864 - 2.0866 in)
52.988 - 52.994 mm
(2.0861 - 2.0864 in)
52.982 - 52.988 mm
(2.0859 - 2.0861 in)
52.976 - 52.982 mm
(2.0857 - 2.0859 in)
BEARING
SUPPORT I.D.
58.010 - 58.016 mm
(2.2839 - 2.2841 in)
58.016 - 58.022 mm
(2.2841 - 2.2843 in)
D
(Green)
C
(Brown)
B
(Black)
A
(Blue)
C
(Brown)
B
(Black)
A
(Blue)
A
(Blue)
58.022- 58.034 mm
. 12.2&43';- 2.2848 in)
B
(Black)
A
(Blue)
A
(Blue)
O.S.G
(Red)
mm
..
A
(Blue)
O.S.G
(Red)
0.5. G
(Red)
0.5. F
(Pink)
58.046-'- 58.058mm
(2.2853::
2
?;2857 in)
O.S.G
(Red)
0.5. F
(Pink)
0.5. F
(Pink)
0.5. E
(Yellow)
58.058
(2.2857 ",:.
0.5. F
(Pink)
O.S. E
(Yellow)
0.5. E
(Yellow)
0.5. E
(Yellow)
13-18
-----------' - --
BEARINGTHICKNESS:
IDENTIFICATIONCOLOR
0.5.E(Yellow): Thick
0.5.F(Pink):
0.5.G(Red):
A(Blue): Middle
B(Black):
!
C(Brown):
o(Green): Thin
BEARINGINSTALLATION
Applyengineoi.1 tqiiel(llbeafingsurface.
Setnewbearin"gi totf1e metal installer aligning its
sideedgewiththemetalinstallergrooves.
"
TOOL:
Metalinstallerset 070MF-MEG0200
Tighten the boltsalternatelyinseveral steps to the
specifiedtorque.
BOLTS
~ g n
, BEARING
Set the bearings and special tools assembly on
inside ofthe crankcase, fitting the bearing edge in
thecrankcasemainjournal.
AlignthetTlatinglineofthebearingswiththeindex
markonthecrankcaseas shown.
Setthehyaraulicpress.
TOOL:
M.eialinstaller set 070MFMEG0200
METAL
INSTALLERSET
BEARING
13-19
Press the new bearings until the metal installer
INSTALLERSET
flangefullyseated.
I BEARING
Make sure the bearing mating line aligns with the
indexmarkonthecrankcase.
Checktheoilclearance(page13-16).
After selecting newbearings, recheck the clear-
ance. Incorrect clearance can cause severe
enginedamage.
Installthecrankshaft(page13-13).
TRANSMISSION
REMOVAL
Separatethecrankcase(page13-9).
Removetheforkshaftfromtheshiftforks.
Removetheshiftforksand shiftdrum.
13-20
Remove the mainshaft and countershaft together.
MAINSHAFT
TRANSMISSIONDISASSEMBLY
Disassemble the mainshaft and countershaft.
MAINSHAFT
INSPECTION
GEARS
Check the gear dogs. dog slots and teeth for dam-
age or excessive wear.
COUNTERSHAFT
DOG
Measure the I.D. of each gear.
SERVICE LIMITS:
M3, M5 gears: 28.04 mm (1.104 in)
C1, C4 gears: 31.05 mm (1.222 in)
C2 gear: 24.04 mm (0.946 in)
SLOT
13-21
--
CRANKSHAFTITRANSMISSIOI\l
BUSHINGS
Checkthebushingsforwearordamage.
Measurethe0.0.ofeach bushing.
SERVICE LIMITS:
M3,M5,gearbushings:27.94mm(1.100in)
C1,C4gearbushings: 30.93mm(1.218in)
C2 gearbushing: 23.94mm(0.943 in)
Measurethe1.0. ofeach bushing.
SERVICELIMITS:
M3gearbushing: 25.04mm(0.986in)
C2gearbushing: 20.04mm(0.789in)
MAINSHAFTICOUNTERSHAFT
Check the spline grooves and sliding surfaces for
abnormalwearordamage.
Measljretl1e0,0.ofthemainshaftandcountershaft
atthegearand bushingslidingareas.
SERVICE LIMiTS:
Mainshaft(atM3gearbushing):
24.94mm(0.982in)
Cauntershaft(atC2 gearbushing):
19.96mm(0.786in)
Calculate the gear-to-bushing and bushing-to-shaft
clearance.
SERVICE LIMITS:
Gear-ta-bushing
M3,M5,C2: 0.10mm(0.004in)
C1,C4: 0.11 mm(0.004in)
Bushing-ta-shaft
M3: 0.10mm(0.004in)
C2: 0.07 mm(0.003in)
SHIfTFORK
Checkforodeformationorabnormalwear.
Measure};theshiftforkclawthickness.

SERVICE'L1MIT: 5.6mm(0.22in)
Measuretheshiftfork1.0.
t
C2
13-22
____0 _
SHIFTFORKSHAFT
Check the shift fork shaft for bend, abnormal wear
ordamage.
Measuretheshiftforkshaft0.0.
SHIFTDRUM/SHIFTDRUMBEARING
Removetheboltandgearshiftcam plate.
CAM PLATE BOLT
Removethedowelpinandbearing.
Remove the dowel pins from the gearshift cam
DOWELPINS
plate.
\

DOWELPIN
CAM PLATE
13-23
Temporarilyinstallthebearing on theshiftdrum.
BEARINGS
Turntheouterrace ofthebearing withyourfinger.
Thebearingshouldturnsmoothlyandquietly.
Alsocheckthatthebearing innerracefitstightlyon
theshiftdrum.
Removeand discardthe bearing iftheraces donot
turnsmoothly,quietly,orifitfitslooselyontheshift
drum.
Checkthe shift drum end forscoring, scratches, or
evidenceofinsufficientlubrication.
Checktheshiftdrum groovesforabnormalwearor
damage.
MeasuretheshiftdrumO.D. atleftend.
SERVICE I.IMIT: 11.94mm(0.470in)
Checktheshiftdrumjournalintheleftcrankcasefor
excessjvewearordamage.
Measuretheshiftdrumjournall.D.
Calculatetheshiftarum-to-shiftdrumjournal clear-
ance.
S R V I ~ I LIMIT: 0.09mm(0.035in)
InstalLthe dowel pins into the gearshift cam plate
holes. .
CAM PLATE
13-24
CAM PLATE
",
...;/
BOLT ew
Installthebearingontheshiftdrum.
BEARING
Installthedowelpin intotheshiftdrumhole.
/
Install the gearshift cam plate by aligning its hole
withthedowel pin.
Cleanandapplyalockingagenttothegearshiftcam
platebolt(page1-19).
13-25
M5GEAR BUSHING

SNAPRING
M3GEAR(23T)
M1 GEAR (15T)
M4GEAR(25T)
TRANSMISSIONASSEMBLY
Clean all partsinsolvent.
Applyengineoiltotheallgearteeth.
Applymolybdenumdisulfideoiltothegearbushing
sliding surface and shiftforkgroovestoensure ini-
tiallubrication.
Assembleall partsintotheiroriginal positions.
NOTE:
Checkthe gears for freedom of movement or
rotationontheshaft.
Installthe washers and snap rings with the
chamferededgesfacingthethrustloadside.
Do notreuseawornsnapringwhichcouldeasily
spininthegroove.
Check that the snap rings are seated in the
grooves and align their end gaps with the
groovesofthespline..
Ali9'1;thelockwashertabswiththesplinewasher
grooves.
Alignthe oil holes in the M5 gear bushing and
m<:linshaft,andC1, C4 gearbushingand counter-
shaft
MAINSHAFT
M2GEAR(20T)
COUNTERSHAFT
C2 GEAR (31T)
C2 GEAR BUSHING
COUNTERSHAFT
THRUSTWASHER FAINAL DRIVE GEAR (37T)
INSTALLATION
Install the mainshaft and countershaft together into
MAINSHAFT
the left crankcase.
Be sure to install the thrust washers of the counter-
shaft both ends.
The shift forks have the following identification
marks.
"L": Left shift fork
"C": Center shift fork
"R": Right shift fork
"R" MARK "C" MARK
13-27
Install the shift forks into the shifter gear grooves
with the markings facing up (right crankcase side).
Install the shift drum by aligning the shift fork guide
pins with the shift drum guide grooves.
Apply engine oil to the shift fork shaft whole sur-
face.
Insert the shift fork shaft through the shift forks into
the right crankcase.
After installation, check for smooth transmission
operation.
Assemble the crankcase (page 13-49).
OUTPUT GEAR
Descriptionof theoutputgearassembly:
DAMPER CAM
--- ----
--------
REMOVAL
Separatethecrankcase (page 13-9).
i THRUSTWASHER
Removethefollowing:
- Transmission (page13-20)
Removethethrustwasherandoutputgear.
Remove the bushing from the output drive gear
BUSHING
shaft.
(E).Ccept U$.A.)
Sefthedamperspringcompressorontothedamper
camandoutputclrivegears.haft.
Compressthe damper spring by turning the com- _ I I l I I I ~
pressor bolt clockwise until the snap ring can be
removed.
TOOL:
Damperspringcompressor 07964-ME90000
13-29
----- ------ -----
(U.S.A.only)
Place thethreadedadaptorin the end ofthe output
drivegearshaftandtightentheadaptor.
Place the compressorseat overthethreaded adap-
torwiththesteppedsidefacingupward.
Installthe assembly boltthrough the assemblycol-
larandattach ittothethreadedadaptor.
Center the compressor seat with the damper cam
thenbegintotightenthe23mmnutoftheassembly
bolt until the snap ring is visible so it can be
remoVed.
TOQLS; .
AsserntilYcbolt 07965-1660200
Assemblycollar 07965-166030Aor
07965-1660302
Compressorseat 07967-9690200
Threadedadaptor 07965-KA30000
Snapringpliers 07914-5670101 not
availableinU.S.A.
or
07914-5670100
Remove the snap ring, special tools, damper cam
andspringfromthedrivegearshaft.
Removetheboltandstay.
Removetheoutputgearcase mountingbolts.
RemovetheoutputgearcaseassemblyandO-ring.
ASSEMBLYBOLT
ASSEMBLYCOLLAR
It::::: THREADEDADAPTOR
COMPRESSORSEAT
SNAPRING
DAMPERCAM
OUTPUTDRIVEGEARSHAFT
-
13-aO
--- --- --- -------
Removetheorificeand O-rings.
Checktheorificeforclogordamage.
Replace itifnecessary.
INSPECTION
DAMPERCAM
Checktheprojectionsofdampercamfordamageor
excessivewear.
PROJECTIONS
OUTPUTGEAR
Check the,output gearteeth for damage or exces-
sivewear,andthegeardog holesfordamage.
MeasuretheoutputgearI.D.
SERVICELIMIT: 24.04mm10.946in)
BUSHING
Checktheoutputgearbushingforwearordamage.
MeasurethebushingI.D.andO.D.
SERVICELIMIT: 0.0. 23.70mm(0.933in)
1.0. 20.06mm(0.7g0in)
Calculatetheoutputgear-to-bushingclearance.
13-31
OUTPUTDRIVEGEARSHAFT
Measure the 0.0. ofthe output drive gear shaft at
thebushingslidingarea.
Calculatethebushing-to-shaftclearance.
SERVICE LIMIT: 0.08 mm(0.003in)
DAMPERSPRING
Measurethedamperspringfreelength.
SERVICE LIMIT: 59mm(2.3in)
Turn the outputdrivegearshaftand checkthatthe
output drive and driven gearshafts turn smoothly
andquietlywithoLltbinding.
Ifthe shafts do not turn smoothly or quietly, the
gearsand/orbearing maybedamagedorfaulty.
They must be checked after disassembly; replace
faultyparts/assembliesas required.
BACKLASHINSPECTION/GEAR
TOOTHCONTACTPATrERNCHECK
NOTE:
Performthebacklashinspectionandcontactpattern
checkwheneveryou replacetheoutputdriven/drJve
gears, bearings, bearing holderand gearcase. The
extension linesfromthegearengagementsurfaces
shouldintersectatonepoint.
13-32
BACKLASHINSPECTION
Settheoutputgearcaseinavisewithsoftjaws.
OUTPUTDRIVE GEAR SHAFT
Set a horizontal type dial indicator on the output
drivengear,throughtheVS sensorhole.
Holdtheoutputdrivegearshaftwithyourhandand
rotatethedriven gearshaft until gearslackis taken
up.
Turn the driven gear shaft back and forth to read
backlash.
STANDARD: 0.08- 0.23mOl(0.003- 0.009in)
SERVICE LIMIT: 0.40mOl(0.016in)
Remove the dial indicator. Turn the driven gear
\
shaft120
0
andmeasurebacklash. Repeatthisproce-
dureoncemore.
Comparethedifferenceofthethreemeasurements.
Backlashdifferencebetweenmeasurements
SERVICELIMIT: 0.10mOl(0.004in)
Ifthe difference in measurements exceeds the ser-
vice limit, it indicates that the bearing is not
installedsquarelyorthecase isdeformed.
Inspectthebearingsandcase.
OUTPUT
DRIVEN GEAR DIALINDICATOR
Ifthe backlash is.E!xcessive,replacetheoutputdrive
gear one.
Ifthe backlash replacetheoutputdrive
shim.witha
0.06- 0.07 mm(0.002
-O'Q,O:.tihl when.$himthickness ischanged by0.10
mm(O:pJ)4 in).
.OUTPUT'DFlI\(EGEARSHIMS:
0;30.mm(O;012in)
.Cijsmm(0.014in)
mOl (0.016in)
0.45mOl (0.018in)
0.50mOl (0.020in)- Standard
0.55mm(0.022in)
0.60mOl(0.024in)
O.65rrirn(0.026in)
0.70mOl(0.028in)
0.75mOl (0.030in)
OUTPUTDRIVEGEARSHIMREPLACEMENT
Removetheboltsanddrivegearassemblyfromthe
BOLTS
gearcase.
13-33
Remove the dowel pin, shim and O-ring from the
bearing holder.
Selectthereplacementshim(page13-33).
Coata newO-ring withengineoiland install itinto
thebearing holdergroove.
Installthedowelpinandshim.
Install the drive gear assembly into the gear case
andtightenthebolts(page13-44),
Recheckthebacklash(page13-32).
After backlash adjustment has been made, check
thegeartoothcontactpatternas describedbelow.
SHIM DOWELPIN
GEARTOOTHCONTACTPATTERNCHECK
O-RING fI"7I
Description of the tooth:
COASTSIDE
(contactswhenenginebrakeisapplied)
------
DRIVE SIDE
(contactswhenenginepowerisapplied)
Removethedrivegearassemblyfromthegearcase
DRIVEN GEARTEETH
(page13-33).
Apply a thin coat of Prussian Blue to the output
drivengearteeth.
Reinstallthedrivegearwiththeshim.
Rotatethedrivegearshaftseveraltimesinthe nor-
maldirectionofrotation.
Removethedrivegearassemblyandcheckthegear
toothcontactpattern.
Contact is normal ifPrussian Blue is transferred to
theapproximatecenterofeachtoothandslightlyto
thetoe.
Ifthepattern is notcorrect, removeand replace the
outputdrivengearshim.
SHIM HEEL
--
TOE _ HEEL
FACE

FLANK ..
13-34
Replace the shim with athinner one ifthe contact
pattern istoohigh,towardtheface.
Replace the shim with a thicker one ifthe contact
pattern istoolow,towardtheflank.
Thepatternwillshiftabout1.5- 2.0mm(0.06- 0.08
in)whentheshimthicknessischanged by0.10mm
(0.04in).
OUTPUTDRIVENGEARSHIMS:
0.20 mm(O.OOBin)
0.25mm(0.010in)
0.30mril(0.012in)
0.35mm(0.014in)
0.4Q I'Ilm (0.016in)- Standard
0;45mm(0.Q_1Sin)
0.50mm in)
0.55mm(O.022in)
0.60mOl (0.024in)
OUTPUTDRIVENGEARSHIMREPLACEMENT
Holdtheoutputgearcasein avisewithsoftjaws.
Removetneboltsand outputdrivengearassembly.
Remove the shim and O-ring from the bearing
holOer.
Selectthereelacementshim (page13-35).
CQat!'! oil and install itinto
gXbove.
ltista'lltieshim; .' ..
assembly to the gear case
ancftightentt1e 13-41).
(page13-34).
Toohigh:
DRIVE SIDE COASTSIDE
FACE
COASTSIDE

Toolow:
DRIVE SIDE

OUTPUTDRIVEN GEARASSEMBLY
fI "71O-RING
SHIM
13-35
----- ---------------------
OUTPUTDRIVEGEARDISASSEMBLY
Hold the output gear case in a vise with soft jaws.
Unstake the bearing inner/outer race lock nuts.
Remove the bearing inner race lock nut using the
special tools.
TOOLS:
07923-6890101
(U.S.A. only)
Holderhandle 07PAB0010400
Locknutwrench,36x47.8 mm 07916-MB00002
Remove the bearing outer race lock nut using a spe-
cial tool.
TOOL:
Remove the two bolts and drive gear assembly from
the gear case.
13-36
Remove the dowel pin, shim and O-ring from the
O-RING
bearing holder.
SHIM DOWEL PIN
Press the drive gear out of the bearing using a
hydraulic press.
Press the drive gear bearing out of the bearing
holder using the special tools and a hYdraulic press.
TOOLS:
Driver. 07749-0010000
Attacblllent, 52 x 55 mm 07746-0010400
PiJot,30mm 07746-0040700
OU"rpUTDRIVENGEAR
DISASSEMBLY
HoJ<jthe<jutllutgear case in a vise with soft jaws.
STOPPER RING
ring and oil seal.
13-37
Unstakethebearing innerand outerrace locknuts.
Holdthe driven gearshaftand remove the bearing INSPECTIONTOOL
SHAFTHOLDER
innerrace locknutusingthespecialtools.
TOOLS:
ShaftholderA 07PAB-0010100 or
079236890101
(U.S.A. only)
Locknutwrench,36x47.8mm 07916-MB00002
Differentialinspectiontool 07KMK-HC50101 or
07KMK-HC5010A
(U.S.A.only)
Removethebearingouterrace locknutusingaspe-
cialtool.
TOOL:
Remove the bolts and driven gear assembly from
thegearcase.
LOCKNUTWRENCH
13-38
Remove the shim and O-ring from the bearing
O-RING
holder.
SHIM
Press the driven gear out of the bearing using a
hydraulicpress.
Press the driven gear bearing out of the bearing
holderusingthespecialtoolsandahydraulicpress.
TOOLS:
Driver 07749-0010000
Attachment,52x55 mm 07746-0010400
Pilot,30mm 07746-0040700
Removethedrivengearcasebearing usingthespe-
cialtools.
TOOLS:
Bearingremoverset,17mm 07936-3710300
Removerhandle 07936-3710100
Removerweight 07741-0010201 or
07936371020Aor
07936-3710200
(U.S.A.only)
BEARING
,
13-39
Blow oil passage in the output gear case with com-
pressed air.
OUTPUTDRIVENGEARASSEMBLV
"71
$I O-RING
"71 31 Nm (3.2kgfm. 23 IbHt) SHIM
Drive a new bearing into the gear case with the
DRIVER
marked side facing up until it is fully seated.
TOQLS:
077490010000

