VLX VT600 88-89 91-96 Service Manual

Transcription

.-----
IMPORTANT SAFETY NOTICE
--------.
Indicates a strong possibility of severe personal injury or death if instructions are not followed.
CAUTION:
Indicates a possibility of eqiupment damage if instructions are not followed.
NOTE:
Gives helpful information.
Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. It is
important to note that this manual contains some warnings and cautions against some specific service methods which
could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand
that those warnings could not cover all conceivable
w ays
in which service, whether or not recommended by Honda,
might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda investigate all
such ways. Anyone using service procedures or tools, whether or not recommended by Honda, must satisfy himself
thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected.
HOW TO USE TH IS MANUAL
CONTENTS
Follow the Maintenance Schedule (Section 3)
recommendations to ensure that the vehicle is
in peak operating condition and the emission
levels are within the standards set by the U.S.
Environmental Protection Agency and Califor
nia Air Resources Board. Performing the first
scheduled maintenance is very important. It
compensates for the initial wear that occurs
during the break-in period.
Sections 1 through 3 apply to the whole
motorcycle, while sections 4 through 1 9
describe parts of the motorcycle, grouped ac
cording to location.
Find the section you want on this page, then
turn to the table of contents on the first page
of that section.
GENERAL INFORMATION
LUBRICATION
MAINTENANCE
FUEL SYSTEM
COOLING SYSTEM
ENGINE REMOVAL/INSTALLATION
w
�
orii
CLUTCH/GEARSHIFT LINKAGE
��======
ALTERNATOR/STARTER CLUTCH
.
CYLINDER HEADIVALVE
Most sections start with an assembly or
system illustration, service l nform�tion and
troubleshooting for the section. The subse
quent pages give detailed procedures.
If you don't know the source of the trouble,
go to section 20, TROUBLESHOOTING.
CYLINDER/PISTON
CRANKSHAFT/TRANSMISSION
(I)
0 �======
en
ALL INFORMATION, ILLUSTRATIONS, DI
RECTIONS AND SPECIFICATIONS INCLUDED IN
THIS PUBLICATION ARE BASED ON THE LATEST
PRODUCT INFORMATION AVAIL ABLE AT THE
TIME OF APPROVAL FOR PRINTING. HONDA
FRONT WHEEL/SUSPENSION/STEERING
�
0
REAR WHEEL/BRAKE/SUSPENSION
�======
HYDRAULIC DISC BRAKE
BATTERY/CHARGING SYSTEM
MOTOR CO., L TO. RESERVES THE RIGHT TO
MAKE
CHANGES
AT
ANY
TIME WITHOUT
NOTICE AND WITHOUT INCURRING ANY OBLI
GATION WHATEVER. NO PART OF THIS PUBLI
CATION MAY BE REPRODUCED WITHOUT
WRITTEN PERMISSION.
HONDA MOTOR CO., LTD.
SERVICE PUBLICATIONS OFFICE
ELECTRIC STARTER
LIGHTS/METER/SWITCHES
WIRING DIAGRAM
TROUBLESHOOTING
INDEX
Date of Issue:
June, 19 9 4
© HONDA MOTOR CO . , LTO.
1 . GEN E RAL INFORMATION
G E N ERAL SAFETY
1 -1
TOOLS
1 -8
S ERVI C E R U LES
1 -1
CABLE & HARNESS ROUTING
1-10
M O D E L I D EN T I F I CATI O N
1 -2
EMISSION CONTROL SYSTEMS
1 -21
SPECIFICATI O N S
1 -3
T O RQ U E VAL U ES
1 -5
EMISSION CONTROL I N FORMATION
LABELS
1 - 22
GENERAL SAFETY
If the engine must be running to do some work, make sure the
areals well-ventilated. Never run the engine in an enclosed
area. The exhaust contains posisonous carbon monoxide gas
that may cause loss of consciousness and lead to death.
Gasoline is extremely flammable and is explosive under certain
conditions Work in a well ventilated area with the engine
stopped. Do not smoke or allow flames or sparks in the work
area or where gasoline is stored.
The battery generates hydrogen gas which can be highly explo
sive. Do not smoke or allow flames or sparks near the battery,
especially while charging it.
The battery electrolyte contains sulfuric acid. Protect your
eyes, skin and clothing. In case of contact, flush thoroughly
with water and call a doctor if electrolyte gets in your eyes.
CAUTION :
Inhaled asbestos fibers have been found to cause respiratory
disease and cancer. Never use an air hose or dry brush to clean
brake assemblies. Use an OSHA-approved vacuum cleaner or
alternate method approved by OSHA designed to minimize
the hazard caused by airborne asbestos fibers.
Used engine oil may cause skin cancer if repeatedly left in con
tact with the skin for prolonged periods. A lthough this is
unlikely unless you handle used oil on a daily basis, it is still
adviseable to thoroughly wash your hands with soap and
water as soon as possible after handling used oil.
SERVICE RULES
1.
2.
3.
4.
5.
6.
7.
8.
Use genuine H O N DA or HON DA-recommended parts and lubricants or their equivalents . Parts that don ' t meet H O N DA ' s
design specifications may damage to the vehicle .
Use the special tools designed for this product to avoid damage and incorrect assembly.
Use only metric tools when servicing the vehicle . Metric bolts, nuts, and screws are not i nterchangeable with English fas
teners.
I nstal l new gaskets, 0-rings, cott e r pins, and lock plates when reassembling .
When tightening bolts or nuts, beg i n with the larger-diameter or inner bolts first. Then tighten to the specified torque diagonally in 1-5 steps, u nless a particular sequence is specified .
Clean parts in non-flammable or h i gh flash point solvent upon disassembly.
Lubricate a ny sliding surfaces before reassembly.
After reassembly, check all parts for proper installation and operation .
1 -1
GENERAL I N F O RMATION
MODEL I DENTI FICATION
(1 )
VEHI CLE I DENTIFICATIO N N U M BE R
The vehicle identification number (VIN) is attached on the
left side of the steering head .
The frame serial number i s stamped o n the right side o f the
steering head.
The engine serial number is stamped on the right crank
case below the rear cylinder.
(5)
The carburetor identification numbers are on the carbure
tor body i ntake side.
1 -2
COLOR LAB E L
The color label is attached on the frame under t h e seat.
When ordering a color coded part, always specify its desig
nated color code.
G E N ERAL I N FO R MATIO N
SPECIFICATIONS
ITEM
DIME N S I O N S
FRAM E
ENGINE
Overall length
Overall width '88 , '89 , ' 9 1 -'94:
After' 94 :
Overall height
Wheelbase
Seat height
Footpeg height
G ro u n d clearance
Dry weight '88 , ' 89 , ' 9 1 -93 :
'94 :
After'94 (Standard type) :
After' 94 ( Delux type) :
Curb weight ' 8 8 , '89 , ' 9 1 -93 :
'94 :
After' 94 ( Standard type) :
After' 94 ( Deluxe type) :
After'94 ( Standard/California type) :
After'94 ( Deluxe/California type) :
Type
Front suspension , travel
Rear suspension , travel
Front tire size
Rear tire size
Front
Cold tire
U p to maximum
pressu re
vehicle capacity
Rear
Front
U p to 90 kg
(200 l bs) load
Rear
Front b ra ke
Swept a rea '88 , '89 , ' 9 1 -'93 :
After'93:
Rear brake
Swept a rea
Fuel capacity ' 8 8 , '89 , ' 9 1 -'93 :
After' 9 3 :
Fuel reserve capacity ' 88 , ' 89 , '9 1 -' 9 3 :
After' 93
Caster angle
Trail
Fork leg o i l capacity '88 , ' 89 :
' 9 1 -'93 :
After' 93 :
Type
Cylinder a rrangement
Bore a n d stroke
Displacement
Compressio n ratio
Valve train
Oil capacity
Lu b ricatio n system
Air filtratio n
Cylinder compression
S PECI F I CATIO N S
2 , 3 1 0m m (90 . 9 in)
7 60mm (29 . 9 in)
890mm ( 3 5.0 i n )
1 , 1 25 m m (44.3 i n )
1 , 60 5 m m (63 . 2 i n )
6 9 0 m m ( 2 7 . 2 in)
28 5 m m ( 1 1 .2 in)
1 40mm ( 5.5 in)
1 9 6 kg (432 1b)
1 99 kg (439 lb)
1 99 kg (43 9 1b)
202kg (445 lb)
207 kg (456 lb)
2 1 3 kg (470 lb)
2 1 3 kg (470 lb)
2 1 6 kg (47 6 lb)
2 1 4kg (472 lb)
2 1 7 kg (478 1b)
Double cradle
Telescopic fork, 1 46 . 5mm ( 5 . 7 7 in)
Swingarm, 90mm (3. 5 in)
1 00/90- 1 9 5 7 S
1 7 0/80- 1 5 M/C 7 7 S
200 kPa (2.00 kg/cm 2 , 29 psi)
250 kPa (2.50 kg/cm2,36 psi)
200 kPa (2 . 00 kg/cm2 , 29 psi)
200 kPa (2.00 kg/cm2,29 psi)
Hydraulic single d isc
448cm 2 ( 6 9 . 4 sq in)
482 . 3cm 2 (74 . 8 sq in)
M echanical leading & trailing
20 1 cm 2 (3 1 .2 sq in)
9 . 0 liters (2 . 4 US gal , 2.0 Imp gal)
1 1 .0 liters (2.9 U S gal ,2.4 Imp gal)
1 .9 liters (0.5 U S gai, 0.42 Imp gal)
3.4 liters (0.9 U S gai , O. 74 I m p gal)
3 5'
1 64mm ( 6.5 in)
463cc ( 1 5.7 U S oz, 1 3 . 0 Imp oz)
468cc ( 1 5 . 8 US oz, 1 3 . 2 1 m p oz)
449cc ( 1 6 . 9 US oz, 1 5 . 8 Imp oz)
Water cooled 4-stroke SO H C
52' V2 cylinders
7 5 . 0x6 6.0mm (2 . 9 5x2.60 in)
583cc ( 3 5 . 5 cu-in)
9 .2: 1
Silent, m u lti-link chain d rive and O H C with rocker arms
2 . 8 lit (2 . 94 U S qt,2.46 I m p qt) after d isassem bly
2 . 1 lit (2.2 1 US qt, 1 .85 Imp qt) after d raining
Forced pressu re and wet su m p
Paper filter
1 , 324 kPa ( 1 3. 5 kg/cm2 , 1 92 psi)
1 -3
G E N ERAL I N FO RMATIO N
ITEM
S PECI F I CATI O N S
1 0" ( BTDC) at 1 mm lift
I ntake valve O pens
Closes
3 0" (AB DC)
Exhaust valve O pens
3 0" ( B B DC)
ENGINE
1 0· (ATDC)
Closes
Valve clearance (cold) intake
0. 1 5±0.02m m (0.006±0 . 0008 in)
exhaust
0.20±0.02mm (0.008±0 . 0008 in)
Engine d ry weight '88 , '89 , ' 9 1 -'93 :
6 1 kg ( 1 34 1b)
After'9 3 :
62kg ( 1 3 6 . 7 lb)
After' 94 (standard type) :
6 1 kg ( 1 34 1b)
After' 94 ( Deluxe type) :
64kg ( 1 4 1 lb)
Piston valve,dual carbu retor
CAR B U R ETO R Type
See page 4- 1
I . D. n u m ber
F R O NT:# 1 1 5 R EAR:# 1 1 5
Main jet
See page 4- 1 5
Pilot screw opening
7 .0 m m ( 0.28 in)
Float level
1 ,200± 1 00 rpm
Idle speed
Wet,mu lti-plate
D R IVE TRAI N Clutch
4-speed constant mesh
Transmission
1 .8 8 8 ( 6 8/3 6 )
Primary redu ction
2.7 50 (44/ 1 6 )
Final reductio n
2. 5 7 1 ( 3 6/ 1 4)
Gear ratio I
1 . 700(34/20)
Gear ratio II
1 .227 (27 /22)
Gear ratio Ill
0.9 3 1 (27 /29 )
G ea r ratio IV
Left foot o perated return system, 1 -N -2-3-4
Gear shift pattern
Ignitio n
Battery ignition ( Full transistor)
E LECT R I CAL
Ignition timing I n itial
'88, ' 8 9 , ' 9 1 -' 9 3 : 6.2· BTDC at idle
After ' 9 3 :
6 . 5" BTDC at idle
Full advance
30" BTDC at 6,000 rpm
Alternator
345W/5,000 rpm
B attery capacity
1 2V BAH
S pa rk plug ��-----------------�--�----------------,-------------------�
N I P PO N D ENSO
NGK
----
Standard
D PR B EA-9
X24 E P R - U 9
For cold climate
( B elow 5" C,4 1 " F)
D P R 7 EA-9
X22EPR-U9
For extended high speed
riding
D P R 9 EA-9
X27 E P R-U 9
Spark plug gap
Fuse
Starting system
H eadlight
Turn signal light
B ra ke & taillight
M eter light
Indicator light
Licence light
Firing o rder
1 -4
Main
Sub
Front
Rear
Neutral
High beam
Tu rn signal
0.8-0.9 m m ( 0.03 1 -0.03 5 i n )
30 A
1 0 AX3, 1 5 AX 1
Electrical starter
1 2 v 60/ 5 5 w
1 2 V 32/3 C P (23/8 W )X2 S A E No. 1 034
1 2 V 32 C P(23 W)X2 SAE N o. 1 0 7 3
1 2 V 32/3 C P (23/8 W)X2 S A E No. 1 034
1 2 v 3.4 w
1 2 V 1 .7 W
1 2 V 1 .7 W
1 2 V 1 .7 W
1 2 V 4 CP
Front(2)- R ear( 1 )308"
G E N ERAL I N FO RMAT IO N
TORQU E VALU ES
ENG I N E
ITEM
Cylinder head cover bolt
Camshaft holder bolt
nut
bolt
Cylinder head n ut
bolt
nut
bolt
Camshaft sprocket bolt
Primary d rive gear bolt
Flywheel bolt
Connecting rod bearing cap n ut
Clutch lock n ut
Oil pressure switch
Spark plug
Oil d rain bolt
Starter clutch torx bolt
Oli pump d riven sprocket
Oil pass pipe bolt
Valve adjustin g screw lock n ut
Gearshift retu rn spring pin
Starter motor cable nut
Clutch lifter plate bolt
Cam chain tensioner bolt
Oil filter
Drive sprocket bolt
Timing hole cap
Crankshaft h ole cap
Cylinder stu d bolt ' 88 , ' 8 9 , ' 9 1 -' 9 5 :
Drum stopper plate bolt
Stator bolt
Stator wire clamp bolt
Right cra n kcase cover bolt
Left crankcase cover bolt
Q'ty
Thread dia .
(mm)
Torque
m ( kg-m , ft-lb)
4
6
2
4
8
2
4
2
4
1
1
4
1
1
4
1
6
1
6
8
8
6
10
8
8
6
7
12
12
8
18
12
14
8
6
1 0 ( 1 . 0 , 7 . 2)
23 (2 . 3 , 1 7 )
23 (2 . 3 , 1 7 )
1 0 ( 1 . 0 , 7 . 2)
48 (4 . 8 , 3 5 )
23 (2 . 3 , 1 7 )
23 (2 . 3 , 1 7 )
1 0 ( 1 . 0 , 7 . 2)
23 (2 . 3 , 1 7 )
90 ( 9 . 0 , 6 5 )
1 30 ( 1 3 . 0 , 94)
34 (3 . 4 , 25 )
1 30 ( 1 3 . 0 , 94)
1 2 ( 1 . 2 , 9)
1 4 ( 1 . 5 , 1 0)
3 5 (3 . 5 , 25)
30 (3 . 0 , 22)
1 5(1 .5, 1 1 )
2
1
6
1
1
4
4
1
2
1
1
8
7
8
7
8
6
6
6
20
6
22
30
10
2
8
1
4
2
13
10
6
6
6
6
1 0 ( 1 . 0 , 7 . 2)
23 (2 . 3 , 1 7 )
23 (2 . 3 , 1 7 )
26 (2 . 6 , 1 9)
1 0 ( 1 . 0 , 7 . 2)
1 0 ( 1 . 0 , 7 . 2)
1 0 ( 1 . 0 , 7 . 2)
1 0 ( 1 . 0 , 7 . 2)
1 0 ( 1 .0, 7 .2)
3 . 5 (0 . 3 5 , 2 . 5 )
1 5(1 .5, 1 1 )
30-50 (3 . 0-5 . 0 .
22-3 6 )
20-30 (2 . 0-3 . 0 ,
1 4-22)
1 2 ( 1 . 2 , 9)
1 2 ( 1 . 2 , 9)
1 2 ( 1 . 2 , 9)
1 2 ( 1 . 2 , 9)
1 2 ( 1 . 2 , 9)
Remark
Special bolt
Apply locking agent
U BS bolt
U BS bolt left hand threads
Apply oil to t h e threads
Apply sealant
Apply locking agent
Flange socket bolt . Apply locking agent .
Apply oil
Flange bolt
Flange bolt
Apply g rease t o the threads
Apply g rease to the threads
Apply locking agent .
1 -5
G E N E RA L I N FO RMATIO N
FRAM E
Steering stem nut
Steeri ng bearing adjustment n ut
Fork top pinch bolt
Fork bottom pinch bolt
Front axle
Front axle pinch bolt
Rear axle nut
B ra ke torque rod nut
'88, ' 8 9, ' 9 1 - ' 93, After '94:
'94.:
Middle brake a rm
M id d le rod joint n ut
Caliper mounting bol�
B ra ke hose oil bolt
After ' 9 4 :
'88,'89,' 9 1 -'93:
After '93:
'88,'89,'9 1 -'93:
After '93:
B leed valve
B ra ke master cylinder holder bolt
B ra ke master cylinder cover screw
B rake lever pivot bolt
nut
B ra ke d isc mounting bolt
Caliper pin bolt
Caliper bracket pin bolt
Pad pin
Pad pin plug
Shock a bsorber u pper mounting bolt
Shock a bsorber lower mounting bolt
Gearshift arm bolt
Foot p e g bracket bolt
Swingarm pivot bolt
Front u pper engine mounting bolt
Front u pper engine bracket bolt
Front lower engine mounting bolt
Rear u pper engine mounting bolt
Rear u pper engine bracket bolt
Exhaust pipe joint n ut
Fuel tan k mounting bolt
Ignition switch mounting bolt
Exhaust pipe cover bolt
Exhaust m uffler bracket bolt/nut
' 88 , ' 8 9 , ' 9 1 -' 93 :
After '93
Helmet holder mounting bolt
Side stan d pivot bolt
nut
Driven sprocket nut
Fork tube cap
Front socket bolt
'88,'89,'9 1 ,'92:
Damper rod lock nut
Spokes
Handlebar mounting nut
Ha ndlebar upper holder bolt
After ' 9 4 :
H a ndlebar lower holder n ut
After ' 9 4 :
Fuel valve body
Throttle l i n k cover stay screw
Rear ignitio n coil stay bolt
Battery cover mounting bolt
F u e l p u m p stay mou nting nut
1 -6
Thread dia.
(mm)
Torque
N · m ( Kg-m,ft-lb)
2
2
1
2
2
2
2
2
1
2
2
1
1
5
1
1
1
1
1
1
1
4
1
1
2
1
1
2
4
1
2
3
24
26
7
10
18
7
16
8
8
8
8
6
8
8
10
10
8
6
4
6
6
8
8
8
10
10
10
10
6
10
14
10
8
10
10
8
8
8
6
6
1 05 ( 1 0.5,7 6 )
25 (2.5, 1 8 )
1 1 ( 1 . 1 ,8 )
5 0 ( 5 .0,3 6 )
7 5 ( 7 . 5,54)
22(2.2, 1 6)
90(9.0, 6 5 )
27 (2.7,20)
22(2.2, 1 6)
27 (2.7,20)
27 (2.7,20)
9 (0.9, 6 . 5 )
27 (2.7,20)
3 1 (3. 1 ,22)
30(3.0,22)
3 5 (3 . 5,25 )
5 . 5 (0. 5 5,4)
1 2( 1 .2,9)
1 . 5 ( 0. 1 5, 1 . 1 )
1 (0. 1 ,0. 7 )
6 ( 0. 6,43 )
40(4.0,29)
22(2.2, 1 6)
1 2( 1 .2, 9 )
1 8 ( 1 .8, 1 3 )
2.5 (0.25, 1 .8 )
4 5 (4.5,33 )
45 (4.5,33 )
1 2( 1 .2, 9 )
40(4.0,29 )
90(9.0, 6 5 )
5 5 ( 5. 5.40)
27 (2.7,20)
5 5 ( 5. 5,40)
5 5 ( 5. 5.40)
27 (2.7,20)
25 (2.5, 1 8 )
1 9 ( 1 .9, 1 3 . 7 )
1 1 ( 1 . 1 ,8}
1 2( 1 .2,9)
1/1
1 /4
2
1
1
5
2
2
1
1 08
2
8
8
6
10
10
10
34
10
14
4
8
27 (2.7,20)
20(2.0, 1 4)
1 3 ( 1 .3,9)
1 0( 1 .0,7.2)
30(3.0,22)
6 5 ( 6.5,47 )
22(2.2, 1 6)
30(3.0,22)
7 0 ( 7 .0,5 1 )
4(0.4,2.9 )
25 (2.5, 1 8)
2
8
3 0 ( 3 . 0, 22)
2
1
2
2
2
1
8
22
4
6
6
6
O'ty
ITEM
1
1
2
2
1
2
1
23 (2. 3 , 1 6)
23 (2.3, 1 6 )
2. 1 (0.2 1 ' 1 . 5 )
9 (0.9,6. 5 )
9 (0.9, 6 . 5 )
9 (0.9,6 . 5 )
Remark
See page 1 2-23
Apply o i l t o the threads
Apply locking agent
Apply locking agent
Apply locking agent
Socket bolt
Flange nut
Flange bolt
Shear bolt
Shear bolt
Socket bolt
Apply locking agent
GEN ERAL I N FORMATION
Torque specifications listed above are for specific tightening points. If a specification is not listed, follow the standard torque
values below .