42 x 47mm 07746-0010300
Pilot, 17 mm 07746-0040400
BEARING
"
13-40

Pressanewbearingintothebearingholderwiththe
marked side facing up until it is fully seated and
makesureitrotatesfreelyafterinstallation.
TOOL:
Oilsealdriver 07965-KE80200
If the output driven Supportthebearing innerrace andpresstheoutput
gear requires drivengearintothebearing holderusingthespecial
replacement, the tools.
driven and drive
gear must be
TOOLS:
replaced asaset. Driver,40mm1.0. 07746-0030100
Attachment,30mm1.0. 07746-0030300
Coat anewO-ring with engine oil and install itinto .,--:7M O-RING
thebearing holdergroove. __
Installtheshim.
NOTE:
When the-bearing, gear, holder and/or case have
been replaced, use the0.40 mm (0.016 in) shimfor
.initialreference.
DRIVER
.,
BEARING
.,.
.
ATTACHMENT
. II
SHIM
Holdthl;loutputgearcaseinavisewithsoftjaws.
Install thedriven gearassemblyintothegearcase,
aligningwiththeboltholes.
Applyengine oil tothethreads and seatingsurface
oftheboltsandtightenthem.
13-41
Refer to torque
wrench reading
information, on
page 13-3'Service
information'.
Refer to torque
wrench reading
information, on
page 13-3'Service
information'.
Applyengine oil tothethreadsand seating surface
ofanewbearingouterrace locknutandtightenitto
thespecifiedtorqueusingaspecialtool.
TOOL:
TORQUE:
Actual: 98 Nm(10.0kgfm,72Ibf.ft)
Indicated:89Nm(9.1 kgfm,66Ibf.ft)
Applyengineoil tothethreads and seating surface
ofanewinnerrace locknut.
Holdthedrivengearshaftandtightenittothespec-
ifiedtorqueusingthespecialtools.
TOOLS:'
07923-6890101
(U.S.A.only)
Differentialinspectiontool 07KMK-HC50101 or
07KMK-HC5010A
(U.S.A.only)
TORQUE:
Actual: 73 Nm(7.4kgfm,54Ibfft)
Indicated:66Nm(6.7kgfm,49lbfft)
Stakethebearinginnerandouterrace locknuts.
Pack grease intotheseal lipcavityofanewoil seal
and installitimtilthe ring groove is visible so the
stopperringcan be installed.
Install the stopper ring into the bearing holder
groovesecurely.
NOTE:
Installthestopperring withthechamfered edge
facingthethrustloadside.
Do notreusewornstopperringwhichcouldeas-
ilyspininthegroove.
Check that the stopper ring is seated in the
groove.
INSPECTIONTOOL SHAFTHOLDER
...,,/It
II lIliijjll
INNERLOCK NUT
13-42
OUTPUTDRIVEGEARASSEMBLV
13-43
If the output drive
gear requires
replacement, the
drive and driven
gears must be
replaced as aset.
OUTPUTGEAR
O-RINGS
.t'"7I
fII:
, >
""7J31 Nm(3.2 kgfm,23 IbHt)
Pressanewbearingintothebearingholderwiththe
facing upuntllitisfullyseated.
TOOLS:
Driver 07749-0010000
62x68mm 07746-0010500
P!lot,30.mll1 07746-0040700
Supportthebearing innerraceand presstheoutput
drivegearusingthespecialtools.
TOOLS:
Driver,.40mm1.0.
30mm1.0.
fum
NOTE:
Place the pilot's threaded end into the drive
shaft.
If the bearing, gear, holder and/or case is
replaced,anewshimmustbeselected(Seepage
13-33,Backlash Inspection).
07746-0030100
07746-0030300
07746-004UjOO
Refer to torque
wrench reading
information, on
page 13-3'Service
information',
Coat anewO-ring with engine oil and install itinto
thebearing holdergroove.
Installthedowelpinandshim.
NOTE:
Whenthe bearing,gear,holderand/orcase have
been replaced, use the 0.50 mm (0.020 in) shim
forinitial reference.
Installthedrivegearassemblyintothegearcase.
Applyengineoiltotheboltthreadsandseatingsur-
face.
Tightentheboltstothespecifiedtorque.
Holdthegearcase in avisewithsoftjaws.
Applyengine oil tothethreadsand seating surface
ofanewbearingouterrace locknutandtightenitto
thespecifiedtorqueusingaspecialtool.
TOOL:
Locknutwrench,36x 47.8 mm 07916MB00002
TORQUE:
Actual: 98 Nm(10.0kgfm,72Ibfft)
N'm(9.1 kgfm,66Ibfft)
APJ:lly,engine oil threadsand seating surface
cof bearingir:merracelOcknutandtightenitto
thespecifiedtorqueusingthespecialtools.
TOOtS:
Lockntitwrench,36x 47.8 mm 07916MB00002
ShaftholderA 07PAB0010100or
079236890101
(U.S,A.
Holderetiandle 07PAB-0010400
TORQUE:
AC'b,(al: 73 Nm(7.4kgfm,54Ibfft)
Indlcated:66Nm(6.7kgfm,49Ibfft)
O-RING ..
...jjilllfil
DOWELPIN
INNER LOCK NUT
at,
I
I
." 'Il
IIliijjIII OUTER LOCK NUT
13-44
Stakethebearing innerand outerrace locknuts.
INSTALLATION
Coat new ~ r i n s with engine oil and install them
intothe6rificegrooves.
Installtheorificeintothecrankcase.
Coata newO-ring with engineoil and install itinto
thegrooveinthegearcase.
Install the output gear case assembly into the left ..0
crankcase byaligningthedowelpinwiththecrank- "0.
case hole.
Applysealanttotheoutputgearcase mountingbolt
threads.
TORQUE:31 Nm(3.2kgfm,23 Ibfft)
Install thestay, aligning its hole with thegearcase
bossandtightentheboltsecurely.
13-45
---------- -- --
13-46
Apply 1 g of molybdenum disulfide grease to the
outputdrivegearanddampercamsplines.
Installthedamperspringovertheoutputdrivegear
withthetightlywoundcoilfacingtheleftcrankcase.
Installthedampercamontothespring.
Installthesnapringonthedampercam.
(ExceptU.S.A.)
Setthedamperspringcompressorontothedamper
cam and drivegearshaft.
Compress the damper spring by turning the com-
pressor boltclockwise untilthesnap ring groove is
visible.
TOOL:
Damperspringcompressor 07964ME90000
(U.S.A.only)
Place thethreaded adaptorin theendofthe output
drivegearshaftandtightentheadaptor.
Place the compressorseat overthethreaded adap-
torwiththesteppedsidefacing upward.
InstalltheasselT!blybolt]hrqughthe assemblycol-
lar and attachit tothetnfe.aejedadaptor.
Centerthe, compressor:seatwith the damper cam
thenbegintotightenthe23mm nutoftheassembly
boltuntilthesnaprihggrOOveisvisiblesosnapring
Cah be1Ilstalledintothegroove.
T O t l s ~ ~
Assemblybolt 079651660200
Assemblycollar 07965166030Aor
079651660302
Compressorseat 079679690200
Threadedadaptor 07965KA30000
Installthesnapringintothegrooveintheshaft.
TOOLS:
Snapringpliers_ 079145670101
notavailablein
U.S.A.or
07914-5670100
NotE:
Install the snap ring with the chamfered edges
facingthethrustloadside;
Do notreuse wornsnap ring which could easily
spininthegroove;
Checkthatthesnapring isseatedinthegroove.
Loosen and removethespecialtool.
ASSEMBLYBOLT
ASSEMBLYCOLLAR
THREADEDADAPTOR
COMPRESSOR SEAT
I --- SNAPRING
DAMPER CAM
OUTPUTDRIVE GEAR SHAFT
Installthebushingintotheoutputgearshaft.
OUTPUTGEAR
Install theoutputgearontothe gearshaftbyalign-
ing the damper cam projections with the output
gearholes.
Installthethrustwasher.
.7 Transmission(page13-27)
':"Oilpump(page5-11)
Assemblethecrankcase(page13-49).
THRUSTWASHER
CRANKCASEBEARINGREPLACEMENT
INSPECTION
Removethefollowing:
- Cranksnaft(page13-10)
- Transmission(page13-20)
- Outputgear{page13-29)
- Oil pump(page5-6)
Turntheinnerraceofeach bearingwithyourfinger.
.Thebearipgssh041dturnsmoothlyand quietly.
Also'checktnatihebearingouterrace fitstightlyin
thecrankcase. ..
Remove and discardthEfoearihgsifthe races does
not turn smoothly, quietlY, or ifthey fit loosely in
thecrankcase.
LEFTCRANKeASEBEARINGS
",-Cr- --. -; -'=._.\
and countershaft bearings
usingthe'specialtools.
TOols:
Bearirtgremoverset,20mm
handle .
07936-3710600
07936-3710100
"",,eight 07741-0010201 or
07936-371020Aor
07936':3710200
(U.S.A.'onlyJ
BEARING
13-47
Removetheoil guideplatefromthecrankcase.
Checktheoilguideplateforclogordeformation.
Installtheoilguideplateintothecrankcase.
Drive newbearings intothe left crankcase withthe
markedsidefacingupuntiltheyarefullyseated.
TOOLS:
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
RIGHTCRANKCASEBEARINGS
Drivethebearingsoutoftherightcrankcase.
OUTPUTDRIVEGEAR
SHAFTBEARING
Drivenewbearingsintotherightcrankcasewiththe
markedsidefacingupuntiltheyarefullyseated.
TOOLS:
Mainshaft bearing:
Driver 07749-0010000
Attachment, 52 x 55 mm 07746-0010400
Pilot, 22 mm 07746-Q041000
Countershaftloutput drive gear shaft bearillgs:
Driver 07749':0010000
Attachment, 42 x 47 mm 0774&-0010300
Pilot,20mm 07746-0040500
13-48
----- ------
CRANKCASEASSEMBLY
Clean the left and right crankcase mating surfaces
thoroughly,beingcarefulnottodamagethem.
Makesuretheall partsareinstalledintheleftcrank-
case.
Apply liquid sealant tothe right and left crankcase
matingsurfaces.
Installthetwodowelpinsintotheleftcrankcase.
Coatanewpipeseal withengineoil and installitto
;theojlpipe.
~ : . . .
NOTE:
Install a new pipe seal with itstapered sidefacing
out.
Installtherightcrankcaseovertheleftcrankcase.
Turntheshiftdrumuntilthepositionas shown.
InstalltherightcrankcaseCboltswiththewasher.
Tighten the 8 mm boltl; in a crisscross pattern in
severalsteps.
TORQUE:
8rnmbolt:23 N;m(2.3kgfm,17Ibfft)
Tightenthe6mmboltssecurely.
13-49
--- ----------------
Installtheleftcrankcase boltsandtightenthe8mm
boltsinacrisscrosspattern inseveral steps.
TORQUE:
8mmbolt:23Nm(2.3kgfm,17Ibfft)
Tightenthe6mmboltssecurely.
Clean and apply locking agent to the bolt threads
(page 1-19).
Install the bearing setting plate and tighten the
bolts.
r ~
Installandtightentheboltwiththewasher byhold-
SHAFTHOLDERA BOLTIWASHER
ing the output driven gear shaft using the special
tools.
TOOLS:
07923-6890101
(U.S.A.only)
Holderhandle 07PAB-0010400
Rechecl('theall crankcase bolttorquevalues.
Installthecamchains.
Applylockingagenttothecam chaintensionerset-
tingplateboltthreads(page1-19).
Install the cam chain tensioner setting plates and
tightenthebolts.
Installtheremaining parts(page13-3).
Installtheengineintotheframe(page8-7).
j.
13-50
----------
14. FINALDRIVE
COMPONENTLOCATION....14-2 FINALDRIVEDISASSEMBLYI
INS,PECTION 14-8
FINALDRIVEASSEMBLy 14-17
FINALDRIVEINSTALLATION 14-22
FII\lALDRIVEREMOVAL 14-7
14-1
FINALDRIVE
COMPONENTLOCATION
22 Nm (2.2 kgfm, 16 Ibfft)
14-2
---- ---------------
FINALDRIVE
SERVICEINFORMATION
GENERAL
Thefinal drivegearassemblyandfinal driveshaftmustbe removedtogether.
Perform the gearcontactpattern and backlash inspection wheneveryou replace the bearings, gears orgearcase. ~
extension linesfromthegearengagementsurfacesshouldintersectatonepoint.
Protectthegearcase withashoptowelorsoftjawswhileholdingitinavise. Do notclampthegearcasetootightlyor
itcould bedamaged.
Replacethering andpiniongearsas aset.
SPECIFICATIONS
Unit:mm(in)
Recommendedfinal driveoil Hypoidgearoil,SAE#80 -
Final driveoilcapacity
I
Atdraining 160 cm
3
(5.4 USOZ, 5.6 Impoz) -
I
Atdisassembly 170 cm
3
(5.7 USOZ, 6.0 Impoz) -
Final drivegearbacklash 0.05 - 0.15 (0.002 - 0.006) 0.30 (0.012)
Backlashdifferencebetweenmeasurements - 0.10 (0.004)
Ring gear-to-stoppinclearance 0.30 - 0.60 (0.012 - 0.024)
-
Finaldrivegearassemblypre-load 0.2 - 0.4 N'm(2 - 4 kgf'cm,
-
0.1 - 0.3 Ibfft)
TORQUEVALUES
Pinionretainer
Pinionretainerlocktabbolt
Pinionjointnut
Dustguardplatebolt
Finalgearcasecover10 mmbolt
Finalgearcasecover8mmbolt
Finalgearcaseassemblymountingnut
Rearshockabsorberlower.mountingbolt
(leftside)
Finalgearcasestudbolt
108 N'm(11.0 kgf'm,80 Ibfft)
10 N'm(1.0 kgfm,7 Ibfft)
108 N'm(11.0 kgf'm,80 Ibfft)
10 N'm(1.0 kgf'm,7Ibfft)
See page14-22
14-3
FINALDRIVE
TOOLS
Driver Attachment,32 x35 mm Attachment,52x 55 mm
07749-0010000 07746-0010100 07746-0010400
Attachment,72x75 mm Pilot, 19mm Driver,40 mm1.0.
07746-0010600 077460041400 07746-0030100
Attachment,25 mm1.0. Pinionholderplate Collarset"C"
07746-0030200 07924-ME40010 07924-ME40020
Oil seal driver Retainerwrench Pinionpullerbase
070MF-MEG0300 07910-MA10100 07HMC-MM80110
(
or07HMC-MM8011A(U.S.A.only)
14-4
FINALDRIVE
Puller shaft
07931-ME40000
or 07931-ME4010B and
07931-HB3020A (U.S.A. only)
Bearing remover, 35 mm
07936-3710400
Remover handle
07936-3710100
Remover weight
07741-0010201
or 07936-371020A or
07936-3710200 (U.S.A. only)
Bearing remover, 20 mm
07936-3710600
or equivalent commercially
available in U.S.A.
Bearing driver attachment
07GAD-SD40101
Oil seal driver attachment
07LAD-SM40100
or 07LAD-SM4A100 (U.S.A. only)
Oil seal driver, 55.7 x 60.3 mm
07965-KE80200
Attachment, 44 x 49.5 mm
07945-3330300
14':..5
FINALDRIVE
TROUBLESHOOTING
Excessive noise
Worn or scored ring gear shaft and driven flange
Scored driven flange and wheel hub (page 16-7)
Worn or scored drive pinion and splines
Worn pinion and ring gears
Excessive backlash between pinion and ring gears
Oil level too low
Worn or damaged pinion gear and/or pinion joint splines
Oil leak
Clogged breather
Oil level too high
Damaged seals
Loose case cover bolts
Excessiverearwheelbacklash
Worn drive shaft splines
Excessive backlash between pinion and ring gears
Worn driven flange and ring gear splines
Excessive play in final drive case bearings
Worn drive shaft, universal joint and/or pinion joint splines
Excessive play or worn universal joint bearing
~ 6
FINALDRIVE
FINALDRIVEREMOVAL
Drainthefinal driveoil(page4-18).
Removetherearwheel(page 16-6).
Remove the left shock absorber lower mounting
bolt.
Removethefourmountingnutsandfinaldrivegear
caseassembly.
Remove the drive shaft from the final drive gear
case assemblybygentlyturningthedriveshaftand
pullingit.
~
~ R C S E
NUTS ASSEMBLY
DRIVE SHAFT
Remove the spring, oil seal and stopper ring from
thedriveshaft.
INSPECTION
Checkthesplinesofthedriveshaftforwearordam-
age.
Ifthesplines ofthe driveshaftare damaged,check
theuniversaljointsplinesalso(page16-24).
SPRING
Turn the pinionjointand checkthatthe pinion and
PINIONJOINT RING GEAR SHAFT
ring gearsturnsmoothlyand quietlywithout bind-
ing.
If the gears do not turn smoothly or quietly, the
gearsand/orbearing maybe damagedorfaulty.
They must be checked after disassembly; replace
faultyparts/assembliesas required.
14-7
FINALDRIVE
FINALDRIVEDISASSEMBLYI
INSPECTION
NOTE:
Performthebacklashinspectionandcontactpattern
check whenever you replace the pinion gear, ring
gear, bearings and gear case. The extension lines
fromthegearengagementsurfacesshouldintersect
atonepoint.
Removethefinal driveanddriveshaft(page14-7).
BACKLASHINSPECTION
Removetheoilfillercap.
Do not over-tighten Hold the final drive gear case assembly in a vise
the vice on the final withsoftjaws.
drive case.
Install the special tools ontothe gearcase and into
thepinionjointtoholdthepiniongear.
TOOLS:
Pinionholderplate 07924-ME40010
Collarset"C" 07924-ME40020
Set ahorizontaltypedial indicatoronthering gear,
throughtheoilfillerhole.
Turnthe ring gearback and forth to read the back-
lash.
STANDARD: 0.05- 0.15mm(0.002- 0.006in)
Remove'thedial indicatorand specialtools.
Turntheringgear120
0
and measurethebacklash.
Repeatthisprocedureoncemore.
Comparethedifferenceofthethreemeasurements.
Ifthe difference in measurements exceeds theser-
vice limit, it indicates that the bearing is not
installedsquarely,orthecase isdeformed.
Inspectthebearingsandcase.
Ifthe backlash is excessive, replace the ring gear
shimwithathickerone.
Ifthe backlash is too small, replace the ring gear
shimwithathinnerone.
RING GEARSHIMS:
A: 1.82mm(0.072in) G:2.18mm(0.086in)
B: 1.88mm(0.074in) H:2.24mm(0.088in)
C: 1.94mm(0.076in). I: 2.30mm(0.091 in)
D: 2.00mm(0.079in)- Standard
E: 2.06mm(0.081 in)
F: 2.12mm(0.083in)
Forring gearshimreplacement(page14-11).
POINTOF INTERSECTION
PINION GEAR RING GEAR SHIM
-----!+-'81--++-++-
, RING GEAR
14-8
FINALDRIVE
FINALGEARCASESEPARATION
Remove the bolt, washer and the dust guard plate
byturningitclockwise.
Removethea-ring.
Loosenthecoverboltsin acrisscrosspatterninsev-
eral stepsand removethem.
Prythegearcasecoverand removeitfromthecase.
Removethewavewasher.
GEARTOOTH CONTACTPATTERN
CHECK
Descriptionofthetooth:
COASTSIDE
Keep dust and dirt Cleanthesealingmaterialoffthematingsurfacesof
ApplyPrussianBlue
out ofthe case and the gear-case and cover, being careful notto dam-
cover. agethem.
ApplyathincoatofPrussianBluetothepiniongear
teeth.
Installthewavewasher.
GEAR CASE COVER a-RING
TOE (insideofgear)
(contactswhenenginebrakeisapplied)
---------
(contactswhenenginepowerisapplied)
WAVEWASHER
14-9
--
---- ------------ --- ------ --------------
FINALDRIVE
Replace the pinion gear shim with a thicker one if ,-----------------------,
thecontactpattern istoohigh,towardtheface. TooHigh: PINIONSHIM
14-10
Installthecasecoverandtightentheboltsinacriss-
cross pattern in several stepsuntilthecoverevenly
touchesthegearcase.
Tightenthetwo10 mmboltstothespecifiedtorque
inseveral stepsalternately.
Tightenthesix8mmboltstothespecifiedtorquein
acrisscrosspatterninseveraltimes.
Removetheoilfillercap.
Rotate the ring gear several times in normal direc-
tionofrotation.
Checkthegeartoothcontactpatternthroughtheoil
fillerhole.
Contactis normalifthePrussian Blueistransferred
totheapproximatecenterofeachtoothand slightly
towardstheface.
Ifthe patterns are notcorrect, remove and replace
thepiniongearshimwithasuitableone
(page 14-12).
Replace the pinion gear shim with athinner one if
thecontactpatternistoolow,towardtheflank.
The patterns will shift about 1.5 - 2.0 mm (0.06 -
0.08 in) whenthethickness ofthe shim ischanged
by0.1 mm(0.004in).
PINIONGEARSHIMS:
A: 1.82mm(0.072in)
B: 1.88mm(0.074in)
C: 1.94 mm(().076in)
D: 2.00mm(0.079in)- Standard
E: 2.06mm(0.081 in)
F: 2.12mm(0.083in)
G:2.18mm(0.086in)
Forpiniongearshimreplacement(page14-13).
8mmBOLTS GEAR CASECOVER
Normal:
TOE
TOE HEEL
HEEL
-

COASTSIDE FLANK FLANK DRIVESIDE
FACE

SIDE
TooLow:

+ DRIVE
COAST
FLANK SIDE SIDE FLANK
FACE

COAST i
SIDE
-------------- ----
FINALDRIVE
RINGGEARREMOVAL/SHIM
REPLACEMENT
Remove the final gear case cover (page 14-9).
If the ring gear stays in the cover, remove it as fol-
lows:
Press the ring gear out of the gear case cover using
the special tools and hydraulic press.
TOOLS:
Driver 077490010000
Oil seal driver attachment 07LAD-SM40100 or
07LAD-SM4A100
(U.S.A. only)
Remove the oil seal.
If the bearing remained in the cover, remove it as
follows:
Press the ail seal and bearing out of the cover using
the special tools and hydraulic press.
TOOLS:
Driver 07749-0010000
Oiheal driver 070MFMEG0300
Attachment, 72 x 75 mm 07746-0010600
If the bearing remained on the ring gear, remove it
as follows:
Remove the ring gear bearing using a commercially
avaiiapJe/bearingpulier.
This. b.earing may not need to be replaced after
inspect the bearing for excessive
play after removal.
Replace it if necessary.
14-11
FII\IALDRIVE
Selectthereplacementshim(page14-8).
NOTE:
Whenthegearset, pinionbearing,ringgearbearing
and/orgearcase has been replaced, use a2.00 mm
(0.079 in)thicknessshimforinitial reference.
SHIM
\
CJ
BEARING
Press the ring gear bearing intothe cover with the
markedsidefacinginsideuntilitisfullyseated.
TOOLS:
Driver 07749-0010000
Bearing:driverattachment 07GAD-SD40101
PINIONGEARREMOVAL
Holdthegearcaseinavisewithsoftjaws.
HOLDER PLATE
Hold the pinion joint and remove the pinion joint
nutusingthespecialtools.
TOOLS:
Removethepinionjoint.
Removetheboltandretainerlocktab.
COLLAR

14-12
------------------------------
--
FINALDRIVE
Removethepinionretainerusingthespecialtool.
RETAINER WRENCH
TOOL:
Retainerwrench 07910-MA10100
Remove the O-ring and oil seal from the pinion
OILSEAL
retainer.
O-RING
Install the special tools onto the pinion gear shaft
PULLERSHAFT
andgearcase.
TOOLS:
ExceptU.S.A.
Pinionpullinbase 07HMC-MM80110
Pullershaft 07931-ME40000
U.S.A.only
.Pullerbase"A" 07HMC-MM8011A
Assemblyshaft,22x 1.5x240mm
07931-ME4010Band
Specialnut 07931HB3020A
Pullthepiniongearassemblyoutofthegearcase.
Check the pinion gear needle bearing in the gear
caseforwearordamage.
PII\JIOI\Jc..;EAR REMOVALI
SHIMREPLACEMENT
Pull the pinion gear bearing from the shaftwith a
commerciallyavailablebearing puller.
This bearing may not need to be replaced after
removal.However,inspectthebearingforexcessive
playafterremoval.
Removethepinionshim.
Replace the pinion Replace itifnecessary.
gear bearing and
inner races as a set.
BEARING/SHIM
14-13
----------- -_.._-- --._------------
FINALDRIVE
Select the replacement shim (page 14-10).
Install the shim, bearing and inner races onto the
pinion gear.
NOTE:
When the gear set, pinion bearing, ring gear bearing
and/or gear case has been replaced, use a 2.00 mm
(0.079 in) thickness shim for initial reference.
INNER RACES
PINION GEAR
BEARING
Drive the bearing with the marked side facing up.
TOOLS:
Driver, 40 mm 1.0. 07746-0030100
Attach"!lent, 25 mm 1.0. 07746-0030200
CASE BEARING REPLACEMENT
RING GEAR CASE BEARING
Be sure to wear Heat the gear case to 80C (176F) evenly using a
BEARING REMOVER WEIGHT
heavy gloves when heat gun.
handling the heated Remove the ring gear case bearing from the gear
gear case. caseiJsing the special tools.
TOOLS:
~ r i g g remover, 35 mm 07936-3710400
Remover handle 07936-3710100
Remo""r weight 07741-0010201 or
07936-371020A or
07936-3710200
(U.S.A. only)
Remove the oil seal.
BEARING
14-14
FINALDRIVE
Removethe breathercap and blowcompressed air
throughthehole.
Installthebreathercap.
Applygreasetoanewoilseal lips.
Drivetheoilseal intothegearcasewiththemarked
sidefacing downuntilitisfullyseated.
TOOLS:
Driver 07749-0010000
Attachment, 44 x 49.5 mm 079453330300
Drive a new ring gear case bearing into the gear
case with the marked side facing inside until it is
fullyseated usingthespecialtools.
TOOLS:
Driver 07749-0010000
Attachment, 52 x 55 mm 077460010400
PINION
... ..r ringuntiltheend ofthestopper ...'

. - hoJe.
$tri!Cec .c,/c. ring with apunch

Gi"aspthe with needle-nose pliers
and pUll the stopper ring out through the access
hohi .
14-15
FINALDRIVE
Be sure to wear Heat the gearcase to80C (176F) and remove the
heavy gloves when needlebearing usingthespecialtools.
handling the heated
gear case.
TOOLS:
Bearingremover,20mm 079363710600or
equivalentcommer
ciallyavailablein
U.S.A.
Removerhandle 079363710100
Removerweight 07741-0010201 or
07936371020Aor
079363710200
(U.S.A.only)
Install a newstopper ring intothe grooveofa new
bearingsecurely.
Placetheneedlebearing inafreezer.
Heatthegearcaseto80C (176F).
Remove the needle bearing from the freezer and
driveitin1:b thegearcase withthemarked sidefac-
ing upuntilitisfuHyseated.
TOOLS:
Drivei'
.
Attachment,32x
Pilot,19 mm
.
35mm
077490010000
077460010100
07746-0041400
Make sure the stopper ring is securely set in the
grooveofthegearcase.
WEIGHT
STOPPER RING ....
IlIiijII
.,BEARING
DRIVER
14-16
FINALDRIVE
FINALDRIVEASSEMBLV
PINIONGEARINSTALLATION
PINIONGEAR
SHIM
_"O-RING

,
108Nm(11.0kgf'm,80Ibf.ft)
10Nm(1.0kgfm,7Ibf.ft)

108Nm
-
(11.0kgf.m,80Ibf.ft)
PINIONJOINT
gear assemblyinto the gear case
usingt6espeCialtool.
--. _-
1'g91,::
Oil'Seal' drive..,55.7x60.3mm 07965KE80200
into the pinion retainer with the
upuntilitisfullyseated.
Ydt;)LS:-
.. 071490010000
Amthfu_nt,#x49.5rttm 079453330300
Packgreaseintotheseal lipcavity.
OILSEALDRIVER
/
....
....
....
....
....
ATIACHMENT
14-17

FINALDRIVE
CoatanewO-ringwithgreaseand installitintothe
PINION RETAINER
retainergroove.

The lock tab is
available in the two
types (A and B)as
shown.
111 ....... O-RING
Holdthegearcaseinavisewithsoftjaws.
RETAINERWRENCH
Install the pinion retainer into the gear case and
tightenittothespecifiedtorqueusingaspecialtool.
TOOL:
Retainerwrench 07910-MA10100
TORQUE:108N'm(11.0kgfm,80IbUt)
Installthelocktabwithitstabfacing up,depending
on the position of the pinion retainer grooves in
relationtothelocktabandtightenthebolt.
TORQUE: 10Nm(1.0 kgf'm,7Ibfft)
Clean the threads ofthe pinion gearshaftand pin-
ionjointnutthoroughly.
Apply locking agent to the joint nut threads and
installthe pinionjointand jointnutontothe pinion
gearshaft.
JOINTNUT
ew
14-18
FINALDRIVE
Hold the pinion joint with the special tools and
tightenthepinionjointnuttothespecifiedtorque.
TOOLS:
TORQUE: 108Nm(11.0 kgfm,80 Ibfft)
RING GEARINSTALLATION
RING GEAR
WAVEWASHER
DUSTGUARDPLATE
BEARING (57/34) $I
fI OllSEAl
~ ~ a-RING It _ ~
GEARCASECOVER
SHIM
BEARING (16012)
Insta.lIthEls,hil1"lontotheringgear.
SUPPoJ'tJhe.bearing innerracewiththespecial tool
andp're'ss the ring gear into the bearing using a
hydraulicpress.
TOOL:
Oilseafdriver 070MF-MEG0300
14-19
FINAL DRIVE
Measure the clearance between the ring gear and
stoppinwithafeelergauge.
CLEARANCE: 0.30- 0.60 mm(0.012- 0.024in)
Remove the ring gearifthe clearance does notfall
withinthespecification.
Be sure to wear Heat the gear case cover to approximately 80C
heavygloves when (176F). Heat the case cover evenly and slowly to
handling the heated preventwarpage.
gearcase. When the gearcase cover is heated to the proper
temperature, remove the stop pin by tapping the
cover.
STOPPIN
Select a stop pin shim to obtain the correct c1ear- ,-----------R-IN-G-G-E-A-R---------,
ance.
SHIMTHICKNESS: A: 0.10mm(0.004in)
B:0.15mm(0.006in)
Installtheshimanddrivethestoppin intothegear
casecover.
Installtheoilseal untilitisflushwiththecoversur-
face usingthespecialtools.
TOOLS:
Driver 077490010000
Oilsealdriver 070MF-MEG0300
Attachment,72x75mm 07746-0010600
0.30- 0.60 mm
(0.012- 0.024in)
ft
s ........
...... _-=IJi'II1iII1
OILSEAL
14-20
FINALDRIVE
14-21
------------ - -- ------------ ----
Keep dust and dirt
out of the case and
cover.
FINALGEARCASEASSEMBLY
NOTE:
When the gear set, bearing and/or gear case has
been replaced,checkthetoothcontactpattern(page
14-9)and gearcase backlash (page14-8).
Cleanthematingsurfaceofthegearcaseandcover,
beingcareful nottodamagethem.
Apply liquid sealant to the mating surface ofthe
gearcase.
Installthewavewasher.
Installthecasecoverontothegearcase.
Applylocking agenttothethreadsofthecasecover
10 mmbolts.
Install the bolts, and tighten them in a crisscross
pattern in several steps until the cover evenly
touchesthegearcase.
Tightenthetwo10 mmboltstothespecifiedtorque
inseveralstepsalternately.
Tightenthesix8 mmboltstothespecifiedtorquein
acrisscrosspatterninseveral steps.
Apply r ~ s toanewG-ring.
InstalltheG-ring inthering geargroove.
Checkthatthegearassemblyturns smoothlywith-
out binding.
ME;lasurethefinal gearassemblypre-load.
STANDARD:
0.2- 0.4Nm(2- 4kgfcm,0.1 - 0.3Ibfft)
Ifthepreload reading does notfallwithinthespeci-
fication,oheckthebearingsforproperinstallation.
WAVEWASHER
..---
fIG-RING
FINALDRIVE
Installthedustguardplate,aligningitstabswiththe
covergrooves.
Turn the dust guard plate counterclockwise and
installtheboltandwasher.
DUSTGUARDPLATE