STANDARD TORQUE VALUES
TYPE
5
6
8
10
12
mm
mm
mm
mm
mm
bolt,
bolt,
bolt,
bolt,
bolt,
TORQU E N•m ( kg-m, ft-lbl
nut
nut
nut
nut
nut
5
10
22
35
55
(0.50, 3.6)
( 1 .0, 7 . 2 )
( 2 . 2 , 1 6)
(3.5, 25)
(5 .5, 40)
TYPE
TORQU E N·m (kg-m, ft-lbl
5 mm screw
6 mm screw, 6 mm
bolt with 8 mm head
6 mm flange bolt, nut
8 mm flange bolt, nut
1 0 mm flange bolt, nut
4 (0.40, 2 . 9 )
9
12
27
40
(0.9,
( 1 .2,
(2.7,
(4.0,
6.5)
9)
20)
29)
1 -7
G E N ERAL I N FO RM ATIO N
TOOLS
SPECIAL
Description
Oil pressure gauge
Oil pressure gauge attachment
Oil filter wrench
Vacuum gauge
Valve adjusting wrench
Vacuum/Pressure pump
Snap ring pliers
Steering stem socket
Clutch center holder
Bottom holder pipe
- holder attachment
- holder handle
Bearing remover set
- remover handle
- bearing remover set
- remover weight
Valve guide driver attachment
(IN)
Valve guide driver attachment
( EX)
Bearing race remover
Steering stem driver
D river shaft
Fork seal driver , 3 9 m m
Ball race remover
- driver attachment
- driver handle
Main bearing d river attachment
Valve guide reamer, 5 . 5 1 0 mm
(IN)
Valve guide reamer, 6 . 6 1 2 mm
(EX)
Attachment, 28 x 30 mm
* Drive chain cutter
* Shock absorber compressor attachment
* : New for this mode l .
1 -8
Tool number
07 506 - 3000000
07 5 1 0 - 4220 1 00
07HAA - PJ 7 0 1 00
Alternate tool
tJ Equ ivalent
commercially
'
available
in U . S.A.
07404 - 0030000
Vacuum gauge
N ot availa ble
07908 - KE90000
in U . S . A .
Vacuum pump
A937X - 04 1 - XXXXX
L Pressure pump
Equivalent
079 1 4 - 323000 1
commercially
available
in U.S.A.
07 9 1 6 - 3 7 1 0 1 00
07923 - K E 1 0000
1- N ot available
07930 - KA 50000
I- i n U . S . A .
07930 - KA50 1 00
07930- KA40200
II07936 - 3 7 1 000 1
07936 - 37 1 0 1 00
07936 - 37 1 0600
0774 1 - 00 1 020 1
Remover
weight
Tool number
Refer to
section
2
2
2
07 LMJ -00 1 OOOA
07908 - KE90 1 00
3
ST - AH - 260 - MC 7
ST - AH - 2 55 - MC 7
4
4
2, 1 3,
14
07 H G B -00 1 OOOA
12
7
12
11
07936 - 3 7 1 0200
07943 - M F50 1 00
9
07943 - M F50200
07946 - 3 7 1 0500
07946 - M BOOOOO
07946 - MJ00 1 00
07947 - 4630 1 00
07953 - MJ 1 0000
07953 - MJ 1 0 1 00
07953 - MJ 1 0200
9
12
12
13
12
12
re Attachment
D river
D river handle
Attachment,
32X35mm
07H M F - M M 90400
07984 - 200000 1
07984 -ZE2000 1
07746 - 1 870 1 00
07 H M H - MR 1 01 03
07JM E - M R 1 0 1 00
0 7 9 5 3 - MJ 1 OOOA ,
0 7 9 5 3 - MJ 1 OOOB or
07 949- 3 7 1 000 1 and
07746- 00 1 0 1 00
07 9 8 4
0 79 84
N ot available
in U . S .A.
-
2 00000 D
ZE2 000 D
0 7 H M H- M R1010B
11
9
9
13
COMMON
Description
Tool number
Float level gauge
Lock nut wrench , 1 7 x 2 7 m m
Gear holder
Flywheel holder
Torx bit
Rotor puller
Valve guide remover, 5 . 5 m m
Valve gu ide remover, 6 . 6 m m
0740 1 - 00 1 0000
07 7 1 6 - 0020300
07724 - 00 1 0 1 00
07725 - 0040000
07 703 - 00 1 0 1 00
07733 - 002000 1
07742 - 00 1 0 1 00
07 742 - 00 1 0200
Attachment, 32 x 35 m m
Attachment, 42 x 4 7 mm
07 746 - 00 1 0 1 00
07 746 - 00 1 0300
Pilot, 1 5 mm
Pilot, 1 7 mm
Pilot, 20 mm
Pilot, 22 mm
Pilot, 2 5 mm
Bearing remover head, 1 7 m m
Bearing remover shaft
Bearing remover head, 20 m m
07 746 - 00 1 0400
07 746 - 0040300
077 46 - 0040400
07 746 - 0040 500
07 746 - 004 1 000
07 746 - 0040600
07 746 - 0050 500
07746 - 0050 1 00
07 746 - 0050600
Driver
07 749 - 00 1 0000
Valve spring compressor
07757 - 00 1 0000
Shock absorber compressor
- compressor screw
Spoke wrench
07G M E - 00 1 0000
07G M E - 00 1 0 1 00
07JMA - M R601 00
Alternate tool
Equivalent
commercially
available
in U . S . A .
1--
�
N ot available
in U . S . A.
0 7 933-32 9000 1
07942-657 0 1 00
Refer to
section
4
7
7
8
8
8
9
9
13
11'
13
11'
13
13
11'
11'
11
13
13
12
:quivalent
commercially
available
in U .S.A.
Valve spring
compressor
I--
Tool number
07957 - 32 9000 1
1 2,
12
12
13
1 1 ' 1 2,
13
9
13
N ot available
in U . S . A .
VALVE SEAT CUTTERS (NOT AVAILABLE IN U. S. A. )
Description
Valve seat cutter, 2 7 . 5 m m
Valve seat cutter, 35 mm
Valve seat cutter, 37.5 m m
Cutter holder, 5.5 mm
Cutter holder, 6 . 6 m m
Tool number
07780 - 00 1 0200
07780 - 00 1 0400
07780 - 00 1 2 1 00
07780 - 00 1 2300
07780 - 00 1 4000
07780.,-00 1 4 1 00
0778 1 - 00 1 0 1 0 1
0778 1 - 00 1 020 1
Remarks
45 ° IN
45 ° EX
32 ° I N
32 ° EX
60 ° IN
60 ° EX
Valve guide I N
Valve guide EX
1 -9
G E N ERAL I N FORMATI O N
CABLE & HARN ESS ROUTI N G
Note the following when routing cables and wire harnesses:
•
•
•
•
•
•
•
•
•
•
•
•
•
A loose wire, harness or cable can be a safety hazard . After
clamping, check each wire to be sure it is secure .
Do not squeeze wires against welds or clamps.
0
X
�
Secure wires and wire harnesses to the frame with their re
spective wire bands at the designated locations. Tighten
the bands so that only the insulated surfaces contact the
wires or wire harnesses.
Route harnesses so they are neither pulled taut nor have ex
cessive slack.
Protect wires and harnesses with electrical tape or a tube if
they contact a sharp edge or corner. Clean the attaching
surface thoroughly before applying tape.
Do not use a wire or harness with broken insulation. Repair
by wrapping them with protective tape or replace them.
Route wire harnesses to avoid sharp edges or corners. Also
avoid the projected ends of bolts and screws.
Keep wire harnesses away from the exhaust pipes and
other hot parts .
Be sure grommets are seated in their grooves properly.
After clamping, check each harness to be certain that it
does not interfere with any moving or sliding parts .
After routing, check that the wire harnesses are not twisted
or kinked.
X
Wire harnesses routed along the handlebars should not be
pulled taut, have excessive slack, be pinched by or interfere
with adjacent or surrounding parts in all steering positions.
Do not bend or twist the control cables.
Damaged control cables will not operate smoothly and may
stick or bind .
0:
x:
1 -1 0
C O RRECT
INCORRECT
GENERAL INFORMATION
'88- '89 ; '91 :
(2) CLUTCH CABLE
( 3) LEFT HANDLEBAR
SWITCH W I RE
(8) RIGHT HANDLEBAR
SWITCH W I RE
( 7 ) HORN
W I RE
'92-'93 :
(2) CL UTCH CABLE
(3) LEFT HAN DLEBAR
SWITCH WI RE
(4) SPEEDOMETE R
CABLE
(9) F RONT B RAKE HOSE
(8) RIGHT HAN DLEBA R
SWITCH W I R E
1-11
GENERAL INFORMATION
'
94:
(1 ) THROTTLE CABLES
(3) LEFT HANDLEBAR
SWITCH WIRE
(4) SPEEDOMETER
CABLE
(9)
FRONT BRAKE HOSE
(5) HEADLIGHT
CONNECTOR
(8) RIGHT HANDLEBAR
SWITCH WIRE
After '94:
( 1 ) TH ROTTLE CAB LES
(3) LEFT HAN D LE B A R
SWITC H WI R E
( 3 ) LEFT HAN D LE B A R
SWITC H WI R E
).::;�1t::::
:i ::::=- ( 1 ) TH ROTTL E
,
CAB LES
\-1-'7"'7�7T---t-- (4) SPE ED O M ETER
CAB LE
(9) R I G HT HAN D LE B A R
SWITCH WI R E
(9) R I G HT HAN D LE B A R
SWITC H WI R E
( 8 ) H O R N WI R E
11@f�o ,:....\-mTt-t--+---,_
�
(6) H EA D Li G HT
-(7) H O R N
1-12
�
(2) CLUTCH CAB LE
C O N N ECTO R
GENERAL INFORMATION
'88-'89 '9 1 :
'
(2 ) HANDLEBAR SWITCH
W I RE BANDS
(13) C RANKCASE BREATHER
TUBE
(12) WATER HOSE
(11 ) ENGINE BREATHER
T UBE
(9)
(6)
(7)
I G N ITI O N P U LS E
GENERATOR
W I RE
CLUTCH CABLE
(1 ) HANDLEBA R SWITCH
WI RE BANDS
'92-'93:
(2) C RANKCASE
B REATHER
SE PA RATO R
(11 ) ENGINE B REATHER
TUBE
(10 ) STARTER
M OTO R
(8) G RO U ND
CABLE
(7)
CLUTCH CABLE
(6)
GENE RATO R W I R E
( 5 ) A I R CLEANE R
HOUSING
1 - 13
G E N E R A L I N F O R MAT I O N
'
94 :
( 13) CRANKCASE BREATHER
( 1 ) ·HANDLEBAR SWITCH
WIRE BANDS
TUBE
( 1 1 ) ENGINE B REATHE R
TUBE
(2) CRANKCASE
BREATHER
SEPARATO R
�-��--l-1£<:�::.;..1--l-�#�-;.+---(3)
EVA PORATIVE
EM ISSION
PURGE CONTROL
VALVE (California
model only)
(9) STARTER
M OTOR
CABLE
(4) SUB-AIR
CLEANER
(7)
CLUTCH CABLE
After '94
(1) HANDLE BAR SWITCH
WIRE BANDS
(2) CRANKCASE
BREATHER
SE PA R ATO R
( 1) HANDLE BAR
SWITCH WIRE
BANDS
( 1 0) STA RTE R
MOTO R
( 9 ) STA RTE R
MOTO R
CA BLE
(4) SUB-A I R
( 8 ) G ROUND
CA BLE
�
r------------------------------------
: �
0
'
'
::
'
(6) IGNIT ION PULSE
GENERATOR WIRE
1 -1 4
]
-------� After' 9 5 : G
________
�
( 5 ) A IR CLEANER
HOUSING
CLEANE R
GENERAL INFORMATION
( 1 ) THROTTLE
CABLES
(2) FRONT IGNITION COIL
(3) FUEL TANK BREATHER TUBE
(California model only)
(6) NE UTRAL SWITCH
W I RE
( 7 ) RIGHT CHOKE CABLE
( 1 0)
PEEDOMETER (9)
CLEANE R HOUSING (
CABLE HOLDER
BREATHE R TUBE
THERMOSTATI C SWITCH
'88-'89, '91-'93:
( 1 1 ) I G N ITI O N PULSE GENERATOR
4P WHITE CONNECTOR
( 1 2) HORN/FAN MOTOR
2P BLA CK CONNECTOR
�:J��ID��
�
-(0
.- -----
(13)
T U RN SIGNAL
9P WHITE CONNECTOR
( 1 4) INDICATOR PANEL
6 P GREEN CONNECTOR
( 1 5) SPEEDOMETER
6P BLACK CONNECTOR
(16) RIGHT HANDLEBA R SWITCH
9P RED CONNECTOR
1-1 5
GEN ERAL I N F O RMATION
'94 :
( 2)
FRONT B RA K E H O S E
(3) I G N ITI O N P U LS E G E N E RATO R
4 P WH ITE CO N N ECTO R
(4) H O R N/FAN M OTO R
2 P B LA C K C O N N ECTO R
� TU9 P RWHN SITEI G NACOLN N ECTO R
(6) I N D I CATO R PAN EL
6 P G R EE N CO N N ECTO R
( 7 ) S P E E D O M ETER
6 P B LACK C O N N ECTO R
(8) R I G HT HAN D LEBAR SWITC H
9 P R E D C O N N ECTO R
After '94 :
( 9 ) C RAN K CASE B R EATH E R D RAI N TU B E
(10)
MAI N WI R E HAR N ESS
( 11 )
( 1 2 ) EVAPO RATIVE EM ISSION P U R G E
C O N T R O L VALVE (California model o n ly)
1-16
FAN MOTO R WI R E
GENERAL INFORMATION
(1)
T U RN SIGNAL RELAY
(2) FUEL
FILTER
(6) BATTERY
SUB-FUSE BOX
( 8 ) REAR BRAKE LIGHT
SWITCH
(1) T U RN SIGNAL RELAY
(7)
(9) COOLANT RESERVE
TANK OVERFLOW TUBE
(23) S I DE STAND
2P G REEN CONNECJOR
(24) IGNITION SWITCH
""'�
2P BLACK COINNI�Cl"OR
-.... '-
1 1 ) FUEL
PU M P
�-----;��of-41-�_�17) •REGULATOR/
RECTIFIER
(21 I
( 1 9 ) IGNITION SWITCH
OIL PRESSURE
SWITCH
S I DE STAND SWITCH
1 -17
GENERAL INFORMATION
( 9 1 GROUND
( 1 ) STATOR COIL
( 2 ) CLAMPS
PO INT
(3) GROM METS
(7) THERMOSTATI C
SWITCH W I RE
( 6 1 RIGHT
( 5 ) IGNITION P ULSE
CRANKCASE
GENERATOR
( 1 1 I BRAKE/TA ILLIGHT
CASE
( 1 21 TU RN SIGNAL
LIGHT
W I RE
( 1 3) LI CENCE LIGHT
WIRE
1 -1 8
G E N E RA L I N F O R MATI O N
After '93 :
( 1 ) ALTE RNATO R WI RE
(4) SIDE STAND SWITCH
(3) OIL PRESSU RE SWITCH
1-19
GENERAL INFORMATION
EVAPORATIVE EMISSION CONTROL SYSTEM (California model only)
NOTE
•
The hoses shown below are n u mbered as they appear on the Vacu u m Hose Routing Diagram Labe l .
( 1 ) @TUBE
( 7 ) EVAPORAT IVE EMISSION
,...::....��r=="1
PU RGE CONTROL VALVE
JL\..-bi-\----
(5) @T UBE
( 7 ) EVAPORATIVE EMISSION
PU RGE CONTROL
VALVE
( 1 5 ) ENGINE
(3)
@T UBE
BREATHER
TUBE
(FROM REAR
CYLINDER
HEAD )
(6) EVA PO RAT IVE EMISS ION CARBURETOR
AIR VENT CONTROL VALVE
(5)
@TUBE
( 1 4) COOLANT RESERVE TANK
DRAIN TUBE
( 1 0) TO EVAPORATIVE
EM ISS ION CANISTER
(9) AIR CHA MBER
DU CT
( 1 21 EVAPORATIVE
EMISSION
CANISTER
OPEN
AIR TUBE
1 - 20
( 1 1 l EVAPORAT IVE EM ISS ION CANISTER
( 1 31 REA R SHOCK ABSORBER TUBE
EMISSION CONTROL SYSTEMS
The U . S . Environmental Protection Agency and California Air Resources Board (CARB) requ ire manufacturers to certify that
their motorcycles comply with applicable exhaust emissions standards during their useful life, when operated and maintained
according to the instructions provided, and that motorcycles built after January 1 , 1 983 comply with applicable noise emis
sion standards for one year or 6,000 km (3, 7 30 miles) after the time of sale to the ultimate purchaser, when operated and
maintained according to the instructions provided . Compliance with the terms of the Distributor ' s Limited Warranty for Honda
Motorcycle Emission Control System is necessary i n order to keep the emissions system warranty in effect.
SOURCE OF E M I SS I O N S
·
The combustion process p roduces carbon monoxide and hydrocarbons. Control o f hydrocarbons i s very important because,
under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not
react in the same way, but it is toxic.
Honda Motor Co . , Ltd . utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydro
carbons.
EXHAUST E M I S S I O N C O N T R O L SYST E M
The exhaust emission control system is composed o f a l e a n carburetor setting, and no adjustments should be m a d e except
idle speed adjustment with the throttle stop screw. The exhaust emission control-system is separate from the crankcase
emission control syste m .
CRA N K C A S E E M I S S I O N C O N T R O L S Y S T E M
The engine is equipped with a closed crankcase system which routes crankcase emissions through the air cleaner into the
combustion chamber.
( 1 l CRAN KCASE BREATHER
SEPARATOR
c::::>
-+
(2) AIR CLEANER HOUSING
FRESH A I R
BLOW-BY GAS
1 -21
G E N ERA L I N FORMATION
EVAPORATIVE EMISSION CONTROL SYSTEM (California model only)
This model complies with California Air R eso u rces Board evaporative emissio n requirements.
Fuel vapor from the fuel tan k and carbureto r is d irected into the evaporative emission canister where it is adsorbed a n d sto red
while the engine is stopped.When the engine is running and the evaporative emissio n purge control diaphragm valve is o pen,
fuel vapor i n the evaporative emissio n canister is d rawn i nto the engine through the carbu retor.
TO
OPEN
AIR
I (3) DRAIN
(4) EVAPO RATIVE EMISSIO N
CAN I STER
��-- ( 5 ) EVAPO RATIVE E M I S S I O N
CAR B U R ETO R
AI R VENT CONTRO L VALVE
•
IT
'
( 7 ) TO OPEN
AIR
( 6 ) EVAPO RATIVE E M I S S I O N
CAR B U R ETO R
AI R VENT CO NTROL
VALVE
( E N G I N E STO P)
NOISE EMISSION CONTROL SYSTEM
TAM PE R I N G WITH THE NOISE CONTROL SYSTEM IS PRO H I BITED : Federal law prohibits the fol lowing acts or the causing
thereof: ( 1 ) The removal or rendering inoperative by any person , other than for purposes of maintenance, repair, or replace
ment, of any device or element of design i ncorporated into any new vehicle for the purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is in use; or (2) the use of the vehicle after such device or element of design has
been removed or rendered inoperative by any person .
AMONG THOSE ACTS PRESU MED T O CONSTITUTE TAMPERING A R E T H E ACTS LISTED BELOW:
1 . Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust gases .
2 . Removal of, or puncturing of any part of the intake system .
3. Lack of proper maintenance .
4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified
by the manufacturer.
EM ISSION CONTROL I N FO RMATION LABELS
An Emission Control I nformation Label is located on the inside of the left side cover as show n . It contains basic tune-up speci
fications.
( 1 ) VEHICLE EMISSION CONTROL
I N FORMATION LABEL
1-22
G E N ERAL I N F O RMATI O N
VACUUM HOSE ROUTING DIAGRAM LABEL (California model only)
The Vacuu m Hose Routing Diagram label is on the inside of the left side cover. Route the vacuum hoses as shown on this
label.
1-23
L U B R I CATIO N
'88, '89:
(1)
ROCKER A R M
( 2 ) O I L PIPE
( 1 2 ) PISTON
l
(7) OIL FILTER
2-0
( 6 ) PRESSU R E
R E L I E F VALVE
( 5 ) O I L STRA I N E R
MAIN SHAFT
2. LU B R I CATI O N
After '89:
(1)
(12)
ROCK E R A R M
CAMSH A FT
(11)
PISTO N
(10)
O I L JET
(9) C R A N KSH A FT
( 2)
MA I NSH A FT
( 8) CO U NT E R S H A F T
�
(7) O I L P R ESSU R E
SW ITCH
(@n
( 3) O I L PUMP
(4) O I L ST R A I N E R
( 5) P R ESSU R E
R E L I E F VALVE
2- 1
L U BRICATI O N
S ERVIC E I N FO R M ATIO N
2-2
O I L P R ESS U R E C H ECK
2-5
TROUBLESHO OT I N G
2- 3
OIL P U MP
2-6
E N G I N E O I L LEVEL
2-4
CO NTROL CABLE L U BR I CATI O N
2- 1 2
ENGINE O I L C H AN G E
2-4
L U BRIC ATIO N P O I NTS
2- 1 2
O I L FILTER C H A N G E
2-5
SERVICE I N FO RMATION
•
If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.
CAUTION
•
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. A lthough this is unlikely
unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possi
ble after handling used oil.
G E N ERAL
• The o i l p u m p c a n be serviced a f t e r r e m o v i n g the e n g i n e from the fra m e .
S P E C I F I CATI O N S
Engine oil
O i l c a p a city
2 . 8 lit ( 2 . 94 U S qt, 2 . 4 6 I m p qt) after d i sasse m b l y .
2 . 2 5 lit ( 2 . 3 6 U S q t , 1 . 9 8 I m p q t ) at o i l filter a n d o i l c h a n g e .
2 . 1 lit ( 2 . 2 1 U S q t , 1 . 8 5 I m p qt) after d r a i n i n g .
Oil recomm e n d a t i o n
H O N DA GN4 4-stroke o i l o r eq u ivalent API
se rvice class ification: S F o r SG
V I SCOS ITY: SAE 1 0W - 40
O I L V I SCO S I T I E S
Other viscosities s h o w n i n t h e c h a rt m a y
be u s e d w h e n the average tem perature
i n your riding area i s w i t h i n the i n d i cated
range .
0
-20
Oil
20
-10
60
40
0
10
100
80
20
30
40
°F"
•c
pump
ITEM
R o t o r tip c l e a r a n c e
STA N DA R D
0 . 1 5 m m ( 0 . 006 i n )
S E R V I C E LI M I T
0 . 20 m m ( 0 . 008 i n )
Pump body clearance
0 . 1 5 - 0 . 2 2 m m ( 0 . 006 - 0 . 009 i n )
0.35 mm (0.0 1 4 in)
P u m p end c l e a r a n c e
0 . 0 2 - 0 . 0 7 m m ( 0 . 00 1 - 0 . 003 i n )
0 . 1 0 m m ( 0 . 004 i n )
44 1 kPa ( 4 . 5 kg/cm2, 64 psi) at 6,000 r p m
--
O i l pressure
T O R Q U E VALU E S
O i l pressure s w itch
Engine o i l d r a i n bolt
Oil filter
2-2
1 2 N•m ( 1 . 2 kg-m, 9 ft-lb)
3 5 N•m ( 3 . 5 kg-m, 25 ft-l b )
1 0 N · m ( 1 . 0 k g - m , 7 . 2 ft- l b )
L U BRICATIO N
T O O LS
Special
Oil filter wrench
Oil pressure gauge
Oil pressure gauge attachment
Snap ring pliers
07HAA - PJ 70 1 00
07 506 - 3000000 or equivalent commercially available in U . S . A .
0 7 5 1 0- 4220 1 00 J
079 1 4 - 323000 1 - or equivalent commercially available in U . S . A
TROUBLESHOOTI NG
Oil level too low
•
•
•
Normal oil consumption
External oil leaks
Worn piston rings
Oil contamination
•
•
•
Oil not changed often enough
Faulty head gasket
Worn piston rings
Low oil pressure
•
•
•
•
•
Faulty oil pump
Clogged oil strainer
Low oil level
Faulty pressure relief valve
Oil leaks
High oil pressure
•
•
Faulty pressure relief valve
Clogged oil filter or oil orifice
No oil pressure
•
•
•
•
•
Oil level too low
Broken oil pump drive or d riven sprockets
Broken oil pump drive chain
Faulty oil pump
Oil leaks
2-3
LUB R I CATIO N
ENGI N E OIL LEVEL
Support t h e motorcycle i n a n upright a n d level position using
a hoist or a jack under the engine.
Start the engine and let it idle for a few minutes.
Stop the engine, remove the oil fi ller cap/di pstick and wipe it
clean.
Check the oil level with the oil filler cap/d ipstick by inserting it
without screwing it in.
NOTE
•
Do not screw the cap in when making this check.
If the oil level is below the lower level mark on the di pstick, fill
to the upper level mark with the recommended oil .
Check the 0-ring for damage.
ENGI N E OIL CHANGE
NOTE
•
Change the engine oil with the engine warm and the motor
cycle on its side stand to assu re complete and rapid drain
ing .
R emove the o i l f i l ler cap/d ipst ick and d rain bo lt.
W ith the engine stop sw itch OFF, push the starter button for
a few seconds to drain any o i l which may be left in the eng ine.
( 1 ) DRA IN BOLT
( 1 ) D RA IN BOLT
NOTE
•
Do not operate the motor for more than few seconds.
After the oil has drained, check that the drain bolt sealing
washer is in good condition, and instal l the bolt.
TORQUE: 35 N•m (3.5 kg-m, 25 ft-lbl
Fill the crankcase with the correct quantity of the recommend
ed o i l .
( 2 ) SEALING WASHER
OIL CAPACITY:
2. 8 lit (2.94 US qt, 2.46 Imp qt) after disassembly
2.25 lit (2.36 US qt, 1 .98 Imp qt) at oil filter and oil change
2.1 lit (2.21 US qt, 1 . 85 Imp qtl after draining
RECOMMENDED OIL: Honda GN4 4-stroke oil or equivalent
API service classification: SF or SG
VISCOSITY: SAE 1 0W - 40
Install the oil filler cap/dipstick.
Start the engine and let it idle for
2 or 3 minutes.
Stop the engine and wait a few m inutes, then check that the
oil level is at the upper level mark with the motorcycle upright.
Check that there are no oil leaks .
2-4
\
LUB R I CATION
O I L FI LTER CHANGE
Drain the engine o i l ( page 2-4) .
CAUTION
•
Do not replace the oil filter when the exhaust system is hot.
Remove the oil filter with a filter wrench .
TOOL:
Oil filter wrench
07HAA - PJ70 1 00
(2) OIL FILTER WRENCH
Apply oil to the new oil filter 0-ring and install the new oil filter.
Tighten the oil filter with a filter wrench .
(1 l OIL F I LTER
TORQUE: 1 0 N • m ( 1 .0 kg-m, 7 . 2 ft-lb)
Fill the engine with recommended oil (page 2-4) .
O I L P RESSU R E CHECK
Remove the following:
- drive sprocket cover (page 1 3 - 1 4)
- drive sprocket cover bracket
- switch cover and switch screw
(2)
0-RING
Disconnect the wire from the oil pressure switch, remove the
switch and connect an oil pressure gauge to the switch hole.
TOOLS :
Oil pressure gauge
Attachment
07506 - 0 7 506 - 3000000
07 5 1 0 - 4220 1 00 or
equivalent commercially
available in U . S . A .
Check the oil leve l .
Start the engine and allow it to warm-up to operating tempera
ture .
Check the oil pressure at 6,000 rpm.
STAN DARD OIL PRESSURE: 44 1 kPa (4. 5 kg/cm2, 64 psi)
Stop the engine.
Apply sealant to the pressure switch threads and install it.
TORQUE : 1 2 N • m ( 1 . 2 kg-m, 8.7 ft-lb)
Connect the oil pressure switch wire and pull the dust cover
over the switch body securely.
Start the engine and check that the oil pressure warning light
goes out after one or two- seconds.
NOTE
•
Route the oil pressure switch wire properly ( page 1 - 1 5)
2-5
LU BRICATION
O I L PUM P
( 1 ) PRESSURE RELIEF VALVE COVER-
®
PRESS U R E R E L I E F VALVE R E M OV A L
�
Separate the crankcase (Section 1 1 ) .
Remove the bolt and pressure relief valve cover.
Remove the pressure relief valve from the oil pump.
PRES S U R E R E L I E F V A L V E D I SA S S E M B LY
Remove the snap ring and disassemble the relief valve .
TOOL:
Snap ring pliers
079 1 4 - 323000 1
or equivalent commercially
available in U . S.A.
I N S PECTI O N
Check the spring, 0-ring and valve for fatigue, wear or dam
age.
Check the body for clogging or damage .
Replace the relief valve as an assembly.
�
( 1 ) 0-R I N G
Q
( 2 1 BOOY
( 3 ) VALVE
Clean all the parts and assemble them i n the reverse order of
disassembly.
�
( 5 ) SNAP R I N G
OIL PU M P R E M OVAL/ D I SA S S E M BLY
Remove the oil pump by removing two mounting bolts .
Remove the dowel pins and 0-rings.
2-6
L UB R I CATIO N
Remove the oil strainer and oil pipe from the oil pump.
Check the 0-rings and oil seal for fatigue or damage.
(1 l O I L STRA I N ER
( 1 l O I L SEAL
Clean the oil strainer and oil pipe w ith non-flammable or high
flash point solvent.
(21 OIL STRA I N E R
/
0
(31 0-R I N G S
Remove the three cover bolts.
Disassem bled parts and clean them with non-flammable or
high flash point solvent.
( 1 l C O V E R BOLTS
O I L PUMP I N S P ECTI O N
I nstall t h e outer a n d inner rotors to the pump body.
Measure the outer rotor-to-pump body clearance .
SERVICE LIMIT: 0.35 mm (0.01 4 in)
2-7
LUBRICATI O N
Remove the oil pump shaft from the oil pump and measure the
pump end clearance.
SERVICE LIMIT: 0.1 0
mm (0.004 in)
Temporarily install the shaft i n the pump body.
Measure the inner rotor tip clearance.
SERVICE LIMIT: 0.20
mm (0.008 in)
Replace the oil pump, if necessary as a n assembly.
O I L PU M P A S S E M B LY
'88 , '89 , '91 -93:
(1 I
PU M P BODY
( 1 0 1 0-RI N G
( 1 1 I O I L STRA I N E R
2-8
LUB R I CATI O N
After '93:
(4) P R ESS U R E R ELI EF VALVE B O DY
( 1 ) PU M P B O DY
( 2 ) 0 UT E R R OTO R
(3 ) 1 N N E R R OTO R
(8)WASHER
(9)SPRING
I
( 1 4) D R IVE P I N
( 1 3 ) PU M P SHAFT
1 1 ) O I L STRAI N E R
I nstal l the outer rotor in the pump body with the punch mark
facing the cover, then i nstall the inner rotor.
I nstall the drive pin and spacer on the shaft.
I nstall the shaft i n the body, aligning the drive pin with the
inner rotor groove.
(6)
I N N E R ROTOR
'88 , '89 , '9 1 -'93:
( 1 ) O I L PU M P BODY
I nstall the dowel pin and a new gasket on the pump body, then
install the cover.
(2)
OIL PU M P COVER
2-9
LABRICATION
After '93:
( 1 ) O I L P U M P B O DY
I nstall the dowel pins on the p u m p cover,then i nstall the pump
body.
( 3 ) 0 1 L P U M P COVER
( 1 ) COVER BOLTS
Tighten the cover bolts securely .
Install the 0-rings, oil seal, oil strainer and oil pipe on the oil
pump.
(2)
0-R I NG
(3) 0-R INGS
CAUTION
•
Install the 0-rings on the oil pipe with the tapered side facing
out as sho wn, or the engine will be damaged.
( 5) 0-R I NGS
After '93:
Insta l l the oil seal on the oil pump.
Align the edge of oil strainer with the g roove of the pump
cover,then i nstall the oil strainer as shown.
( 1 ) 01L S EAL
(4) 0 1 L STRAI N E R
2-10
(4)
O I L PIPE
( 2 ) E DG E
L UB R I CATI O N
O I L PU M P I N STALLAT I O N
I nstal l the dowel pins a n d n e w 0-rings.
I nstall the oil pump as an assembly .
( 2 ) DOWEL PIN
I nstall the pressure relief valve in the oil pump.
I nstall the pressu re relief valve cover with the bolt.
Assemble the crankcase (Section 11 ).
(1 l
PRESSU R E RELIEF VALVE COVER
2- 1 1
LUBRICATI O N
CONTROL CABLE LUBRICATION
Periodically disconnect the throttle and choke cable a t their
upper ends. Thoroughly lubricate the cables and their pivot
points with a commercially available cable lubricant or a light
weight oil .
LUBRICATION POI NTS
Use gen e ral purpose grease when not otherwise specified
here .
Apply oil or grease to the other sliding surfaces and cables not
shown here .
(1 l
-
,
CLUTCH AND BRAKE
LEVER
( 2 ) TH ROTTLE
GRIP
----
(11 l
STE E R I N G
HEAD BEAR I N G
..
I
I
I
I
I
-
----
-
-
(8)
2-12
BRAKE & CHANGE
CALI PER PIVOTS
(SILICON G R EASE)
�
( 5 ) SWI NGARM
PIVOT BALL
AND N EEDLE
BEARINGS
( 7 ) BRAKE PEDAL
PIVOT
- lijiVft
(6)
S I D E STAND
PIVOT
,
(4) DRIVE CHAIN
( PR O HO N DA CHA I N LU B E )
3. MAI NTENANCE
S E R V I C E I N FORMAT I O N
3- 1
M A I NTENANC E S C H E D U L E
'88; 3-3
MAI NT E NA N C E S C H E D U LE '8 9,'9 1 -'93; 3-4
MAI NT E N A N C E S CH E D U LE
After 93; 3-5
< EN G I N E>
FUEL LINE
3-6
T H ROTTLE OP E RATIO N
3-6
CA R B U R ETO R C HO K E
3- 7
A I R C LEAN E R
3- 7
C RA N KCAS E B R EAT H E R
3-8
S PA R K PLUGS
3-8
VALV E CLEARANC E
3-8
CAR B U R ETO R S Y N C H RO N IZATIO N
3- 1 0
CA R B U R ETO R I D L E SP E E D
3- 1 1
RADIATO R COO LA N T
3- 1 1
C OO LI N G SYSTEM
3- 1 2
C Y LI N D E R CO MP RESS IO N
3- 1 2
EVA PO RATIVE E M IS S IO N
CONTROL S YSTEM
3-1 3
< C HASSIS>
D R I V E CHAIN
3-1 3
BRAKE F L U I D
3-1 5
BRAKE S H O E/PAD WEAR
3-1 6
BRAKE SYSTEM
3- 1 6
BRAKE L I G HT SWITCH
3-1 7
H EADLIGHT AIM
3- 1 8
CLUTCH SYSTEM
3-1 8
S I D E S TAND
3-1 9
S US PE N S IO N
3-1 9
N UTS, BO LTS, FASTENERS
3 -20
W H E E LS/TIRES
3 - 20
S T E E R I N G H EAD BEA R I N G S
3-21
SERVICE I N FORMATION
•
•
Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area with the engine stopped.
Do not smoke or allow flames or sparks in the work area or where gasoline is stored.
G E N ERAL
•
•
Engine oil
Engine oil filter change
See page 2-4
See page 2-5
�E N G I N E�
Ignition timing
Spark plug
Initial '88 . ' 8 9 ,'9 1 - ' 9 3; 6 . 2 ° BTDC at idle
After ' 93;
6 . 5 ° BTDC at idle
30° BTDC at 6 , 000 rpm
Full advance
Spark plug gap
IN
Valve clearance
(COLD)
EX
Idle speed
Cylinder compression
Throttle grip free play
Standard
For cold climate ( below 5 ° C/4 1 ° F)
For extended high speed driving
0 . 8 - 0 . 9 mm (0.03 1 - 0.035 in)
0 . 1 5 ± 0.02 mm (0.006 ± 0 . 0008 in)
0 . 20 ± 0.02 mm (0.008 ± 0 . 0008 in)
1 , 200 ± 1 00 rpm
1 , 324 ± 98 kPa ( 1 3 . 5 ± 1 .0 kg/cm2, 1 92
2 - 6 mm ( 1 / 1 6 - 1 /4 in)
±
NGK
N I PPON DENSO
DPR8EA-9
DPR7 EA-9
DPR9EA-9
X24EPR-U9
X22EPR-U9
X27 EPR-U9
1 4 psi)
3- 1
Ill
MAINTENAN CE
�C H A S S I S�
20 - 30 mm
43 mm ( 1 . 7
1 0 - 20 mm
20 - 30 mm
Rear brake free play
Brake pedal height
C l utch lever free play
D rive chain slack
(3/4 - 1 -3/1 6 in)
in)
( 3/8 - 3/4 in)
( 3/4 - 1 -3/ 1 6 in)
Tires
Tire size
Cold tire pressures
kPa (kg/cm2, psi)
U p to vehicle capacity load
Up to 90 kg ( 200 lbs) load
M aximum weight capacity
Tire brand
Bridgestone
Dunlop
Front
Rear
1 00/90- 1 9 57S
200 ( 2 . 00, 29)
1 70/80- 1 5 7 7 S
2 50 ( 2 . 50, 3 6 )
2 0 0 ( 2 . 00, 2 9 )
200 ( 2 . 00, 29)
1 6 1 kg ( 3 5 5 lbs)
G 546
L309
F24
K555
TO R Q U E VALU E S
Rear axle nut
Valve adjusting screw lock nut
S pokes (front/rear)
Timing hole cap
Crankshasft hole cap
90 N· m ( 9 . 0 kg-m, 65 ft-lb)
23 N•m ( 2 . 3 kg-m, 1 7 ft-lb)
4 N•m (0.4 kg-m, 2.9 ft-lb)
3 . 5 N•m (0. 3 5 kg-m, 2 . 5 ft-lb)
1 5 N ·m ( 1 . 5 kg-m, 1 1 ft-lb)
T O O LS
Special
Vacuum gauge
Drive chain cutter
Spoke wrench
3-2
07 908 - KE90000
07908 - KE90 1 00
07404-0030000 or
07 LMJ - 00 1 000A
07HMH- M R 1 0 1 00 or
07HMH- M R 1 0 1 0 B
07J MA- M R 6 0 1 00
N ot available in U . S . A .
U . S . A . Only
U . S . A . Only
U . S . A . Only
MAINTENANCE
MAI NTENANCE SCHEDULE '88;
Perform the PRE-RI D E I N SPECTI O N in the Owner ' s Manual at each scheduled maintenance period .
1: I N SPECT AND C LEAN , ADJUST, LUBRICATE OR REPLAC E I F N ECESSARY .
C : CLEAN R : REPLAC E L : L U B R I CATE
FREQU E N CY
ITEM
*
*
*
en
�
FUEL L I N E
THROTTLE OPERATI O N
CARBU RETOR CHO K E
A I R CLEANER
CRANKCASE BREATHER
*
SPARK PLUG
VALVE C LEARA N C E
ENGINE OIL
a:
z
0
*
E N G I N E O I L F I LTER
CARBU RETORSYNCHRO N IZAT I O N
en
*
w
!::::
0
I<{
w
...J
w
U5
�
w
*
*
WHICHEVER
COMES
FI RST
•
EVERY
ODOMETER READI N G ( N OTE 1 )
..
x 1 ,000 mi 0.6
4
8
x 1 00 km
64
1 28
10
(NOTE 4)
BRAKE FLU I D
�
w
!::::
0
I<{
w
*
...J
w
*
a:
z
0
U5
en
�
w
z
0
z
*
*
BRAKE SHOE/PAD WEAR
BRAKE SYSTEM
BRAKE LIGHT SWITCH
HEADLIGHT A I M
CLUTCH SYSTEM
S I D E STAND
REFER TO
PAG E
c
c
c
c
c
R
R
R
I
R
R
R
I
R
R
I
R
R
R
R
R
R
I
I
I
I
3- 1 0
I
*R
I
3- 1 1
3- 1 1
3- 1 2
I
3-1 3
I
EVAPO RATIVE E M I S S I O N
CONTROL SYSTEM
24
c
(NOTE 3)
2 YEARS * R
20
3-6
3-6
3-7
3-7
3-8
3-8
3-8
2 -4
2-5
(NOTE 2 )
CARBURETOR-IDLE SPEED
RADIATOR COOLANT
COOLING SYSTEM
16
1 92 256 320 384
I
I
I
I
I
I
I
I
I
I
I
I
I
I
R
I
I
I
I
I
I
DRIVE CHAIN
en
12
R
EVERY 600 mi ( 1 ,000 km) I. L
*R
*R
I
I
I
I
2 YEARS * R
I
I
I
I
I
I
I
I
I
SUSPE N S I O N
NUTS, BOLTS, FASTEN ERS
I
** WHEELS/TIRES
** STE E R I N G HEAD BEA R I N G S
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
3- 1 3
3-1 5
3- 1 6
3- 1 6
3-1 7
3- 1 8
3-1 8
3-1 9
3-1 9
3-20
3-2 0
3-2 1
I
I
I
I
* Should be serviced by a n authorized Honda dealer, unless the owner has proper tools and service data and is mechanically
qualified .
** I n the interest of safety, we recommend these items be serviced only by an authorized Honda dealer.
NOTES : 1 . At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3 . Service more frequently when riding in rain or at full throttle.
4 . California model only.
3-3
MAINTENANCE
MAI NTENANCE SCHEDULE '89 , ' 9 1-' 9 3;
Perform the PRE-RIDE I N SPECTION in the Owner ' s Manual at each scheduled maintenance period .
1: I N SPECT AND C LEAN , ADJ U ST, LUBRICATE OR REPLACE I F NECESSARY .
C : CLEAN R : REPLACE L: LU BRICATE
The following items require some mechanical knowledge . Certain items ( particularly those m arked * and * * ) may requ i re
more tec h nical i nformation and tools . Consult their authorized Honda deale r .
�
M
O D O METER READ I N G ( N OTE 1 )
NOTE
x 1 ,000 mi
0.6
4
x 1 ,000 km
1
6.4
* FUEL LINE
* THROTTLE OPERATION
* CARBU RETOR CHOKE
(/)
:2
w
!:::
A I R CLEANER
C RA N KCASE BREATHER
8
c
16
20
24
1 2 . 8 1 9 . 2 2 5 . 6 32.0 38.4
I
I
I
I
I
I
I
I
I
( NOTE 2 )
( N OTE 3 )
12
c
R
c
R
c
c
c
REFER TO
PAG E
3-6
3-6
3-7
3-7
3-8
R
R
R
R
R
R
SPARK PLUG
3-8
* VALVE CLEARANCE
I
I
I
I
3-8
....J
R
R
R
R
2-4
ENG I N E O I L
w
a:
R
2-5
R
R
R
ENG I N E O I L FILTER
z
Q * CARBURETOR SYNCHRON IZATION
I
I
I
I
3- 1 0
(/)
(/)
- * CARBURETOR IDLE SPEED
I
I
I
I
I
I
I
311
:2
w
*
( N OTE 5 )
I
R
RAD IATOR COOLANT
I
3- 1 1
* COOLING SYSTEM
3- 1 2
I
I
I
* EVAPORATIVE EMISSION CON( NOTE 4)
I
I
3- 1 3
TROL SYSTEM
DRIVE CHA I N
I , L EVERY 600 mi ( 1 ,000 km)
3- 1 3
*
*
R
I
(/)
I
( N OTE 5)
B R A K E FLU I D
I
3- 1 5
I
R
:2
w
BRAKE SHOES/PADS WEAR
I
I
I
I
I
I
3- 1 6
!:::
I
I
BRAKE
SYSTEM
I
I
316
c
w
1- * BRAKE LIGHT SWITCH
I
I
I
3- 1 7
<(
....J
w * HEADLIGHT AIM
I
I
I
3- 1 8
a:
z
I
CLUTCH SYSTEM
I
I
I
3-1 8
I
I
I
0
U5
I
S
I
DE
STAND
I
I
3- 1 9
(/)
*
I
3- 1 9
SUSPENSION
I
I
�
w
*
N UTS, BOLTS, FASTENERS
I
I
I
I
3-20
z
0
z ** WHEELS/TI RES
I
3-20
I
I
I
I
I
I
** STEERING HEAD BEARI N G
3-2 1
I
I
I
I
* SHOU L D BE SERVICED BY AN AUTHORIZED HONDA DEALER, U N LESS THE OWN ER HAS PROPER TOOLS A N D SER
VICE DATA AND IS M ECHANICALLY QUALI FIED.
** I N THE I NTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED O N LY BY AN AUTHORIZED HONDA
DEALE R .
NOTES : 1 . A t higher odometer readings, repeat a t the frequency interval established here .
2 . Service more frequently when riding in unusually wet or dusty areas.
3 . Service more frequently when riding in rain or at ful l throttle.
4 . California type only.
5 . Replace every 2 years, or at indicated odometer interval , whichever comes first . Replacement requires me
chanical skill.
c
1<(
w
3-4
MAI NTE N A N C E
MAI NTE NANCE SCHEDULE After '9 3;
Perfo rm t h e P R E - R I D E I N SPECTI O N i n the Ownera n u a l at each sched u led mai ntenance period .
! : I N S P E CT A N D C L E N A , ADJ U ST , LU B R I CATE O R R E PLACE I F N E C ESSARY .
C : C LEAN R : R E P LAC E L : LU B R I CAT E
The following items req u i re mech a n ical kn owle dge . Certa i n items (parti c u l a rly th o se ma rked
•
and
•
•
) may req u i re more tec h n ical
i nformatio n and tools, Consu lt their a uth orized Honda dealer.