WASHER I
DRIVE SHAFT
14-22
FINALDRIVEINSTALLATION
Checkthatthegearcase stud boltsaretight.
Ifany are loose, remove them, clean theirthreads
withcontactcleaner,then installthem using alock-
ing agent.
After installation, be sure to measure the distance
fromthetopofeachstudtothegearcasesurfaceas
shown.
Install a new stopper ring into the drive shaft
groove.
Installthespringintothedriveshaft.
Apply 0.5 g of melybdenum disulfide grease to a
newoilseal lipsandinstallitontothedriveshaft.
Apply 1 g of molybdenum disulfide grease to the
universaljointsidesplinesofthedriveshaft.
Apply2g ormoreofmolybdenum disulfidegrease
tothepinionjointsplines.
.
Makesurethe Install the drive shaft intothe pinionjointuntil the
stopperringis stopperringseatsinthepinionjointsplinegroove.
seatedproperlyby
pullingon thedrive
shaftlightly.
Be carefulnotto
damage thedrive
shaftoilseal.
STUDBOLT
261 mm
(1.00.04in)
"
SPRING
FINALDRIVE
Insert the final drive assembly into the swingarm
and align the drive shaftsplines withthe universal
jointsplines.
Installthegearcase mountingnuts.
Tightenthegearcase mountingnutsin acrisscross
pattern inseveral steps.
TORQUE:64Nm(6.5kgfm.47Ibfft)
Tightentheshockabsorberlowermounting boltto
thespecifiedtorque.
Installtherearwheel (page16-13).
Fillthegearcase withtherecommended final drive
gearoil(page4-18).
14-23

MEMO
------------ ------------
15. FRONTWHEEL/SUSPENSION/STEERING
COMPONENTLOCATION............ .. .. 15-2
FRONTWHEEL.... .. .. 15-13
FORK 15-19
SERVICEINFORMATION .. 15-3
TROUBLESHOOTING.. 15-5
STEERINGSTEM 15-28
HANDLEBAR 15-6
..
15-1
COMPONENT LOCATION
30 N'm (3.1 kgfm, 22 IbHt)
22 Nm (2.2 kgf'm, 161bHt)
~ ~
~ 103 Nm (10.5 kgfm. 761bHI'
~ ~
I I - I ~ ~ ~
15-2
SERVICEINFORMATION
GENERAL
Riding on damaged rimsimpairssafe operationofthevehicle.
Acontaminated brake discorpad reduces stopping power. Discardcontaminated pads and clean acontaminated disc
withahighqualitybrakedegreasingagent.
Ahoistorequivalentis requiredtosupportthemotorcyclewhenservicingthefrontwheel,forkand steeringstem.
Forhydraulicbrakesystemservice(page17-2).
SPECIFICATIONS
Unit:mm(in)
Minimumtiretreaddepth - 1.5(0.06)
Coldtirepres-
sure
Upto90 kg (200Ibs) load 200kPa (2.00kgf/cm
2
, 29 psi) -
Uptomaximumweightcapacity 200kPa (2.00kgf/cm
2
, 29 psi) -
Axle runout - 0.2 (0.01)
Wheel rim Radial - 2.0 (0.08)
runout Axial - 2.0 (0.08)
Wheel balanceweight - 60 g max.
Fork Springfreelength 371.8(14.64) 364.4(14.35)
Tube runout - 0.2(0.01)
Recommendedforkfluid Pro HondaSuspensionFluidSS-8
(10W)
-
Fluidlevel 100(3.9) -
Fluidcapacity 478 2.5em"(16.2 0.08USOZ,
16.80.09Impoz)
-
Steering head bearingpre-load 8.5-12.7N(0.9-1.3kgf) -
TORQUEVALUES
Handlebarupperholderbolt
Handlebarlowerholdernut
Frontmastercylinderholderbolt
Frontbrakediscbolt
Spoke
Frontaxlebolt
Frontaxlepinch bolt
Forkcentersocketbolt
Forkcap
Forktopbridgepinch bolt
Forkbottombridgepinch bolt
Frontbrakecalipermountingbolt
Steeringtopthread
Steeringtopthreadlocknut
Steeringstem nut
Clutch leverpivotbolt
Clutch leverpivotnut
23 Nm(2.3 kgfm, 17 IbHt)
23Nm(2.3kgfm, 17 IbHt)
12 Nm(1.2 kgfm,9IbHt)
4.2Nm(0.4kgfm,3.1 Ibfft)
29.5N'm(3.0kgf'm,22Ibfft)
22.1 N'm(2.3kgfm,16Ibfft)
See page15-32
See page15-32
103N'm(10.5kgf'm,76 Ibfft)
1Nm(0.1 kgf'm,0.7Ibfft)
6Nm(0.6 kgfm,4.4Ibfft)
ALOC bolt;replacewithanewone
15-3
FRONTWHEEUSUSPENSION/STEERING
TOOLS
Driver
07749-0010000
07746-0010300
07746-0010400
Pilot, 20 mm
07746-0040500
Bearing remover shaft
07GGD-0010100
Bearing remover head, 20 mm
07746-0050600
Spoke wrench
07JMA-MR60100
Slider weight
07947-KA50100
Driver attachment
07947-KF00100
Attachment, 30 mm I.D.
07746-0030300
Steering stem socket
07916-3710101
or 07916-3710100 (U.S.A. only)
Bearing remover
07946-3710500
15-4
Ball race remover set
07953-MJ10000
or 07953-MJ1000B (U.S.A. only)
TROUBLESHOOTING
Hard steering
Steering top thread too tight
Worn or damaged steering head bearings
Bent steering stem
Insufficient tire pressure
Faulty tire
Steers to one side or does not track straight
Bent fork leg
Damaged steering head bearings
Loose steering top thread
Bent frame
Worn wheel bearings
Bent front axle
Worn swingarm pivot components (page 16-22)
Front wheel wobbles
Bent rim
Worn wheel bearings
Faulty tire
Unbalanced tire and wheel
Axle fastener not tightened properly
Wheel hard to turn
Faulty wheel bearings
Bent axle
Brake drag (page 17-4)
Soft suspension
Weak forkspring
Low fluid level in fork
Insufficient fluid weight (low viscosity)
Low tire pressure
Stiff suspension
High tire pressure
Bent fork tube
Fork slider binds
High fluid level in fork leg
Incorrect fluid weight (high viscosity)
Clogged fork fluid passage
Front suspension noise
Loose fork fasteners
Insufficient fluid weight (low viscosity)
Worn slider or fork tube bushing
FROI\lTWHEEL/SUSPENSION/STEERING
HANDLEBAR
REMOVAL
Remove the rearview mirrors.
REARVIEW MIRRORS
Release the handlebar switch wires from the wire
clips.
Remove the pivot bolt, nut and clutch lever from the
clutch lever bracket.
Disconnect the clutch switch connectors from the
clutch switch.
Remove the bolts, holder and clutch lever bracket.
HOLDER BRACKET
Remove the clutch switch from the clutch lever
BRACKET
bracket.
CLUTCH SWITCH
15-6
Removethescrewsand lefthandlebarswitch hous-
ing.
Removethelefthandlebargripand housingcap.
SWITCH HOUSING
_/
SCREWS CAP
Disconnectthefrontbrake lightswitchwireconnec- MASTERCYLINDER
HOLDER
torsfromtheswitch.
Keep the reservoir Remove the bolts, holder and master cylinder
upright to prevent assembly.
air from entering
the hydraulic
system.
Removethe righthandlebarswitchlthrottlehousing
screws.
Disconnectthethrottlecablesfromthethrottlepipe
and removethethrottlegripfromthe righthandle-
bar.
Removethe righthandlebarswitchlthrottlehousing
fromthehandlebar.
SWITCHfTHROnLEHOUSING
15-7
FRONT WHEEL/SUSPENSION/STEERING
Loosen the handlebar lower holder nuts.
Remove the bolt caps.
Remove the bolts, upper holders and handlebar.
Remove the lower holder nuts, washers, setting
rubbers and handlebar lower holders.
BOLTS UPPER HOLDERS
158
INSTALLATION
NOTE:
Routethecable, hoseandwiresproperly
(page1-22).
Checkthebushingsforabnormalwearordamage.
BUSHINGS
Install thesetting rubbers ontothetop bridgewith
itssmall1.0.sidefacingupas shown.
Install the'handlebar lower holders, washers and
nutsontothetopbridge.
Place the handlebar on the lower holders aligning
the punch markon the handlebarwiththetopsur-
face ofthelowerholders.
Installtheupperholderswith itspunch markfacing
forward.
Tighten thefrontside boltsfirst, then the rear side
TORQUE:23Nm(2.3 kgfm, 17IbHt)
LOWERHOLDERS
UPPER HOLDERS
15-9
Tighten the handlebar lower holder nuts to the
specifiedtorque.
INNERWEIGHTREMOVAUINSTALLATION
Remove the grip orthrottle pipe from the handle-
RETAINER RING
bar.
Straighten the weight retainer tabs by the screw-
driverorpunch.
Remove the innerweight assembly from the han-
RUBBER CUSHIONS
dlebar.
Discardtheretainerring.
Checktherubbercushionsforwearordamage.
Installanewretainerringontotheinnerweight.
Inserttheinnerweightassemblyintothehandlebar
by hooking the retainer ring tabs withthe holes in
thehandlebar.
INNERWEIGHT
15-1.0
Install the housing cap onto the left side of the han-
HOUSING CAP
dlebar.
/
Clean the inside surface of the handlebar grip and
the outside surface of the handlebar and throttle
pipe.
Apply Pro Honda Handgrip Cement or equivalent to
.the inside surface of the handlebar grip and to the
'Outside surface of the handlebar and throttle pipe.
Wait 3 - 5 minutes and install the grip.
Allow the adhesive Rotate the grip for even application of the adhesive.
to dry for 1 hour
before using.
Apply grease 0.2 - 0.3 g to the throttle pipe flange
groove and sliding surface.
Install the throttle pipe onto the handlebar.
Connect the throttle cables to the throttle pipe
flange.
Install the right handlebar switch/throttle housing
with the two screws, aligning the locating pin with
the hole in the handlebar.
THROTTLE PIPE
15-11
Tighten the front long screwfirst, then tighten the SHORT
SWITCHfTHROTILEHOUSING
rearshortscrew.
Installthe holder Installthemastercylinder,holderandbolts.
withits 'UP'mark Align the edge of the master cylinder with the
facing up. punch markonthehandlebarandtightentheupper
boltfirst,thentightenthelowerbolt.
Connectthefrontbrakelightswitchconnectors.
Setthe housingcap Install the left handlebar switch housing and
LEFTHANDLEBAR
flange into the screws,aligningthelocatingpinwiththeholeinthe
SWITCH HOUSING
housinggroove. handlebar.
Tightenthefrontshortscrewfirst, thentightenthe
rearlongscrew.
I
LONG
Install the clutch switch into the bracket, aligning
the tab of the clutch switch and groove of the
bracket.
CAP SHORT
,.
CLUTCH SWITCH
15-12
Install the holder Installtheclutch leverbracket,holderand bolts.
with its 'UP' mark Align the edge ofthe bracket withthe punch mark
facing up. on the handlebar and tighten the upper bolt first,
thentightenthe lowerboltsecurely.
Connecttheclutchswitchconnectors.
CLUTCH LEVER
Connecttheclutchcableontheclutch lever.
~ BOLT/NUT
Apply grease to the Install the clutch leverontothe bracket and tighten
clutch lever pivot theclutch leverpivotbolttothespecifiedtorque.
bolt sliding surface. TORQUE: 1N'm(0.1 kgfm,0.7Ibf.ft)
Tighten the nuttothe specified torque while hold-
ingthepivotbolt.
TORQUE:6Nm(0.6kgfm,4.4Ibf.ft)
Installthewireclipsontothetabsonthehandlebar.
REARVIEWMIRRORS
Securetheswitchwireswiththewireclips.
Installtherearviewmirrors.
Adjusttheclutch leverfreeplay(page4-23).
FRONTWHEEL
REMOVAL
Remove the axle bolt and loosen the right axle ...----
pinchbolts.
15-13
~ ----- - ~
Do not operate the
brake lever after
removing the
wheel. To do sowill
cause difficulty in
fitting the brake
disc between the
brake pads.
Loosentheleftaxlepinch bolts.
wheel offtheground.
Removetheaxleandfrontwheel.
Removethesidecollars.
INSPECTION
AXLE
SettheaxleinV-blocks.
Turn the axle and measure the runout using a dial
indicator. ,
Actual runoutis1/2thetotalindicatorreading.
WHEELRIM
Checktherimrunoutbyplacingthewheel inatrue-
ingstand.
Spin the wheel s ~ w y and read the runoutusing a
dialindicator.
Actualrunoutis1/2thetotalindicatorreading.
SERVICE LIMITS:
Radial: 2.0mm(0.08in)
Axial: 2.0mm(0.08in)
15-14
FRONTWHEEL/SUSPENSION/S"rEERING
WHEELBEARING
Turn the inner race of each bearing with your finger.
The bearings should turn smoothly and quietly.
Also check that the bearing outer race fits tightly in
the hub.
Replace the wheel Remove and discard the bearings if the races do not
bearings in pairs. turn smoothly and quietly, or if they fit loosely in the
hub (page 15-15).
DISASSEMBLY
Remove the dust seals from both sides of the hub.
Do not reuse the Remove the bolts in a crisscross pattern in several
bolts. steps and remove the brake disc.
Replace the wheel Install the remover head into the bearing.
bearings in pairs. From the opposite side of the wheel, install the
Do not reuse old remover sbaft and drive the bearing out of the
bearing. wheel hub.
Remove the distance collar and drive out the other
bearing.
TOOLS:
Bearing removershaft 07GGD-0010100
Bearingretnoverhead,20mm 077460050600
15-15
ASSEMBLY
..
DISTANCECOLLAR
.. DUSTSEAL
BEARING
S (6204UU)
Driveinanewleftbearingsquarelywiththemarked
sidefacing upuntilitisfullyseated.
Installthedistancecollar.
Drive in a new right bearing squarely with the
markedsidefacingupuntilitisseatedonthecollar.
TOOLS:
Driver
Attachli1ent,42x47mm
Pilot,20mm
07749-0010000
07746-0010300
07746-0040500
WHEELCENTERADJUSTMENT
.,
42 N'm(4.3 kgfm,31 Ibf-ft)
BRAKEDISC
Measure the distance B (rim width) and calculate ,---------A--B-----------,
distanceA as follows:
A=79mm(3.11 in)- 8/2
AdjusttherimpositionanddistanceA bytightening
the spokes to the specified torque in several pro-
gressivesteps.
TOOL:
Spokewrench 07.IMA-MR60100
TORQUE:4.2Nm(0.4kgfm,3.1 Ibfft)
79mm
(3.11 in)
15-16
Do not get grease Install the brake disc with the marked side facing
on the brake disc or out.
stopping power will Install new bolts and tighten them in a crisscross
be reduced. patterninseveral steps.
TORQUE: 42Nm(4.3 kgfm,31 Ibfft)
WHEELBALANCE
NOTE:
Carefully check balance before installing the
wheel.
'. Mountthetirewiththearrowmarkfacing inthe
directionofrotation.
The wheel balance must be checked when the
tireisremounted.
Foroptimumbalance,thetirebalancemark(light
masspoint:apaintdotonthesidewall) mustbe
located nexttothevalve stem. Remountthetire
ifnecessary.
Mountthe wheel,tire and brake disc assembly on
aninspection
Spinthewpeel,al!pvvitt9stop,andmarkthelowest
(heaviest) withchalk.
Do this two or three times to verify the heaviest
area.
Ifthewheel isbalanced,itwill notstopconsistently
inthesameposition.
To balancethewheel, install a newbalanceweight
on the lightestsideof tliEf spoke, on theside oppo-
sitethechalkrnarks.Addjustenoughweightsothe
wheelliVi!Jnolongerstopinthesamepositionwhen
itisspun:
Dqnotaddmorethan60 gtothefrontwheel.
NO"fEi;
Nev8(re!Jsethe balance weight ifonce removed
from spoke.
BALANCEWEIGHT
15-17
Apply grease to new dust seal lips and install the
dust seals until they are flush with the wheel hub.
INSTALLAl"ION
Install the right side Install the side collars.
(disc side] collar
with it flange side
facing out.
Be careful not to Place the front wheel between the fork legs so the
damage the pads. brake disc is positioned between the brake pads.
Apply thin coat of grease to the axle sliding surface.
Insert the axle froro the left side.
Tighten the axle bolt to the specified torque.
TORQUE: 59 Nm 16.0 kgfm, 44 Ibfft)
Tighten the right axle pinch bolts to the specified
torque.
TORQUE: 22 Nm 12.2 kgfm, 16 Ibfft)
With the front brake applied, pump the forks up and
down several times to seat the axle and check brake
operation.
15-18
Tighten the left axle pinch bolts to the specified
torque.
FORK
REMOVAL
Removethefollowing:
- Frontwheel(page15-13)
- Frontfender(page3-6)
Rightforkonly: Removetheboltsand brakecaliperassembly.
Do notreuse NOTE:
calipermounting
bolts. Supportthe brake caliperso itdoes not hang from
thebrake hose.
BRAKECALIPERASSEMBLY
Loosenthetopbridgepinch bolt.
Whentheforkwillbedisassembled.Loosenthefork
cap butdonotremoveyet.
Removethebolt,collarandturnsignal light.
TURN SIGNALLIGHT
I
15-19
/
/
SPRINGSEAT
Loosen the bottom bridge pinch bolt, then remove
theforkleg.
DISASSEMBLY
Removethedustseal.
Donotscratch the Removetheoil seal stopperring.
forktubesliding
surface.
The forkcapis Removetheforkcapand O-ring.
underspring
O-RING
pressure;usecare
/
/
whenlooseningit.
/
/
/
/
Removethespacerand spring seat.
FORK CAP
. ""."".".. "' ..'.'.'.'.".' ..... "x.
15-20
Removetheforkspring fromtheforktube.
Pourouttheforkfluid bypumpingtheforktubesev-
eraltimes.
Do notover-tighten Holdtheforkslider in avise withsoftjaws.
the vise onthe fork
slider.
Ifthe fork piston Remove the fork center socket bolt and sealing
turnswith the fork washer.
centersocketbolt,
temporarilyinstall
the forkspring,
springseat, spacer
andforkcap.
Do notremove the Removetheforkpiston and rebound spring.
forkpistonring,
unlessitis
necessaryto
replace withanew
one.
FORK PISTON
Using quick successive motions, pull the fork tube
outoftheforkslider.
15-21
Remove the spring and oil lockpiece from the fork
slider.
SPRING
I
/
OILLOCKPIECE
Do notdamage the Carefully remove the slider bushing by prying the
sliderbushing, slot with a screwdriver until the bushing can be
especiallythe pulledoffbyhand.
slidingsurface. To Removethefollowing:
preventlossof
tension, donot - Guidebushing
openthebushing - Back-upring
morethan - Oil seal
necessary.
BACK-UPRING OILSEAL
SLIDER BUSHING GUIDE BUSHING
INSPECTION
OILLOCKPIECE/SPRING
Checktheoil lockpieceforwearordamage.
OILLOCK PIECE
\
SPRING
FORKSPRING
Measuretheforkspringfreelength.
..
"15-22
FORKTUBE/SLIDER/PISTON
Checkthe forktube and forksliderforscore marks,
andexcessiveorabnormalwear.
Replace anydamagedcomponentifnecessary.
FORKTUBE
Checktheforkpistonforscoremarks,andexcessive
FORK PISTON RING
orabnormalwear.
Checktheforkpiston ringforwearordamage.
Checkthereboundspringforfatigueordamage.
Replace anydamagedcomponentifnecessary.
REBOUNDSPRING
Set the forktube in V-blocks and measurethefork r--------------------,
tuberunoutwithadial indicator.
Actual runoutis 1/2 thetotal indicatorreading.
SERVICE l:IMIT: 0.2 mm(0.01 in)
Visuallyinspectthesliderandguidebushings.
Replacethebushingsifthereisexcessivescoringor
scratching,orifthetefloniswornsothecoppersur-
BUSHING
faceappearson morethan 3/4 oftheentiresurface.
Checktheback-upring; replace itifthereisanydis-
BACK-UPRING
tortion atthepointsshown.
Checkpoints
COPPER SURFACES
15-23
ASSEMBLY
Before assembly, wash all parts with a high flash
point or non-flammable solvent and wipe them off
completely.
..
22.1 N7kgt.m. 161bf.ftl
.. DUST SEAL
lIIiil'
PISTON RING
n--o.RING-:
STOPPER RING
!jSPACER
.." OIL SEAL
SPRING SEAT
FORK SPRING
REBOUND SPRING
FORK TUBE
Do not open the Install the slider bushing being careful not to dam-
bushing slit more age the coating of the bushing, if it has been
than necessary. removed.
Remove the burrs from the bushing mating surface,
being careful not to peel off the coating.
Install the oil seal Apply fork fluid to the new oil seal lips.
with its marked Install the guide bushing, back-up ring and new oil
side facing up. seal onto the fork tube.
SLIDER BUSHING
Install the rebound spring to the fork piston, then
install theminto the fork tube.
If the piston ring is removed, install a new piston
ring into the fork piston groove.
REBOUND SPRING
FORK PISTON PISTON RING
15-24
Do not over-tighten
the vise on the fork
slider.
If the fork piston
turns with the fork
center socket bolt,
temporarily install
the fork spring,
spring seat, spacer
and fork cap.
Installtheoil lockpieceandspringtotheforkpiston
FORKSLIDER
end.
Installtheforktubeassemblyintotheforkslider.
/" SPRING
, / FORKPISTON
/ @ I
OILLOCKPIECE
Holdtheforksliderinavisewithsoftjaws.
C)y SOCKETBOLT
Apply locking agent to the fork center socket bolt
threads.
Installthesocketboltwithanewsealingwasher.
Tighten the forkcenter socket boltto the specified
SOCKETBOLT
torque.
TORQUE: 29.5Nm(3.0kgf'm,22Ibfft)
Drivetheoilsealuntilthestopperringgrooveisvis-
ibleusingthespecial tools.
TOOLS:
Sliderweight 07947-KA50100
Driverattachment 07947-KF00100
OilSEAL
BACK-UP
RING
DUSTSEAL
STOPPER
~ . . . . . I I : : o : RING
DRIVER
ATTACHMENTSET
15-25
Pour the specified amount of the recommended fork
FORK FLUID
fluid into the fork tube.
RECOMMENDED FORK FLUID:
Pro Honda Suspension Fluid SS-8 (10W)
FORK FLUID CAPACITY:
478 2.5 cm
3
(16.2 0.08 US OZ, 16.8 0.09 Imp oz)
Slowly pump the fork tube several times to remove
any trapped air from the lower portion of the fork
tube.
Compress the fork tube fully. Measure the fluid level
from the top of the fork tube.
FORK FLUID LEVEL: 100 mm (3.9 in)
Pull the fork tube up and install the fork spring with
FORK SPRING
the tightly wound coil side facing up.
t
UP
100mm
(3.9 in)
Install the spring seat and spacer.
SPRING SEAT SPACER
Coat a new O-ring with fork fluid and install it into
the fork cap groove.
Be careful not to Hold the fork cap securely and install it into the fork
cross-thread the tube.
fork cap.
Tighten the fork cap
after installing the
fork leg into the
steering stem and
top bridge.
15-26
~ ~
Install the stopper ring into the groove into the fork
DUST SEAL'"
slider, being careful not to scratch the fork tube slid-
ing surface.
Coat a new dust seal lips with fork fluid and install
it.
..-'
.......
INSTALLATION
Install the fork leg into the steering stem and top
bridge.
Align the fork tube top end surface with the top
bridge as shown.
Tighten the bottom bridge pinch bolts to the speci-
fied torque.
TORQUE:~ Nm (5.0 kgfm, 36Ibfft)
Install the turn signal light, collar and bolt.
Tighten the bolt securely.
15-27
Tighten the top bridge pinch bolt to the specified
torque.
TORQUE:22Nm(2.2 kgfm.16Ibf.ft)
Tightentheforkcaptothespecifiedtorque.
TORQUE:22.1 Nm(2.3 kgfm.16Ibfft)
Rightforkonly: Install the brake caliper with new mounting bolts
and tightenthebolts.
- Frontwheel(page 15-18)
STEERINGSTEM
REMOVAL
Removethefollowing:
TOPBRIDGE
- Handlebar(pl::!t:Je15-6)
- Frontwheeltpage15"13)
- Headlight s ~ { p g e 21-5)
- Turnsignallighr(page21-6)
Removethesteeringstemnutandwasher.
Removetheforklegs(page15-19).
Removethetopbridge.
Removetheboltandfrontbrakehose.
............".,.....
BRAKECALIPERASSEMBLY
15-28
Remove the bolts, nuts, headlight case brackets and
BOLTS/NUTS BRACKETS
steering stem cover.
Straighten the lock washer tabs.
LOCK NUT
Remove the steering top thread lock nut and lock
washer.
Loosen the steering top thread using the special
tool.
TOOL:
Steering stem socket 07916-3710101 or
07916-3710100
(U.S.A only)
While holding the steering stem, remove the steer-
ing top thread.
Steering stem
- Dust.seal
- LJpperinner race
- head bearing
- Lowersteering head bearing
15-29
BEARINGREPLACEMENT
Removetheupperbearingouterrace usingthespe- ".
cialtools.
TOOLS:
Ballraceremoverset 07953-MJ10000
- Removerattachment 07946-MJ10100
- Drivershaft 07946MJ10200or
07953MJ1000B
(U.S.A. only)
Removethelowerbearingouterrace usingthespe-
cial tool andsuitableshaft.
TOOL: .
Bearingtemover 07946-3710500
Install thesteering stem nutontothesteering stem
to prevent the threads from being damaged when
removingthelowerbearinginnerrace.
Remove the lowerbearing inner race with a chisel
orequivalenttool;being careful notto damagethe
stem.
Removethedustseal.
DUSTSEAL
INNERRACE
Apply specified grease (page 1-19) to a new dust
seal lipandinstallitontothesteeringstem.
Pressanewlowerbearinginnerraceusingaspecial
toolandhyoraulicpress.
TOOL:
Attachment,30mm1.0. 07746-0030300
15-30
Drive in a new upper bearing outer race into the
steering headpipeusingthespecialtools.
TOOLS:
Driver 077490010000
Attachment, 42 x 47 mm 077460010300
Drive in a newlowerbearing outer race intosteer-
ingheadpipeusingthespecialtools.
TOOLS:
Driver 07749-0010000
AttaChment, 52x 55 mm 07746-0010400
INSTALLATION
HEADLIGHTCASEBRACKETS
LOCKNUT
/ S
LOCKWASHER
TOPTHREAD-""'71
DUSTSEAL
--- UPPER INNERRACE
UPPERSTEERING
,/ HEADBEARING
/
UPPER OUTER RACE ..
Iliiijjlll
LOWER OUTER RACE .,
LOWERSTEERING HEADBEARING
..
: DUSTSEAL

- LOWERINI\IER RACE .JI!