F R EQU E N CY
x
ITEM
* F U EL LI N E
* TH R OTTLE O PE RATI O N
* CAR B U R ETO R C H O K E
AI R C LEAN E R
(/)
:2:
w
C RAN KCAS E B R EATH E R
!:::
S PA R K PLU G
c
w
* VALVE C LEARAN CE
ENGINE OIL
w
a:
E N G I N E O I L F I LTER
z
0 * CAR B U R ETO R SYN C H R O N IZATIO N
en
(/) * CAR B U R ETO R I D LE S P E E D
:2:
w
R A D I ATO R COOLANT ( N OTE5)
* C O O LI N G SYSTEM
N OTE
( N OTE2)
( N OTE3)
�
*
(/)
:2:
w
!:::
c
�
w
a:
z
0
w
en
�
:2:
w
I
z
0
z
*
*
*
*
**
**
EVAPO RATIVE E M I SS I O N C O N T R O L SYSTEM
D R IVE CHAI N
B RA K E F LU I D
B RA K E S H O ES/ PADS WEAR
B RA K E SYSTEM
B RA K E LI G HT SWITC H
H EA D L I G HT A I M
C LUTCH SYSTEM
S I D E STA N D
SUSPENSION
N UTS , B O LTS , FASTEN E R S
W H E E LS/TI R ES
STE E R I N G H EAD B EAR I N G
1 , 000mi
1 00km
x
O D O M ET E R R EAD I N G ( N OTE 1 )
0.6
1 6 20 24
12
4
8
1 0 64 1 2 8 1 92 2 5 6 3 2 0 384
I
I
I
I
I
I
I
I
I
R
R
I
R
R
I
I
( N OTE4)
c
c
c
c
c
c
R
R
I
R
R
I
I
I
I
R
R
I
R
R
I
I
I
I
R
R
I
R
R
I
I
R
I
PAG E
3-6
3-6
3-7
3-7
3-8
3-8
3-8
2 -4
2-5
3- 1 0
3- 1 1
3- 1 1
3- 1 2
I
3- 1 3
R
I
I
I
I
I
I
I
I
I
I
3-1 3
3- 1 5
3- 1 6
3- 1 6
3- 1 7
3- 1 8
3- 1 8
3- 1 9
3- 1 9
3-20
3-20
3-2 1
I
I
I
I
( N OTE5)
I
I
I
I
I
R E F E R TO
I , L EVERY 500mi (80 0 km )
I
I
I
I
R
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
* S H O U LD B E S E RVICED BY YO U R AUTH O R IZ E D H O N DA D EALE R , U N LESS TH E OWN E R HAS P R O P E R TOO LS AN D
S E RV I C E DATA AN D IS M EC H AN I CALLY QUALI F I E D .
* * I N TH E I NT E R EST O F SAF ETY , W E R E CO M M E N D THESE ITEM S B E S E RVI C E D O N LY BY YO U R AUTH O R IZ E D
H O N DA D EALE R .
N OTES : 1 . At higher odometer readings, rep eat a t the frequency interval established here .
2 . Service more frequently when riding in u nusually wet or d u sty a reas .
3 . Service more frequently when rid i n g in rain or at fu ll throttle .
4 . California type only .
5 . Replace every 2 years , or at indicated odometer interva l , whichever comes first . Replacement requ i res me
chanical skill .
3-5
MAI NTENAN C E
FUEL LI N E
Remove the seat .
Check the fuel li nes for deterioration, damage or leakage .
Replace the fuel l ines if necessary .
F U E L F I LTER
Pul l the fuel filter out, clip the inlet line closed and remove the
filter.
Replace the fuel filter with new one, if necessary (page 4-3 ) .
TH ROTTLE O P E RATION
Check for smooth throttle grip full opening and automatic full
closing in all steering positions.
C heck the throttle cables and replace them if they are deterio
rated , kinked or damaged .
Lubricate the throttle cables, if throttle operation is not
smooth .
M easure the free play at the throttle grip flange .
FREE PLA Y :
2 - 6 mm ( 1 / 1 6 - 1 /4 in)
Throttle grip free play can be adjusted at either end of the
throttle cable. Minor adjustments are made with the upper ad
juster.
Major adjustments are mode with the lower adjuster.
Adjust the free play by loosening the lock nut and turning the
adjusting nut. Tighten the lock nuts .
Recheck throttle operatio n . Replace any damaged parts, if
necessary.
3-6
t
M A I NTENANC E
CARBU RETOR CHOKE
NOTE
•
C hoke knob operating friction can be adjusted by turning
the adjuster.
Check for smooth operation of the choke knob.
Lubricate the choke cable and/or adjust the choke knob operat
ing friction if operation is not smooth.
To adjust the friction, pull the rubber cover away and turn the
adjuster.
Direction
Friction
A
B
Increase
Decrease
Loosen the choke valve nut and remove the choke valve from
the carburetor.
Pull the choke knob all the way out to fully open position and
recheck for smooth operation of the choke knob.
There should be no free play.
Check the valve seat on the choke valve for damage. Reinstall
the choke valve in the reverse order of removal .
AI R CLEANER
Remove the a i r cleaner housing cover bolt and cover.
Remove the holder bolts and the air cleaner element.
Replace the element i n accordance with the maintenance
schedule.
Also, replace the element any time it is excessively dirty or
damaged .
3- 7
MAINTENANCE
CRAN KCASE BREATHE R
The crankcase breather drain tube i s behind the left frame pipe
and front cylinder head .
Pull the drain tube out of the frame clamp.
Remove the drain plug from the tube to empty any deposits .
Reinstal l the drain plug.
NOTE
•
Service more frequently when ridden in rain, at full throttle,
or after the motorcycle is washed or overturned . Service if
the deposit level can be seen i n the transparent section of
the drain tube.
(1 )
SPARK PLUGS
PLUG GAP
0 . 8 - 0 . 9 mm
(0.03 1 - 0.035 in)
Disconnect the spark plug cap and remove the spark plugs.
( 3 ) CENTER
ELECTRODE
RECOMMENDED SPARK PLUG :
Standard
For cold climate
( below 5 ° C/4 1 ° F)
For extended high speed
driving
NGK
NIPPON DENSO
DPR8EA-9
X24EPR-U9
DPR7 EA-9
X22EPR-U 9
DPR9EA-9
X27EPR-U 9
Measure the spark plug gap with a wire-type feeler gauge .
S PARK PLUG GAP: 0 . 8 - 0 . 9 mm (0.03 1 - 0 . 035 in)
Adjust by bending the side electrode carefully. With the plug
washer attached, thread each spark plug i n by hand to prevent
c rossthreading . Continue tightening by hand until the spark
plug bottoms.
Then, tighten the spark plugs a nother 1 /2 turn with a spark
plug wrench to compress the plug washer.
Connect the spark plug caps.
VALVE CLEARANCE
NOTE
•
I nspect and adjust valve clearance while the engine is cold
( below 3 5 ° C/9 5 ° F) .
Remove the following parts :
- fuel tank ( page 4-3)
- air cleaner housing (page 4-4)
- air cleaner chamber and intake duct.
3 -8
•
(2) SIDE ELECTRODE
MAINTENAN CE
Remove the crankshaft and timing hole caps.
Remove the valve adjusting covers from the cylinder head cov
ers.
NOTE
•
Adjust the front cylinder valves first.
F R O N T C Y L I N D E R H EA D
Rotate the flywheel counterclockwise to align the " FT" mark
with the index notch on the left crankcase cover. Make sure
the piston is at TDC (Top Dead Center) on the compression
stroke.
I nspect the clearance of all three valves by inserting a feeler
gauge between the adjusting screw and the valve .
VALVE CLEARANCES :
Intake : 0 . 1 5 ± 0 . 02 mm (0.006
Exhaust : 0 . 20 ± 0 . 02 mm (0.008
±
±
0 . 0008 in)
0 . 0008 in)
Adjust by loosening the lock nut and turning the adjusting
screw until there is a slight drag on the feeler gauge.
Hold the adjusting screw and tighten the lock nut.
TOOL:
0790 8 - K E90000
N ot ava i lable i n U . S . A .
07908- K E 9 0 1 00
TORQUE : 23 N · m ( 2 . 3 kg-m, 1 7 ft-lbl
Apply oil to the nut and bolt threads.
3- 9
MAINTENANCE
R E A R C Y L I N D E R H EA D
Rotate the flywheel counterclockwise to align the " RT" mark
with the index notch on the left crankcase cover. Make sure
the piston is at TDC on the compression stroke.
Check the 0-rings of the valve adjusting covers ( I N/EX) for
damage and replace if necessary .
I nsta l l the front and rear valve adjusting covers.
Apply g rease to the timing and crankcase hole caps, then
install and tighten them .
TORQUE
Timing hole cap:
3.5 N·m (0.35 kg-m, 2 . 5 ft-lbl
Crankshaft hole cap:
1 5 N•m ( 1 . 5 kg-m, 1 1 ft-lb)
CARBU RETOR SYNCH RON IZATION
N OTE
•
Perform this maintenance with the engine at normal operat
ing temperature .
Remove the fuel tank mounting bolt. Carefully raise the tank
and support it in the frame using a suitable base (see page 39) . .
Remove the air cleaner case ( page 4-4) . Remove the plugs from
the cylinder intake ports and install the vacuum gauge
adaptors as shown .
1l
Connect the vacuum gauge.
TOOL:
Vacuum gauge
07404 - 0030000
N ot ava i lable in U . S . A .
07 LMJ - 0 0 1 OOOA
Warm up the engine and adjust the idle speed with the throttle
stop screw.
I DLE SPEED: 1 , 200
3- 1 0
±
1 0 0 rpm
VAC U U M GAUGE
M A I NTENANC E
Check that the difference in vacuum readings is 40 mm ( 1 . 6
i n ) Hg or less.
NOTE
•
The rea r cylinder carburetor is the base carburetor .
If necessary, synchronize t o t h e specification b y turning the
synchronization adjusting screw.
Recheck the idle speed and synchronization.
Disconnect the gauge and adaptors and install the removed
parts .
CARBU RETOR I DLE SPEED
NOTE
•
•
Inspect and adjust idle speed after all other engine adjust
ments are within specifications .
The engine must be warm for accurate adjustment . Ten
m inutes of stop-and-go riding is sufficient.
Warm up the engine, shift to N EUTRAL, and place the motor
cycle on its side stand .
Turn the throttle stop screw as required to obtain the specified
idle speed .
IDLE SPEED: 1 , 200
±
1 00 rpm
RADIATOR COOLANT
Check the coolant level of the reserve tank with the engine
running at normal operating temperature .
The level should be between the " U P" and " LOW" level lines.
If necessary, remove the right side cover and then remove the
reserve tank cap.
Fill up to the upper level line with 50/ 50 mixture of distilled
water and antifreeze .
Reinstall the reserve tank cap and right sider cover .
3- 1 1
MAI NTENAN C E
COOLI NG SYSTEM
Remove the radiator shroud and check the radiator air pas
sages for clogging or damage .
Straighten bent fins or collapsed core tubes with a small flat
blade screwdriver as shown and remove insects, mud or any
obstructions with compressed air or low pressure water.
Replace the radiator if the air flow is restricted over more than
20 % of the radiated surface .
For radiator replacement, refer to page 5-5.
..
llllf
·--
---
--·
--
.
-
Make sure the hoses are in good condition .
Replace any hose that shows any sign of deterioration.
Check that all hose clamps are tight.
(1 l
CYLI N DER COM P R ESSION
Warm up the engine.
Stop the engine and remove the spark plug.
Connect a compression gauge.
Turn the engine stop switch OFF.
O pen the throttle grip fully. Crank the engine with the starter
motor until the gauge stops rising.
Check the gauge reading .
NOTE
•
•
Check that there is no leakage at the gauge connection .
The maximum reading is usually reached within 4-7 sec
onds.
COMPRESSION :
1 ,324 ± 98 kPa ( 1 3 . 5
±
1 . 0 kg/cm2, 1 92
±
1 4 psi)
Low compression can be caused by :
•
•
•
•
Improper valve clearance adjustment
Valve leakage
Leaking cylinder head gasket
Worn piston rings or cylinder
High compression can be caused by:
•
Carbon deposits in the combustion chamber or on the
piston head .
3- 1 2
RESERVE TAN K
( 2 ) RADIATOR
MAINTENAN CE
EVAPORATIVE EM ISSION CONTROL
SYSTEM (California model only)
Check the hoses between the fuel tan k,evaporative emission
canister,evaporative emissio n purge control valve(EVAP
PU R G E CONTRO L VALVE),evaporative emission carburetor
air vent control valve(EVAP CAV C O NTRO L VALVE),and
carbu retor for deterioration,damage o r loose connections.
( 1 )EVAP CAN I STER
Also check the tubes for clogging due to bending or twisting.
Check the evaporative emissio n canister for cracks deterio
ration,or other damage.
Refer to the vacuu m h ose routing diagram label for hose
connections.
VACUIII HOSE ROUTI NG DIAGRAM
ENGINE FAMILY-c=�
EYAI'tiiA T IVE FAMILY-c=:_._ . .=::J
CALl FDRII I A VEHICLE
DRIVE CHAIN
CHAIN SLACK INSPECTION
•
Never inspect or adjust the drive chain while the engine is run
ning.
Turn the ignition switch off, su pport the motorcycle on its
stand, and shift the transmission into n e utr a l .
side
Check slack in the d rive chain lower run midway between the
sprockets .
SLACK: 20 - 30 mm (3/4- 1 -3/ 1 6 in)
"'
CHAIN ADJ USTMENT
Loosen the axle nut .
Loosen both lock nuts and turn both adjusting bolts as neces
sary.
Make sure the index m arks on both the adjuster collars are
aligned with the corresponding scale grad uations on both
sides of the swingarm . Tighten both lock nuts, then tighten
the rear axle nut.
TORQUE:
90 N•m (9.0 kg-m,
65
ft-lb)
3- 1 3
MAINTENANCE
Recheck chain slack and free wheel rotation .
Lubricate the d rive chain with Pro Honda Chain Lube o r equiv
alent chain l ubrica nt designed specifically for use on 0-ring
chains .
Check the chain wear label. If the red zone on the label aligns
with the arrow mark of the chain adjuster after the chain has
been adjusted , the chain must be replaced .
REPLACEMENT CHAI N : R K525 S M 5
0 1 0525 VB
L U B R I CATI O N A N D C LE A N I N G
(1) W I PE D RY
When the drive chain becomes extremely dirty, i t should be
cleaned prior to lubrication.
Clean the drive chain with a non-flammable or high flash point
and wipe dry.
The d rive chain on this motorcycle is equipped with small 0rings between the link plates . The 0-rings can be damaged by
stea m cleaners, high pressure washers and certain solvents .
Lubricate the d rive chain with Pro Honda Chain Lube or equiv
alent chain l ubricant desig ned specifically for use on 0-ring
chains .
C H A I N R E PLAC E M E N T
The VT600C uses a drive chain ( 1 20 pins) with a staked
master link.
Loosen the drive chain (page 3- 1 3 ) .
Locate the crimped pin ends of the master link from the out
side of the chain and remove the link with the chain cutter.
TOOL:
Drive chain cutter
07HMH
M R 1 0 1 03
N ot ava i l a b l e i n U . S . A .
07 H M H - M R 1 0 1 0B
-
NOTE
•
When using the special tool, follow the manufacturer ' s op
erating instructions.
(1) SWINGARM
CAUTION
•
Never reuse the old drive chain, master link, master link plate
and 0-rings.
REPLACEMENT CHAI N : RK525 SM 5
0 1 0 52 5 VB
I nstal l the new drive chain through the swingarm as shown.
3- 1 4
(2) D RIVE CHA IN
MAINTENANCE
Assemble the new master link, 0-rings and plate .
(2) 0-RINGS
CAUTION
•
Insert the master link from the inside of the drive chain and in
stall the plate with the identification mark facing the outside.
Make sure that the master link pins are installed properly.
Measuring the master link pin length projected from the plate.
Standard length: R K: 1 .2-1 .4 m m (0.05 -0.06 i n )
L
MASTER
LI N K
(5) STAN DAR D
LEN GTH
D I D : 1 . 1 5-1 . 5 5 mm (0.05 -0.06 i n )
Stake the master link pins using the special tool.
Make sure that the pins a re staked properly by measuring the
diameter of the staked a rea using a slide calipers.
D I A M ET E R
OF
(4) D R IVE CHAI N CUTIER
( 1 ) SLI DE CALI PER
1m
(2) GOOD
TH E STA K E D A R EA:
5.50-5.80 m m (0.2 1 7-0.228 i n )
After staking, check the staked area of the master link for
cracks.
If there is any cracking , replace the master link, 0-rings and
plate .
(3) N O G O O D
( 4 ) CRACKED
CAUTION
•
Drive chain with clip-type master link must not be used.
D R I V E A N D D R I V E N SPRO C K ET
Inspect the sprocket teeth for excessive wear or damage . Re
place if necessary .
NOTE
•
Never install a new d rive chain on worn sprockets or a worn
chain on new sprockets . Both chain and sprockets must be
in good condition, or the new replacement chain or sprock
ets will wear repidly.
(2) NORMAL
I
BRAKE FLU I D
Check the front brake fluid through the sight glass; if the level
is visible, remove the cover, set plate and diaphrag m . Fill the
reservoir to the upper level with DOT 4 fluid from a sealed con
tainer. Check the system for leaks.
CAUTION
•
•
•
•
Do not remo ve the reservoir cover until the handlebar has been
turned so that the reservoir is level.
Do not mix different types offluid, as they are not compatible
with each other.
Do not allo w foreign material to enter the system when filling
the reservoir.
A void spilling the fluid on painted, plastic or rubber parts.
Place a rag o ver these parts whenever the system is serviced.
Refer to section 14 for brake bleeding procedures .
3- 1 5
MAINTENAN C E
BRAKE SHOE/ PAD WEAR
BRAKE PAD W E A R
'88 , '89 , '9 1 -93 :
Check the brake pads for wear by looking through the slot indi
cated by the arrow cast on the caliper assembly.
Replace the brake pads if the wear grooves in the pads are visi
ble (page 1 4-5) .
CAUTION
A lways replace the brake pads as a set to assure even disc pres
sure.
•
After '93 :
I nspect the pads visually from under the caliper to determine
the pad wear.
Replace the brake pads if the wear grooves in the pads are visi
ble (page 1 4-5 ) .
CAUTION
•
A lways replace the brake pads as a set to assure even disc pres
sure.
B R A K E S H O E I N S P E CT I O N
Replace t h e brake shoes i f the arrow on t h e brake a r m aligns
with the reference mark " !::. " on full application of the rear
brake pedal.
BRAKE SYSTEM
I nspect the brake hoses and fittings for deterioration, cracks
and signs of leakage. Tighten any loose fittings.
Replace hoses and fittings as required .
BRAKE P E D A L H E I G H T
Adjust the brake pedal so that the pedal height is 43 mm ( 1 . 7
in) above the top of the footpeg .
3- 1 6
MAINTENANCE
To Adjust :
Loosen the stopper bolt lock nut and turn the stopper bolt .
Retighten the lock nut .
NOTE
•
After a djusting the brake pedal height, check the rear brake
light switch and brake pedal free play and adjust if neces
sary.
B R A K E P E D A L F R E E P LAY
NOTE
•
Perform brake pedal free play adjustment after adjusting
brake pedal height.
Check the brake pedal free play.
t
20 - 30 mm
( 3/4 - 1 - 1 /4 in)
FR EE PLAY : 20 - 30 mm (3/4 - 1 - 1 /4 in )
If adjustment is necessary. use the rear brake adjusting nut.
NOTE
•
After adjusting the brake pedal free play, check the rear
brake l ight switch operation and adjust if necessary.
B RAKE LIGHT SWITCH
N OTE
•
•
Perform rear brake light switch adjustment after adjusting
the brake pedal play and height.
The front brake light switch does not require adjustment.
Adjust the brake light switch so that the brake light will come
on when the brake pedal is depressed 20 mm (3/4 in). and
brake engagement begins. Hold the switch body and turn the
adjusting nut. Do not turn the switch body .
3- 1 7
MAINTENANCE
HEADLIGHT AI M
( 1 ) HORIZONTAL ADJUSTING
SCREW
Adjust vertically by turning the vertical adjustment screw .
Adjust horizontally by turning the horizontal adjusting screw .
NOTE
•
•
Adjust the headlight beam as specified by local laws and
regulations.
A n improperly adjusted headlight may blind oncoming drivers,
or it may fail to light the road for a safe distance.
(2) VERTICAL ADJUSTING
SCREW
----
CLUTCH SYSTEM
Measure the clutch lever free play at the lever end.
FREE PLAY : 1 0 - 20 mm (3/8 - 3/4 in)
i
( 1 ) 1 0 - 20 mm
( 3/8 - 3/4 in)
Minor adjustments are made with the upper adjuster.
Pul l the lever cover back, loosen the lock nut and turn the ad
juster to obtain the specified free play.
Tighten the lock nut and install the cover.
\
( 1 ) U PPER ADJ U STER
I
"" L .
Check clutch operation .
After'9 5 :
M ajor adjustments are made with the lower adjuster.
Loosen the lock nut and turn the adjusting nut to obtain the
specified free play.
Tighten the lock nut and check the clutch operation .
( 1 ) LOWE R ADJ U ST E R
3- 1 8
MAI NTENANCE
SI DE STAND
Check the spring for damage o r loss of tension.
Check the side stand assembly for freedom of movement.
Lubricate the pivot bolt and the side stand pivot area if neces
sary.
Tighten the pivot bolt and nut.
TORQUE: BOLT: 10 N·m 1 1 . 0 kg-m, 7.2 ft-lbl
NUT: 30 N•m (3.0 kg-m, 22 ft-lbl
Check the side stand ignition cut-off system :
- Sit astride t h e motorcycle and raise t h e side stan d .
- Start t h e engine with t h e transmission in neutral , t h e n shift
the transmission into gear, with the clutch lever squeezed .
- Move the side stand full dow n .
- The engine should stop as t h e side stand is lowered .
If there is a problem with the system , check the side stand
switch (section 1 6 1 .
SUSPENSION
FRONT
Check the suspension action by compressing it several times .
Check the entire fork leg assembly for signs of leaks or dam
age .
Replace any components which are unrepairable.
Tighten a l l nuts and bolts to the specified torque value.
•
D o n o t ride a vehicle with faulty suspension. Loose, worn, or
damaged suspension parts may affect stability and rider con
trol.
REAR
Check the action of the rear suspension components by com
pressing them several times.
Check the entire suspension assembly, being sure it is securely
mounted and not damaged or distored .
!
Tighten a l l nuts and bolts to the specified torque value.
3- 1 9
MAI NTENAN C E
N UTS, BOLTS, FASTEN ERS
Tighten the bolts, nuts and fasteners at the i ntervals shown in
the Maintenance Schedule (page 3-3 ) .
Check that a l l chassis nuts and bolts are tightened t o their cor
rect torque values ( page 1 -5 , 6 and 7 ) .