IlIijjlII
DUSTSEAL .,
Apply3- 5gofspecifiedgrease(page1-19)toeach
newsteering head bearing and fill itup. Install the
lowersteering headbearingontothestem.
Applygreasetoanewupperdustseal lip.
Applyengine oil tothe threads ofthesteering top
thread.
Insert,thesteering stem intothesteering head pipe
thefollowingwhileholdingthestem:
- .Uppersteeringheadbearing
- Upperinnerrace .
- Dust seal
-Steering thread

15-31
Tighten the steering top thread to the specified
torque.
TOOL:
Steering stem socket 07916-3710101 or
07916-3710100
(U.S.A. only)
TORQUE: 25 Nm (2.5 kgfm, 18 Ibf.ft)
Turn the steering stem left and right, lock-to-Iock
five times to seat the bearings.
Retighten the steering top thread to the specified
torque.
TORQUE: 25 Nm (2.5 kgfm, 18 Ibf.ft)
Install a new lock washer, aligning its bent tabs with
the grooves in the steering top thread.
Install the lock nut until it contacts with the lock
washer.
Further tighten the locknut, within 90, to align its
grooves with thetabs of the lock washer.
Bend up the lock washer tabs into the grooves of
the locknut.
LOCK NUT TABS
15-32
Install the steering stem cover onto the steering
stem.
Tighten the nuts Temporarily install the headlight case bracket, bolts
securely after and nuts.
installing the
headlight case.
Install the front brake hose, bolt and tighten the bolt
securely.
Install the top bridge, washer and stem nut.
Install the fork legs into the steering stem and top
bridges (page 15-27).
Tighten the stem nut to the specified torque.
TORQUE: ;03Nm(10.5 kgfm,76Ibfft)
Turn the steering stem left and right, lock-to-Iock
several times to make sure the steering stem moves
smoothly, without play or binding.
Route the hose, Install the following:
wires and cables
- Front wheel (page 15-18)
into the cable
- Front fender (page 3-6)
guides properly
- Handlebar (page 15-9)
(page 1-22).
- Headlight case (page 21-5)
- Turn signal light (page 21-6)
Tighten the headlight case bracket nuts securely.
BOLTS/NUTS BRACKETS
15-33
Make sure there is
no cable, wire
harness or hose
interference.
STEERING BEARING PRE-LOAD
wheelofftheground.
Positionthesteeringstem straightahead.
Hook a spring scale to the fork tube between the
forktopandbottombridges.
Pullthespringscalekeeping itatarightangletothe
steeringstem.
Read thescale atthepointwherethesteering stem
juststartstomove.
STEERING BEARING PRE-LOAD:
8.5 -12.7 N (0.9 -1.3 kgf)
Ifthe readingsdQ notfall withinthe limits,readjust
thesteeringt6j:llhread.
15-34
16. REAR WHEEL/BRAKE/SUSPENSION
REAR BRAKE 16-14
SERVICE INFORMATION 16-3 BRAKE PEDAL 1617
TROUBLESHOOTING 16-5 SHOCK ABSORBER 1621
REAR WHEEL .. 16-6 SWINGARM 16-22
~
REARWHEEL/BRAKE/SUSPENSION
COMPONENTLOCATION
103 Nm (10.5 kgfm, 76 IbHt)
64 N'm (6.5 kgf'm, 47 IbHt)
22 N'm (2.2 kgfm, 161bHt)
88 N'm (9.9 kgfm, 65 IbHt)
REAR WHEEL/BRAKE/SUSPENSION
SERVICEINFORMATION
GENERAL
ACAUTION
Frequentinhalationofbrakeshoedust,regardlessofmaterialcompositioncouldbehazardoustoyourhealth.
Avoid breathingdustparticles.
Neveruseanairhoseorbrushtoclean brakeassemblies. Use an OSHA-approvedvacuumcleaner.
Ridingondamaged rimsimpairssafeoperationofthevehicle.
A hoist or equivalent is required to support the motorcycle when servicing the rear wheel, shock absorber, or
swingarm.
UseonlygenuineHondareplacementboltsand nutsforallsuspensionpivotand mountingpoints.
When using the lock nutwrench forthe adjusting bolt locknut, use adeflecting beam typetorquewrench 20 inches
long. The locknutwrenchincreasesthetorquewrench's leverage, sothetorquewrench readingwill be lessthanthe
torqueactuallyappliedtotheswingarmrightpivotlocknut.Thespecification given intheactualtorqueappliedtothe
swingarm rightpivotlocknut, notthereading onthetorquewrench.Do notovertightenthelocknut.Thespecification
laterinthetextgivesbothactual and indicated.
SPECIFICArlONS
Unitmm(in)
Minimumtiretreaddepth - 2.0(0.08)
Coldtirepres- I Upto90kg (200 Ibs) load 200kPa (2.00kgf/cm
2
, 29 psi) -
sure
I
Uptomaximumweightcapacity 250 kPa (2.50kgf/cm
2
, 36 psi) -
Axlerunout - 0.2(0.01)
Wheel rim
I
Radial - 2.0(0.08)
runout
I
Axial - 2.0(0.08)
Wheel balanceweight - 709 max.
Brakedrum1.0. 180.0-180.3(7.09-7.10) 181 (7.1)
Brakepedalheight 75 mm(3.0in)abovethetopofthe
-
footpeg
I
Brake pedalfreeplay . 20- 30(13/16-1-3/16) -
Shockabsorberspringpre-loadadjustersetting 2ndposition -
TORQUEVALUES
Spoke
Rearaxlenut
Swingarm leftpivotbolt
Swingarm rightpivotbolt
Swingarm rightpivotlocknut
Stopperplatebolt
Rearaxlepinchbolt
Rear brakestopperarm nut
Rear brakearm pinch bolt
Rearshockabsorberuppermountingbolt
Rear shockabsorberlowermountingbolt
(rightside)
Rearshockabsorberlowermountingbolt
(leftside)
4.2N'm(0.4kgf'm,3.1 Ibfft)
88 Nm (9.0kgf'm,65 Ibfft)
103N'm(10.5kgfm,76Ibfft)
Seepage16-26
103N'm(10.5kgfm,76Ibfft)
20 N'm(2.0 kgfm, 15 Ibfft)
27 N'm(2.8kgfm,20Ibfft)
22 Nm (2.2kgf'm,16Ibfft)
26 N'm(2.7kgf'm,19 Ibfft)
34Nm (3.5 kgf'm,25 Ibfft)
U-nut
6 ~
TOOLS
Driver
07749-0010000
07746-0010200
07746-0010300
Pilot, 20 mm
07746-0040500
Bearing remover shaft
07GGD-0010100
Bearing remover head, 20 mm
07746-0050600
S
W)
..... _.--'

Spoke wrench

Lock nut wrench
07908-4690003
16..4
TROUBLESHOOTING
Softsuspension
Incorrectsuspensionadjustment
Weakshockabsorberspring
Oil leakagefromdamperunit
Lowtirepressure
Stiffsuspension
Incorrectsuspensionadjustment
Bentdamperrod
Damagedshockabsorberrubbermounts
Damagedswingarmpivotbearings
HightirepressurEl
Rearsuspensionnoise
Loosesuspensionfasteners
Bindingshockabs.orbercase
Wornshockabsorberrubbermounts
Faultyrearshockabsorber
Rearwheelwobbles
Bentrim ,';!?
Unbalanced reartireandwheel
Insufficienttirepressure
Faultyswingarmpivotbearings
Axlefastenernottightenedproperly
Faultytire
Rearwheelturnshard
Faultywheel bearings
Bentaxle
Brakedrag
Finalgearbearingsdamaged(page 14-7)
Poorbrakeperforrnallce
Improperbrakeadjustrnent
Wornbrakeshoes
greasyordirty
WornbtakEfcam
WOfnsbrsxedrtim
improperlyengaged
BrakeshoElswornatcamcontactarea
16-5
",
REARWHEEL
REMOVAL
Removetheexhaustsystem (page3-8).
Removetheaxlenut.
wheelofftheground.
Removetheadjusting nut,jointpinandspring.
Removethe cotter pin, nut, washer, rubberwasher
and bolt.
Loosenthepinchboltand removetheaxleandright ~ S i COLLAR
sidecollar.
Movetherearwheeltotherighttoseparate itfrom
the final drive gear case and carefully remove the
rearwheeloutoftheframe.
Removethe leftsidecollarfromthering gear.
16-6
INSPEC"nON
AXLE
SettheaxleinV-blocks.
Turnthe axle and measure the runout using a dial
indicator.
Actual runoutis1/2 thetotalindicatorreading.
SERVICE LIMIT: 0.2mm(0.01 in)
WHEELRIM
Checkthe rim runoutbyplacingthe wheel in atru-
ingstand.
Spinthe wheel slowlyand read the runoutusing a
dialindicator.
Actual runoutis1/2thetotalindicatorreading.
SERVICE LIMITS:
. Radial: 2.0mm(0.08in)
Axial: 2.0mm(0.08in)
FINALDRIYENFLANGE
Checkthedrivenflangesplinesforwearordamage.
If damaged,checkthesplinesoftheringgearalso.
WHEELBALANCE
Forwheel balance(page15-17). Do notadd balance
weight 70gtotherearwheel.
WHEELBEARING
RemovethebraKepanelanddrivenflange
(page16-8).
.Turntheinnerraceofeach bearingwithyourfinger.
The bearingsshouldturnsmoothlyandquietly.
Also thebearing outerracefitstightlyin
thehub.
Replace the wheel Removeanddiscardthebearingsiftheracesdonot
bearings in pairs. turnsmoothlyandquietly,orjftheyfitlooselyinthe
hub.
16-7
DISASSEMBLY
Remove the brake panel assembly from the right
wheelhub.
RemovetheO-ring.
Removethefinal drivenflange from the leftwheel
hub.
Removethethrustwasher.
00 not reuse the Remove the boltsin acrisscross pattern in several
bolts. steps.
RemovetheO-ring.
16-8
Align the arrow on the stopper plate between the
projectionsonthewheel hubbyturningthestopper
plateand removethestopperplate.
Removetherubberdampers.
Replace the rubber Checktherubberdampersfordeteriorationordam-
dampersasaset. age.
Replace the wheel Installtheremoverheadintothebearing.
bearingsinpairs. From the opposite side of the wheel, install the
Donotreuseold remover shaft and drive the bearing out of the
bearing. wheel hub.
Removethe distance collarand driveoutthe otheL
bearing.
TOOLS:
Bearing removershaft 07GGD-0010100
Bearingremoverhead,20mm 07746-0050600
16-9
ASSEMBLY
RUBBERDAMPERS
THRUSTWASHER ..--'iB
20 Nm(2.0 kgfm, 15Ibf.ft)
111
II O-RING
Drive in a new right bearing squarely with the
markedsidefacing upuntilitisfullyseated.
Installthedistancecollar.
Drivein newleftbearing squarelywiththemarked
sidefacingupuntilitisfullyseated.
TOOLS:
Driver 07749-0010000
Attachment,42x47 mm 07746-0010300
Pilot, 20 mm 07146-0040500
16-10
----------
WHEEL CENTER ADJUSTMENT
Measure the distance B (rim width) and calculate
B A
distance A as follows:
A =70.5 mm (2.78 in) - 8/2
Adjust the rim position and distance A by tightening
Q
the spokes to the specified torque in several pro-
/ I \1 70.5mm
gressive steps.
I I I'
)i I 1\ (2.78 in)
/' I
TOOL:
Spoke wrench 07JMA-MR60100
I
TORQUE: 4.2 Nm (0.4 kgfm, 3.1 Ibfft)
Install the stopper Install the stopper plate, aligning the arrow between
plate with the 'OUT the projections on the wheel hub.
SIDE' mark facing Align the bolt holes by turning the stopper ring.
up_
Pack molybdenum disulfide paste into the G-ring
groove inthe wheel hub.
Coat a disulfide paste
and install it into hub groove.
Install and tighten new bolts to the specified torque.
TORQUE: 20 Nm (2.0kgfm, 15 Ibfft)
16-11
Apply 2 - 3 g of molybdenum disulfide paste to the
mating surface of the thrust washer and rear wheel
hub end (driven flange side).
Apply 0.5 - 1.0 g of molybdenum disulfide s t ~ to
the rear wheel hub mating surface of the final
driven flange.
Coat a new O-ring with molybdenum disulfide paste
and install it into the driven flange groove.
Install the driven flange into the left wheel hub.
Install the brake panel assembly into the right wheel
hub.
16-12
INSTALLATION
Install the left side collar into the ring gear.
Apply 4 - 5 g of molybdenum disulfide paste to the
joint surface of the final gear case O-ring guide and
driven flange.
Hold the wheel Place the rear wheel into the swingarm and engage
securely and be the driven flange spline with the ring gear spline.
careful not to
damage the gear
case.
Install the right side collar and rear axle.
Install and tighten the axle nut to the specified
torque while holding the axle.
TORQUE: 88N'm19.0kgfm,65Ibfft)
SPLINES
16-13
-------------------------------------------------
Withthe rearbrake applied, pumptheswingarmup
anddownseveraltimestoseattheaxle.
Tightenthepinchbolttothespecifiedtorque.
TORQUE: 27 Nm(2.8kgf'm,20Ibfft)
Connect the stopper arm to the brake panel with
bolt,rubberwasher,washerand nut.
Tightenthenuttothespecifiedtorque.
n s t ~ anewcotterpin.
Installthespring,jointpinandadjusting nut.
Installtheexhaustsystem(page3-11).
Adjustthebrakepedal freeplay(page4-21).
REAR BRAKE
R.EMOVAL
Removetherearwheel(page 16-6).
Removethebrakepanelfromtherearwheel
(page 16-8).
INSPECTION
MeasurethebrakedrumI.D.
SERVICELIMIT: 181 mm(7.1 in)
16-l4
DISASSEMBLY
Removethecotterpinsand setting plate.
NOTE:
Alwaysreplacethebrakeshoesas aset.
Whenthe brake shoesare reused, markall parts
before disassembly so they can be installed in
theiroriginal locations.
Removethebrakeshoesand springs.
Removetheboltand brakearm.
Removetheindicatorplate,brakecam andfeltseal.
16-15
ASSEMBLY
BRAKE PANEL
SETIINGPLATE CaTIERPINS f1I
Apply0.5- 1.0g ofgrease tothe brakecam sliding
surface.
Installthebrakecam intothebrakepanel.
Applyengineoiltoanewfeltseal andinstall itonto
thebrakepanel.
Install the wear indicator plate on the brake cam
alignHigitswidetoothwiththewidegrooveonthe
brakecam.
16-16
Install the brake arm aligning the punch marks of
thearmandthebrakecam.
Install and tighten the brake arm pinch bolt to the
specifiedtorque.
TORQUE:26N'm(2.7 kgfm, 19Ibf.ft)
Apply 0.5:-.J.{) to the brake shoe-to-
anchor . ace,'
sa(idSprings.
NOTE: ..... ' .
j . bfake;. shoesar;reused, the shoes and
in their original
locations. .
iristafithespringswiththeirendsfacing up.
cotter pins as
SPRINGS
setting plate and new
kepanelintothewheel hub
BRAKE PEDAL
REMOVAL
Removetheexhaustsystem (page3-8).
Removetheadjustingnut,jointpinandspring.
16-17
----- ---------
Removetheboltandmiddlerodjoint.
Removethemiddlerodjointpivotand dustseals.
Unhookthebrake pedal and rear brake lightswitch
returnsprings.
Remove the snap ring, washer and brake pedal
assembly.
Removethedustseals.
Removethecotterpinandjointpin.
JOINTPIN
16-18
Remove the cotter pins and joint pins.
COTTER PINS/JOINT PINS
Check the brake pedal, rods, middle rod joint and
pivot for wear or damage.
Check the joint pins for wear or damage.
Replace these parts if necessary.
MIDDLE ROD JOINT
INSTALLATION
"BRAKE ROD

DUST SEALS ..........
.; .
-.ItCOTTER PINS
.... ds;Joint pins and new cotter pins
lIiiiII'
to' the rnl dlEl'rQd joint. .
0.:- - _C.- - _' - . "" _"
..........
JOINT PINS
16-19
Applygreasetothejointpin.
Installthe middle brake rod, jointpin and newcot-
ter.
Applygreasetothedustseal lips.
Installthedustsealsintothebrake pedal.
..
Apply grease to the brake pedal pivot sliding sur-
face.
Installthebrakepedalassemblytothebracketprop-
erly.
Installthewasherandsnapring.
NOTE:
Install the washers and snap rings with the
chamferededgesfacingthethrustloadside.
Do notreuse wornsnap ring which could easily
spin inthegroove.
Checkthatthesnapring isseatedinthegrooves.
Hook the brake pedal and rear brake light switch
returnspringstothepedal.
Apply grease to the dust seal lips and middle rod
jointpivotslidingsurface.
Installthedustsealsandmiddlerodjointpivot.
Install the middle rod jointtothe pivotandtighten
theboltsecurely.
...---

16-20
Installthespring,jointpinandadjustingnut.
Installtheexhaustsystem(page3-11).
Adjustthefollowing:
- Brakepedalfreeplay(page4-21)
- Brakepedal height(page4-21)
Supportthe frame and swingarm securely using a
hoistorequivalent.
bolts, washers, and the
shockabsorber.'
Replace the shock Checkfordeformationoroilleakage.
absorber asan Check the rubber mounts and collars for wear or
assembly. damage,repJacethemifnecessary.
AIlPlygreasetoilie mount inner
surfaCe.
Install the shock absorber in the reverse order of
remo\ial;
TORQUE:
bllller ......;:c ..,
. 26 . ( . '.. . ... i:1fllJ)t:Jtl
LT)de):
34 ... ).
Ii$Id.): RUBBER MOUNTS/COLLARS

16-21
SWINGARM
REMOVAL
Removethefollowing:
- Rearwheel(page16-6)
- Final drivegearcase(page 14-7)
Remove the right shock absorber lower mounting
bolt.
Californiatypeonly: DisconnecttheEVAPcanisterairventhosefromthe
EVAP
Removetheboth pivotboltcaps.
Loosen the rightpivotlocknutusing a special tool
andremoveit.
TOOL:
Locknutwrench 07908-4690003
Loosentherightpivotbolt,butdonotremoveityet.
w-..................'!"""""!'"
Loosen the left pivot bolt, but do not remove it yet.
Release the joint boot from the output gear case.
Remove the left and right pivot bolts, and swingarm
from the frame.
Remove the universaljoint from the output shaft.
- Cotter pin
Nut
- Washer
- Spring,washer
- Bolt
- Stopper arm
Remove the pivot bearings and joint boot.
INSPECTION
Check the boot for cuts or other damage.
STOPPER ARM NUTIWASHERS/BOLT
BEARING
16-23
Checkthattheuniversaljointmovessmoothlywith-
outbindingornoise.
Checkthesplinesforwearordamage.
Ifdamaged, checkthesplines ofthe outputdriven
gearshaftanddriveshaftalso.
Both bearings, Checkthebearingsanddustsealsforwearordam-
outer races and age.
grease holders Check theouter races.f()r wear or damage.
must be replaced Check thEt grease holders for damage or deforma-
as a set if any part tion. .
is damaged or
worn.
PIVOTBEARINGOUTERRACE
REPLACEMENT
Punch or drill an appropriate hole into the grease
holder.
Insert a suitable driver through the swingarm and
drivethe other grease holderoutof
theswing.ar
rn
:.,. ....
Drivethe puhchedor drilled side outer race and
greaseholderputoftheswingarm.
Installanewgreaseholderintothepivot.
Drive in anewouter race squarely until it is fully
seated.
TOOLS:
Driver 07749-0010000
. 37x 040 mm 077460010200
SPLINES
DUSTSEAL OUTER RACE

I
I
I
I
I
I
I
I
I
,
GREASE HOLDER
16-24
INSlALLAliON
JOINT BOOT
OUTER RACE
PIVOT BEARING
.......
SPRING WASHER
STOPPER ARM
Appl'(l.q - grease (page 1-19) to
of each bearing.
swi ngarm pivots.
.e;:,1
groove prop-
erly ifie:l.ler up.
...--
16-25
STOPPER ARM NUTIWASHERS/BOLT
Carefullyalign the
swingarmpivots
withthepivotbolts.
- Stopperarm
- Bolt
- Springwasher
- Washer
- Nut
Tightenthenutandinstallanewcotterpin.
Apply 1 g ofmolybdenum disulfide grease to the
outputshaftsplines.
Installtheuniversaljointontotheoutputshaft.
Settheswingarmintotheframeand holdit.
Installthejointbo.otovert!leoutputgearcase.
- ,- ,-- --
!ett..al1dr;igh!'Il!M-ofbolts.
, - -C-, '-'0:--'_--'.-'-:'-:-
Tightentheleftpiv,Ptbolttdthespecifiedtorque.
TORQUE: 103N:rri,(10.5kgfm,76Ibfft)
Temporarilytightentherightpivotbolttothespeci-
fiedtorque. '
up and down several times to
seatlhe
Loosen the right pivot bolt counterclockwise 1/4
tUrn{90o) ittothespecifiedtorque.
TORQUE:22N;gHZ:Zkgfm, 16Ibfft)
16-26
---------------------
Refer to torque
wrench reading
information on page
16-3 'Service
Information'.
California type only:
Installtherightpivotlocknut.
Tighten the lock nut using the special tool while
holdingthepivotbolt.
TOOL:
Locknutwrench 079084690003
TORQUE:
Actual: 103Nm(10.5 kgfm,76Ibfft)
Indicated: 93N'm(9.5 kgfm,69Ibfft)
Installthebothpivotboltcaps.
Connect the EVAP canister air vent hose to the
EVAPcanister.
Install and tighten the right shock absorber lower
mountingbolttothespecifiedtorque.
- Final drivegearcase (page14-22)
- Rearwheel (page16-13)
16-27
MEMO
17. HYDRAULICBRAKE
17-7
BRAKE PAD/DISC
SERVICE INFORMATION .. 17-3 MASTER CYLINDER.. 17-8
TROUBLESHOOTING 17-4 FRONT BRAKE CALIPER 17-13
BRAKE FLUID REPLACEMENT/
AIR BLEEDING ....17-5