Check a l l cotter pins and safety clips.
WHEELS/TI RES
TI R E P R E S S U R E
NOTE
•
Tire pressure should be checked when the tires are COLD .
Front
Rear
1 00/90- 1 9 5 7 S 1 70/80- 1 5 7 7 S
Tire size
C o l d tire
pressures
kPa
( kg/cm2,
psi)
Up to
vehicle
200 ( 2 . 00, 29) 2 50 ( 2 . 50, 36)
capacity
load
U p to 90 kg
200 ( 2 .00, 29) 200 ( 2 .00, 29)
(200 lbs)
load
Maximum weight capacity
1 61 kg ( 3 5 5 lbs)
Tire
brand
Bridgestone
Dunlop
L 3 09
F24
G 546
K555
Check t h e tires for cuts, imbedded nails, or other sharp ob
jects .
Check the front and rear wheels for trueness ( Section 1 2 and
13).
Measure the tread depth at the center of the tires .
Replace the tires if the tread depth reaches the following limit:
MINIMUM TREAD DEPTH :
Front: 1 . 5 mm (0.06 in)
Rear: 2.0 mm (0.08 in)
Tighten the wheel spokes periodically.
TORQUE (front/rear) : 4 N•m ( 0 . 4 kg-m , 2 . 9 ft-lb)
TOOL:
Spoke wrench
3 -20
07JMA - MR601 00
N ot ava i l a b l e in U . S . A .
( 1 ) SPO K E
M AI N T E N A N C E
STE ER I N G H EAD BEAR I NGS
NOTE
•
Check that the control cables do not interfere with handle
bar rotatio n .
Raise t h e front w heel off the ground.
Check that the fork pivots freely from side to side. If the fork
pivots unevenly, binds, or has vertical movement, inspect the
steering head bearings ( Section 1 2 ) .
3-2 1
FUEL SYSTEM
1 9 N ·m ( 1 . 9 kg-m, 1 3 . 7 ft-lbl
4-0
4. FU EL SYSTEM
S ERV I C E I N FO RMATIO N
4- 1
CARBU R ETO R I NS TALLATIO N
4- 1 5
T RO U BLESHOO T I N G
4-2
PILO T S C R EW ADJ USTMENT
4- 1 5
F U EL TAN K
4-3
A I R CLEAN ER H O U S I N G
4-4
H I G H ALTIT U D E ADJ USTMENT
( U . S . A . ONL V)
4- 1 6
CARB U R ETO R REM OVAL
4-6
CAR B U R ETO R D I SASS E M BL V
4-6
CA R B U R ETO R ASS E M B L V
4- 1 0
CARB U R ETO R
S E PA RATIO N / ASS E M B L V
4- 1 3
EVA P O R AT I V E E MI S S I O N
PU R G E CO NT RO L VALVE I N S PECTIO N
( California model only)
4- 1 6
EVA P O R ATIVE E M I S S IO N C A R B U R ETO R
A I R VENT CO NTRO L VALVE
4- 1 7
I NS PECTIO N ( Californ ia model only)
SERVICE I N FORMATIO N
•
•
Gasoline is extremely flammable and is explosive under certain conditions work in a well ventilated area a with the engine stopped.
Work in a well ventilated area.
G E N ERAL
•
•
•
•
•
Refer to Section 3 for carburetor synchronization, throttle cable and choke cable adjustments .
When d isassembling fuel system parts, note the locations of the 0-rings; replace them with new ones on reassembly .
The carburetor float chambers have d rain screws that can be loosened to drain residual gasol ine .
For fuel pump refer to section 1 8 .
All hoses used in the evaporative emission control system are numbered for identification . When connecti ng one of these
hoses, compare the hose number with the Vacuum Hose Routing Diagram Label on page 4- 1 6 (California model only) . for
its routing.
CAUTION
•
Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind.
N OTE
•
If vehicle is to be stored for more that one month , drain the float bowls. Fuel left in the float blowls will cause clogged jets
resulting in starting and drivability complaints .
Item
49
Type
Throttle bore
Identification No.
Float level
Main jet
Slow jet
Idle speed
Throttle grip free play
Pilot screw initial opening
34
7.0
Front :
California model
St. model
mm
Constant Vacuum dual carburetor
34 mm
in)
( 1 .4
VDFDA
mm ( 0 . 2 8 i n )
# 1 1 5,
Rear:
2-6
mm
±
1 00
in)
VD FEA
7 . 0 mm ( 0 . 2 8 i n )
Front : # 1 1 5, Rear: # 1
#1 1 5
15
#40
#40
1 , 200
( 1 .4
rpm
( 1 / 8 - 1 /4
1 , 200
in)
2-6
mm
±
1 00
rpm
( 1 /8 - 1 /4
in)
See page 4-15.
4- 1
Ill
F U E L SYSTEM
TO R Q U E VA LU E
Fuel tank mounting bolt
1 9 N•m ( 1 . 9 kg-m , 1 3 . 7 ft-lb)
TOOLS
Special
Pressure pump
Vacuum pump
Valve guide driver, 7 mm
A937X - 04 1 - XXXXX or
ST - AH- 2 5 5 - M C 7 ( U S A . only)
ST - AH - 260 - M C 7 ( U . S A . only)
07942 - 8230000 ( U . S A. only)
.
.
.
.
Common
Float level gauge
0740 1 - 00 1 0000
TROU BLESHOOTI NG
Engine cranks but won't start
•
•
•
•
•
•
•
•
No fuel in tank
No fuel to carburetor
Engine flooded with fuel
No spark at plug (ignition system faulty)
Clogged air cleaner
Intake air leak
Improper choke operation
Improper throttle operation
Misfiring during acceleration
•
Backfiring
•
•
•
•
•
•
•
•
•
•
•
Ignition malfunction
Faulty carburetor
Fuel contaminated
Intake air leak
Incorrect idle speed
Incorrect valve clearance (Section 3 )
Incorrect carburetor synchronization (Section 3)
Improper choke valve operatio n .
•
•
•
•
•
•
•
•
Faulty ignition system
Incorrect idle speed
Incorrect valve clearance (Section 3 1
Incorrect carburetor synchronization
Faulty carburetor
Fuel contaminated
Faulty air cut off valve
(California model only : )
: Fau lty evaporative em ission purge control valve
: Fau lty evaporative em issio n carbu retor air vent
control valve
: Worn/damaged emission system hoses
Afterburning during deceleration
•
•
•
Faulty air cut off valve
Lean mixture
: Worn/damaged emission system hoses
4- 2
Clogged fuel system
Dirty air cleaner
: Faulty evaporative emissio n carbu retor a i r vent
control valve
: Warn/damaged emission system hoses
Lean mixture
Rough idle
•
faulty carburetor
Poor performance (driveability) and poor fuel economy
•
Hard starting or stalling after starting
•
•
Clogged fuel jets
Stuck vacuum piston
Faulty float valve
Low float level
Clogged fuel tank breather
Clogged fuel strainer
Restricted fuel line
I ntake air leak
Restricted or faulty fuel pump
Rich mixture
•
•
•
•
Clogged air jets
Faulty float valve
Float level too high
Dirty air cleaner
F U EL SYSTEM
FUEL TAN K
( 2 ) FUEL TAN K
MOUNTING
BOLT
REMOVAL
•
conditions. Work in a well ventilated area with the engine
Remove the seat and turn the fuel valve off.
Remove the fuel valve knob mounting bolt and fuel valve knob
from the fuel tank body.
Remove the fuel tank mounting bolt.
Disconnect the fuel tube from the fuel tank and fuel breather
tube (t o canister: California model only) .
Check that fuel flows out of the fuel valve freely.
If flow is restricted , clean the fuel strainer.
Remove the fuel tank from the frame.
I N STALLAT I O N
Install the fuel tank in the reverse order o f remova l .
Install t h e f u e l valve knob onto t h e fuel valve as shown a n d
tighten t h e bolt . .
Tighten the fuel tan k mounting bolt securely.
( 1 ) FUEL TAN K
(3)
F U E L STRAINER SCREEN
(5) FUEL FILTER
N OTE
l1i<
�
171 FUEL VALVE K N O B
�($.,
'
.
i .
�
t.
(8) TO FUEL
PU MP
�
� rt. ( 9 ) TO CARBU R ETOR
�
The fuel pipe joint with its nar
NOTE
•
�
The fuel filter with its narrow
pointing toward the outside .
•
( 2 ) FUEL PIPE JOINT
_
row end toward outside .
4-3
FUEL S YSTEM
AI R C LEA N ER HOUSING
REM OVAL
�
( 1 ) A I R CLEAN ER H O U S I N G� "
MOUNTING BOLTS
1""'"'
Remove the fuel tank mounting, and lift the tank and remove
the air cleaner housing mounting bolts .
Loosen the air cleaner housing -to-air cleaner chamber band .
Disconnect the crankcase breather tube from the air cleaner
housi ng.
I N STALLATI O N
Wipe clean the mating surfaces shown and apply a cemment
(or equivalent) .
I nstall the removed parts i n the reverse order of removal .
S U B-A I R C L E A N E R E L E M E N T
Remove t h e fol lowing :
- seat (page 1 3- 1 8) and fuel tank (page 4-3)
- air cleaner housing
Disconnect the air hoses (carburetors-to-sub-air cleaner cov
er) .
Remove the sub-air cleaner mounting bolt and cover and
remove the element.
4-4
'
F U E L SYSTEM
Wash the element in non-flammable or high flash point sol
vent, squeeze out the solvent thoroughly, and allow the ele
ment to dry.
Soak the element in gear oil (SAE #80 - 90) and squeeze out
the excess .
Reinstal l the element and cover, and tighten the bolt.
Reconnect the air tubes from the carburetors .
¢�¢
!
(1 )
WASH I N
SOLVENT
(3)
DRY
¢ �¢�
�
J
t
!
(2)
(4)
(5)
S Q U E EZ E O U T
GEAR O I L
S Q U E EZ E OUT
SOLVENT
(SAE #80 - 90 1 EXCESS O I L
T H O R O U G H LY
A I R C L EA N E R C H A M B E R
R E M OV A L/ I N STA LLAT I O N
Remove t h e air cleaner housing and sub-air cleaner element
( page 4-4 ) .
Loosen t h e intake duct hose b a n d s a t t h e carburetors and
unhook the air cleaner chamber drain tube from the frame .
Remove the air cleaner chamber from the frame .
To reinstal l the chamber: position it i n the frame, and connect
the i ntake ducts to the carburetors and tighten the band
screws .
I nstall the sub-element and cover ( page 4-4) .
I nstall the air cleaner housing (page 4-4) .
----- ( 8 )
PLUG
(3)
(6)
A I R CLEA N E R H O U S I N G
HOLDER
4- 5
FUEL SYSTEM
CARBURETOR REMOVAL
•
conditions. Work in a well ventilated area with the engine
Loosen the drain screws and drain the fuel into a container.
Remove the sub-air cleaner chamber ( page 4-4) .
Remove the throttle cable cover and disconnect the throttle
cables from the carburetor.
Remove the left choke valve from the carburetor and loosen
the carburetor insulator bands.
Disco n nect the evaporative emission p u rge control valve No.5
tubes and evaporative emission carburetor air vent control
valve No.6 and 1 0 tubes from the carburetor (California model
only) .
Pull the carbu retors the u pward and out of the engine.
CARBURETOR DISASSEM BLY
NOTE
•
The carburetors can be disassembled without being sepa
rated .
Remove the air tubes (carburetors-to-sub-air cleaner) , and fuel
tube from the carburetor.
Remove the choke cable and right choke valve from the carbu
retor by loosening each lock nut.
VAC U U M C H A M B E R
Remove the four screws a n d vacuum chamber cover.
4-6
.
(2) C H O K E
CABLE
LOCK
'
FUEL SYSTEM
Remove the spring, and diaphragm/vacumm piston.
Inspect the vacuum piston for wear, nicks, scratches or other
damage.
( 1 I D IAPHRAG M/PISTON
(2) SPRING
Make sure the piston moves up and down freely in the cham
ber.
Push the needle jet holder in and turn it in 90 degrees counter
clockwise.
(1 I
Then remove the needle holder, spring, jet needle and washer
from the piston .
Inspect the needle for excessive wear a t the tip, bending or
other damge .
Inspect the diaphragm for damage, fatigue or pin holes.
Inspect the vacuum piston for wear or damage.
(1
NEEDLE J ET HOLDER
( 2 ) J ET
(3) HOLDER
N EEDLE
I
(4) SPRING
FLOAT CHAMBER, FLOAT AND JETS
Remove the four screws and float chamber.
4- 7
F U E L SYSTEM
Remove the float pin, float and float valves.
Check the float valve and valve seat for scratches, clogging or
damage.
Inspect the operation of the float valve.
Remove the main jet, needle jet holder, slow jet and valve seat/
filter.
(2)
Check each part for wear or damage .
Blow open all jets with compressed air.
Clean each jet with non-flammable or high flash point solvent.
Inspect the float valve seat and filter for grooves, nicks or de
posits .
Clean the filter with low-pressure compressed air.
PILOT SCREW
NOTE
•
•
•
The pilot screws are factory pre-set and should not be re
moved u nless the carburetors are overhauled .
The pilot screw plugs are factory i nstalled to prevent pilot
screw misadjustment. Do not remove the plugs unless the
pilot screws are being removed.
Cover all openings with tape to keep metal particles out
when the plugs are drilled .
4-8
/ lt.
ow •
�
( 5 ) F I LTER
(4) VALVE SEAT
�' ·
/''
' ,..,
SLOW J ET
(3)
MAIN
J ET
FUEL SYSTEM
Center punch the pilot screw plug to center the drill point.
Drill throug h the plug with a 4 mm ( 5/32 in) drill bit. Attach a
drill stop to the bit 3 m m (1/8 i n ) from the end to prevent
drilling into the pilot screw .
CAUTION
•
•
Be careful not to drill into the pilot screw.
Both pilot screws must be replaced even if only one requires it,
for proper pilot screw adjustment (page 4-15).
Force a self-tapping 4 mm screw, P/N 93903 - 3 5410) i nto
the drilled plug and continue turning the screwdriver until the
plug rotates with the screw.
Pull on the screw head with pliers to remove the plug.
Use compressed air to clean the p ilot screw area and remove
metal shavings.
Turn each pilot screw in and carefully count the n umber of
turns until it seats lightly. Make a note of this to use as a refer
ence when reinstalling the pilot screws .
CAUTION
•
Damage to the pilot screw seat will occur if the pilot screw is
tightened against the seat.
Remove the pilot screws and inspect them. Replace them if
they are worn or damaged .
0
(4)
/
WASHER
(3)
PILOT SCREW /
�
A I R C U T O F F V A LV E
Remove t h e two screws, t h e set plate and t h e air cut off valve
cover.
NOTE
•
The air cut off valve cover is under spring pressure. Do not
loose the spring and screws.
4-9
FUEL SYSTEM
0-RING
Visually check the following :
- diaphragm for deterioration, pin hole or other damage.
- spring for deterioration or other damage.
- diaphragm needle for excessive wear at the tip or other
damage.
- orifice of air vent for clogging.
- 0-ring for damage.
(3) DIAPHRAG M
cl
Replace the air cut off valve as an assembly, if necessary.
(4)
/
S PR I N G
Separate the carburetors ( page 4- 1 3 ) .
Blow open all passages with compressed air before i nstalling
jets and valves .
CARBU R ETOR ASSEMBLY
( 5 ) HOLDER
( 1 4) PISTON
( 1 5) FLOAT
( 1 3) FLOAT
CHAMBER --:-i��
( 1 2) VALVE ( 1 0) SLOW JET
SEAT
4- 1 0
(9) A I R-CUT
VALVE
COVER
F U E L SYSTEM
ER
P I LOT S C R EW ·
I nstall the pilot screws and return them to their original posi
tion as noted during remova l .
Perform pilot screw adjustment if n e w pilot screws are in
stalled .
NOTE
•
•
(4)
Do not install new plugs on new pilot screw holes until after
adjustment has been made.
If you replace the pilot screw i n one carburetor, you must
replace the pilot screw in the other carburetor for proper
pilot screw adjustment.
(3)
PILO T SCREW
1 /
SPRING
FLOAT C H A M B E R , F LOAT A N D J ETS
I nstall the pilot screw and turn it i n until it seats lightly.
Turn the pilot screw out the number of turns recorded during
remova l .
CAUTION
•
I nstall the valve seat, slow jet, needle jet holder and main jet.
Install the float with float valve i n the carburetor body, then in
stall the float arm pin through the body and the float.
GAUGE
FLOAT L E V E L
Measure the float level with the float tang just contacting the
float valve.
TOOL:
Float level gauge
0740 1 - 00 1 0000
FLOAT LEVEL: 7 mm (0.28 in)
Adjust the float level by carefully bending the float tang .
4- 1 1
FUEL SYSTEM
I nstall the 0-ring on the float chamber groove.
I nstall the float chamber and tighten the screws securely .
NOTE
•
I nstall the fuel tube clamp.
VAC U U M CHAM B E R
I nstall t h e washer, jet needle, spring and needle holder t o the
vacuum piston.
Push the jet needle holder i n and turn it in 9 0 degrees cloc
kwise .
Hold vacuum piston u p to almost full open to avoid pinching
the diaphragm with the chamber cover.
(1 l
The vacuum piston with the tab of the diaphragm aligned with
the groove of the carburetor.
I nstall the chamber cover with the spring, aligning the cover
cavity with the hole i n the carburetor, and secure with at least
two screws before releasing the vacuum piston.
4- 1 2
J ET NEEDLE
HOLDER
( 2 ) CAVITY
(4) F I N G E R
FUEL SYSTEM
Install the right choke valve and choke knob.
· ·� ·
(21
Install the fuel and air tubes as shown.
CHOKE KNOB
( 1I
.
....-.......
FUEL TUBE;:,p:s
.lib
CARBU RETOR
SEPARATIO N / ASSEM BLY
SEPARATION
Loosen the synchronization adjusting screw.
NOTE
•
When separating the carburetors, be take careful not to lose
the thrust spring and synchronization adjusting spring.
Separate the carburetors by removing two attaching screws.
Remove the synchronization spring.
(2)
SYNCHRON
IZATION SPRING
. ..
4- 1 3
FUEL SYSTEM
ASSEMBLY
111
THRUST
SPRING
loosen the synchronization adjusting screw until there is no
spring tension.
Install the thrust spring between the throttle links.
Secure the carburetors together with the two screws.
-
Install the synchronization spring and synchronization adjust
ing screw.
121
SYN C H RON IZATION
ADJUSTING SCREW
Inspect throttle operation a s described below :
•
Open the throttle slightly by rotating the throttle valve, then
release the throttle. M ake sure that there is no drag when
opening and closing the throttle.
Turn the throttle stop screw to align the rear cyli nder carbure
tor throttle valve with the edge of the by-pass hole.
(2)
Align the front cylinder carburetor throttle valve with the by
pass hole edge by turning the synchronization adjusting
screw.
Make sure the throttle returns smoothly.
4- 1 4
(1 )
THROTTLE STOP SCREW
SYN C H RO N IZATION ADJUSTIN G
REW
FUEL SYSTEM
CARB U RETOR I NSTALLATION
I nstall t h e carburetors onto the cylinder heads a n d tighten the
insulator bands securely.
I nstal l the following parts
- air cleaner chamber
- air cleaner housing
- fuel tank
- throttle cables
Adjust as follows:
- pilot screw ( page 4- 1 51
- carburetor synchronization ( page 3- 1 0 ) .
- throttle grip free play ( page 3-6 )
- carburetor idle speed ( page 3- 1 1 )
- carburetor choke ( page 3-7 ) 0
0
0
P I LOT SCR EW ADJ USTM ENT
I D L E D R O P P R O C E D U R E ( U . S . A . O N LY l
NOTE
The pilot screws are factory p re-set and no adjustment is
necessary u nless the pilot screws are replaced .
Use a tachometer with graduations of 50 rpm or smaller
that will accurately indicate a 50 rpm change .
•
•
Remove the pilot screw plugs ( page 4-8)
Turn each pilot screw clockwise until it seats lightly and
back it out to the specification give n .
1.
2
0
o
CAUTION
•
This is an initial setting prior to the final pilot screw adjust
ment.
I NITIAL OPENI N G : 1 - 1 /4 turns out
3 . Warm u p the engine to operating temperature .
Stop and go driving for 1 0 minutes is sufficient.
4 . Attach a tachometer according to the manufacturer ' s in
structions .
5 0 Adjust the idle speed to the specified rpm with the throttle
sto p screw .
I D LE S P E E D : 1 , 200 ± 1 00rpm
6 Turn each pilot screw 1 /2 turn out from the initial setting .
7 . If the engine speed increase by 5 0 rpm o r more , turn each
pilot screw out by successive 1 /2 turn increments u ntil
engine speed does not increase 0
8 Adjust the idle speed with the throttle stop screw .
9 . Turn the rear cylinder carburetor pilot screw i n until the
engine speed drops 50 rpm .
1 0 . Turn the rear cylinder carburetor pilot screw 1 turn out
from the position obtained in step 9
1 1 Adjust the idle speed with the throttle stop screw.
1 2 Perform steps 9, 1 0 and 1 1 for the front cylinder carbu
retor pilot screw
1 3 0 Drive new pilot screw plugs i nto the pilot screw bores
with a 7 mm valve guide driver (P/N 07 942 - 8230000 ) .
W h e n fully seated the plug surfaces w i l l b e recessed 1
mm.
0
0
0
0
o
0
( 1 I PLUG
4- 1 5
F U E L SYSTEM
H IGH ALTITUDE ADJ USTM ENT (U.S.A. only)
When the vehicle is to be operated continuously above 2 , 000
m (6, 500 feet) the carburetors must be readjusted as follows
to improve driveability and decrease exhaust emissions.
Remove each pilot screw plug ( page 4-8) .
Warm up the engine to operating temperature . Stop and go
d riving for 1 0 minutes is sufficient.
Turn each pilot screw to the specification below .
H I G H ALTITU D E S ETTI N G :
1/2 Turns in
Adjust the idle speed to 1 , 2 00 ± 1 00 rpm , with the th rottle
stop screw .
Drive new pilot screw plugs i nto the pilot screw bores ( page 41 5) .
NOTE
This adjustment must be made at high altitude to ensure
proper high altitude operation .
�
LE E M ISSION CONTROL
I N FOR MATI O N UP DATE LAB E L
•
Attach a Vehicle Emission Control I nformation u p date label
o nto the inside of the left side cover as shown.See S L# 1 3 2 for
information on o btaining the label.
NOTE
Do not attach the label to any part that can be easily re
moved from the vehicle.