17-1
-------
HYDRAULICBRAKE
COMPONENT LOCATION
1.5 N'm (0.2 kgf'm, 1.1 Ibf.ft)
12 N'm (1.2 kgf'm, 9Ibfft)
34 N'm (3.5 kgf'm, 25 Ibfft)
34 N'm (3.5 kgf'm,
25Ibf.ft)
2.5 N'm (0.3 kgfm, 1.8Ibfft)
17-2
HYDRAULICBRAKE
SERVICEINFORMATION
GENERAL
ACAUTION
Frequentinhalationofbrakepaddust,regardlessofmaterialcompositioncouldbe hazardoustoyourhealth.
Avoid breathingdustparticles.
Neverusean airhoseorbrushtoclean brakeassemblies. Usean OSHA-approvedvacuumcleaner.
I NOTICE I
Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber parts. Be
careful whenever you remove the reservoir cap; make sure the front reservoir is horizontal first.
A contaminated brakediscorpad reducesstopping power. Discard contaminated padsand clean acontaminated disc
withahighqualitybrakedegreasingagent.
Neverallowcontaminants(e.g.,dirt,water)toenteran open reservoir.
Oncethehydraulicsystem hasbeen opened,orifthebrakefeelsspongy,thesystem mustbe bled.
Alwaysusefresh DOT4 brakefluidfrom asealed containerwhen servicing thesystem. Do notmixdifferenttypesof
fluidastheymaynotbecompatible.
Alwayscheckbrakeoperationbeforeridingthemotorcycle.
SPECIFICATIONS
Unit:mm(in)
Recommendedbrakefluid DOT4 -
Front Brakediscthickness 5.8 - 6.2 (0.23 - 0.24) 5.0 (0.20)
Brakediscwarpage - 0.30 (0.012)
Mastercylinder1.0. 11.000 - 11.043 (0.4331 - 0.4348) 11.05 (0.435)
Masterpiston0.0. 10.957 - 10.984 (0.4314 - 0.4324) 10.945(0.4309)
Calipercylinder1.0. 27.000 - 27.050 (1.0630 - 1.0650) 27.060 (1.0654)
Caliperpiston0.0. 26.935 - 26.968 (1.0604-1.0617) 26.930 (1.0602)
TORQUEVALUES
Brakecaliperbleed valve
Frontmastercylinderreservoircapscrew
Brakepad pin
Brake pad pinplug
Brakehoseoil bolt
Brakeleverpivotbolt
Brake leverpivotnut
Frontbrakelightswitchscrew
Frontmastercylinderholderbolt
Frontbrakecaliperbracketpin
Frontbrakecaliperpin
Frontbrakecalipermountingbolt
5.5 Nm(0.6 kgfm,4.1 Ibf.ft)
1.5 N'm(0.2 kgf'm,1.1 Ibf.ft
18 Nm(1.8 kgf'm,13 Ibf.ft)
2.5 N'm(0.3 kgfm,1.8 Ibfft)
1 N'm(0.1 kgfm,0.7 Ibfft)
6 N'm(0.6 kgfm,4.4 Ibfft)
1.2 Nm(O:I kgf'm,0.9 Ibfft)
27 Nm(2.8 kgfm,20 Ibfft)
ALOCbolt;replacewithanewone
17-3
HYDRAUUCBRAKE
TOOL
Snap ring pliers
07914-SA50001
TROUBLESHOOTING
Brakeleversoft orspongy
Air in hydraulic system
Leaking hydraulic system
Contaminated brake pads/disc
Worn caliper piston seals
Worn master cylinder piston cups
Worn brake pads/disc
Contaminated caliper
Contaminated master cylinder
Caliper not sliding properly
Low brake fluid level
Clogged fluid passage
Warped/deformed brake disc
Sticking/worn caliper pistons
Sticking/worn master piston
Bent brake lever
Brakeleverhard
Clogged/restricted hydraulic system
Sticking/worn caliper pistons
Stickinglworn master piston
Bent brake lever
Brakedrag
Contaminated brake pads/disc
Misaligned wheel
Badly worn brake pads/disc
Warped/deformed brake disc
Clogged/restricted fluid passage
Sticking caliper pistons
-----_. ----------------'-
17-4
HYDRAULICBRAKE
BRAKE FLUID REPLACEMENT/AIR
BLEEDING
NOTE:
- Donotallowforeignmaterialtoenterthesystem
whenfillingthereservoir.
- When using a commercially available brake
bleeder, follow the manufacturer's operating
instructions.
BRAKE FLUIDDRAINING
Turnthehandlebartothe leftuntilthefrontmaster ,----------------------,
cylinder reservoir is level before removing the res-
ervoircap.
Removethefollowing:
- Screws
- Reservoircap
Setplate
,r Diaphragm
Connectableed hosetothebleedvalve.
Loosen the bleed valve and pump the brake lever
untilnomorefluidflowsoutofthebleedvalve.
Tightenthebleedvalve.
r.
'
SCREWS
.BMKEFLUIDFILLING/BLEEDING
sealedcontainer.
Connect a commercially available brake bleederto
thebleedvalve.
Operate the brake bleeder and loosen the bleed
valve.
Ifanautomatic refill system is not used, add brake
fluidwhentl:l,efluid level inthereservoirislow.
NOTE:
-<:;neck,theflUid level oftenwhilebleedingtopre-
'YE;lntairfrombeing pumpedintothesystem.
-Wtu,musinga brake bleeding tool, follow the
flianufat:turer's'Operatinginstructions.
17-5
HYDRAULICBRAKE
Perform thebleeding procedure until thesystem is
completelyflushed/bled.
NOTE:
If air is entering the bleeder from around the
bleedvalve threads, seal thethreadswithteflon
tape.
Closethe bleedvalveandoperatethebrakelever.If
itisstillspongy,bleedthesystemagain.
Ifabrake bleederis notavailable, usethefollowing
procedure:
sealedcontainer.
Connect"a bleedhosetothebleedvalve.
Pressurize the system with the brake lever until
leverresistanceisfelt.
Do not release the 1. Squeezethebrakelever,openthebleedvalve1/4
lever until the bleed turnandthencloseit.
valve has been
closed.
2. Release the brake lever slowly and waitseveral
secondsafteritreachestheendofitstravel.
Repeatsteps1and2untilairbubblesdonotappear
inthebleedhose. "
the,aircompletely,tightenthe bleed
vaIXEl c!o thespecifiedtorque.
TORQt;.lE{.5.5Nm(0.6kgfm,4.1 IbHt)
FilUhe reservoir to the casting ledge with DOT 4
brakefluid;'.
--
HYDRAULICBRAKE
SCREWS
- Diaphragm
- Setplate
- Reservoircap
- Screws
Tightenthescrewstothespecifiedtorque.
TORQUE: 1.5Nm(0.2kgfm,1.1 Ibfft)
BRAKE PAD/DISC
BRAKEPADREPLACEMENT
Checkthebrake Pushthecaliperpistonallthewayintoallowinstal-
fluidlevelin the fationofnewbrakepads.
reservoiras this
operationcauses
theleveltorise.
Removethepadpinplugandloosenthepadpin.
Pullthepad pin outofthecaliperbodywhilepush-
inginthepadsagainstthepadspring.
Removethebrakepads.
Makesurethepad Install newbrake padsintothecaliperso theirends
springisinstalled restintothepadretaineronthebracketproperly.
correctly. Always
replace thebrake
padsinpairsto
ensureevendisc
pressure.
17-7
HYDRAULICBRAKE
Install the pad pin by pushing in the pads against
the pad spring to align the pad pin holes in the pads
with the caliper body.
Tighten the pad pin to the specified torque.
TORQUE: 18 Nm (1.8 kgf'm, 13 Ibftt)
Install the pad pin plug and tighten it to the speci-
fied torque.
Operate the brake lever to seat the caliper piston
against the pads.
BRAKEDISCINSPECTION
Visually inspect the disc for damage or cracks.
Measure the brake disc thickness at several points.
LIMIT: 5.0 mm (0.20 in)
Measure the brake disc warpage with a dial indica-
tor.
SERVICEUMIT:0.30mm (0.012 in)
Checkthe bearing for excessive play, if the warpage
exceeds the service limit.
. Replace the brake disc if the bearings are normal.
For brake disc replacement (page 15-15).
MASTERCYLINDER
DISASSEMElLY

Drain the'f)raka fluid from the hydraulic system
(page 17-5):
Remove therearview mirror.
When removing the Remove the oil bolt and sealing washers.
oil bolt, cover the Disconnect the front brake light switch connectors.
end of the hose to
prevent
contamination.
17-8
HYDRAULICBRAKE
Remove the bolts, holder and master cylinder.
MASTER CYLINDER
Remove the nut, pivot bolt and brake lever.
LEVER:
PIVOT BOLT/NUT
Remove the screw and front brake light switch.
SCREW SWITCH
Remove the boot.
BOOT
17-9
HYDRAULICBRAKE
Removethesnapring usingaspecialtool.
TOOL:
Snapringpliers 07914SA50001
Removethewasher, masterpistonandspring.
Cleanthemastercylinder,reservoirand masterpis-
tonincleanbrakefluid.
INSPECTION
Checkthepiston cups and bootforwear,deteriora-
tionordamage.
Check the master cylinder and piston for scoring,
scratchesordamage.
MASTERPISTON WASHER
Measurethemastercylinder1.0.
SERVICELIMIT: 11,05mm(0,435in)
Measurethemasterpiston0.0.
17-10
HYDRAULICBRAKE
ASSEMBLY
BOOT
6Nm(0.6kgfm,4.4Ibf.ft) 1.2N'm(0.1 kgf'm,0.9Ibfft)
Do not allow the
piston cup lips to
turn inside out.
BRAKE LIGHTSWITCH
NOTE:
Replace the piston, spring, cups, washer and snap
ringas aset.
Coat the masterpiston and piston cups with clean
brakefluid.
Installthespringontothepistonend.
,Install themasterpiston/spring intothe mastercyl-
inder.
Installthewasheronthepiston.
Install the snap ring into the groove in the master
cylinderusingaspecialtool.
1"9,OL:
Snapringpliers 07914-SA50001
Instal1 thesnap ring and washerwiththecham-
ferededgesfacingthethrustloadside.
DonotreUse wornsnap ring whichcould easily
spininthegroove.
Checkthatthesnapringisseatedinthegrooves.
Install the bootintothe mastercylinder and piston
groove.
Apply0.1 gofsiliconegreasetothebrakelevercon-
tactingareaofthepiston. .
SPRING
WASHER IMASTER PISTON
I
17-11
~ ~ ~ _ _ ~ _ ~ _ ~
HYDRAULICBRAKE
Install the brake lightswitch, aligning its bosswith
thegrooveofthemastercylinder.
Install andtightenthescrewtothespecifiedtorque.
TORQUE: 1.2Nm(0.1 kgfm,0.9Ibfft)
Apply 0.1 g of silicone grease to the brake lever
pivotslidingsurface.
Install the brake lever and pivot bolt,and tighten it
TORQUE: 1Nm(0.1 kgfm,0.7Ibfft)
Tighten the nuttothespecified torque while hold-
ingthepivotbolt.
TORQUE:6Nm(0.6kgfm,4.4Ibfft)
Installthe holder Install the master cylinderwiththe holder and two
withits 'UP'mark bolts.
facing up. Align the edge of the master cylinder with the
punchmarkon thehandlebarandtightentheupper
boltfirst,thentightenthelowerbolttothespecified
torque.
TORQUE: 12Nm(1.2 kgfm,9Ibfft)
Be sure to restthe Connectthebrake hosetothe mastercylinderwith
hosejointagainst theoilboltandnewsealingwashers.
thestopper. Tightentheoilbolttothespecifiedtorque.
Installtherearviewmirror.
Connectthebrakelightswitchconnectors.
Fill andbleedthehydraulicsystem (page 17-5).
SCREW
PIVOTBOLT/NUT
MASTERCYLINDER
17-12
HYDRAULICBRAKE
FRONTBRAKECALIPER
DISASSEMBLY
Drain the brake fluid from the hydraulic system
(page17-5).
Removethebrake pads(page 17-7).
When removing the Removetheoilboltandsealingwashers.
oilbolt, coverthe
endof hoseto
prevent
contamination.
Donotreuse the Remove the
calipermounting assembly:
bolts.
CALIPER ASSEMBlYJ
caliperbody.
-' . CALIPER BODY
.
Removethe._9rcrcket pin boot and pad spring from
the -
17-13
HYDRAULICBRAKE
Remove thecaliper pin boot and pad retainerfrom
PADRETAINER BOOT
thebracket.
Clean the retainerand bracketmatingsurfaces.
BRACKET
Do not use high Placeashoptoweloverthepistons.
pressure air or bring Position the caliper body with the piston facing
the nozzle too close down and applysmallsquirtsofairpressuretothe
the inlet. fluidinlettoremovethepistons.
Be careful not to Pushthedustand pistonsealsinandliftthemout.
damage the piston Clean the seal grooves, caliper cylinders and pis-
sliding surface. tonswithclean brakefluid.

/
INSPECl"ION
Checkthecalipercylindersforscoring, scratches or
damage.
MeasurethecalipercylinderI.D.
17-14
PADPIN
/
HYDRAULICBRAKE
Check the caliper pistons for scoring, scratches or
damage.
Measurethecaliperpiston0.0.
ASSEMBLY
CALIPER BRACKET
17-15
PAD PIN PLUG .....-'iiiSiIt BRACKETPIN BOOT PADSPRING BRAKE PADS
seals with clean brake fluid, new
.PISTON SEALS $I I
wIthsiliconegreaseand installthem into
these-aFgroovesinthecaliper.
_ .,:_" _.
pistonswith clean brake fluid and
in' calipercylinderswiththeopen-
pads.
If
$I
.....-'iiiSiIt DUSTSEALS PISTONS I
HYDRAULICBRAKE
Checkthecaliperpinbootand replace itifitis hard,
PAD RETAINER
deterioratedordamaged.
Apply 0.4 g ofsilicone grease to the inside ofthe
'. 800\...-'iiSiIi
caliperpinboot.
Installthecaliperpinbootinthebracket.
Apply Honda Bond A or equivalent to the pad
retainermatingsurface.
Installtheretainerontothebracket.
Ifthebracketpin is removed,applylockingagentto
thethreadsandtightenit.
TORQUE:12Nm(1.2kgfm,9 Ibf.ft)
PIN
BRACKET
Checkthebracketpinbootand replaceitifitis hard,
deterioratedordamaged.
Apply 0.4 g ofsilicone grease to the inside ofthe
bracketpinboot.
Installthebracketpinbootandpadspringinthecal-
iper.
Ifthecaliperpinis removed,applylocking agentto
thethreadsandtightenit.
TORQUE:27 N'm(2.8kgf'm,20Ibf.ft)
Installthecaliperbrackettothecaliperbody.
Installthebrakecaliperassemblysothediscisposi-
tioned betwe@fl thepads, being careful nottodam-
agethepads.
Installnewcalipermountingboltsandtightenthem
TORQUE:30NIri(3.1kgfl1'!,22Ibfft)
t
ew
PAD SPRING

PIN .ew

17-.16
HYDRAULIC BRAKE
Connectthebrake hosetothecaliperbodywiththe
oilboltandnewsealingwashers,andtightentheoil
TORQUE:34Nm(3.5 kgfm,25 Ibfft)
Installthebrake pads(page 17-7).
Fill and bleedthe hydraulicsystem (page 17-5).
17-17
MEMO
18. BATTERYICHARGINGSYSTEM
BATTERY 18-6
SYSTEM LOCATION.. .. ..18-2
SYSTEMDIAGRAM18-2 CHARGINGSYSTEMINSPECTION18-7
SERVICEINFORMATION18-3 REGULATOR/RECTIFIER... 18-8
TROUBLESHOOTING18-5 ALTERNATORCHARGINGCOIL18-9
18-1
-- --
--------------- --------- -- ---
BATTERYICHARGINGSYSTEM
SYSTEMLOCATION
.
ALTERNATOR
SYSTEMDIAGRAM
MAIN FUSE
30A
Y Y YR/W G
ffi e
REGULATOR/RECTIFIER
BATTERY
ALTERNATOR
8 ~
Y: Yellow
G: Green
R: Red
W: White
SERVICEINFORMATION
GENERAL
AWARNING
Thebatterygivesoffexplosivegases;keepsparks,flamesandcigarettesaway. Provideadequateventilationwhen
charging.
Thebatterycontainssulfuricacid (electrolyte).Contactwithskin oreyesmaycausesevere burns.Wearprotective
clothingandafaceshield.
-Ifelectrolytegetsonyourskin,flushwithwater.
- Ifelectrolytegetsinyoureyes,flushwithwaterforatleast15 minutesandcall aphysician immediately.
Electrolyteis poisonous.
- Ifswallowed,drinklargequantitiesofwaterormilkandcallyourlocalPoisonControlCenteroracall aphysician
immediately.
NOTICE I
Alwaysturnoff theignitionswitchbeforedisconnectinganyelectricalcomponent.
Someelectricalcomponentsmaybedamagedifterminalsorconnectorsareconnectedordisconnectedwhiletheigni-
tionswitchisturnedto ONandcurrentispresent.
Forextendedstorage,removethebattery,giveitafullcharge,andstoreitinacool,dryspace.
Forabatteryremaininginastored motorcycle,disconnectthenegativebatterycablefromthebatteryterminal.
Thebatterysealingcapsshouldnotbe removed.Attemptingtoremovethesealingcapsfromthecellsmaydamagethe
battery.
Themaintenancefree(MF) batterymustbe replacedwhenitreachestheend ofitsservicelife.
The batterycan be damagedifoverchargedorundercharged,oriflefttodischargeforlong period.Thesesamecondi-
tionscontributetoshorteningthe"lifespan"ofthebattery.Even undernormaluse,theperformanceofthebatterydete-
rioratesafter2- 3years.
Battery voltage may recover after battery charging, but under heavy load, the batteryvoltage will drop quickly and
eventuallydie out. Forthis reason, thecharging system is often suspected as the problem. Battery overcharge often
resultsfromproblemsinthebatteryitself,whichmayappeartobean overchargingsymptom.Ifoneofthebatterycells
is shorted and batteryvoltage does notincrease,the regulator/rectifiersupplies excess voltagetothe battery. Under
theseconditions,theelectrolyte levelgoesdownquickly.
Beforetroubleshootingthechargingsystem,checkforproperuseand maintenanceofthebattery. Checkifthe battery
isfrequentlyunderheavyload,suchas havingtheheadlightandtaillightON forlongperiodsoftimewithoutridingthe
motorcycle.
The batterywill self-dischargewhenthemotorcycleisnotin use. Forthisreason, chargethe batteryevery2weeksto
preventsulfationfromoccurring.
Whenservicingthechargingsystem,alwaysfollowthestepsinthetroubleshootingflowchart(page 18-5).
Foralternatorservice(page12-4).
BATrERYCHARGING
TurnpowerON/OFFatthecharger,notatthebatteryterminal.
Forbatterycharging,donotexceedthechargingcurrentandtimespecified on thebattery. Usingexcessivecurrentor
extendingthechargingtimemaydamagethebattery.
Quickchargingshouldonlybedoneinan emergency;slowchargingis preferred.
BATTERYTESTING
Refertothebatterytester'sOperationManualfortherecommended batterytesterfordetailsaboutbatterytesting.
The recommended batterytesterputsa"load"onthebatterysotheactual batteryconditionoftheloadcan bemeasured.
RecommendedBatteryTester:BM-210-AH(U.S.A.only),BM-210orBATTERYMATE(MTP08-0192,U.S.A.only)orequivalent
SPECIFICATIONS
ITEM SPECIFICATIONS
Battery Capacity 12 V - 10 Ah or 12 V -11 Ah
Current leakage 1 mAmax.
Voltage (20C/
B8F)
Fully
charged
13.0 -13.2 V
Needs
charging
Below 12.4 V
Charging current Normal 1.1 A/5 -10 h
Quick 5.5 A/1.0 h
Alternator Capacity 0.35 kW/5,000 rpm
Charging coil resistance (20C/68F) 0.1 -1.0 n
TORQUEVALUE
Battery case cover screw 1 N'm (0.1 kgfm, 0.7 Ibf.ft)
TOOLS
Battery tester Christie battery charger Battery Mate tester/charger
BM-210-AH (U.S.A. only) MC101212 (U.S.A. only) MTP08-0192 (U.S.A. only)
18-4
------------- -- -
TROUBLESHOOTING
BATIERYISDAMAGEDORWEAK
1.. BATIERYTEST
Removethebattery(page 18-6).
Checkthebatterycondition usingtherecommended batterytester.
RECOMMENDEDBATIERYTESTER:BM210.AH(U.S.A.only),BM210orBATIERYMATE(MTP08
0192,U.S.A.only)orequivalent
Isthebatterygoodcondition?
NO - Faultybattery.
YES - GO TO STEP 2.
2. CURRENTLEAKAGETEST
Installthebattery(page18-6).
Checkthebatterycurrentleakagetest(Leaktest;page18-7).
Isthecurrentleakagebelow1mAl
YES - GO TO STEP 4.
NO - GO TO STEP3.
3. CURRENTLEAKAGETESTWITHOUTREGURETOR/RECTIRRECONNECTOR
Disconnecttheregulator/rectifierconnectorand recheckthebatterycurrentleakage.
Isthecurrentleakagebelow1mAl
YES - Faultyregulator/rectifier.
NO -.Shortedwireharness
Faultyignitionswitch
4. ALTERNATORCHARGINGCOILINSPECTION
Checkthealternatorchargingcoil(page 18-8).
Isthealternatorchargingcoilresistancewithin0.1- 1.0n (20OCI68Fj?
NO - Faultychargingcoil.
YES - GO TO STEP5..
5. CHA.89INGVOLTAGEINSPECTION
Measureand thebatteryvoltageusingadigitalmultimeter(page18-6).
Startthe
ithargingvoltage(page18-7).
toresultofthefollowingcalculation.
voltage<Measuredchargingvoltage<15.5V
withinthestandardvoltage?
YES
t\lP - GQ:rOSTEP6.
6. REGlfLATOR/RECTIRERSYSTEMINSPEC"nON
Checkthevoltageand resistanceattheregulator/rectifierconnectors(page 18-8).
Aretheresuhsof checkedvohageandresistancecorrect?
YES - Faultyregulator/rectifier.
NO _. Opencircuitinrelatedwire
Looseorpoorcontactsofrelatedterminal
Shortedwireharness
BATTERY
Removethefollowing:
- Seat(page3-3)
POSITIVE (+) CABLE
- ICM (page 19-9)
Removethescrew.
Remove the battery case cover by unhooking the
batterycase hooks.
With the ignition switch turned to OFF, disconnect
the battery negative (-) cable first, then disconnect
thebatterypositive(+) cable.
Removethebatteryfromthe batterycase.
Installthebatteryinthereverseorderofremoval.
NOTE:
Connectthe positive (+) cablefirst,then connect
thenegative(-)cable.
Afterconnectingthe batterycables, coattheter-
minalswithgrease.
TORQUE:
Batterycasecoverscrew:
1Nm(O.1 kgfm,0.7Ibf.ft)
BATIERYCASECOVER
VOLTAGEINSPECTION
Removethebatterycasecover(page18-6).
Measure the battery voltage using a commercially
availabledigitalmulti meter.
VOLTAGE{20C/68F):Fullycharged:13.0- 13.2V
Needscharging:Below12.4V
CHARGINGSYSTEMINSPECTION
CURRENTLEAKAGETEST
Removethebatterycase cover(page 18-6).
thenegative(-)cablefromthebattery.
,Connectthe ammeter(+) probe tothe negative H
cable and the ammeterH probeto the battery (-)
terminal.
With the ignitionswitch turned to OFF, check for
currentleakage.
NOTE,
' whehrrieasuringcurrentusingatester,setittoa
rangedowntoan
higher than the
rangeselected'n1ih'''filg\ft thefuseinthetester.
While notturntheignition
switch to ON.'Asudc!en surge of current may
blowthefuseintheteSter.
SPECIFIEDCURRENTLEAKAGE:1mAmaximum
If current leakage exceeds the specified value, a
shortedcircuitistheprobablecause.
Locate theshortbydisconnecting connections one
byoneandmeasuringthecurrent.
CHARGINGVOLTAGEINSPECTION
NOTE:
MakeureJM isin good condition before
.... ' .
Start itup to the operating
temperature;thenstoptheengine.
Donotdisconnect Removethe. batterycasecover(page 18-6).
thebatt/fry.orany
cablein the the positive and
chargingsystem
witboutJirst !o,;" ','c'. ..
switching offthEf N.OTEf C-_- --
ignitio'!
olutely certain which
Failure to followthis 'at .th
rminalsorcable.
ptecauiiorfcarJ'
damagethetester Wit
.m,restarttheengine.
p-multimeter when the
orelectrical
components,
'BV<'Measuredcv<15.5V
Voltage(page18-6)
CV=ChargingVoltage
18-7
.._-- ----
REGULATOR/RECTIFIER
WIRE HARNESS INSPEC"nON
BATrERYCHARGINGLINE
Removetherightsidecover(page3-3).
theregulator/rectifier5P connector.
Measure the voltage between the Red/white wire
terminal (+) ofthewireharness sideconnectorand
ground(__).
Thereshouldbebatteryvoltageatalltimes.
GROUNDLINE
Checkforcontinuitybetween theGreen wiretermi-
nalofthewireharnesssideconnectorand ground.
Thereshouldbecontinuityatalltimes.
CHARGING: COILLINE
CheckthecejrltinuitybetweentheYellowwiretermi-
nala,ndgl"qllnd.
nocontinuity.
between the Yellow wire'
terminals. ..
If regulator/rectifier
5PconneCt6risabnormal,measuretheresistanceat
thealternator3P connector(page18-9).
18-8
REMOVAUINSTALLATION
Removetherightsidecover(page
theregulator/rectifier5Pconnector.
Removethenuts,regulator/rectifierandspacer.
Install the regulator/rectifier in the orderof
removal.
ALTERNATORCHARGINGCOIL
INSPECTION
thealternator3P(Natural)connector.
Measure the resistance between the Yellow wire
terminalsofalternator/statorsideconnector.
STANDARD: 0.1 - 1.0n at 20C(68F)
Checkforcontinuitybetweeneachwireterminalsof
thealternator/statorsideconnectorandground.
Thereshouldbenocontinuity.
Replacethestatorifthe resistance isoutofspecifi-
cation,orifanywirehascontinuitytoground.
Foralternator/starterreplacement(page
18-9
MEMO
-------- ---
19. IGNITIONSYSTEM
SYSTEM LOCA'ION 19-2 IGNITIONCOIL , 19-8
ICM 19-9
SYSTEM DIAGRAM..19-2
SERVICEINFORMATION19-3
IGNITIONTIMING 19-9
TROUBLESHOOTING.. .. .. .. 19-4 TPSENSOR.. .. .. .. .. 19-10
IGNITIONSYSTEMINSPECTION..19-5
~
IGNITIONSYSTEM
SYSTEM LOCATION
NEUTRALSWITCH
TPSENSOR
SYSTEMDIAGRAM
IGNITION MAIN
FUSE lOA SWITCH FUSE30A
r--
BVG
1
L..o"'-0- BIIW
currC" sw""" eI
1
ENGINE STOP
SWITCH
9Y
BI BI
To Neutral
indicator
6P(BLUE)
DIODEr-----4---,
.-LgIR--+*.......--.
DOWN
GIW ,p SIDESTAND
6" SWITCH
GIW
-e::'-o--Lg
G
_ NEUTRALSWITCH
-L
BVW
.........L....L..L.-....lIC-M-J.....L.....L...L...J,
l
l
1k IGNITION
COIL
V
e
U
FRONT REAR
IGNITIONPULSE BI: Black
SPARK U"
GENERATOR Y Yellow
PLUGS
Bu Blue
G Green
R Red
W Whtte
Lg UghlGreen
19-2
IGNI1"IONSYSTEM
SERVICEINFORMATION
GENERAL
NOTICE
The ICMmaybedamagedifdropped.Also,iftheconnectorisdisconnectedwhencurrentisflowing,theexcessivevolt-
agemaydamagetheICM.Alwaysturntheignitionswitchto OFFbeforeservicing. .
Usesparkplugswiththecorrectheatrange. Usingsparkplugswithanincorrectheatrangecandamagetheengine.
Someelectricalcomponentsmaybe damagedifterminalsorconnectorsareconnectedordisconnectedwhiletheigni-
tionswitchisturnedtoON andcurrentispresent.
Whenservicingtheignitionsystem,alwaysfollowthestepsinthetroubleshootingtableon page19-4.
Thetransistorized ignitionsystem usesan electricallycontrolled ignitiontimingsystem. Noadjustmentscan be made
totheignitiontiming.
TheICMvariesignitiontimingaccordingtotheenginespeed.TheTPsensorsignalstheICMtocompensatetheignition
timingaccordingtothethrottleopening.
Afaultyignitionsystem isoftenrelatedtopoorconnections. Checkthoseconnectionsbeforeproceeding.
Make sure the battery is adequately charged. Using the startermotorwith aweak battery results in a slowerengine
cranking speed aswellas nosparkatthesparkplugs.
Forsparkpluginspection(page4-9).
Refertothefollowingcomponentsinformations:
- Ignitionswitch (page21-16)
- Enginestopswitch(page21-17)
- Neutralswitch (page21-19)
- Sidestandswitch (page21-20)
- Diode(page20-16)
SPECIFICATIONS
ITEM SPECIFICATIONS
Sparkplug
I
Standard
I
Forextended highspeed riding
Sparkpluggap
Ignitioncoilprimarypeakvoltage
DPR6EA-9 (NGK),X20EPR-U9(DENSO)
DPR7EA-9(NGK),X22EPR-U9 (DENSO)
0.8- 0.9 mm(0.03- 0.04in)
100Vminimum
Ignitionpulsegeneratorpeakvoltage 0.7Vminimum
Ignitiontiming("F"mark) 13BTDCatidle
TPsensor
I
Resistance(20C/68F)
I
Inputvoltage
4-6kn
5V
TORQUEVALUES
Alternatorcoversocketbolt 10N'm(1.0kgfm,7Ibfft)
Timingholecap 10N'm(1.0kgf'm,7Ibfft) Applygreasetothethreads
TOOLS
Peakvoltageadaptor IgnitionMatepeakvoltagetester
07HGJ-0020100(notavailablein only)
U.S.A.)
withcommerciallyavailabledigital
multimeter(impedance10MWDCV
minimum)orpeakvoltagetester
(U.S.A. only)
IGNITIONSYSTEM
TROUBLESHOOTING
Inspectthefollowingbeforediagnosingthesystem.
- Faultysparkplug
- Loosesparkplugcaporsparkplugwireconnection
- Waterinthesparkplugcap (Leakingtheignitioncoilsecondaryvoltage)
Ifthere is nospark at eithercylinder,temporarilyexchangethe ignition coil with a known-good one and performthe
sparktest. Ifthereisspark,theoriginalignitioncoilisfaulty.
"Initialvoltage"oftheignitionprimarycoil is thebatteryvoltagewiththeignitionswitchturnedtoON and theengine
stopswitchat"0".(Theengineisnotcranked bythestartermotor.)
Nosparkatsparkplugs
UNUSUALCONDITION PROBABLECAUSE(Checkinnumericalorder)
Ignitioncoil
primaryvolt-
age
Noinitialvoltagewiththeignition
switchturnedtoON andthe
enginestopswitchat"0".(Other
electricalcomponentsare nor-
mal)
1. Faultyenginestopswitch.
2. AnopencircuitinBlackJwhitewirebetweentheignition
coilandenginestopswitch.
3. Looseorpoorconnectionoftheprimaryterminal,oran
opencircuitintheprimarycoil.
4. FaultyrCM (incasewhentheinitialvoltageis normal
withtheICMconnectordisconnected).
1. Incorrectpeakvoltageadaptorconnections.(System is
normalifmeasuredvoltageisoverthespecifications
withreverseconnections.)
2. Batteryisundercharged.(Voltagedropslargelywhenthe
engineisstarted.)
3. NovoltageattheBlackwireoftheICMconnector,or
looseorpoorlyconnectedICM connector.
4. Looseorpoorconnectionoran opencircuitinBlue/
yelloworYellow/bluewirebetweentheignitioncoilsand
ICM.
5. Ashortcircuitintheignitionprimarycoil.
6. Faultysidestandswitchorneutralswitch.
7. Looseorpoorconnectionoran opencircuitinNo.6
relatedwires.
- Sidestandswitch line:Greenlwhitewire
- Neutralswitch line: Lightgreenwire
8. Faultyignitionpulsegenerator.(Measurepeakvoltage.)
9. FaultyICM (incase whenaboveNo.1through8arenor-
mal).
1. Incorrectpeakvoltageadaptorconnections.(System is
normalifmeasuredvoltageisoverthespecifications
with reverseconnections.)
2. Faultypeakvoltageadaptor.
3. FaultyICM(incase whenaboveNo.1 and 2arenormal).
1. ThemiJltimeterimpedanceistoolow;below10MQ/DCV.
2. Crankingspeedistooslow.(Batteryisundercharged.)
3. Thesamplingtimingofthetesterand measuredpulse
werenotsynchronized.(Systemisnormalifmeasured
voltageisoverthestandardvoltageatleastonce.)
4. FaultyICM(incasewhenaboveNo.1through3are nor-
mal).
1, Faultysparkplugorleakingignitioncoilsecondarycur-
rentampere.
2. Faultyignitioncoil(s).
1. Themultimeterimpedanceistoolow;below10 MQ/DCV.
2. Crankingspeedistooslow.(Batteryisundercharged.)
3. Thesamplingtimingofthetesterand measuredpulse
werenotsynchronized.(Systemisnormalifmeasured
voltageisoverthestandardvoltageatleastonce.)
4. Faultyignitionpulsegenerator(incasewhenaboveNo.1
through are normal).
1- Faultypeakvoltageadaptor.
2. Faultyignitionpulsegenerator.
Initialvoltageisnormal,butit
dropsby2- 4Vwhilecranking
theengine.
.
Initialvoltageisnormalbutthere
isnopeakvoltagewhilecranking
theengine.
Initialvoltageisnormalbutpeak
voltageislowerthanthestandard
value.
Initialandpeakvoltagesarenor-
mal butnosparkjumps.
Ignitionpulse
generator
Peakvoltageislowerthanthe
standardvalue.
Nopeakvoltage.
IGNITIONSYSTEM
IGNITIONSYSTEMINSPECTION
NOTE:
Ifno spark jumps atthe plug, check all connec-
tionsforlooseorpoorcontactbefore measuring
thepeakvoltage.
Use a commercially available digital multimeter
withan impedanceof10Mil/DCVminimum.
The displayvaliJe,differs depending upon the
internalimpedahceofthemultimeter.
Connect the peak voltage adaptor to the digital
rnultimeterorusethepeakvoltagetester.