•
•·'·'5111¥1d
VEHICLE EMISSION CONTROL INFORMATION UPDATE
• HONDA MOTOR CO., LTD
THIS VEHICLE HAS BEEN ADJUSTED TO
IMPROVE EMISSION CONTROL PERFORMANCE
WHEN OPERATED AT HIGH ALmUDE.
�
�
�.
ALmuDE PERFORMANCE ADJUSTMENT INSTRUCTIONS
ARE AVAILABLE AT YOUR AUTHORIZED HONDA DEALER.
Sustained operation at an altitude lower than 1, 500 m
(5, 000 feet) with the carburetors adjusted for high alti
tude may cause the engine to idle roughly and engine
may stall in traffic and may cause engine damage due to
overheating.
•
When the vehicle is to be operated continuously below
1 , 500m (5 , 000 feet), turn each pilot screw to the specificatio n
below, its o riginal position .
LOW A LTITU D E S ETTI N G :
1/2 turn out
Adjust the idle speed to 1 , 2 00 ± 1 00 rpm with the th rottle
stop screw .
D rive new pilot screw plugs into the pilot screw bores ( page 4
- 1 5) .
Be sure to make these adjustments at low altitude . Remove
the Vehicle Emission Control U pdate Label that attached to
the inside of the left side cover after adjusti ng for the low
altitude .
EVAPORATIVE E M ISSION
P U RG E CONTROL VALVE INSPECTION
(Ca l iforn ia mod e l o n l y)
NOTE
The evaporative em1ss1o n p u rge control valve should be
inspected if hot restart is d ifficult.
•
Check all fuel tan k, Evaporative Emission Purge Control Valve
( EVAP P U R G E CONTROL VALVE),and evaporative emission
canister hoses to be su re they a re not kin ked and a re secu rely
connected. Replace any hose that shows signs of damage or
d eterioration.
NOTE
· The EVAP PU R G E CONTROL VALVE is located u nder the
fuel tan k.
4- 1 6
VACUUM HOSE ROUTI NG DIAGRAM
ENGI NE FAMI LY- ';:;-;-;-; ==---::
------,:J
EVAPORAT I VE FAMILY;r:
L
=:::
CAL l FORNIA VEHI C L E
____
"'
..:
z
w
"0
EVAP
CAN I ST E R
MZS -930
F U E L SYSTEM
Disconnect the EVAP P U R G E CONTROL VALVE hoses from
their connections and rem ove the EVAP P U R G E CONTRO L
VALVE from its mou nt. R efer t o the routin g label on the i nside
of the left side cover for hose connections.
Connect a vacuum p u m p to the 8 m m (0.3 1 in.) I . D.hose No.5
that goes to the 3-way joint.Apply the specified vacu u m to the
EVAP PU R G E CONTR O L VALVE.
SPECIFIED VACUUM: 250 mm (9.8 in) Hg
The specified vacuu m should be m aintained.
Replace the EVAP PU R G E CO NTRO L VALVE if vacuu m is not
maintained.
TOOL:
Vacuum pump
A937X - 041 - XXXXX or
ST - AH - 260- MC7
( U .S.A. only)
Remove the vacu um p u m p a n d con n ect it to the vacuum hose
N o . 1 1 that goes to the left carbu retor body.
Apply the specified vac u u m to the EVAP P U R G E CONTRO L
VALVE.
SPECIFIED VACUU M : 250 mm (9.8 in) Hg
( 1 ) EVAPO RATIVE E M I S S I O N
P U R G E CONT R O L VALVE
I
�
( 1 ) VAC U U M PUMP
I
The specified vacu u m should be maintained.
Replace the EVAP PU R G E CO NTRO L VALVE if vacuu m is not
maintained.
TOOL:
Vacuum pump
\'
\
( 5 ) T VAPO RATIVE
E M I S S I O N CAN I STER
( 2 ) VACUUM PUMP
(4) TO CARBU RETOR
BODY
ST - AH - 260- MC7
( U . S.A. only)
Con nect a p ressu re p u m p to the 8 m m (0.3 1 in. ) I . D .hose N o.4
that goes to the evaporative emission canister.While a pplying
the specified vacu u m to the EVAP PU R G E CONTROL VALVE
hose that goes to the 3-way joint p u m p air through the
evaporative emission canister hose.Air shoud flow through the
EVAP PU R G E CONTR O L VALVE and out the hose that goes to
the 3-way joint.
R eplace the EVAP P U R G E CONTROL VALVE if air does not
flow out.
CAUTION
•
To preven t damage to the evaporative emission purge con trol valve,
do not use high air pressure sources. Use a hand operated air pump
only.
TOOL:
Vacuum pump
Pressure pump
ST -AH - 260- MC7
ST -AH - 255 - MC7
( U . S.A. only)
( 2 ) VACUUM PU MP
R emove the p u m ps, i n stal l the EVAP P U R G E CONTR O L
VALVE on its mount, route and reconnect the house accord
ing to the routing label.
EVAPORATIVE EM ISSION CARBU R ETOR
AIR VENT CONTROL VALVE INSPECTION
(Ca l iforn i a mod e l o n l y)
D isconnect the Evaporative Emission Carburetor Air Vent
Control Valve( EVAP CAV CONTR O L VALVE)hoses from their
connections and remove the EVAP CAV CO NTRO L VALVE
from its mou nt. R efer to the routing label on left side cover for
hose connections.
4- 1 7
F U EL SYSTEM
Connect a vac u u m pump to the No. 1 0 hose that goes to the
rig ht carbu retor body.
Apply t h e specified vacuum t o t h e EVAP CAV CONTR O L
VALVE.
SPECIFIED VACU U M : 250 mm (9.8 in) Hg
TOOL:
Vacuum pump
A937X - 04 1 - XXXXX or
ST - AH - 260 - MC7
( U .S.A. only)
The specified vacuu m should be maintained.
Replace the EVAP CAV CONTRO L VALVE if vacuum is not
maintained.
(21 TO OPEN A I R
( 1 1 TO A I R
J O I NT PIPE
( 3 ) EVAPO RATIVE E M I SS I O N
N o . 6 HOSE
CAR B U R ETO R AI R V E NT
CONTROL VALVE
(4) TO
EVAPO RATIVE
EM ISSION
CAN I STER
N o . 4 HOSE
/
( 5 ) TO R I G HT
CARBU RETOR
BODY No. 1 0 HOSE
CAUTION
•
To prevent damage to the evaporative emission carburetor air vent
con trol valve, do not use high air pressure sources. Use a hand
operated air pump only.
Connect the vacuum pump to the air vent port of the EVAP
CAV CONTROL VALVE.
Apply vacuum to the EVAP CAV CONTROL VALVE.The
vacuum should hold steady.
R eplace the EVAP CAV CONTRO L VALVE if vacuum leaks.
TOOL:
Vacuum pump
A937X - 04 1 - XXXXX or
ST - AH - 260 - MC7
( U .S.A. only)
Connect the vacuum pump to the No. 1 0 hose that goes to the
right carb u retor body.
Connect the pressu re pump to the air vent port of the EVAP
CAV CONTROL VALVE.
While a pplying the vacuu m to the EVAP CAV CONTR O L
VALVE N o . 1 0 hose that goes t o t h e rig ht carburetor body,
pump air through the air vent port.
Air should flow through the EVAP CAV CONTROL VALVE and
out the hose that goes to the carb u retor air joint pipe.
TOOL:
Vacuum pump
Pressure pump
A937X - 04 1 - XXXXX or
ST - AH - 260 - MC7
ST - AH - 25 5 - MC7
( U .S.A. only)
Plug the hose that goes to the carburetor air joint pipe.
While applying vacuu m to the EVAP CAV CONTROL VALVE
No. 1 0 hose that goes to the rig ht carburetor body,apply air
pressure.
It should hold steady.
R eplace the EVAP CAV CONTR O L VALVE if pressure is not
retained.
Remove the p u m ps,install the EVAP CAV CONTROL VALVE
o n its mou nt,route and reconnect the hoses according to the
routing label.
TOOL:
Vacuum pump
Pressure pump
4- 1 8
A937 X - 04 1 - XXXXX or
ST - AH - 260- MC7
ST - AH - 25 5 - MC7
( U .S.A. only)
c..,_,��'
( 6 1 VAC U U M PU M P
M EMO
COO L I N G SYSTEM
5-0
5. COOLI NG SYSTEM
S ER V IC E I N FO RMAT I O N
5- 1
THERMOSTAT
5-3
T R O U BL ES HOO T I N G
5- 1
RADIATOR/CO O LING FAN
5-5
S Y S T E M TESTING
5-2
WATER P U M P
5-7
C O O LA N T REPLAC E M E N T
5-3
COO LANT/RESERVE TAN K
5-9
G E N ERAL
•
•
•
•
•
•
•
•
Do not remove the radiator cap when the engine is hot. The coolant is under pressure and severe scalding could result. The engine
m ust be cool before servicing the cooling system.
Use only distil led water and ethylene glycol in the cooling system. A 50 - 50 mixture is recommended for maximum corro
sion protection. Do not use alcohol-based antifreeze .
Add coolant at the reserve tank. Do not remove the radiator cap except to refi l l , coolant mixture testing or drain the system, or to test the coolant mixture.
Avoid spilling coolant on painted surfaces .
After servicing the system , check for leaks with a cooling system tester.
For thermosensor and thermostatic switch removal and inspection, refer to section 1 8 .
To service the water pump, the engine must be removed from the frame.
S P E C I F I CAT I O N S
ITEM
SPEC I F I CATIONS
Radiator cap relief pressu re
Freezing point (Hydrometer test ) :
Coolant capacity:
Coolant change :
Total system:
88 - 1 27 kPa (0. 9 - 1 . 3 kg/cm2, 1 3 - 1 8 psi)
55 % Distilled water + 45 % ethylene glycol: -32 ° C (-2 5 ° F)
50 % Distilled water + 50 % ethylene glycol: -37 ° C (-34 ° F)
45% Distilled water + 5 5 % ethylene glycol : -44. 5 ° C (-48 ° F)
1 .45 lit ( 1 . 3 7 U S qt, 1 . 28 Imp qt)
1 . 6 lit ( 1 . 5 1 US qt, 1 .4 1 Imp qt)
Thermostat
Begins to open: 80 ° to 84 ° C ( 1 7 6 ° to 1 83 ° F)
Valve lift: Minimum of 8 m m at 9 5 ° C (0.3 in at 203 ° F)
Boiling point (with 50 - 50 mixture ) :
Unpressurized : 1 07 . 7 ° C (226 ° F)
Cap on, pressurized : 1 2 5 . 6 ° C ( 2 58 ° F)
TROUBLESHOOTI NG
Engine temperature too high
Faulty thermosensor bulb or sensor
Thermostat stuck closed
Faulty radiator cap
I nsufficient coolant or coolant l evel too low
Passages blocked in radiator, h oses or water jacket
Cooling fan motor does not turn
- Burned or loose sub fuse
- Faulty fan motor
- Faulty thermostatic switch
- Poor connector contact or open circuit in harness
Faulty water pump
Engine temperature too low
•
•
Faulty thermosensor bulb or sensor
Thermostat stuck open
Coolant leaks
•
•
Faulty pump mechanical seal
Deteriorated 0-rings
5- 1
COO LING SYSTEM
SYSTEM TESTI NG
C O O LANT M I XT U R E
Remove the fuel tank (page 4-3) .
Remove the steering covers by removing the bolt.
Remove the radiator cap.
•
Be sure the engine is cool before removing the cap or you may
be severely scalded.
Test the coolant mixture with an antifreeze tester.
For maximum corrosion protection, a 50- 50% solution of
ethylene glycol and distilled water is recommended.
RAD I ATOR CAP
Wet the radiator cap sealing surface, install the cap on the
tester, and apply pressure.
Replace the radiator cap if it does not hold pressure, or if it ' s
relief pressure is too high or too low. It must hold specified
pressure for at least six seconds.
·
-
RADIATOR CAP RELIEF PRESSURE:
88 - 1 27 kPa (0. 9 - 1 . 3 kg/cm2, 1 3 - 1 8 psi)
i
�
t
.
I
( 1 I RAD IATO R
CAP
SYSTEM PRES S U R E TEST
Remove the steering covers and radiator cap.
Attach the tester to the radiator and apply enough pressure to
test the radiator, engine and hoses.
Check for leaks.
CAUTION
•
Excessive pressure can damage the radiator. Do not exceed 125
kPa (1 . 25 kg!cm2, 18 psi)
Repair or replace components if the system will not hold speci
fied pressure for at least six seconds .
5-2
COOLING SYSTEM
COOLANT R E P LACE M ENT
•
(2) REAR CYLINDER
DRAIN BOLT
The engine must be cool before replacing the coolant or severe
scalding may result.
Remove the radiator cap ( page 5-2 ) .
Drain the coolant from the system by removing the drain bolt
on the water pump cover.
Remove the rea r cylinder coolant drain bolt and drain the
collant using a vinyl as shown .
Reinstal l the drain bolt.
( 1 ) DRAIN BOLT
(3) VINYL
Fill the system with 50 - 50 mixture of distilled water and eth
ylene glyco l .
Bleed a i r from t h e cooling system .
Lower the side stand and shift the transmission into neutra l .
Start the engine and snap the throttle grip, 3 - 4 times at
4,000 - 5,000 rpm . Then add coolant up to the radiator
filler neck.
Reinstall the radiator cap.
Check the level of coolant in the reserve tank and fill to the
correct level if the level is low.
•
•
•
•
THERMOSTAT
R E M O VAL
Remove the following :
- air cleaner housing ( page 4-4)
- steering covers ( page 5-2)
- radiator cap
Drain the coolant.
Remove the thermostat housing and radiator filler mounting
bolts .
Disconnect the siphon tube from the radiator filler.
Disconnect the u pper radiator hose at the radiator and remove
filler and the radiator hose from the frame.
Remove the thermostat housing cover.
5-3
COOLI N G SYSTEM
Remove the thermostat from the housing .
I N S P E CT I O N
( 1 ) THERMOSTAT
I nspect t h e thermostat visually for damage .
Suspend the thermostat in heated water to check its opera
tion.
NOTE
•
If the thermostat or thermometer touches the pan, you ' l l
get a false reading.
Replace thermostat if valve stays open at room temperature,
or if it responds at temperatures other than those specified.
Data :
Start to open
Valve lift
80° to 84 ° C ( 1 7 6 - 1 8 3 ° F)
8 mm (0.3 in) minimum when
heated to 9 5 ° C (203 ° F) for five
minutes .
I N STALLAT I O N
I nstall t h e thermostat into the housing .
I nstall a new 0-ring on the housing cover and i nstall the hous
ing cover onto the housing.
5-4
COOLING SYSTEM
Tighten the thermostat housing cover mounting bolts .
NOTE
Be sure to secure the thermostat ground wire with the
cover mounting bolt shown.
I nstall a new 0-ring on the radiator filler, and connect the
u pper radiator hose to the radiator.
I nstall the radiator filler onto the thermostat housing.
Tighten the filler and thermostat housing mounting bolts .
Install the remaining removed parts in the reverse order of re
mova l .
F i l l t h e system with coolant.
RADIATOR/COOLI NG FAN
REM OVAL
NOTE
•
For fan motor i nspection, refer to section 1 8 .
Remove the steering cover and disconnect the fan motor con
nector ( 2 P BLACK)
Remove the horn mounting bolt and horn, then disconnect the
horn wires.
Remove the radiator mounting bolt and disconnect the lower
radiator hose from the radiator by loosening the hose band.
5- 5
COOLI N G SYSTE M
U nhock the radiator mounts from the grommets from in frame.
Unclamp the upper radiator hose and disconnect the hose from
the radiator.
D I SAS S E M B LY
( 1 ) G R O U N D "-..
TERM INAL /""'
Disconnect the thermostatic switch wire connector from the
switch and remove the wire from the clamp.
Remove the ground wire terminal bolt.
Remove the fan motor shroud mounting bolts, and remove the
fan motor shroud and fan motor as an assembly.
( 2 ) WIRE CONN ECTO R
( 1 ) NUT
Remove the nut to separate the fan from the shroud .
( 2 ) FAN
Remove the fan motor mounting nuts and fan motor from the
shroud.
5-6
COOLING SYSTEM
A S S EM B LY
Inspect the radiator soldered joints and seams for leaks.
Blow dirt out from between core fins with compressed air. If
insects, etc . , are clogging the radiator, wash them off with
low pressure water.
Carefully straighten any bent fins.
I nstal l the motor on the shroud and tighten the nuts .
Install the fan to the fan motor shaft, aligning the boss of the
shaft with the groove of the fan .
Assemble the remained components in the reverse order of the
disassembly.
If removed the thermostatic switch from the radiator, refer to
page 1 8-8.
NOTE
•
Do not overtighten the thermostatic switch, when reinstall
it.
TORQU E :
1 8 N • m ( 1 . 8 kg-m , 1 3 ft-lb) .
WATE R P U M P
ME C H A N I CA L S E A L I N S P E C T I O N
NOTE
•
The w ater pump cover and 0-ring can be removed with
engine i n the frame .
Inspect the telltale hole for signs of mechanical seal coolant
leakage .
Replace the water pump as an assembly if the mechanical seal
is leaking.
REMOVAL
Remove the engine from the frame (section 6).
Remove the water pump cover mounting bolts and cover.
Remove the 0-ring and dowel pins from the water pump as
sembly and disconnect the water hose .
Remove the water pump from the crankcase.
( 3 ) WATER HOSE
5- 7
COOLING SYSTEM
I N S P E CTI O N
( 1 ) 0-RING
Check t h e water pump f o r mechanical seal leakage a n d bear
ing deterioration. Replace the water pump as an assembly if
necessary .
(4) 0-RING
I N STA L LAT I O N
Apply a coat of clean engine oil to a new 0-ring and install it i n
t h e water p u m p shaft housing groove .
Align the water pump shaft g roove with the oil pump shaft and
insert the water pump into the crankcase.
Apply a coat of engine oil to a new 0-ring and install it around
the impeller housing .
I nstal l the two dowel pins.
Connect the water hose with the clamp.
I nstall the water pump cover and tighten the cover mounting
bolts .
Connect the water hose with the clamp.
I nstall the engine in the frame (section 6 ) .
Fill the system with coolant ( page 5-3 ) .
Fill the engine with the recommended engine o i l (page 2-4) .
Check the cooling system for leakage.
5-8
( 2 ) WATER P U M P ASSEM BLY
COOLI N G SYSTEM
COOLANT / R ESERVE TANK
(1 I
G R O M M ET
(21
TAB
REMOVAL/INSTALLATION
Raise and support the motorcycle rear frame using a hoist or
jack u nder the engine.
Remove the evaporative emission canister(California model
only) .
Place a clean container u nder the reserve tank.
Disconnect the radiator siphon tube at the reserve tank.
Remove the reserve tank mounting bolt, filler mounting nut
and the reserve tank.
Hold the overflow tube u pright and remove the reserve tank
from the frame.
Empty the tank, if necessary.
I nstall the reserve tank i n the reverse order of removal .
Fill the tank with coolant, i f necessary.
CAUTION
•
The tab of the reserve tank should be aligned with the grommet
in the frame.
5-9
EN G I N E REM OVAL/INSTALLAT I O N
�
2 5 N•m, ( 2 . 5 kg-m, 1 8 ft-lb)
2 7 N•m, ( 2 . 7 kg-m, 20 ft-lb)
6-0
6. ENG INE REMOVAL/ I NSTALLATION
S ERVI C E I N F O RMAT I O N
6-2
E N G I N E R E M OVAL
6-3
6- 5
EN G I N E I N STALLATION
Ill
5 5 N • m ( 5 . 5 kg-m,
40 ft-lb)
27
N·m (2. 7 kg-m,
20ft-lb)
6- 1
E N G I N E REM OVAL/ I N STALLATION
SERVICE I N FO RMATION
G E N E RAL
•
•
•
Support the motorcycle using a hoist, a floor jack or other adjustable support.
The following parts can be serviced with the engine i nstalled in the frame:
•
•
Alternator
Clutch
•
•
Starter motor
Gearshift linkage
•
•
Carburetors
Camshafts
•
Front cylinder head/cylinder
To service the water pump body, oil pump, and rear cylinder head/cylinder the engine m ust be removed from the frame.
Engine dry weight
Oil capacity
Coolant capacity
6 1 kg ( 1 34 lb)
2 . 8 l it ( 2 . 94 U S qt, 2.46 Imp qt) at disassembly
1 . 6 1it ( 1 . 5 1 U S qt, 1 .4 1 Imp qt) total
TO R Q U E VALU E S
Rear axle
Shock absorber lower mounting bolt
Gearshift arm bolt
Foot peg bracket bolt
Swingarm pivot bolt
Front upper engine mounting bolt
Front upper engine bracket bolt
Front lower engine mounting bolt
Rear upper engine mounting bolt
Rear upper engine bracket bolt
Exhaust pipe joint nut
Fuel tank mounting bolt
Exhaust muffler bracket bolt
6-2
90
45
12
40
90
55
27
55
55
27
25
19
27
N•m
N•m
N·m
N•m
N·m
N·m
N•m
N·m
N•m
N•m
N·m
N•m
N·m
(9.0
(4. 5
( 1 .2
(4.0
(9.0
(5.5
(2. 7
(5.5
(5.5
(2. 7
(2.5
( 1 .9
(2. 7
kg-m , 65 ft-lb)
kg-m , 33 ft-lb)
kg-m , 9 ft-lb)
kg-m , 29 ft-lb)
kg-m , 65 ft-lb)
kg-m , 40 ft-lb)
kg-m, 20 ft-lb)
kg-m, 40 ft-lb)
kg-m, 40 ft-lb)
kg-m , 20 ft-lb)
kg-m, 1 8 ft-lb)
kg-m , 1 3 . 7 ft-lb)
kg-m , 20 ft-lb)
E N G I N E REM OVAL/ I N STALLATION
ENG I N E REMOVAL
Support the motorcycle using a hoist or a jack.
CAUTION
•
Do not jack up the engine at the oil filter.
Drain the engine oil (page 2-4) and the radiator coolant (page
5-3 ) .
Disconnect the battery negative cable from the battery termi
nal .
- fuel tank (page 4-3)
- air cleaner chamber ( page 4-4)
- carburetor (page 4-6)
- exhaust pipe protectors
- exhaust pipe and muffle rs
Loosen the drive chain ( page 3 - 1 3 ) .
Remove the drive sprocket cover ( page 1 3- 1 4 ) . then remove
the sprocket from the drive chain by removing the two sprock
et bolts.
Disconnect the oil pressu re and neutral switch wires from the
switch terminals and free the switch wire harness from the
engine and frame.
Remove the gearshift arm from the gearshift spindle.
Disconnect the starter motor cable and ground cable from the
starter motor.
Disconnect the clutch cable from the clutch lifter arm by re
moving the holder bolt.
Remove the right foot peg and rear brake pedal by removing
the two bracket mounting bolts.