Peak adalJtor 07HGJ-0020100
(notava'ilablein
U.S.A.)
multimeter
or
Igtlitiolll\l!atJ
- . .' MTP070286
(U.S.A.only)
.IGNITION.COILPRIMARYPEAK
VOLTAGE
NOTE:
Check all system connections before performing
this inspection. Loose connectors can cause
incorrectreadings.
Check that the cylinder compression is normal
for each cylinder and the spark plugs are
installedcorrectlyineach cylinderhead.
Disconnect' allsparkplugcapsfromthesparkplugs.
Connect the known-good spark plugs to all spark
plugcapsandgroundthemtothecylinderheadsas
doneinasparktest.
DIGITALMULTIMETER
.........\
............,....
I
II; ill
FI

!@ ":
PEAKVOLTAGEADAPTOR
19-5
---
IGNITIONSYSTEM
FRONT: Removethefueltank(page3-4).
REAR: Removethefollowing:
- Rightsidecover(page3-3)
- Fuse box/turnsignal relay(page 19-8)
Withtheignitioncoil primarywiresconnected,con-
nectthepeakvoltagetesteroradaptorprobestothe
ignitioncoil primaryterminal and ground.
TOOLS:
Peakvoltageadaptor 07HGJ-0020100
(notavailablein
U.S.A.)
withcommerciallyavailabledigitalmultimeter
(impedance10Mn/DCVminimum)or
IgnitionMatepeakvoltagetester
MTP07-0286
(U.S.A.only)
CONNECTIONS:
FRONT:Blue/yellow(+) - ground(-)
REAR: Yellow/blue(+) - ground(-)
TurntheignitionswitchtoONwiththeenginestop
switchat"0".
Checktheinitialvoltageatthistime.
Thebatteryvoltageshouldbemeasured.
Iftheinitialvoltagecannotbemeasured,followthe
checksinthetroubleshootingtable(page19-4).
Crank the engine with the starter motor and mea-
suretheignitioncoil primarypeakvoltage.
PEAKVOLTAGE: 100V minimum
NOTE:
Although measured values are different for each
ignition coil, theyaren6rr;rialas long as voltage is
higherthanthe
Ifthepeakvoltageislowertllanthestandardvalue,
followthe'Checksinthetroubleshootingtable
..
InstallThe removed parts i.n the reverse order of
removal.
19-6
IGNITIONSYSTEM
IGNITIONPULSEGENERATORPEAK
VOLTAGE
NOTE:
Check that the cylinder compression is normal for
each cylinder and the spark plug is installed cor-
rectlyinthecylinderhead.
RemovetheICM (page 19-9).
Connect the peak voltage tester or adaptor probes
tothewireharl)esssideICM connectorterminals.
TOOLS:
Peakvoltage 07HGJ-0020100
(notavailablein
U.S.A.)
withc:o' . igitalmultimeter

."'um)or
IgnitiQn 8 tester
MTP07-0286
(U.S.A.only)
CONNECTION:White/yellow(+)- YellowH
TurntheignitionswitchtoON withtheenginestop
switchat"0".
Crank the engine with the starter motor and mea-
suretheignitionpulsegeneratorpeakvoltage.
PEAKVOLTAGE: 0.7Vminimum
If the voltage measured at the (CM connector is
abnormal, measurethepeakvoltage attheignition
pulsegeneratorconnector.
TurntheignitionswitchtoOFF.
Disconnect the ignition pulse generator 2P (Red)
connector and connect the peak voltage tester or
adaptor probes to the connector terminals of the
ignitionpulsegeneratorside.
connector, mea-
ittothevoltage

If th. . .)mel3suredatthe(CM isabnor-
at the ignition pulse
-the wire harness has an
orl()oseconnection.
If standardvalue,
chac ;tbEL t-roubleshooting table
(page19-'4j-; . ....
.removed parts in the reverse order of
removal:
--------------- ._--
19-7
IGNITIONSYSTEM
IGNITIONCOIL
FRONTIGNITIONCOIL
Removethefollowing:
- Fueltank(page3-4)
Disconnectthesparkplugcaps.
Disconnect the ignition coil primary wire connec-
tors.
Remove the bolts, spacers and front ignition coil
fromtheframe.
Route the spark Install thefrontignition coil in the reverse orderof
plug wires properly removal. .
(page 1-22).

Removethefuse box/turn signal relaywiththestay
fromthebatteryboxbyreleasingtheirtabs.
Discon pllJgcpaps.
Disconnect igi)iti9n'coil primary wire connec-
tors: .
the bolts, spacers and rear ignition coil,
fromthebracket. ... .. .
Route the spark .Install the rear ignition coil in the reverse order of
plug wires properly removal.
(page 1-22).
FUSE BOXfTURNSIGNALRELAY
.
19-8
IGNITIONSYSTEM
ICM
Remove the ICM from the battery case cover and
disconnecttheICM22Pconnector.
InstalltheICM inthereverseorderofremoval.
IGNITIONTIMING
Start the engine, warm it up to normal operating
temperatureandthenstopit.
.
Removethetimingholecap.
Connect. atachometer.
Read the Cormect the timing lightto the front or rear spark
manufacturers pIlJ$lvvi reo
instructions for
S1:a"rtthe engine, letit idle and check the ignition
timing light
timing.-
operation.
IDLESPEED: 1,200100 rpm
19-9
IGNITIONSYSTEM
Thetimingiscorrectifthe "F" markontheflywheel
"F" MARK
aligns with the index notch on the left crankcase
cover.
Coatanewa-ringwithengineoil and install itinto
thetimingholecap groove.
Applygreasetothethreadsofthetimingholecap.
Installthetimingholecap andtightenittothespec-
ifiedtorque.
Install the alternator cover and tighten the socket
, a-RING
"
INDEXNOTCH
TPSENSOR
INSPECTION
RemovetheICM(page19-9).
Measuretheresistance betweentheYellow/redand
Blue/greenwireterminals ofthe wire harness side
connector.
STANDARD: 4- 6k.Q (20C/68F)
Check that the resistance between the Red/yellow
andBlue/greenwireterminalsvaries withthethrot-
tlepositionwhileoperatingthethrottlegrip.
Fullyopen- Fullyclosedposition:
Resistancedecreases
Fuliyclosed- Fullyopenposition:
Resistanceincreases
19-10
IGNITIONSYSTEM
If the correct measurements cannot be obtained,
removethefueltank(page3-4).
DisconnecttheTPsensor3Pconnector.
Measuretheresistance betweenthe Blueand Black
wireterminalsoftheTP sensorsideconnector.
STANDARD: 4- 6k.Q (20C/68F)
Check that the resistance between the Yellow and
Blackwireterminalsvarieswiththethrottleposition
whileoperatingthethrottlegrip.
Fullyopen- Fullyclosedposition:
Resistancedecreases
Fullyclosed- Fullyopenposition:
Resistanceincreases
Ifthe measurementatthe ICM is abnormal and
theoneattheTP sensor is normal,checkforan
open or short circuit, or loose or poor connec-
tionsinthewireharness.
Ifboth measurementsare abnormal, removethe
carburetorand replacetheTPsensor(page6-10).
ConnecttheICM 22Pconnector.
Turnthe ignitionswitchtoON withtheenginestop
switchat"0".
Measure the inputvoltage between the Yellow/red
(+) andBlue/green(-)wireterminalsofthewirehar-
nesssideoftheTPsensor3P connector.
STANDARD: 5V
Ifthe input voltage is abnormal, or ifthere is no
inputvoltage, checkforan open or shortcircuit in
the wire harness, or loose or poor ICM connector
contact.
Install the' removed parts in the reverse order of
removal.
19-11
~ ~ ~ ~ _
MEMO
20. ELECTRICSTARTER
SYSTEMLOCATION 20-2 STARTERMOTOR .. 20-6
SYSTEM DIAGRAM 20-2 STARTERRELAYSWiTCH 20-15
SERVICE INFORMATION 20-3 DIODE ..20-16
..
20-1
ELECTRICSTARTER
SYSTEMLOCATION
ENGINE STOPSWITCH
STARTER SWITCH
IGNITIONSWITCH
CLUTCH SWITCH
SIDESTANDSWITCH
STARTER MOTOR BATIERY
FUSE BOX
.DIODE
.SUB FUSE 10A
MAIN FUSE 30 AJ
STARTER RELAYSWITCH
SYSTEMDIAGRAM
IGNITION
SWITCH
R --C-o RlBI------.
6P(RED) JSUBFUSE
MAINFUSE
30A
'----Y/R-0-0-- BI/W---0-0- BI/G-.JL;LBI 10A
STARTER ENGINE ---v.r
SWITCH STOPSWITCH
STARTER
GlR RELAYSWITCH 6P(BLUE) CLUTCHSWITCH

DIODE GJW BI
UP DOWN
L.l:!JLLg/R----...To NEUTRAL
1
SIDESTAND
SWITCH
Lg INDICATOR
A NEUTRAL
BI: Black R: Red
SWITCH
G: Green Y: Yellow
Lg: Lightgreen W: White
STARTER
MOTOR
20-2
ELECTRICSTARTER
SERVICEINFORMATION
GENERAL
NOTICE
Ifthecurrentiskeptflowingthroughthestartermotorto turnitwhiletheengineisnotcrankingover, thestartermotor
maybedamaged. .
Alwaysturntheignitionswitchto OFFbeforeservicingthestartermotor. The motorcouldsuddenlystart,causingseri-
ousinjury.
Thestartermotorcan beservicedwiththeengineintheframe.
Whencheckingthestartersystem,alwaysfollowthestepsinthetroubleshootingflowchart(page20-4).
Aweakbatterymaybeunabletoturnthestartermotorquicklyenough,orsupplyadequateignitioncurrent.
Refertothefollowingcomponentsinformation:
- Ignitionswitch(page21-16)
- Enginestopswitch(page21-17)
- Starterswitch(page21-17)
- Neutralswitch(page21-19)
- Sidestandswitch(page21-20)
- Clutchswitch(page21-19)
SPECIFICATION
Unit:mm(in)
Startermotorbrush length 12.5(0.49) 6.5(0.26)
TORQUEVALUES
Startermotorcableterminalnut
Startermotorassemblybolt
Negativebrush screw
4.9Nm(0.5kgfm,3.6Ibfft)
3.7 N'm(0.4kgf'm,2.7Ibfft)
20..3
ELECTRICSTARTER
TROUBLESHOOTING
Startermotordoesnotturn
1. FuseInspection
Checkforblownmainfuse30 Aorsubfuse 10 A.
Is the fuse blown?
YES - Replacethefuse.
NO - GO TO STEP 2.
2. BatteryInspection
Makesurethebatteryisfullychargedand ingoodcondition(page 18-6).
Is the battery in good condition?
YES - GO TO STEP 3.
NO - Chargeorreplacethebattery.
3. StarterRelaySwitchOperation
Checkthestarterrelayswitchoperation.
You shouldheartherelay"CLICK" whenthestarterswitch buttonisdepressed.
Is there a "CUCK'?
YES - GO TO STEP 4.
NO - GO TO STEP 5.
4. StarterMotorInspection
Applybatteryvoltagedirectlytothestartermotorand checktheoperation.
Does the starter motor turn?
YES -.Poorlyconnectedstartermotorcable
Faultystarterrelayswitch(page 20-15)
NO - Faultystartermotor(page20-6).
5. RelayCoilGroundLinesInspection
Disconnectthestarterrelayswitchconnector,andchecktherelaycoilgroundlinesas belowforcon-
tinuity:
1. Green/redterminal- diode- neutral switch line(withthetransmissioninneutralandclutch lever
released).
2.. Green/red terminal - clutch switch - sidestand switch line (in any gear except neutral, and with
theclutch leverpulledinandthesidestand up.
Is there continuity?
NO -.Faultyneutral switch(page21-19)
Faultydiode(page20-16)
Faultyclutchswitch(page21-19)
Faultysidestandswitch(page21-20)
Looseorpoorcontactconnector
Opencircuitinwireharness
YES - GO TO STEP 6.
6. StarterRelayVoltageInspection
Connectthestarterrelayswitchconnector.
With the ignition switch to ON and engine stop switch button "0" and the starter switch button
pushed,measurethevoltageatthestarterrelayswitchconnector(betweenYellow/red(+) andbody
ground(-)).
Is there battery voltage?
NO -.Faultyignitionswitch(page21-16)
Faultystarterswitch(page21-17)
Faultyenginestopswitch(page21-17)
Opencircuitinwireharness
YES - GO TO STEP 7.
20..4
------------ ----
ELECTRICSTARTER
7. StarterRelaySwitchContinuityInspection
Connectthestarterrelayswitchconnector.
TurntheignitionswitchtoON andtheenginestopswitch"0",checkforcontinuityatthestarterrelay
switchterminalswhenthestarterswitchbuttonispushed.
Is there continuity?
NO - Faultystarterrelayswitch.
YES - Looseorpoorcontactstarterrelayswitchconnector.
Thestartermotorturnswhenthetransmissionisinneutral,butdoesnotturnwiththetransmissionin
anypositionexceptneutral,withthesidestandupandtheclutchleverpulledin.
1. ClutchSwitchInspection
Checktheclutchswitchoperation(page21-19).
Is the clutch switch operation normal?
NO - Faultyclutchswitch.
YES - GO TO STEP 2.
2. SidestandSwitchInspection
Checkthesidestandswitchoperation(page21-20).
Is the sidestand switch operation normal?
NO - Faultysidestandswitch(page21-20).
YES -.Opencircuitinwireharness
Startermotorturnsslowly
Lowbatteryvoltage
Poorlyconnected batteryterminalcable
Poorlyconnectedstartermotorcable
Faultystartermotor
Poorlyconnected batterygroundcable
Startermotorturns,butenginedoesnottum
Starter(llotorisrunningbackwards
- Case assembledimproperly
- Terminalsconnectedimproperly
Faultystarterclutch
Damagedorfaultystarteridlegearand/orreduction gear
Starterrelayswitcl1"Clicks",butenginedoesnotturnover
Crankshaftdoesnotturnduetoengineproblems
20-5
ELECTRICSTARTER
STARTERMOTOR
REMOVAL
Disconnectthebatterynegative(-)cable
(page18-6).
Open the terminal cover and remove the terminal
nut.
Disconnectthestartermotorcable.
Removetheboltsandgroundcable.
Removethestartermotorfromthecrankcase.
Removethea-ringfromthestartermotor.
DISASSEMBLVIINSPECTION
Removetheassemblyboltsanda-rings.
20-6
ELECTRICSTARTER
Remove the front cover and O-ring.
FRONT COVER
/
O-RING
Remove the starter motor case and O-ring.
Remove the armature from the rear cover.
REAR COVER O-RING
ARMATURE STARTER MOTOR CASE
Remove the brushes and springs from the brush
holder.
Remove the stopper from the rear cover.
Check for continuity between starter motor cable
terminal and positive brushes.
There should be continuity.
20-7
ELECTRICSTARTER
Check forcontinuity between positive brushes and
REARCOVER NEGATIVEBRUSHES
rearcover.
Thereshouldbe nocontinuity.
Checkforcontinuitybetween negative brushes and

rearcover.
Thereshouldbecontinuity.
Checkforcontinuitybetween positive and negative
brushes.
Thereshouldbenocontinuity.
Removethescrewand negativebrushes.
Removetheterminalnut.
Removethewasher,insulator,terminalstopperand
a-ring.
ELECTRIC STAR"fER
Remove the terminal bolt, positive brushes and
brush holder.
Check the brush holder for crack or damage.