6-3
EN G I N E REMOVAL/ I N STALLATIO N
Disco n ncet the ignition pulse generator wire connector(4P
WH ITE) .
Remove t h e lower radiator hose ( radiator-to-water pump) .
Disconnect the water hoses (thermostat housing-to-cylinder
heads) from the cylinder heads ( page 9-3 ) .
Place a floor jack o r other adjustable support under the engi ne.
NOTE
•
The jack height must be continually adjusted to relieve
stress for ease of bolt removal .
- rear wheel (page 1 3-3)
- swingarm (page 1 3- 1 4)
- front upper engine bracket (two 8 mm bolts, 1 0 mm bolt
and collar)
- front lower engine bracket ( 8 mm bolts and 1 0 mm bolt)
- rear engine bracket (two 8 mm bolts and 1 0 mm bolt)
N OTE
•
Do not damage the radiator fin .
6-4
�
�41
SWI N ARM PIVOT
., , ( 3 ) FRONT LOWER BOLT
BOLT
E N G I N E R E MO VAL/IN STALLATIO N
ENG I N E I N STALLATION
Engine insta l l ation is essentially the reverse order o f removal .
Use a floor jack or other adjustable support t o carefu lly
manuever the engine into place.
CAUTION
•
Carefully align mounting points with the jack to prevent
damage to m ounting bolt threads and wire harness and cables.
NOTE
•
Be sure to i nstall the mounting collars and swingarm dust
seals i n their correct positions.
Tighten all the fasteners to the specified torque given on page
5-0, 1 and 2.
( 1 ) SWI NGARM LEFT S I D E COLLAR
I
--
NOTE
•
•
•
•
Route the w i res and cables properly (section 1 ) .
Fill the cran kcase to the proper level with the recommended
oil (page 2 - 4 ) .
Fill the cooling system (page 5-3) .
Perform the following inspection and adjustments :
Throttle operation ( page 3-6) .
Clutch ( page 3- 1 8 ) .
/
( 2 ) SWI NGARM RIGHT SIDE CO LLARS
6-5
CLUTCH/GEARS H I FT L I N KAGE
1 2 N · m ( 1 . 2 kg-m ,
9ft-lb)
- - - - - - - - - - - - - - - - - - - - - ,
After' 8 9 :
7 -0
'
,
,
'
'
'
'
'
'
'
2 3 N · m (2 . 3 kg-m , 1 7ft-lb)
'
'
'
'
'
'
'
'
'
'
After' 9 5 :
'
'
'I
7. CLUTCH/G EARSH I FT LI N KAG E
S ER V I C E I N FO RMAT I O N
7-1
P RI MARY DRIVE G EAR
7- 1 1
T R O U B L ESHOOTI N G
7-2
CLUTCH I N STALLATION
7- 1 2
R I G H T C RANKCASE C O V ER R E MOVAL
7-3
C L U T C H REMOVAL
7-4
RIGHT CRANKCASE COVER
I N STALLATION
7- 1 4
G EA RS H I FT L I N KA G E
7-8
S E RV I CE I N FORMATION
G E N ERAL
•
This section covers the removal and installation of the clutch, oil pump drive chain, gearshift linkage and primary drive
gear. All these operations can be done with the engine installed in the frame.
•
If the shift fork, drum and transmission require servicing, remove the engine and separate the crankcase (section 1 1 ).
•
C oat the new clutch discs w ith clean engine oil before reassembly.
U nit: mm (in)
ITEM
C l utch
STANDARD
Spring free length
SERVICE LIMIT
39.0 ( 1 . 54)
3 7 . 4 ( 1 .47)
After 88;
Spring preload/length
Disc thickness
A
43 . 2 ( 1 . 70)
25. 2 5 - 27 . 2 5/2 6 . 2 kg/mm
2 . 62 - 2 . 7 8 (0. 1 03 - 0 . 1 07 )
4 1 . 6 ( 1 . 64)
2 . 30 (0. 090)
8
2 . 92 - 3 .08 (0. 1 1 5 - 0. 1 2 1 )
2 . 60 (0. 1 02)
--
0.30 ( 0 . 0 1 2 )
I. D.
2 1 . 9 9 1 - 22 . 0 1 6 (0.8658 - 0 . 8668)
2 2 . 09 (0. 870)
O.D.
3 1 . 9 59 - 3 1 .025
32.000 - 32.025
32.000 - 32.025
2 1 . 967 - 2 1 . 980
3 1 . 98 ( 1 . 2 59)
3 2 . 1 0 ( 1 . 264)
3 2 . 1 0 ( 1 . 2 64)
88;
Plate warpage
Outer guide
Outer I . D .
O i l pump d rive sprocket I . D .
M ainshaft O . D . at clutch outer guide
( 1 . 2 582 - 1 . 2 589)
( 1 . 2 598 - 1 . 2608)
( 1 . 2 598 - 1 . 2608)
(0. 8648 - 0 . 8654)
--
2 1 . 9 2 ( 0 . 863)
T O R Q U E VALU ES
Drum stopper plate bolt
Primary d rive gear bolt
Oil pump d riven sprocket bolt
C lutch lock nut
Oil pass pipe bolt (8 mm)
( 7 mm)
1 2 N·m ( 1 . 2 kg-m, 9 ft-lb) Apply locking agent
90 N•m (9.0 kg-m, 65 ft-lb)
1 5 N•m ( 1 . 5 kg-m, 1 1 ft-lb) Apply locking agent
1 30 N ·m ( 1 3.0 kg-m, 94 ft-lb)
23 N•m ( 2 . 3 kg-m, 1 7 ft-lb)
1 0 N•m ( 1 .0 kg-m, 7.2 ft-lb)
T O O LS
Special
07923 - KE 1 0000 o r 07 H G B -00 1 000A( U . S . A . only)
07724 - 00 1 0 1 00
Gear holder
Common
Luck nut wrench, 1 7
x
27 mm
077 1 6 - 0020300 Equ ivalent com mercially available i n U . S . A .
7- 1
•
CLUTCH/GEARS H I FT LI N KAGE
TROU BLESHOOTI NG
Faulty clutch operation can usually b e corrected b y adjusting the clutch lever free play .
Clutch slips when accelerating
•
•
•
No free play
Discs worn
Springs weak
Clutch will not disengage
•
•
Too much free play
Plates warped
Motorcycle creeps with clutch disengaged
•
•
Too much free play
Plates warped
Excessive lever pressure
•
•
Clutch cable kinked, damaged or dirty
Lifter mechanism damaged
Clutch operation feels rough
•
•
Clutch outer slots rough
Dirty clutch cable
7-2
R IGHT CRAN KCASE COVER REMOVAL
'88, '89:
Drain the engine oil ( page 2 - 4 ) .
Remove the clutch cable holder and disconnect the clutch
cable from the clutch lifter arm .
Loosen the oil pipe holder and remove the oil pipe bolt and seal
ing washers from the right crankcase cover.
Remove the right crankcase cover bolts and cover.
After '89:
Drain the engine oil ( page 2 - 4 ) .
Remove the clutch cable holder and disconnect the clutch
cable from the clutch l ifter arm .
Remove the right crankcase cover bolts and cover.
Remove the dowel pins and gasket.
'88, '89 :
Remove the oil orifice.
C L U T C H L I FT E R S H A FT
Remove the clutch lifter piece, and remove the snap ring and
return spring from the right crankcase cover.
Remove the clutch lifter shaft.
Check the clutch lifter piece and shaft for damage or excessive
scratching .
Check the return spring for fatigue or damage.
7 -3
Check the needle bearing for wear or damage or a loose fit in
the cover.
Check the dust seal for fatigue or damage.
Apply grease to the dust seal and needle bearing .
(1 l
I nstall the clutch lifter shaft, snap ring and return spring.
Hook the spring end in the cover tab securely, and turn the
shaft.
Install the clutch lifter piece, aligning the piece end with the
groove i n the clutch lifter shaft.
CLUTCH REMOVAL
- clutch bolts
- clutch lifter plate
- springs
Unstake the clutch lock nut with a drill or grinder.
NOTE
•
Be careful not to damage the shaft threads .
7 -4
D U ST SEAL
CLUTCH/G EARS H I FT L I N KAGE
Hold the clutch center with the special tool and loosen the
clutch lock nut. Remove the tools and the lock nut.
TOOLS :
Lock nut wrench, 1 7
x
27 mm
07923- K E 1 0 0 00 or
07 H G B-00 1 000A
( U . S.A. only)
077 1 6-0020300
Equivalent com mercially
avai lable in U . S .A.
- spring washer (After' 9 5 o nly)
- washer
- clutch center. judder spring and sprin g seat
- discs a n d plates
- pressu re plate
Remove the thrust washer and clutch outer.
Remove the oil pump d riven sprocket mounting ·bolt, driven
sprocket and oil pump drive cha i n .
-
(1 l
-
O I L PU MP DRIVEN
SPROCKET
7-5
CLUTCH/GEA R S H I FT L I N KAGE
Remove the drive sprocket and clutch outer guide from the
mainshaft.
I N SPECT I O N
(1 1
BEARI N G
Check the lifter plate bearing for damage.
Turn the bearing inner race with your finger.
The bearing should turn smoothly and quietly .
Also check that t h e bearing outer race fits tightly in t h e clutch
lifter plate .
Replace the bearing if necessary .
·�
."--
-�
.. ·
/
..._
___
( 2 ) CLUTCH L I FTER PLATE
Measure the spring free length .
SERVICE LIMIT: 88;
88; 37.4 mm ( 1 .47 in)
After 89; 4 1 , 6 mm ( 1 . 6 5 in)
Replace the � lutch discs if they show signs of s coring or dis
coloration.
Measure the thickness of discs A and B.
SERVICE LIMIT: ( A I 2 . 30 m m (0.090 in)
(8) 2 . 60 mm (0. 1 02 in)
N OTE
•
Replace the discs and plates as a set if any one is beyond
the service limit.
7 -6
-�
-
Check the plate warpage on a su rface plate using a thickness
gauge.
SERVICE LIMIT:
0 . 30 mm (0.0 1 2
in)
111
Check the cl utch center for nicks or indentations made by the
clutch plates.
Check the spring seat and judder spring for distortion, wear or
damage.
Replace them it necessary .
CLUTCH
C ENTER
�,!
(1 I
J U DDER SPRING
. _......... ..
Check the slots in the clutch outer for nicks or indentations
made by the clutch discs.
Measure the
outer guide.
I. D. of the clutch outer and the O . D . of the clutch
SERVICE LIMITS:
Clutch outer I . D.
Clutch outer guide O.D.
32. 1 0 mm ( 1 . 264
3 1 .98 mm ( 1 . 259
in)
in)
7- 7
Check the oil pump drive sprocket for damage.
Measure I . D of the d rive sprocket and the O . D . of the outer
guide.
SERVICE LIMITS:
Oil pump drive sprocket
Clutch outer guide 0 . 0 .
1.0.
32. 1 0 mm ( 1 .264 in)
3 1 .98 mm ( 1 .259 in)
Measure the mainshaft O . D . at the clutch outer guide.
SERVICE LIMIT: 2 1 .92 mm (0.863 in)
GEARSH I FT LI N KAGE
R E M OVAL
- drive sprocket cover ( page 1 3- 1 4)
- gearshift pedal arm from the gearshift spindle
- right crankcase cover ( page 7-3)
- clutch assembly ( page 7-4)
- oil pump drive chain ( page 7-5)
Loosen the two oil pipe stay mounting bolts and remove the oil
pipe mounting bolt.
Pull the oil pipe out of the stay and oil pump.
7 -8
- gearshift spindle
- drum stopper arm bolt, stopper arm, collar and spring
- drum stopper plate bolt and stopper plate/drum
I N S PECTI O N
Check the gearshift spindle for bending o r damage.
Check the return spring for fatigue or damage.
( 1 ) GEARSH
I nspect the gearshift pedal shaft for damage or loose lock
nuts.
Replace the shaft if necessary.
,_
l
r
(2) RETU RN SPRING
PEDAL SHAFT
_ ,_
I nspect the dust seals and pivot collar for wear or damage.
Replace if necessary .
Apply grease to the dust seal lips and pivot collar and install
them into the pedal shaft.
7-9
CLUTCH/GEARS H I FT L I N KA G E
I N STA L LATI O N
I nstall the collar, spring, stopper arm, washer a n d stopper arm
bolt and tighten the bolt.
I nstall the dowel pins into the holes of the gearshift dru m .
Lift up t h e d r u m stopper a r m and install t h e d r u m stopper
plate.
Apply locking agent to the threads of the stopper plate bolt
and tighten the bolt.
TORQUE : 1 2 N·m ( 1 . 2 kg-m, 9 ft-lbl
I nstall the gearshift spindle, aligning the return spring ends
with the pin in the case.
Install the oil pipe with a new 0-ring onto the oil pipe stay and
oil pump.
Tighten the bolts securely.
I nstall the removed parts in the reverse order of removal.
I nstall the gearshift arm to the gearshift spindle.
Align the punch mark on the arm with the punch mark on the
spindle .
Tighten the gearshift arm mounting bolt.
7- 1 0
.,
(1 l
G EARSH I FT SPI N O
!
"
�
C LUTCH/G EARS H I FT L I N KA G E
I nstal l the gearshift pedal mounting bolt and tighten the bolt
securely.
I nstal l the d rive sprocket cover (page 1 3- 1 7 ) .
(1 )
1 FT PEDAL
MOUNTING BOLT
P R I MARY DRIVE GEAR
REMOVAL
Remove the followin g :
- right crankcase cover (page 7-3)
- clutch assembly ( page 7-4)
Remove the ignition pulse generator mounting bolts and
ig nition pu lse generators.
Temporarily install the clutch outer, (page 7- 1 3 ) then install
the gear holder as shown.
TOOL:
Gear holder
07724 - 00 1 0 1 00
Remove the fol lowing:
- ignition p ulse generator rotor bolt and rotor
- clutch outer and gear holder
- primary d rive gear
I N STALLAT I O N
Instal l the primary drive gear with the " O UT" mark facing out.
_,
( 1 ) PRIMARY
DRIVE
,_,
GEAR
NOTE
•
The p ri m a ry d rive gear and ignition p u lse generator rotor
will only g o on i n one position becau se of the extra wide
aligning spline.
Instal l the ignition pulse generator rotor .
(4)
I G N ITI O N P U LS �
G E N E RATO R R OTO R
7- 1 1
Temporarily install the clutch outer and install the gear holder
as shown .
TOOL:
Gear holder
07724 - 00 1 0 1 00
Install the washer and bolt and tighten the bolt.
TORQUE: 90 N • m (9.0 kg-m, 65 ft-lbl
Remove the gear holder and clutch outer.
Install the following:
- ignition pulse generators
- clutch ( page 7 - 1 2 )
NOTE
•
If removed the ignition pulse generator wire grommets were
removed from the case g roove,reinstall them securely.
CLUTCH I NSTALLATION
Apply MoS2 paste grease t o t h e outside o f the clutch outer
guide and install the oil pump d rive sprocket over the outer
guide.
I nstall the oil pump d rive chain on the drive sprocket.
I nstall the oil pump driven sprocket with the " I N " mark facing
inside.
Guide the drive chain over the sprocket.
Apply locking agent to the threads of the driven sprocket
mounting bolt and tighten it with the washer to the specified
torque.
TORQUE: 1 5 N·m ( 1 . 5 kg-m, 1 1 ft-lbl
7- 1 2
'iiToiL PU MP D R I VEN
SPROCKET
CLUTCH/G EARS H I FT L I N KAGE
Align the grooves in the clutch outer with the bosses on the oil
pump drive sprocket while turning the sprocket with the chain
and pushing the clutch outer onto the shaft.
Install the thrust washer onto the m a i nshaft.
I nstall the spring seat, judder sprin g and clutch disc 8 on the
c l utch center.
N OTE
•
N ote the positions of the seat, spring and disc B.
I nstal l clutch discs, clutch plates, clutch disc A, the plates,
d i scs, and pressure plate on the clutch center and install them
in the clutch outer as an assembly.
Align the tabs in the disc 8 w ith the slots on the clutch outer.
N OTE
•
•
(3) DISC B
J U DDER SPRING
( 1 ) SPR I N G SEAT
(2)
Stack the discs and plates alternately as shown.
Coat the new clutch discs with clean engine oil.
I n stall the washer on the mainshaft .
After' 9 5 :
I n stall the spring washer o n the mainshaft with the
" O U T S I D E" mark facing o utside .
7- 1 3
CLUTCH/G EARS H I FT LI N KA G E
Hold the clutch center with the clutch center holder, and tight
en the lock nut to the specified torque .
TO RQU E : 1 30 N·m ( 1 3.0 kg-m , 94 ft-l b)
TOOLS :
Lock nut wrench, 1 7
x
27 mm
07923 - K E 1 0000 or
07 H G B-001 000A
( U . S .A. only)
077 1 6-0020300
Equivalent com mercially
available in U .S .A.
Stake the lock nut with the center punch .
Install the clutch springs, lifter plate and bolts .
Tighten the bolts in a crisscross pattern in 2 or 3 steps.
NOTE
•
Make sure the pressure plate firmly pushes the discs and
plates.
I nstall the bearing into the l ifter plate .
R IGHT CRAN KCASE COVE R I NSTALLATION
'88, '89 :
I nstall a new 0-ring on the oil orifice .
I nstall the oil orifice with its smaller hole facing in.
7- 1 4
CLUTCH/G EARS H I FT LI N KA G E
Install the dowel pins and new gasket.
'88, '89 :
Tighten t h e right c r a n kcase cover mounting bolts in a
crisscross pattern in 2 or 3 steps and install the clutch cable
holder and oil pipe holder at the same time.
Connect the clutch cable to the clutch lifter arm.
Tighten the oil pipe bolt with the sealing washers .
TORQU E : 23 N · m ( 2 . 3 kg-m, 1 7 ft-lbl
Fill the crankcase with engine oil (page 2 -4 )
Adjust the clutch lever free play (page 3- 1 8 )
After '89:
Tighten t h e right c r a n kcase cover m o u nti n g bolts i n a
crisscross pattern in 2 or 3 steps and i nstall the clutch cable
holder and oil pipe holder at the same time.
Connect the clutch cable to the clutch lifter arm .
Fill the crankcase with engine oil (page 2 - 4 )
Adjust the c l utch lever free play (page 3- 1 8 )
7- 1 5
ALTERNATO R/STARTER CLUTCH
8-0
8. ALTERNATOR/STARTE R CLUTCH
S E R V I C E I N FORMATI O N
8- 1
F LYW H E E L I N STALLATION
8- 5
L E F T C R A N KCASE C O V E R R E M OVAL
8-2
F LYW H E E L REMOVAL
8-3
LEFT CRANKCASE COVER
I N STALLAT I O N
8-6
S TA R T E R CLUTCH
8-4
SERV I CE I N FORMATION
GENERAL
•
•
This section covers the removal and i nstallation of the alternator, starter clutch and starter gears.
These o pe ration can be done with the engine installed in the frame.
Refer to section 1 5 for troubleshooti ng and inspection of the alternator.
S P EC I F I CATI O N S
mm (in)
ITEM
Starter d riven gear O . D .
STANDARD
SERVICE L I M IT
5 7 . 749 - 5 7 . 768 ( 2 . 2 7 36 - 2 . 2743)
5 7 . 60 ( 2 . 268)
TORQU E VALUES
Flywheel bolt
Starter clutch torx bolts
1 30 N·m ( 1 3 . 0 kg-m, 94 ft-lb) Left-hand thread
30 N·m ( 3 . 0 kg-m , 22 ft-lb) Apply locking agent
TOOLS
Common
Rotor puller
Flywheel holder
Torx bit
07733- 002000 1 or 0 7 9 3 3 - 3 2 9000 1 ( U . S . A . only)
0 7 7 2 5 - 0040000 Equivalent commercially available in U . S . A .
07 703 - 00 1 0 1 00 Equivalent commercially available in U . S . A .
8- 1
.
ALTE RNATO R/S TARTER CLUTCH
LEFT CRAN KCASE COVE R REMOVAL
Remove the left side cover and disconnect the alternator wire
3P connector (WHITE ) .
Remove the drive sprocket cover (page 1 3- 1 4) .
Place a container under the left crankcase cover to catch the
engine oil .
Remove the eleven left crankcase cover bolts and the cover.
Remove the dowel pins and gasket.
STATOR R E P LAC E M E N T
Remove the wire clamp bolts and the clamps.
Remove the stator mounting bolts and stator.
Position the new stator and the grommets in the cover.
Apply a locking agent to the th reads of the stator
mou nting bolts and wire cla m p bolts .
Tighten the stato r mounting bolts and the clamp bolts .
( 1 ) BOLTS
8-2
FLYWH EEL REMOVAL
Remove the starter d rive and i d l e/reduction gears by removing
the s h afts .
H o l d the flywheel with the f l y w h e e l h o l d e r and remove the fly
wheel bolt a n d w a s h e r .
TOOL:
Flyw heel holder
0 7 7 2 5 - 0040000
Equivalent commerc i a l l y
ava i lable i n U . S . A .
NOTE
•
The flywheel bolt h a s l eft- h a n d thre a d s .
Remove t h e flywheel w ith the rot o r p u l l e r .
TOO L :
Rotor puller
07733 - 002000 1 or
07933-329000 1
( U . S . A . only)
Remove the starter d r i v e n gear, washer and needle bearing
from the c r a n kshaft .
Remove t h e wood ruff key .
8-3
STARTER CLUTCH
( 1 l STARTER DRIVEN GEAR
D I SA S S E M B LY
Reinstall the starter driven gear i nto the flywheel .
I nspect the starter clutch by turning the starter driven gear.
The gear should turn counterclockwise freely and should not
turn clockwise: if it turns i ncorrectly, replace the starter
clutch.
Hold the flywheel with the flywheel holder and remove the
torx bolts using a torx bit.
Remove the starter clutch outer and oneway clutch.
TOOLS :
Flywheel holder
07725-0040000
Equivalent commercia l ly
ava i l a ble in U .S.A.
Torx bit
07703-001 0 1 00
Equivalent commercially
available in U .S.A.
I N S PECTI O N
( 1 l STARTER DRIVEN GEAR
Measure the O . D . of the starter driven gear.
SERVICE LIMIT: 57.6 0 mm (2.268 in)
I nspect the oneway clutch for wear or damage and replace if
necessary .
8-4
( 1 l ON EWAY CLUTCH
ASS E M B LY
Install the oneway clutch i nto the clutch outer with the flange
side facing inside.
(3) ON EWA Y CLUTCH
Hold the flywheel with the flywheel holder. Apply locking
agent to the trox bolt threads and tighten the bolts .
TORQUE : 30 N · m ( 3 . 0 kg-m, 22 ft-lb)
TOOLS :
Flywheel holder
Torx bit
07725-0040000
available i n U . S.A.