BRUSH HOLDER TERMINAL BOLT
INSPECTION
Measure each brush length.
SERVICE UMIT: 6.5 mm (0.26 in)
Check the
wear.
commutator for damage or abnormal
ARMATURE
Do not use emery
or sand paper on
the commutator.
Check the commutator bar for discoloration.
Clean the metallic debris off between commutator
bars..
Replace the armature with a new one if necessary.
20-9
-----------_._--
ELECTRICSTARTER
Checkforcontinuity between each individual com- qNOCONTINUITY:
COMMUTATORBAR
mutatorbarandthearmatureshaft.
Thereshouldbe nocontinuity.
Check the dust seal and ball bearing for wear or
damage.
Checktheball bearing rotatessmoothly.
Check the bushing of the rear cover for wear or
damage.
20-10
REAR COVER
O-RING :II
INSULATOR
TERMINAL STOPPER
4.9 N'm (0.5 kgfm, 3.6 IbHt)
---.......11.
BRUSHES
3.7 N'm (0.4 kgf'm, 2;7 IbHt)
NEGATIVE BRUSHES ~
SPRING
BRUSH HOLDER
ELECTRICSTARTER
Install the brush holder, positive brushes and termi-
BRUSH HOLDER
nal bolt.
TERMINAL BOLT
20-11
ASSEMBLY
:11 O-RING
~ O-RING
ARMATURE
P O S T V ~
Install a new O-ring, terminal stopper, insulator and
washer.
POSITIVE BRUSHES
TERMINAL STOPPER
INSULATOR
/
/-
WASHER
ELECTRICSTARTER
Install and tighten the terminal nut securely.
Install the negative brushes and tighten the screw to
the specified torque.
TORQUE: 3.7 Nm (0.4 kgfm, 2.7Ibfft)
Install the brush springs to the brush holder
grooves.
Install the stopper to the rear cover.
Install the brushes to the brush holder.
SPRINGS
20-12
ELECTRICSTARTER
Installthearmaturetotherearcoverassembly.
ARMATURE
Install anewO-ringtothestartermotorcase.
Install the starter motorcase with its groove with
thestopperontherearcoverassembly.
I NOTICE I
The coil may be damaged if the magnet pulls the
armature against the case.
Install anewO-ringtothestartermotorcase.
Installthefrontcovertothestartermotorcase.
Align the index marks on the front cover, starter
motorcaseandrearcover.
O-RING
Illiiil'
Align STARTER MOTORCASE
20-13
ELECTRICSTARTER
InstallnewO-ringstotheassemblybolts.
Install and tighten the assembly boltsto the speci-
fiedtorque.
TORQUE:4.9Nm(0.5kgfm,3.6Ibf.ft)
20-14
Route the cable
properly
(page 1-22).
Route the cable
properly
(page 1-22).
BOLTS
INSTALLATION
ApplyengineoiltoanewO-ring and installittothe ,"'cF\,,;ri<'
O-RING
startermotorgroove.
.... ,
-,
Installthestartermotorontothecrankcasefromthe
rightside.
Connectthegroundcable.
Installandtighten'theboltssecurely.
Connectthestartermotorcable.
Install and tighten theterminal nuttothe specified
torque.
Closetheterminalcover.
Connectthebatterynegative(-Icable(page18-61.
ELECTRICSTARTER
STARTER RELAYSWITCH
INSPECTION
Removethefollowing:
- Fuse box/turnsignal relay(page19-8)
switchat"0".
Pushthestarterswitchbutton.
Thecoil isnormalifthestarterrelayswitchclicks.
Ifyou do not hear the switch "CLICK", inspect the
relayswitchusingtheprocedurebelow.
GROUNDLINE
Disconnectthestarterrelayswitch4Pconnector.
Check for continuity between the Green/red wire
(groundline)terminalandground.
If there is continuity when the transmission is in
neutral or when the clutch is disengaged and the
sidestandisretracted,thegroundcircuitoftherelay
coilisnormal.(In neutral,thereisaslightresistance
duetothediode.)
STARTER RELAYVOLTAGE
Connectthestarterrelayswitch4Pconnector.
switchat"0".
Measure the voltage between the yellow/red wire
terminal(+) andground(-),
If the battery voltage appears when the starter
switchbuttonispushed,thepowersupplycircuitof
ther ~ y coilisnormal.
20-15
8
ELECTRICSTARTER
OPERATIONCHECK
Removethestarterrelayswitch(page20-16).
Connect a fully charged 12 V battery to the relay
switchas shown.
Thereshouldbecontinuitybetweenthecabletermi-
nalswhilethebatteryisconnected,and no continu-
ity whenthebatteryisdisconnected.
REMQVALIINSTALLATION
Removethefollowing:
- Fuseboxlturnsignal relay(page 19-8)
TurntheignitionswitchtoOFF.
Disconnectthebatterynegative(-)cable
(page18-6).
Disconnectthestarterrelay4Pconnector.
Removethesocketboltsandcables.
Removethestarterrelayswitch.
DIODE
INSPEctiON
Removethe rightsidecover(page3-3).
Openthefuse boxcoverand removethediode.
20-16
ELECTRICSTARTER
Check for continuity between the diode terminals.
DIODE
When there is continuity, a small resistance value
will register.
If there is continuity in one direction, the diode is
normal.
B
20-17
MEMO
21. LIGHTS/METERS/SWITCHES
SYSTEMLOCA...ION .. .. 21-2
SERVICEINFORMATION....21-3
HEADLIGHT 21-5
TURNSIGNALLIGHT .. 21-6
BRAKEITAILLIGHT 21-7
LICENSE LIGHT 21-8
SPEEDOMETER/VSSENSOR.. .. 21-9
COOLANTrEMPERATUREINDICATORI
ECTSENSORSWITCH21-12
FANMOTORSWITCH 21-14
OILPRESSUREINDICATOR 21-15
IGNrnONSWITCH 21-16
HANDLEBARSWITCH 21-17
BRAKELIGHTSWITCH... 21-18
CLUTCHSWITCH 21-19
NEUTRALSWiTCH .. .. .. 21-19
SIDESTANDSWiTCH .... 21-20
HORN 21-21
TURNSIGNALRELAy .....21-21
21-1
SYSTEMLOCATION
FRONT BRAKE LIGHT SWITCH
LEFT HANDLEBAR SWITCH
CLUTCH SWITCH
HORN
FAN MOTOR SWITCH
REAR BRAKE LIGHT SWITCH
SIDESTAND SWITCH
NEUTRAL SWITCH EOP SWITCH
21-2
SERVICEINFORMATION
GENERAL
NOTICE
Notethefollowingwhenreplacingthehalogenheadlightbulb.
- Wearclean gloves while replacing the bulb. Do notputfingerprints on the headlightbulb, as theymaycreate hot
spotsonthebulbandcauseitto fail.
- Ifyoutouchthebulbwith yourbarehands,cleanitwithaclothmoistenedwithalcoholto preventitsearlyfailure.
Be suretoinstallthedustcoverafterreplacingthebulb.
A halogenheadlightbulbbecomesveryhotwhiletheheadlightis on,and remainshotforawhileafteritisturnedoff.
Besuretoletitcool downbeforeservicing.
Checkthebatteryconditionbeforeperforminganyinspectionthatrequiresproperbatteryvoltage.
Acontinuitytestcan be madewiththeswitchesinstalledonthemotorcycle.
Thefollowingcolorcodes usedareindicatedthroughoutthissection.
Bu =Blue
BI =Black
Br=Brown
G=Green
Gr=Gray
Lb=LightBlue
Lg =LightGreen
0=Orange
Y=Yellow
R=Red
W=White,
SPECIFICATIONS
ITEM SPECIFICATIONS
Bulbs Headlight 12V-60/55W
Brake/taillight 12V-21/5W
License light 12V-5W
Frontturnsignal/positionlight 12V-21/5Wx2
Rearturnsignal light 12V-21Wx2
Instrumentlight LEDx6
Turnsignal indicator LED
High beamindicator LED
Neutralindicator LED
Oil pressureindicator LED
Coolanttemperatureindicator LED
Fuse Mainfuse 30A
Subfuse 10Ax 5, 20Ax 1
ECTsensor
switch
Starttoclose(ON) 112-118e(234- 244F)
Stoptoopen(OFF) 108e(226F) minimum
Fan motor
switch
Starttoclose(ON) 103-107C(217- 225F)
Stoptoopen(OFF) 94- 98e(201 - 208F)
TORQUEVALUES
ECTsensorswitch
Fan motorswitch
Ignitionswitch mountingbolt
Ignitionswitchcoverscrew
Neutralswitch
Sidestandswitch bolt
Hornmountingbolt
Speedometermountingsocketbolt
EOP switchterminalscrew
Headlightunitmountingbolt
Brake/tail lightmountingnut
VS sensormountingbolt
7Nm(0.7kgf'm,5.2 Ibfft)
18N'm(1.8kgf'm,13 Ibfft)
1N'm(0.1 kgf'm,0.7 Ibfft)
12Nm(1.2 kgfm,9Ibfft)
1.9N'm(0.2 kgf'm,1.4 Ibfft)
9.8Nm(1.0 kgfm,7.2 Ibfft)
Applysealanttothethreads
ALoebolt;replacewithanewone
~ 3
TOOL
Inspection test harness
07GMJ-ML80100
21-4
HEADLIGHT
BULBREPLACEMENT
Remove the bolts. collars and headlight unitfrom
theheadlightcase.
Disconnecttheheadlight3Pconnector.
HEADLIGHTUNIT
RETAINER
BULB DUSTCOVER
Removethedustcover.
Unhooktheretainerandremovethebulb.
I NOTICE I
Avoid touching the halogen headlight bulb. Finger
prints can create hot spots that cause a bulb to
break.
Installanewbulb.aligningitstabswiththegrooves
intheheadlightunit.
Hooktheretainer.
Installthedustcoverwithits"TOP" markfacingup.
Connecttheheadlight3Pconnector.
Install the'headlight unitintothe headlightcase by
aligning the headlight unithookwiththe headlight
casetab.
Installthecollarsandbolts.
HEADLIGHTUNIT
HEADLIGHTCASEREMOVAL/
INSTALLATION
Removethefollowing:
- Headlightunit(page21-5)
- Frontturnsignallight(page21-6)
Releasethewireharnessesfromtheclamps.
Remove the wire harnesses from the headlight
case.
CLAMPS
HEADLIGHTCASE
21-5
Removethe nuts,boltsand headlightcase fromthe
HEADLIGHTCASE
brackets.
Route the wire Install the headlight case in the reverse order of
harnesses properly removal.
(page 1-22J. Adjusttheheadlightaim(page4-22).
TURNSIGNALLIGHT
BULB REPLACEMENT
/
BOLTS
Removethescrewandturnsignal lightlens.
While pushingthe bulbin,turn itcounterclockwise
toremoveit,and replaceitwithanewone.
Make sure the lens gasket is installed in position
and is in good condition, and replace itwith a new
oneifnecessary.
Install the lens, aligning its slotwith the tabofthe
turnsignal light,andtightenthescrew.
SCREW GASKET LENS
REMOVAUINSTALLATION
FRONT
Removethe headlightunit(page21-5).
Disconnecttheturnsignal3Pconnectors.
Lightblue: Rightturnsignalconnector
Orange: Leftturnsignalconnector
HEADLIGHTCASE
3PCONNECTORS
Removethebolt,collarandturnsignal light.
TURN SIGNALLIGHT
Route the turn Installationisinthereverseorderofremoval.
signal wire properly
(page 1-22J.
'"
21-6
BRAKE/TAILLIGHT
BULBREPLACEMENT
Removethescrews.
Remove the brakeltail light lens while pushing it
downand release itstabsfromtherearfenderA.
LENS
While pushing inthe bulb,turn itcounterclockwise
toremoveit,and replaceit.
Make sure thatthe lens gasket is installed in posi-
tionand is in good condition, and replace itwith a
newoneifnecessary.
Install the removed Pl;Irts in the
removal.
reverse order of
GASKET SCREWS
Align
TURNSIGNALLIGHT
Route the turn
signa/light wire
properly
(page 1-22).
REAR
Removetherearframe/rearfenderA(page3-7).
Releasetheturnsignallightwirefromtheclampsof
therearframe.
Removethe boltandturn signal lightfromthe rear
frame.
Installtheturnsignal light,aligning itstabwiththe
rearframeslotandtightenthebolt.
Installtherearframe/rearfenderA (page3-7).
I.IGHTS/METERS/SWITCHES
RemovetherearframelrearfenderA (page3-7).
Release the brake/tailllicense light wire from the
clampsoftherearframe.
Disconnect the license light 2P connector and
removeitfromtherearfenderA.
Removethenuts,collarsand brake/taillight.
properly
TORQUE:
(page 1-22).
Brake/taillightmountingnut:
6.3Nm10.6kgfm,4.6Ibfft)
COLLAR BRAKEfTAILLIGHT
LICENSE LIGHT
BULBREPLACEMENT
Removethescrewsand licenselightcover.
LICENSE LIGHTCOVER
Removethebulband replaceit.
Make sure thatthe lens gasket is installed in posi-
tion and is in good condition, and replace itwith a
newoneifnecessary.
removal.
GASKET SCREWS
Removetherearframe/rearfenderA (page3-7).
Disconnectthelicenselight2P connector.
Removethenuts,collars,clampand licenselight.
properly
. (page 1-22).
2P CONNECTOR
BULB
CLAMP LICENSE LIGHT
21-8
SPEEDOMETER/VSSENSOR
POWER/GROUNDLINEINSPECTION
POWERINPUTLINE
MeasurethevoltagebetweentheBrownwiretermi-
SPEEDOMETERCONNECTORS
nal (+) of the speedometer 12P connector and
ground(-).
(viewedfromthewireharnessside)
There should be battery voltage with the ignition
switchturnedtoON.
Ifthereis novoltage,checkthefollowing:
- Open circuitintheBrownwire
- Blownsubfuse10A(METER,TAIL)
GROUNDLINE
Checkfor continuity between the Green/blackwire
terminalandground.
Thereshouldbecontinuityatalltimes.
Ifthereis no continuity,checkforan open circuitin
theGreen/blackwire.
BACK-UPVOLTAGELINE
Checkthis line ifthe odometer/trip meterdoes not
function.
MeasurethevoltagebetweenthePinkwireterminal
(+) andground(-).
Thereshouldbebatteryvoltageatalltimes.
Ifthereisnovoltage,checkthefollowing:
- OpencircuitinthePinkwire
- Blownsubfuse10A(ODOMETER)
- OpencircuitintheRed wire
BROWN
SPEEDOMETER CONNECTORS
SPEEDOMETERINSPECTION
Speed()meterdoesnotoperate
el1eCkthattheindicatorsfunction properly.
Iftheydonotfunction,checkthepower/groundline
Cpage 21-9).
wheelofftheground.
Shiftthetransmissionintoneutralandturntheigni-
tionswitchtoON.
Measure the voltage between the Black/yellow (+)
andGreen/black(-)wireterminalsof thespeedome-
terconnector.
Slowlyturntherearwheelbyhand.
Thereshouldbe0Vto5Vpulsevoltage.
Ifpulsevoltage appears, replacethe speedome-
ter.
If pulse voltage does not appear, check the fol-
lowing:
- Black/yellowwireforan openorshortcircuit.
- Green/blackwireforan opencircuit.
IfthewiresareOK,checktheVSsensor
(page21-11).
SPEEDOMETERCONNECTORS
BLACKIYELLOW GREEN/BLACK
21-9
SPEEDOMETERREMOVAL/
INSTALLATION
..
Removethebolts and speedometerassemblyfrom
(SPEEDOMETERASSEMBLY
thefueltank.
Slidethe dustcoverand disconnectthespeedome-
ter12Pconnector.
Remove the screws, switch cover and trip meter
resetswitch.
Remove the screws, clamp, speedometer and 0-
ring.
Check the O-ring is in good condition, replace it if
necessary.
Install the removed parts into the speedometer
coverinthereverseorderofremoval.
NOTE:
Installtheresetswitchwithitsbossfacingdown.
21-10
Connectthespeedometer12Pconnectorand install
12PCONNECTOR
thedustcover.
Install the speedometer assembly on the fuel tank,
aligningthefueltanktabwiththe meterslot.
Installandtightentheboltstothespecifiedtorque.
TORQUE:10Nm(1.0 kgf'm,7Ibfft)
VSSENSORINSPECTION
DisconnecttheVS sensor3P(Natural)connector.
Turn the ignition switch to ON and measure the
voltage at 3P (Natural) connector ofthe wire har-
nessside.
CONNECTION: Brown(+) - Green/Black(-)
STANDARD: BatteryYoltage
Thereshould be batteryvoltage.
Ifthereisnovoltage,checkforan opencircuitinthe
Brownand Green/blackwires.
Supportthe motorcycle securely and raise the rear
wheelofftheground.
ConnectthetestharnessbetweentheVS sensor3P
(Natural)connector.
TOOL:
Inspectiontestharness 07GMJ-MLB0100
Measure thevoltage between the Red clip (+) and
Whiteclip(-).
CONNECTION: Red clip(+) - Whiteclip(-)
STANDARD: Repeat0to5V
Shiftthetransmission intoneutralandturntheigni-
tionswitchtoON.
Slowlyturntherearwheelbyhand.
Ifpulsevoltagedoesnotappear,replacetheVSsen-
sor.
VSSENSORREPLACEMENT
Removethefollowing:
- Seat(page3-3)
- Leftsidecover(page3-3) .
DisconnecttheVS sensor3P(Natural)connector.
21-11
COOLANTTEMPERATUREINDICATORI
ECTSENSORSWITCH
INSPECTION
Thec.Qoh,mttempltratureistoohigh,butthe
indicatordoesnotcomeon
Check that the neutral and oil pressure indicators
function properly.
Iftheydonotfunction,checkthepowerinputlineof
thespeedometer(page21-9).
COOLANTTEMPERATUREINDICATOR
Disconnect the ECT sensor switch connector and
groundit.
TurntheignitionswitchtoON andchecktheindica-
tor.
Iftheindicatorcomeson,inspecttheECTsensor
switch.
Ifthe indicator does notcome on, check for an
open circuit in theGreen/bluewire. Ifthewire is
OK, replacethespeedometer(page21-10).
21-.12
Route the VS
sensor wire
properly
(page 1-22).
Release the VS sensor wire from the clamps and
wirebands.
RemovetheboltandVS sensorfromthecrankcase.
CoatanewO-ring with engineoil and install itinto
theVS sensorgroove.
InstalltheVSsensorand mountingbolt.
Tightenthemountingbolttothespecifiedtorque.
TORQUE:9.8Nm(1.0kgfm,7.2 Ibfft)
removal.
iF"'..... .....
Wear insulated
gloves and
adequate eye
protection.
Keep flammable
materials away
from the burner.
The coolant temperature is low but the indicator
comes on.
TurntheignitionswitchtoON andchecktheindica-
tor.
If the indicator does not come on, inspect the
ECTsensorswitch.
Iftheindicatorcomeson,checkforashortcircuit
in theGreen/bluewire. Ifthewire isOK, replace
thespeedometer(page21-10).
ECTSENSORSWITCHINSPECTION
Drain fromthecoolingsystem
(page
Removethe.ECTsensorswitch(page21-13).
Heatthe'coolant(1 : 1mixturewithdistilledwater)
withan electricheatingelement.
the ECT sensor switch in heated coolant
and checkthe continuitythrough the switch as the
coolantheatsup.
NOTE:
Soakthe ECT sensor switch in coolant up to its
threadswithatleast40 mm(1.6in)fromthebot-
tomofthepantothebottomoftheswitch.
Keeptemperatureconstantfor3minutesbefore
testing. A sudden change of temperature will
result iniricorrect readings. Do not letthe ther-
mometerorECTsensorswitchtouchthepan.
StoptoopenAOFF} Below108C(226F)
THERMOMETER
ECTSENSORSWITCH
ReplacetheECTsensorswitch ifitisoutofspecifi-
cations.
InstalltheECTsensorswitch(page21-13).
ECTSE-NSORSWITCH REPLACEMENT
Rrainthecoolantfromthecoolingsystem
(page'7-7k' '., '. .
RemovethestEl.eringsidecovers(page3-5).
Disconnecttile. ECTsensorswitchconnector.
RemovetheECl'sensorswitchfromthethermostat
hOL!.l:li@
Do not apply ofa new ECT sensor
sealant to the switch. ",' , .. ,.
thread head. Il'lstl:l1landtightentht:jECTsensorswitch.
TORQUE:7Nm(O.7ijt.m,5.2Ibf.ft)
21-13
FAN MOTORSWITCH
INSPECTION
The coolant temperature is low but the fan motor
does not stop
Disconnecttheconnectorfromthefan motorswitch
andturntheignitionswitchtoON.
Ifthefan motordoes notstop, check for ashort
circuitintheBlackwire.
If the fan motor stops, replace the fan motor
switch.
The coolant temperature indicator comes on but
the fan motor does not start
Before testing, check for a blown sub fuse 20 A
(FAN).
Disconnecttheconnectorfromthefan motorswitch
andgroundit.
Turn the ignition switch to ON and check the fan
motor.
Ifthemotorstarts,replacethefan motorswitch.
Ifthefan motordoes notstart,removethesteer-
ingsidecovers(page3-5) anddisconnectthefan
motlif2P (Natural)connector.
MeasurethevoltagebetweentheBlack/bluewire
andground.
...: voltage, replace the fan
motor{page
- Ifthereisnovoltage,checkforan open circuit
intheGreen and Black/bluewires.
21-14
REPLACEMEI\lT
Drainthecoolant(page7-7).
Disconnect the connector from the fan motor
switch.
Removethefan motorswitchfromthe radiator.
Install a new O-ring into the fan motor switch
groove.
Installandtightenthefan motorswitch.
Connecttheconnectortothefan motorswitch.
OILPRESSUREINDICATOR
INSPECTION
Indicatordoesnotcomeonwiththeignitionswitch
turnedtoON
Checkthattheneutralandcoolanttemperatureindi-
catorsfunctionproperly.
Ifthey do not function properly, check the power
inputlineofthespeedometer(page21-9).
Remove the rubber cap, and disconnect the EOP
Groundthewireterminal.
Turn the ignition switch to ON and check the oil
pressureindicator.
If the indicator comes on, replace the EOP
switch.
Ifthe indicator does notcome on, check for an
opencircuitintheBlue/redwire.IfthewireisOK,
replacethespeedometer(page21-10).
Indicatorstaysonwhiletheengineisrunning
Remove the rubber cap, and disconnect the EOP
Checkforcontinuitybetween thewireterminal and
ground.
Ifthereis,checkforashortcircuitintheBlue/red
wire.
Ifthere is no continuity, check the oil pressure
(page5-5).
If the oil pressure is normal, replace the EOP
switch.
After inspection, connect the EOP switch wire and
tightentheterminalscrew.
TORQUE: 1.9Nm(0.2kgfm,1.4Ibfft)
Installtherubbercap properly.
Installtheleftcrankcaserearcover(page3-5).
OILPRESSURE INDICATOR
21-15
IGNITIONSWITCH
INSPEC1"ION
Disconnect the ignition switch 2P (Black) and 1P
(Natural)connectors.
Check for continuity between the switch side con-
nectorterminalsineach switch position.
Continuity should exist between the color coded
wiresas showninthechart.
BulO RlBI R
REMOVAUINSTALLATION
RemovethefollOWing:
- Seat(page3-3)
Disconnect the ignition switch 2P (Black) and 1P
(Natural)connectors.
Releasethewirefromthewireband.
RemovethescrewandIgnitionswitchcover.
Removetheboltsandignitionswitchassembly.
Removethebolts, ignitionswitch,collarand switch
basefromthestay.
Install theswitch base, ignitionswitch and collarto
thestay.
Tighten newboltstothespecifiedtorque.
TORQUE: 12Nm(1.2 kgfm,9Ibf.ft)
Installtheignitionswitchassemblytotheframe.
Install the ignition switch cover and tighten the
screw.
TORQUE: 1Nm(0.1 kgfm,0.7Ibfft)
Routetheignitionswitchwireproperly(page 1-22).
Connecttheignitionswitch2P(Black)and 1P(Natu-
ral) connectors.
- Seat(page3-3)
BOLTS BOLTS
IGNITIONSWITCH/COLLAR/SWITCH BASE
The ignition switch
mounting bolt
heads are broken
by tighten them to
the specified
torque.
21-16
HANDLEBARSWITCH
Removetheheadlightunit(page21-5).
6PCONNECTORS
Disconnectthefollowingconnectors:
Lefthandlebarswitch6P (Blue)
- Lefthandlebarswitch6P (Black)
- Righthandlebarswitch6P (Red)
- Dimmerswitch2P(Black)
- Turnsignallight3P(Lightblue)and3P(Orange)
Check forcontinuity between the connector termi-
nalsineachswitchposition.
Continuity should exist between the color coded
.wiresas showninthecharts.
2PCONNECTOR
RIGHTHANDLEBARSWITCH
ENGINESTOPSWITCH
ENGINE STOPSWITCH
IG BAT2
COLOR BIIW BI/G
STARTERSWITCH

ST IG BAT4 HL
FREE
0-
f-o
PUSH
0-
f-O
COLOR YIR 811W BIIR BulW
STARTERSWITCH
FREE
Ho BAT3
W R L
Gr Lb 0 Br LblW OIW
LEFTHANDLEBARSWITCH
TURNSIGNALSWITCH
COLOR
PUSH
HORNSWITCH
DIMMERSWITCH
COLOR BuNI W Bu
21-17
BRAKELIGHTSWITCH
FRONT
Disconnect the brake light switch connectors and
check for continuity between the switch terminals.
There should be continuity with the brake lever
squeezed and no continuity with the lever released.
REAR
Remove the steering side covers (page 3-5).
Disconnect the rear brake light switch 3P (Light
gray) connector and check for continuity between
the switch side connector terminals.
There should be continuity with the brake pedal
depressed and no continuity with the pedal
released.
REAR BRAKE LIGHTSWITCH
Remove the steering side covers (page 3-5).
Remove the wire band and disconnect the rear
brake light switch 3P (Light gray) connector.
Unhook the return spring and remove the rear brake
light switch.
Route the wire Installation is in the reverse order of removal.
properly Adjust the rear brake light switch (page 4-22).
(page 1-22).
21-18
CLUTCH SWITCH
Disconnect the clutch switch wire connectors and
checkforcontinuitybetweentheswitchterminals.
There should be continuity with the clutch lever
squeezedand nocontinuitywiththeleverreleased.
NEUTRALSWITCH
INSPECTION
Disconnecttheneutralswitch connector.
Check for continuity between the switch terminal
and engineground.
There should be continuity when the transmission
is in neutral, and nocontinuitywhen thetransmis-
sionisingearexceptneutral.
REPLACEMENT
Disconnecttheneutralswitchconnector.
Removetheneutral switch with thesealing washer
fromthecrankcase.
Installtheneutralswitchwithanewsealingwasher
andtightenit.
TORQUE: 12N'm(1.2kgfm,9Ibf.ft)
Connecttheneutralswitchconnector.
Installtheleftcrankcase rearcover(page3-5).
21-19
-- ---- -----------------
SIDESTANDSWITCH
Do not reuse the
sidestand switch
bolt.
INSPECTION
Disconnectthesidestandswitch2P (Green) connec-
tor.
Check for continuity between the switch side con-
nectorterminals.
There should be continuity with the sidestand
retracted and nocontinuitywiththesidestand low-
ered.
REMOVALlINSTAlLATION
Removethefollowing:
- Seat(page3-3)
Supportthemotorcyclesecurely.
Disconnectthesidestandswitch2P(Green)connec-
tor.
Release the sidestand switch wire from the wire
bandsandclamps.
Removethe boltand sidestandswitch.
Install thesidestand switch byaligning its pinwith
the sidestand hole and switch groove with the
bracketpin.
...--"""'"=-....
21-20
Installanewsidestandswitchbolt.
Route the Install the removed parts in the reverse order of
sidestand switch removal.
wire properlv
(page 1-22).
HORN
INSPECTION
Disconnecttheconnectorsfromthehorn.
Connecta12Vbatterytothehornterminals.
The horn is normal ifitsoundswhenthe 12 V bat-
teryisconnectedacrossthehornterminals.
Disconnecttheconnectorsfromthehorn.
Removetheboltandhorn.
Installthehorntotheframe,aligningitsflatwiththe
hornstay.
TORQUE:21 Nm(2.1 kgfm,15Ibfft)
Connecttheconnectors.
... ...._
TURNSIGNALRELAV
Turnsignallightdoesnotblink
Removetheturnsignal relayfromthestay.
Slidetherubbercap anddisconnecttheconnector.
ConnecttheWhite/greenandGraywireterminalsof
thewireharnesssideconnectorwithajumperwire.
Turn the ignition switch to ON and checkthe turn
signallightsbyoperatingtheturnsignalswitch.
Ifthe lightdoes notcomeon,checkforan open
circuitintheWhite/greenand Graywires.
Ifthelightcomes on,checktheconnectortermi-
nalsforlooseorpoorcontact.
If the connector terminals are OK, replace the
turnsignalrelay.
21-21
MEMO
22. WIRINGDIAGRAMS
WIRING DIAGRAM WIRINGDIAGRAM(Californiatype) 22-4
(49statesICanadatype) .. 22-3
"e
22-1
-
-
J
G
L.b
Br
GIBI
BVY
P
GIBu
LgIR
au
o
BuIR
WIRING DIAGRAM (49 statesICanada type)
ENGINESTOPSWITCH STARTERSWITCH
(
COOLANTTEMPERATURE
INDICATOR
NEUiRAlINDICATOR
HIGHBEAMINDICATOR
TURNSIGNALINDICATOR
OILPRESSUREINDICATOR
INSTRUMENTLIGHT
LEDX6 ENGINESTOP-STARTERSWITCH
FRONTBRAKE D
LIGHTSWITCH
--
(

TRIPRESETSWITCH

TURNSIGNALRELAY

FOG LAMP
RIGHTFRONT
(OPTION)
TURN SIGNALLIGHT
12V2115W
mOP
1"a;
YJR=======
LEFTFRONT
BIIW
12V2115W OPO

BllBu-
0&:g:
HORN 3:

:>
?;Omm.9':9 It
!!!"
lD
I'-hTI I

I L-, qh
It lD
III I I

81

0
(
IGNITIONSWITCH
CLUTCHSWITCH TURN SIGNALoDIMMERoHORNSWITCH VS SENSOR FUSEBOX
FAN MOTORSWITCH
FUSE A lOA (HEAOUGHT)
TURNSIGNALLIGHTSWITCH DIMMERSWITCH HORNSWITCH
'"
W R L PO PR PI.
R 0 -0
N
1< - -0
l

""- Hl
La Hi
La
-0
(N)
Hi
B1M (METER-TAIl)
IGNITIONSWITCH
ClOA (lGNITIONoSTARTER)
olOA (TURNoHORNoSTOP)
E 2lIA (FANllOIOR)
FlOA (ODOMETER)
1"'-
FAN IG BAT1 KEY
10rO-
ON
-0
KEY ON
OFF KEYOF!'

EOPSWITCH ""
WIRINGDIAGRAMS

STARTERRELAYSWITCH ....'N FUSE ...
IGNITIONPULSE
GENERATOR

): l
Et>

STARTERMOTOR

IGNITIONCOILS g
-+----- I II

ECTSENSORSWITCH
TPSENSOR +
@=
3P .;;AIY-
:
WIY-
ICM
II
_
o
e
BATTERY
12V 11M
14P Y
LIGHTSWITCH
REARBRAKE

-t'1t.""GRAY

RIGHTREAR
TURNSIGNALLIGHT
aP
f-GlY:uJ:GIY- f-- GIY
'-G G-.--G
L- Br Br - p-- Br
BRAKEITAILLIGHT
12V211SW
2P
c..:::
LICENSELIGHT
12V5W
>->->-
I c..::::= g:OJ:
MaP
2PO
LEFTREAR
TURNSIGNALLIGHT
12V21W
>->->-
f
0
REGULATOR! 0
RECTIFIER
SIDESTANDSWITCH
ALTERNATOR
TRALSWITCH
-

.-
BI BLACK Br BROWN
Y YELLOW 0 ORANGE
Bu BLUE Lb LIGHTBLUE
G GREEN Lg LIGHTGREEN
R RED P PINK
W WHITE Gr GRAY
0030l-MFE-6700
22-3
-
~
J
WIRINGDIAGRAMS
WIRINGDIAGRAM (Californiatype)
ENGINE STOP SW
COOLANTTEMPERATURE
INDICAlOR
NEUTRAL INDICATOR
G
Lb
Br
GlBI
BI/Y
P
G
HIGH BEAM INDICAlOR
l\JRN SIGNAL INDICAlOR
OIL PRESSURE INDICATOR
INSTRUMENT LIGHT
ENGINE smP-STARTEF
FRONT BRAKE D ~
LED X
LIGHT SWITCH ~ W
mm ~ ~ ~ ~ ~
~
TRIP RESET SWITCH
l\JRN
FOG LAMP
RIGHT FRONT
(OPTION)
l\JRN SIGNAL LIGHT
12V2115W
CLUTCH SWITCH l\JRN SIGNALoDlMMERoHORN SWITCH VS SENSOR
I'"
HL Lo HI
Lo 10
(N)
HIIO
rO
TURN SIGNAL LIGHT SWITCH DIMMER SWITCH HORN SWITCH
FUSE AlOA IHEADUGtlT)
BlDA (METER-TAIL)
~
C lOA (lGNmCJNo6TARTER)
D lOA (lURNoH<JRNoSTOP)
E 2DA IFAN NOTOR)
F lOA (ODONETERI
22-4
rCH STARTERSWITCH
D
ECTSENSORSWITCH
14P Y
leM

STARTERMOTOR
TPSENSOR
WN-
Y -
I BuIY-
ym
u
:
--'

IGNmONPULSE
GENERAlOR

FUELCLIT-0FF
SOLENOIDVALVE
SWITCH
IIGNALRELAY
BfiAKEITAILLIGHT
12V2115W
2!'

LICENSELIGHT
12V5W
>
--===g=ill . I

...
LEFTREAR

Ol TURNSIGNALLIGHT
12V21W
o

SIDESTANDSWITCH
B'SJ
ALTERNATOR
CH
EOPSWITCH NEUTRALSWITCH
FAN MOTORSWITCH
ImONSWITCH BI BLACK Br BROWN
Y YELLOW 0 ORANGE
Bu BLUE l.b LIGHTBLUE (
G GREEN- Lg LIGHTGREEN
R RED P PINK
W WHITE Gr GRAY
\ FAN
IG
""'"
KEY

KEVON
,
KEVOF1'
0030Z-MFE-7700
I
23.TROUBLESHOOTING
ENGINEDOESNOTSTARTORISHARD POORPERFORMANCEAT
TOSTART 23-2 HIGHSPEED 23-6
ENGINELACKSPOWER 23-3 POORHANDLING 23-7
POORPERFORMANCEATLOWAND
IDLESPEED 23-5
23-1
TROUBLESHOOTING
ENGINE DOESNOTSTARTOR ISHARDTOSTART
1. FuelLineInspection
Checkfuelflowtocarburetor.
Does fuel reach the carburetor?
NO -.Cloggedfuellineandstrainer
Cloggedfueltankbreather
Stickingfloatvalve
Pinchedfuelvalvevacuum hose
YES - GO TO STEP 2.
2. SparkPlugInspection
Removeandinspectsparkplugs.
Is the spark plug wet?
YES -.Floodedcarburetor
SE valveON position(open)
Throttlevalve open
Dirtyaircleaner
NO - GO TO STEP 3.
3. SparkTest
Performsparktest.
Is there weak or no spark?
YES -.Faultysparkplug
Fouledsparkplug
looseordisconnectedignitionsystemwires
Faultyignitionpulsegenerator-
Faultyignitioncoil
FaultyICM
Faultyenginestopswitch
NO - GO TO STEP 4.
4. CylinderCompfession
Testcylindercompression.
Is the compression low?
YES -.Valvestuckopen
Worncylinderandpistonrings
Damagedcylinderheadgasket
Seizedvalve
Impropervalvetiming
NO - GO TO STEP 5.
5. EngineStartingCondition
Startenginebyfollowingnormalprocedure.
Does the engine start then stops?
YES -.Improperchokeoperation
Incorrectlyadjustedcarburetor
. Leakingcarburetorinsulatororintakemanifold
Improperignitiontiming(FaultyICM,ignitionpulsegeneratororTPsensor)
Contaminatedfuel
23-2
TROUBLESHOOTING
ENGINELACKS POWER
1. DriveTrainInspection
Raisewheeloffthegroundandspinitbyhand.
Does the wheel spin freely?
NO -.Brakedragging
Wornordamagedwheel bearings
Finalgearbearingdamaged
YES - GO TO STEP 2.
2. TirePressureInspection
Checktirepressure.
Are the tire pressures low?
YES -.Faultytirevalve
Puncturedtire
NO - GO TO STEP 3.
3. ClutchInspection
Accelerate rapidlyfromlowtosecond.
Does the engine speed change accordingly when the clutch is engaged?
NO -.Clutch slipping
Wornclutchdiscs/plates
Warpedclutchdiscs/plates
Weakclutchspring
Additiveinengineoil
YES - GO TO STEP 4.
4. EnginePerformanceInspection
Acceleratelightly.
Does the engine speed increase?
NO -::. SEvalveON position(open)
Dirtyaircleaner
.Restrictedfuelflow
Clogged muffler
Cloggedfueltankbreather
FaultyTPsensor
YES - GO TO STEP 5.
5. SparkPlugInspection
Removeand inspectsparkplugs.
Is the spark plug fouled or discolored?
NO _. Plugsnotservicedfrequentlyenough
Incorrectsparkplugheatrange
Incorrectsparkpluggap
YES - GO TO STEP 6.
6. EngineOilInspection
Checkoil levelandcondition.
Is there correct level andgood condition?
NO -.Oil leveltoohigh
Oil leveltoolow
Contaminatedoil
YES - GO TO STEP 7.
---------------- ---
TROUBLESHOOTING
7. IgnitionTimingInspection
Checkignitiontiming.
Is the ignition timing correct?
NO -.FaultyICM
Faultyignitionpulsegenerator
FaultyTP sensor
YES - GO TO STEP 8.
8. CylinderCompressionInspection
Testcylindercompression.
Is the compression low?
YES -.Valveclearancetoosmall
Valvestuckopen
Worncylinderandpistonrings
Damagedcylinderheadgasket
Impropervalvetiming
NO - GO TO STEP 9.
9. CarburetorInspection
Checkcarburetorforclogs.
Is the carburetor clogged?
YES - Carburetornotservicedfrequentlyenough.
NO - GO TO STEP 10.
10.LubricationInspection
Removecylinderhead coverandinspectlubrication.
Is the valve train lubricated properly?
NO -.Cloggedoilpassage
Cloggedoilorifice
YES - GO TO STEP 11.
11.OverHeatingInspection
Checkforengineoverheating.
Is the engine over heating?
YES _. Coolantleveltoolow
Fan motornotworking
Thermostatstuckclosed
Excessivecarbonbuild-upincombustionchamber
Useofpoorqualityfuel
Wrongtypeoffuel
Clutchslipping
NO - GO TO STEP 12.
12.EngineKnockingInspection
Accelerateorrun athighspeed.
Is there knocking?
YES _. Wornpistonandcylinder
Wrongtypeoffuel
Excessivecarbonbuild-upincombustionchamber
Ignitiontimingtooadvance(FaultyICM)
Leanfuel mixture
FaultyTP sensor
NO - Enginedoesnotknock.
23-4
TROUBLESHOOTING
POORPERFORMANCEATLOWANDIDLESPEED
1. PilotScrewInspection
Checkcarburetorpilotscrewadjustment.
Is the adjustment correct?
NO - See page6-25
YES - GO TO STEP 2.
2. IntakeAirLeakInspection
Checkthecarburetorinsulatorand intakemanifoldforleaks.
Are these leaks?
YES -.Looseinsulatorbands
Damagedinsulator
FaultyO-ring
NO - GO TO STEP 3.
3. SparkTest
Performsparktest.
Is there weak or intermittent spark?
YES _. Faultysparkplug
Fouledsparkplug
Looseordisconnectedignitionsystemwires
Faultyignitioncoil
Faultyenginestopswitch
FaultyICM
NO - GO TO STEP 4.
4. IgnitionTImingInspection
NO -.FaultyICM
FaultyTPsensor
23-5
TROUBLESHOOTING
POORPERFORMANCEATHIGHSPEED
1.
2.
3.
4.
5.
6.
7.
FuelLineInspection
Disconnectfuel lineatcarburetor.
Does fuel flow freely?
NO -.Restrictedfuel lineandstrainer
Restrictedfueltankbreather
Faultyfuelvalvevacuumhose
YES - GO TO STEP 2.
SparkPlugInspection
Removeand inspectthesparkplug.
Is the spark plug in good condition?
NO _. Plug notservicedfrequentlyenough
Incorrectsparkplug heatrange
Incorrectsparkpluggap
FaultySE valve
Aircleanerdirty
YES - GO TO STEP 3.
CarburetorInspection
Checkcarburetorforclogging.
Is the carburetor clogged?
YES - Carburetornotservicedfrequentlyenough.
NO - GO TO STEP 4.
IgnitionTimingInspection
NO -.FaultyrCM
FaultyTP sensor
YES - GO TO STEP 5.
ValveTimingInspection
Checkvalvetiming.
Is the valve timing correct?
NO - Cam sprocketsnotinstalledproperly.
YES - GO TO STEP 6.
ValveSpringInspection
Checkvalvesprings.
Is the valve spring free length within specification?
NO - Faultyvalvespring.
YES - GO TO STEP 7.
CamshaftInspection
Removeand inspectthecamshaft.
Is the cam lobe height within specification?
NO - Faultycamshaft.
YES - CamshaftisOK
TROUBLESHOOTING
POOR HANDLING
Steeringisheavy
Steering top thread too tight
Damaged steering head bearings
Low tire pressure
Eitherwheeliswobbling
Excessive wheel bearing play
Bent rim
Improperly installed wheel hub
Excessively worn swingarm pivot bearings
Bentframe
Motorcyclepullstooneside
Front and rear wheels not aligned
Bent fork
Bent swingarm
Bent axle
Bentframe
23-7
MEMO
24. INDEX
AIR CLEANER.. .. .. .. .... ..
AIR CLEANER HOUSING........ .... .. 6-6
ALTERNATORCHARGINGCOIL .. .. 18-9
SPECIFICATIONS.. .. 1-9
BATTERy .. .... .. .. 18-6
BATTERY/CHARGINGSYSTEMSPECIFICATIONS.. 1-12
BRAKE FLUID.. .. .. .. .. .. 4-19
BRAKE FLUID REPLACEMENT/AIRBLEEDING 17-5
BRAKE LIGHTSWITCH
L1GHTS/METERS/SWITCHES .. .. .. 21-18
MAINTENANCE.. .. .. 4-22
BRAKE PAD/DISC .. .. .. .. 17-7
BRAKE PEDAL........ .. .. .. .. 16-17
BRAKE SHOES/PADSWEAR.. ...... .. .... ..4-20
BRAKE SYSTEM.. .. .. .... ........ .. 4-20
BRAKEITAILL1GHT........ .. .. .. ........ 21-7
CABLE &HARNESSROUTING .. .. .. 1-22
CAMSHAFTINSTALLATION.. .. .. .............. 9-26
CAMSHAFT REMOVAL .. .. .. .... .. .. 9-8
CARBURETORASSEMBLY.. .. ........ .. 6-15
CARBURETORDISASSEMBLY/INSPECTION.. .. .. 6-9
CARBURETORINSTALLATION .. .. .... ......6-21
CARBURETORREMOVAL .. .. .. 6-7
CHARGING SYSTEM INSPECTION .. ......18-7
CHOKE OPERATION.. .. .. ..
CLUTCH INSTALLATION.. .. .. ........ .. .... 11-18
CLUTCH REMOVAL .. .. .. 11-7
CLUTCH SWITCH .. .. ..21-19
CLUTCH SYSTEM.. .. .. .. .. .. 4-22
CLUTCH/GEARSHIFTLINKAGE SPECIFICATIONS.....1-9
COMPONENTLOCATION
ALTERNATOR/STARTERCLUTCH .. 12-2
CLUTCH/GEARSHIFTLINKAGE.. 11-2
CRANKSHAFTrrRANSMISSION 13-2
CYLINDERHEADNALVE .... 9-2
CYLINDER/PISTON ............: .. .. .. ..10-2
ENGINE REMOVAUINSTALLATION 8-2
FINALDRiVE .. .. .. ........ ..14-2
FRONTWHEEUSUSPENSION/STEERING.......... 15-2
FUELSYSTEM .. .. .. .. .. .. 6-2
HYDRAULICBRAKE .. .... 17-2
REARWHEEUBRAKE/SUSPENSION.. .. .. 16-2
COOLANTREPLACEMENT ..7-6
COOLANTTEMPERATURE INDICATOR/
ECTSENSORSWITCH .. 21-12
COOLING SYSTEM .. ..
COOLING SYSTEM SPECIFICATIONS .. 1-7
CRANKCASEASSEMBLY .. 13-49
CRANKCASEBEARING REPLACEMENT 13-47
CRANKCASEBREATHER .. ..
CRANKCASESEPARATION.. .. .. .. .. 13-9
CRANKPIN BEARING........ ........ .. ..13-13
CRANKSHAFT/CONNECTING ROD .. .... .. 13-10
SPECIFICA-nONS........ ; .. .. .. ........ .... 1-10
CYLINDERCOMPRESSION .. .. .... 9-6
CYLINDERHEADASSEMBLY...... .. .. .. 9-22
CYLINDER HEADCOVER INSTALLATION ..9-31
CYLINDER HEADCOVER REMOVAL .. ;9-6
CYLINDERHEADDISASSEMBLY .. .. 9-15
CYLINDERHEADINSTALLATION 9-24
CYLINDER HEADREMOVAL...... ; .. 9-14
CYLINDERHEADNALVESPECIFICATIONS.. 1-8
CYLINDER/PISTON INSTALLATION.. ...... .. .. 10-9
CYLINDER/PISTON REMOVAL.. .. .. .. 10-4
CYLINDER/PISTON SPECIFICATIONS 1-8
DIODE 20-16
ELECTRICSTARTERSPECIFICATIONS.... 1-12
EMISSIONCONTROLSYSTEMS........ ........1-39
ENGINE& FRAMETORQUEVALUES .. .. .. .. 1-13
ENGINEIDLE SPEED .. ..4-15
ENGINEINSTALLATION .. .. .. .. 8-7
ENGINEOIL............ .. .. 4-12
ENGINEOILFILTER 4-13
ENGINEREMOVAL .... .. 8-4
EVAPCONTROLSYSTEM (Californiatypeonly)
FUELSYSTEM 6-30
MAINTENANCE 4-17
EXHAUSTSYSTEM 3-8
FAN MOTORSWiTCH.. .. 21-14
FINALDRIVEASSEMBLY ..
FINALDRIVE DISASSEMBLY/INSPECTION.. .. 14-8
FINALDRIVE INSTALLATION .. .. ..
FINALDRIVE OIL.. .......... .. .. ..4-18
FINALDRIVE REMOVAL .. .... .. .. 14-7
FINALDRIVE SPECIFICATIONS.. ...... .. 1-10
FLYWHEEUSTARTERCLUTCH ...... .. 12-5
FORK ................ .. .. 15-19
FRONTBRAKE CALIPER .. .. .. .. .. .. 17-13
FRONTFENDER.. .. .. .. .. .. .. .. .. .. 3-6
FRONTWHEEL .. .. .. 15-13
SPECIFICATIONS .. .. .. 1-11
FUEL LINE .. .. .. .. .. ..
FUELSYSTEMSPECIFICATIONS .. 1-7
FUEL TANK .. 3-4
GEARSHIFTLINKAGE .. .... 11-14
GENERALSPECIFICATIONS 1-5
HANDLEBAR.. .. .. .. .. .. .. 15-6
HANDLEBARSWITCH .... .... .. 21-17
HEADLIGHT 21-5
HEADLIGHTAIM 4-22
HIGHALTITUDEADJUSTMENT 6-26
HORN 21-21
HYDRAULICBRAKE SPECiFiCATIONS ...... 1-11
ICM .. ...... .... .. .. .. .... 19-9
IGNITIONCOIL .. .. .. 19-8
IGNITIONSWITCH 21-16
IGNITIONSYSTEM INSPECTION 19-5
IGNITIONSYSTEMSPECIFICATIONS.. .. 1-12
IGNITIONTIMING .. .... .. .. .. 19-9
INTAKEMANIFOLD 6-23
LEFTCRANKCASEREAR COVER 3-5
LICENSELIGHT 21-8
LIGHTS/METERS/SWITCHESSPECIFICATIONS 1-12
LUBRICATION &SEALPOINTS...... .. 1-19
LUBRICATION SYSTEM DIAGRAM 5-2
LUBRICATION SYSTEMSPECIFICATIONS 1-7
MAINJOURNALBEARING 13-16
MAINTENANCESCHEDULE .. .. .... 4-4
MASTERCyLINDER .. .. .. .. .... ..17-8
MODELIDENTIFICATION 1-2
NEUTRALSWiTCH ..21-19 .
NUTS,BOLTS,FASTENERS .. .
OILPRESSURE INDICATOR 21-15 --.
OILPRESSURE INSPECTION 5-5
OILPUMP.. .. .. 5-6
OUTPUTGEAR .... .. .. .. ..13-28
OXIDATIONCATALYTICCONVERTER
PROTECTION FROM UNBURNEDGASOLINE
(Californiatypeonly) 2-2
PILOTSCREWADJUSTMENT 6-25
PRIMARYDRIVE GEAR .... 11-12
RADIATORCOOLAI\lT .. 15
RADIATORRESERVE TANK .. .. 7-17
RADIATOR/COOLING FAN .... .. .. 7-11
REAR BRAKE .. .. .. ..16-14
24-1
II\1DEX
REAR FENDER .. .. .. .. .. 3-6
REAR WHEEL 16-6
SPECIFICATIONS 1-11
REGULATOR/RECTIFIER .. .. .. .. .. .. .. 18-8
RIGHTCRANKCASECOVER INSTALLATION 11-21
RIGHTCRANKCASECOVER REMOVAL 11-5
SEAT 3-3
FUELSYSTEM 6-28
MAII\lTENAI\lCE.. .... .. 4-16
SERVICE INFORMATION
ALTERNATOR/STARTERCLUTCH 12-3
BATTERY/CHARGING SYSTEM 18-3
CLUTCH/GEARSHIFTLINKAGE .. 11-3
COOLINGSYSTEM 7-3
CRANKSHAFTITRANSMISSION .. .... 13-3
CYLINDERHEADNALVE.. .. .. 9-3
CYLINDER/PISTON .. .. .. 10-3
ELECTRICSTARTER .. .. 20-3
ENGINEREMOVAUII\lSTALLATION 8-3
FINALDRIVE 14-3
FRAME/BODYPANELS/EXHAUSTSySTEM 3-2
FRONTWHEEUSUSPENSION/STEERING 15-3
FUELSYSTEM 6-3
HYDRAULICBRAKE .. .. .. ..17-3
IGNITIONSySTEM .. 19-3
LIGHTS/METERS/SWITCHES 21-3
LUBRICATION SySTEM.... .. .. .. ........5-3
MAINTENANCE 4-2
REARWHEEUBRAKE/SUSPENSION 16-3
SERVICE RULES .. .. .. .. .. .. .. .. 1-2
SHOCKABSORBER 16-21
SIDE COVER 3-3
SIDESTAND .. .. .. .. ..4-23
SIDESTANDSWiTCH.. .. .. 21-20
SPARKPLUG .... .. .... 4-9
SPEEDOMETERIVS SENSOR : 21-9
STANDARDTORQUEVALUES.... .. 1-13
STARTERMOTOR...... .. .. 20-6
STARTERRELAYSWITCH 20-15
STATORINSTALLATION.. .. .. .. 12-11
STATORREMOVAL .. .. 12-4
STEERING HEAD BEARINGS 4-26
STEERINGSIDE COVER 3-5
STEERINGSTEM 15-28
SUBAIRCLEANER 4-8
SUSPENSiON.. .. .. .. 4-24
SWINGARM .... .. .. .. .. .. 16-22
SYSTEM DIAGRAM
BATTERY/CHARGINGSYSTEM .. .. .. 18-2
ELECTRIC STARTER.. .. .. .. .. 20-2
IGNITIONSYSTEM.. .. 19-2
SYSTEM FLOWPATTERN.... .. .. 7-2
SYSTEM LOCATION
BATTERY/CHARGINGSYSTEM.. .. 18-2
ELECTRICSTARTER.. .. .. 20-2
IGNITIONSYSTEM .. 19-2
LIGHTS/METERS/SWITCHES .. .. 21-2
SYSTEMTESTING 7-5
THERMOSTAT 7-8 .,
THERMOSTATHOUSiNG.. 7-9
THROTTLE OPERATION .. ..4-5
TPSENSOR .. .. .. .. 19-10
TRANSMISSION.... ...... .. 13-20
TROUBLESHOOTING
ALTERNATOR/STARTER CLUTCH.. .. 12-3
BATTERY/CHARGINGSYSTEM.... .. .. .. 18-5
CLUTCH/GEARSHIFTLINKAGE.... .. ..11-4
COOLING SYSTEM 7-4
CRANKSHAFTITRANSMISSION .. .. 13-8
CYLINDER HEADNALVE .. .. ..9-5
CYLINDER/PISTON 10-3
ELECTRICSTARTER .. .. ..20-4
ENGINE DOESNOTSTARTOR ISHARD
TO START .. ...... .. 23-2
ENGINE LACKS POWER.. .. 23-3
FINALDRIVE........ ...... .. .. 14-6
FRAME/BODYPANELSIEXHAUSTSYSTEM 3-2
FRONTWHEEUSUSPENSION/STEERING 15-5
FUELSYSTEM 6-4
HYDRAULICBRAKE.. .. .. .. .. 17-4
IGNITIONSYSTEM ..19-4
LUBRICATIONSYSTEM .. .. 5-4
POOR HANDLING.. .. .. 23-7
POOR PERFORMANCEATHIGH SPEED 23-6
POOR PERFORMANCEATLOWAND
IDLESPEED 23-5
REARWHEEUBRAKEISUSPENSION.. 16-5
TURNSIGNALLIGHT .. .. ....21-6
TURN SIGNALRELAY .. 21-21
VALVECLEARANCE .. .. .. ...... .. 4-10
VALVE GUIDE REPLACEMENT .. .. 9-18
VALVE SEATINSPECTION/REFACING.. 9-19
WATERPUMP.. .. .. 7-16
WHEELSITIRES .. .. .. .. ..4-25
WIRINGDIAGRAM
49states/Canadatype 22-3
Californiatype .. ........ ...... .. .... 22-4
24-2

Honda VT750C2 Manual PDF

Hochgeladen von

Dokumentinformationen

Originalbeschreibung:

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Honda VT750C2 Manual PDF

Hochgeladen von

Copyright:

Verfügbare Formate

HOWTO USETHISMANUAL

This service manual describes the service procedures for the

COMESFIRST ODOMETERREADING (NOTE 1)

... ..r ringuntiltheend ofthestopper ...'

- LOWERINI\IER RACE .JI!

DUSTSEAL OUTER RACE

Das könnte Ihnen auch gefallen