07703-00 1 0 1 0 0
avai lable i n U . S.A.
FLYWHEEL I NSTALLATION
Clean the crankshaft and install the woodruff key.
Install the needle bearing onto the crankshaft.
Instal l the starter d riven gear and washer onto the crankshaft .
8- 5
Instal l the flywheel, aligning the woodruff key on the crank
shaft with the flywheel keyway.
Hold the flywheel with the flywheel holder, install the washer
and flywheel bolt and tighten the bolt.
TORQUE: 1 30 N·m ( 1 3 . 0 kg-m, 94 ft-lbl
TOOL:
Flywheel holder
NOTE
•
07725-0040000
Equivalent comm ercially
available i n U . S.A.
The flywheel bolt has left hand threads.
Install the starter idle/reduction gear with the longer shaft .
Install the starter d rive gear with the " O UT" mark facing out
and the shorter shaft .
Install t h e dowel p i n s a n d n e w gasket .
LEFT CRAN KCASE COVER I NSTALLATION
Install the left crankcase cover a n d tighten t h e cover bolts with
the neutral and oil pressure switch wire harness clamps as
shown.
Route the alternator wire and connect the alternator 3P con
nector.
Install the drive sprocket cover and the left side cover.
Check the oil level and add oil if necessary .
8-6
M E MO
CYLI NDER H EAD/VALV E
10
N·m ( 1
.0
kg-m,
7.2
ft- l b l
23
N·m
After
��
ft- l b)
'89 :
'
I
�I
e
�' �
2 3 N • m ( 2 . 3 kg-m
1 7 ft- l b )
48 N · m ( 4 . 8 k g - m,
35 ft- l b )
- "0
"
2 3 N•m ( 2 . 3 k g - m,
�
1 0 N•m ( 1
7 . 2 ft- l b )
.0
()
23 N·m ( 2 . 3 kg-m '
1 7 ft- l b )
kg-m,
/� @
'88, '89 :
1 0 N·m ( 1
7 . 2 ft- l b )
9-0
kg-m, 1 7
:
�
'��
'
(2.3
.0
kg-m,
2 3 N•m ( 2 . 3 k g - m ,
1 7 ft- l b )
�
10
N·m ( 1
ft-l b )
.0
kg-m '
9. CYLI N DE R H EAD/VALVE
SERVICE I N FORMATI O N
9-1
VALVE SEAT I N S PECT I O N / REFAC I N G
9- 1 2
TROUBLES H OOTI N G
9-2
CYLIN DER H EAD ASSEM BLY
9- 1 5
CYL I N D E R H EAD COVER REMOVAL
9-3
CYL I N DER H EAD I N STALLATION
9- 1 6
CAM S HAFT R E M OVAL
9-4
CAMS HAFT I N STALLATION
9- 1 8
CYL I N D E R H EAD
9-8
VALVE G U I D E REPLAC E M ENT
9-1 1
CYL I N DER H EAD COVER
I N STALLATION
9-21
G E N ERAL
•
•
•
•
The front cylinder head can be removed without removing the engine.
To service the rear cylinder head, the engine must be removed from the frame. (See section 6 for engine removal and in
stal lation . ) However, the rear cylinder head cover can be removed to service the camshaft, rocker arms, cam chain and
cam chain tensioner.
Camshaft l ubricating oil is fed through an oil pass pipe. Be sure the holes in the oil pass bolts are not clogged .
D u ring assembly a p ply molybd e n u m disu lfide oil (a 50/50 m ixtu re of engine oil a nd molybde n u m disulfide g rease) to
the camshaft h olders , camshaft journals of the cylinder head , rocker a rm shafts, rocker a rm slipper faces and valve
stems to p rovide initial l u b rication .
Unit: mm (in)
ITEM
STANDARD
Compression pressure
Camshaft
Cam lobe height
EX
Journaf O . D .
Runout
Oil clearance
Rocker arm
Valves and
valve guides
3 7 . 730 ( 1 .48 54)
3 7 . 9 50 ( 1 .494 1 )
37 . 7 50 ( 1 .4862)
2 1 . 9 59 - 2 1 . 980 (0. 8645 - 0 . 8 6 54)
0. 030 (0.00 1 2)
0.050 - 0. 1 1 1 (0.0020 - 0 . 0044)
2 1 . 90 (0.862)
0.05 (0.002)
0. 1 30 (0.005 1 )
±
--
Rocker arm I. D .
IN/EX
1 2 . 000 - 1 2 . 0 1 8 (0.4724 - 0 . 47 3 1 )
1 2 .05 (0.474)
Rocker arm shaft
O.D.
Valve stem O . D .
IN/EX
1 1 . 966 - 1 1 . 984 (0.47 1 1 - 0 . 47 1 8)
1 1 . 83 (0.466)
IN
5 . 47 5 - 5. 490 (0. 2 1 56 - 0 . 2 1 6 1 )
5.45 (0.2 1 5)
EX
6 . 5 5 5 - 6 . 570 (0.2580 - 0 . 2 5 8 7 )
6 . 5 5 (0.258)
Valve guide I . D .
IN
EX
5 . 500 - 5 . 5 1 2 (0.2 1 6 5 - 0 . 2 1 70)
6 . 600- 6 . 6 1 5 (0.2598 - 0 . 2604)
5 . 56 (0.2 1 9)
6 . 6 5 (0.262)
Stem-to-guide
clearance
IN
0 . 0 1 0 - 0.037 (0.0004 - 0 . 00 1 5)
0. 1 0 (0.004)
EX
0 . 030 - 0 .060 (0.00 1 4 - 0 . 0024)
0. 1 1 (0.004)
1 . 5 (0.06)
Valve seat width
Valve guide projection height
Valve springs
1 , 324 kPa
1 .0 kg/cm2, 1 92 ± 1 4 psi)
3 7 . 930 ( 1 .4933)
(1 3.5
IN
SERVICE LIMIT
Free length
IN
EX
OUTER
INNER
Cylinder head warpage
IN
EX
IN
EX
0.9- 1 . 1
1 9.4- 1 9.6
1 7.9- 1 8. 1
42. 1 4
(0.03 5 - 0.043)
(0.76 - 0 . 7 7 )
(0. 7 0 - 0. 7 1 )
( 1 .659)
42.83 ( 1 . 686)
38 . 1 1 ( 1 . 500)
38. 8 1 ( 1 . 765)
--
--
--
40 . 58 ( 1 . 598)
41 .25
36.47
37. 5 1
0. 1 0
( 1 . 624)
( 1 .436)
( 1 .47 7 )
(0.004)
9- 1
g
CYL I N D E R H EAD/VALVE
TORQU E VALU E S
Cylinder head cover bolt
Camshaft holder
8 mm
8 mm
6 mm
1 0 mm
Cylinder head
8 mm
8 mm
6 mm
Camshaft sprocket bolt
Cam chain tensioner bolt
Oil pass pipe
7 mm
8 mm
bolt
nut
bolt
nut
bolt
nut
bolt
bolt
bolt
1 0 N·m
23 N · m
23 N · m
1 0 N·m
48 N · m
23 N • m
23 N · m
1 0 N·m
23 N · m
1 0 N·m
1 0 N•m
23 N · m
( 1 .0 kg-m,
(2.3 kg-m,
( 2 . 3 kg-m,
( 1 .0 kg-m ,
(4.8 kg-m ,
(2.3 kg-m,
( 2 . 3 kg-m,
( 1 .0 kg-m ,
( 2 . 3 kg-m,
( 1 .0 kg-m,
( 1 .0 kg-m,
(2.3 kg-m,
7 . 2 ft-lb)
1 7 ft-lb)
1 7 ft-lb)
7 . 2 ft-lb)
3 5 ft-lb)
1 7 ft-lb)
1 7 ft-lb)
7 . 2 ft-lb)
1 7 ft-lb)
7.2 ft-lb)
7 . 2 ft-lb)
1 7 ft-lb)
TO O L S
Special
Valve
Valve
Valve
Valve
guide
guide
guide
guide
reamer ( I N )
reamer ( E X )
driver attachment ( I N )
driver attachment (EX)
07984 - 200000 1 o r 0 7 9 8 4 - 2 00000D
07984 -ZE2000 1 o r 0 7 9 8 4-ZE2000D
07943 - M F50 1 00
07943 - MF50200
Common
Valve guide driver, 5 . 5 mm ( I N )
Valve guide driver, 6 . 6 mm (EX)
07742 - 00 1 0 1 00
07742 - 00 1 0200 N ot available i n U . S . A . 07942 - 6 5 7 0 1 00
0 7 7 5 7 - 00 1 0000 or 07957 - 329000 1
Valve seat cutter (Not available in U . S . A . )
Cutter holder I N 5 . 5 mm
EX 6 . 6 mm
I N 28 mm (32 ° )
Flat cutter
E X 3 5 m m ( 32 ° )
Interior cutter I N 3 0 m m (60 ° )
E X 3 7 . 5 m m (60 ° )
Seat cutter I N 2 7 . 5 mm (45 ° )
E X 3 5 m m (45 ° )
0778 1 - 00 1 0 1 0 1
0778 1 - 00 1 020 1
07780 - 00 1 2 1 00
07780 - 00 1 2300
07780 - 00 1 4000
07780 - 00 1 4 1 00
07780 - 00 1 0200
07780 - 00 1 0400
TROUBLESHOOTI NG
Engine top-end problems are usually performance-related and can usually be diagonosed by a compressio n test.
Engine noises can usually be traced to the top-end with a sounding rod or stethoscope .
Uneven or low compression
•
•
•
Valves
- Incorrect valve adjustment
- Burned or bent valves
- I ncorrect valve timing
- Broken valve spring
Cylinder head
- Leaking or damaged head gasket
- Warped or cracked cylinder head
Cylinder and piston ( Refer to Section 1 0)
High compression
•
Excessive carbon build-up on piston crown or combus
tion chamber
9-2
Excessive noise
•
•
•
•
•
•
Incorrect valve adjustment
Sticking valve or broken valve spring
Damaged or worn rocker arm or camshaft
Loose or worn cam chain
Worn or damaged cam chain tensioner
Worn cam sprocket teeth
Poor idling
•
Compression too low
CYL I N D E R H EAD/VALVE
CYLI N DE R H EAD COVE R REMOVAL
Remove the following parts:
- steering covers
- fuel tank ( page 4-3 )
- carburetors (page 4-6 )
Drain t h e coolant (page 5-3 ) .
Front:
Disconnect the spark plug caps and the water hose.
Remove the water pipe mounting bolt, front water pipe and 0ring.
NOTE
•
If coolant drips on the engine, wipe it off immediately .
Remove the cylinder head cover bolts and cover.
Rear:
'88-'89 , ' 9 1 -'94 :
Disconnect the spark plug caps, crankcase breather tube and
water hose .
Remove the water pipe mounting bolt, rear water pipe and 0ring .
Remove the cylinder head cover bolts and cover.
Unclamp the wire harness from the frame.
After '94 :
D iscon nect the spark plug caps, c ra nkcase b reather tube and
water hose .
Remove the water p i pe mounting bolt, rea r water pipe and
0-ri n g .
Remove the socket bolt and valve adjusti ng cover.
( 2 ) VALVE ADJ U STI N G COV E R
9-3
C Y L I N D E R H EA D IV ALVE
Remove the cylinder head cover bolts, washers and rubber.
(3)
Alig n the wire harness with the valve adjusting hole, then re
move the rear cylinder head cover forward .
RUBBER
( 1 ) R EA R CYLI N D E R H EA D COVER
CAUTI O N
•
B e careful not t o damage the the wire harness .
CAMSHAFT R EMOVAL
Remove the cylinder head covers.
Remove the timing hole cap and crankshaft hole cap from the
left crankcase cover.
Align the FT mark ( rear: RT mark) on the flywheel with the
index mark on the left crankcase cover timing hole by turning
the crankshaft counterclockwise . Make sure the piston is at
TDC (TOP DEAD CENTER) on the compression stroke .
If the piston is not at TDC, turn the crankshaft 360° counter
clockwise, and re-align the mark and index mark.
Measure the amount of the cam chain tensioner projection as
shown. Replace the cam chain with the new one if the projec
tion exceeds 6 .0 mm (0. 24 i n ) .
T o replace the c a m chain, drain the o i l from t h e engine and
remove the following parts :
FRONT CYLI NDER HEAD
Left crankcase cover
Front camshaft
Flywheel
( 1 ) WEDGE B
6.0 mm
(0.24 in)
REAR CYLINDER H EA D
Right crankcase cover
Rear camshaft
Primary drive gear
( 2 ) CAM C H A I N TEN SIONER
9-4
CYLI N D E R H EAD IVALVE
Pull wedge A straight up while holding wedge 8 down.
Secure wedge A with a 2 m m pin as shown.
Remove the camshaft holder on the cam sprocket side by re
moving the two mounting bolts .
Remove the cam sprocket bolt, rotate the crankshaft counter
clockwise one turn (360 ° ) and remove the other cam sprocket
bolt.
NOTE
•
Be careful not to let the cam sprocket bolts fall into the
crankcase .
'88, '89:
Remove the three camshaft holder mounting bolts and the nut,
the oil plate and the holder.
After '89:
Remove the three camshaft ho ld er mou nting bo lts, nuts,
o i l p late and the ho lder.
Remove the dowel pins.
Hang the cam chain on the camshaft behind the camshaft
flange and remove the cam sprocket while lifting the camshaft
out.
Attach a piece of wire to the cam chain to prevent it from
being d ropped into the crankcase.
9-5
CYLI N D E R H EAD IVALVE
I N S PE CT I O N
Cylinder head
Inspect the camshaft holder and cylinder head journal surfaces
for scoring or evidence of i nsufficient lubrication.
Camshaft runout
Support both ends of the camshaft with V-blocks and check
the camshaft runout with a dial indicator.
SERVICE LIMIT: 0.05 mm (0 .002 in)
Using a micrometer, measure the height of each cam lobe.
SERVICE LIMIT:
IN: 37. 730 mm ( 1 .4854 in)
EX: 3 7 . 7 50 mm ( 1 .4862 in)
Check the camshaft journals for wear or damage .
Measure the O . D . of each journ a l .
Camshaft bearing oil clearance
Wipe any oil from the journals. Lay a strip of plastigauge
lengthwise on top of each camshaft journa l .
NOTE
•
Avoid placing plastigauge over the oil hole .
9-6
CYLI N D E R H EAD/VALVE
2
I nstall the camshaft holders and tighten the mounting bolts in
a crisscross pattern i n or 3 steps .
'
88 '89 :
,
NOTE
•
Do not rotate the camshaft when using plastigauge.
TORQUE:
6 mm flange bolt: 1 2 N·m ( 1 . 2 kg-m, 9 ft-lb)
8 mm flange bolt: 23 N•m ( 2 . 3 kg-m, 1 7 ft-lb)
8 mm flange nut: 23 N•m (2.3 kg-m, 1 7 ft-lb)
/(2) 6 mm FLANGE
i
BOLTS
After '89 :
Remove the camshaft holder and measure the width of each
plastigauge. The widest thickness determines the oil clear
ance.
SERVICE LIMIT: 0.23 mm (0.009 in)
When the service limit exceeded, replace the camshaft and re
check the oil clearance .
Replace the cylinder head and camshaft holder if the clearance
still exceeds the service limit.
Camshaft holder/Rocker arm shaft/Rocker arm
Remove the rocker arm shafts by tapping the holder with a
soft hammer.
( 1 ) ROCKER ARM SHAFTS
9- 7
Remove the rocker arms and wave washers from the shafts .
(2)
Inspect the rocker arm shafts and rocker arms for wear or
damage.
Check the rocker arms for clogged oil holes.
Measure the O . D . of each rocker arm shaft.
SERVICE LIMIT:
IN/EX : 1 1 .83 mm (0.466 in)
Measure the I . D . of each rocker arm.
CYLI N DE R H EAD
REMOVAL
NOTE
•
The front cylinder head can be removed with the engine
installed . The engine must be removed to service the rear
cylinder head .
Drain the coolant (page 5-31 and remove the following:
- front camshaft (page 9-31
- the cam chain tensioner mounting bolts and washers from
the cylinder head and cylinder
- cam chain tensioner
Remove the exhaust pipes as an assembly ( Section 6 ) by re
moving the heat protector and exhaust pipe joint nuts.
Disconnect the clutch cable from the clutch lifter arm by re
moving the clutch cable holder bolt.
Remove the oil pipe from the engine.
NOTE
•
Do not bend the oil pipe during removal .
Loosen the 6 mm bolt, 8 mm bolts, 8 mm nut a n d 1 0 mm nuts/
washers in a criss-cross pattern in 2 or 3 steps.
Remove the bolts and nuts.
9-8
�
WAVE WASHERS
CYLI N D ER H EAD/VALVE
Remove the upper radiator hose and the radiator mounting
bolts (page 5-5 ) .
Release the radiator from t h e frame grommets a n d suspend it
with a piece of rope or something suitable.
Remove the front cylinder head .
Remove the gasket, dowel pins and cam chain guide from the
cylinder.
Rear cylinder head :
- engine (section 6 )
NOTE
•
Make sure the piston is at TDC on the rear cylinder com
pression stroke .
- o i l pass pipe ( '88, ' 89) , cy linder head cover, and cam chain
tensio ner
- head bolts and nuts, as described for front cylinder head re
moval
- cylinder head , head gasket, dowel pins, and cam chain
guide
D I SAS S E M BLY/ I N S P E CT I O N
Cylinder head
Clean the cylinder head surfaces of any gasket materia l .
CAUTION
•
•
A void damaging the gasket surfaces.
Gaskets will come off easier if soaked in solvent.
Check the spark plug hole and valve areas for cracks .
Check the cylinder head for warpage with the straight edge
and thickness gauge.
SERVICE LIMIT: 0 . 1 0 mm (0.004 in)
Remove the valve spring cotters, retainers, springs, and valves
using a Valve Spring Compressor.
TOOL:
07757 -001 0000 or
07957 - 329000 1
CAUTION
•
To prevent loss of tension, do not compress the valve springs
more than necessary to remove the cotters.
NOTE
•
Mark all parts during disassembly so they can be placed
back in their original locations.
9-9
Remove the valve stem seals and valve spring seats.
Remove carbon deposits from the combustion chamber.
Valve springs
Measure the free length of the inner and outer valve springs.
SERVICE LIMITS :
INNER (IN) : 36.47
(EX) : 37 . 5 1
OUTER (IN ) : 40 . 58
(EX) : 41 . 2 5
mm
mm
mm
mm
( 1 .436
( 1 .477
( 1 . 598
( 1 .624
in)
in)
in)
in)
Replace the springs as a set if they a re shorter than the service
limit.
Valve stem-to-guide clearance
Inspect each valve for bending, burning, scratches or
abn o rmal stem wear.
Check valve movement i n the guide and measure and record
each valve stem O . D .
SERVICE LIMITS: I N : 5.45 m m (0. 2 1 5 in)
EX: 6.55 mm (0.258 in)
Measure and record each valve guide I . D .
NOTE
•
Ream the guides to remove any carbon deposits before
checking clearances.
SERVICE LIMIT: IN: 5 . 56 mm (0.2 1 9 in)
EX: 6.65 mm (0. 262 in)
Subtract each valve stem O . D . from the corresponding guide
I . D . to obtai n the stem to guide clearance.
SERVICE LIMIT: IN: 0. 1 0 mm (0.004 in)
EX: 0. 1 1 mm (0.004 in)
9- 1 0
(1 ) V
VE STEM
If the stem-to-guide clearance exceeds the service limits, de
termine if a new guide with standard dimensions would
bring the clearance within tolerance. If so, replace any guides
as necessary and ream to fit.
TOOLS :
Valve guide reamer
IN:
EX:
07984-2000001 or
07984-2000000
07984-Z E2000 1 or
07984-Z E2000D
NOTE
•
It is important that the reamer always be rotated in the
same direction when it is inserted or removed .
If the stem-to-guide clearance exceeds the service limits with
new guides, also, replace the valves.
NOTE
•
Reface the valve seats whenever the valve guides are re
placed .
VALVE G U I DE REPLACEM ENT
Chill the valve guides in the freezer section of a refrigerator for
about an hour.
Heat the cylinder head to 2 1 2 ° F ( 1 00 ° C ) with a hot plate or
ove n . Maximum allowable temperature is 300 ° F ( 1 50 ° C ) .
•
To avoid burns, wear heavy gloves when handling he heated
cylinder head.
CAUTION
•
Do not use a torch to heat the cylinder head; it may cause
warping.
Support the cylinder head and drive out the old guides from the
combustion chamber side of the cylinder head .
TOOL:
Valve guide driver ( I N ) :
(EX) :
07742-00 1 0 1 00
07742-00 1 0200 N ot
ava i l a ble i n U .S.A.
07942-65701 00
NOTE
•
Avoid damaging the cylinder head .
( 1 ) VALVE G U I D E
DRIVER
MENT
Make note of the valve guide projection specifications (follow
ing ) , then drive i n new guides from camshaft side of the cylin
der head .
TOOLS:
Valve guide driver
5 . 5 mm (IN) : 07742 - 00 1 0 1 00
6 . 6 mm (EX) : 07742 - 00 1 0200
Attachment
5 . 5 mm (IN): 07943 - MF50 1 00
6 . 6 mm (EX) : 07943 - MF50200
9- 1 1
CYLI NDER H EAD/VALVE
VALVE GUIDE PROJECTION HEIGHT:
IN: 1 9.4- 1 9 .6 mm (0.76 - 0 . 77 in)
EX: 1 7 . 9 - 1 8 . 1 mm (0.70 - 0 . 7 1 in)
Ream the new valve guides after installation .
NOTE
Use cutting oil on the reamer during this operation .
It is important that the reamer always be rotated i n the
same directio n when it is inserted or removed.
•
•
Clean the head thoroughly after reaming the valve guides.
TOOLS :
Valve guide reamer I N :
EX:
07984-2000001 o r
07984-200000 D
07984-Z E200 0 1 or
07984-Z E2000D
VALVE SEAT I NSPECTION/ REFACI NG
Clean a l l intake a n d exhaust valves thoroughly t o remove
carbon deposits .
Apply a light coating of Prussian Blue to each valve seat. Lap
each valve and seat using a rubber hose or other hand-lapping
tool .
Remove and inspect each valve .
CAUTION
•
The valve cannot be ground. I/ the valve face is burned or badly
worn or if it contacts the seat unevenly, replace the valve.
Inspect the width of each valve seat.
STANDARD:
0 . 9 - 1 . 1 mm (0.035 - 0 . 043 in)
SERVICE LIMIT: 1 . 5 mm (0.06 in)
If the seat is too wide, too narrow or has low spots, the seat
must be ground .
9- 1 2
VALV E S EAT C U TT E R S
Honda Valve Seat Cutters, grinder or equivalent valve seat
refacing equipment are reco m m ended to correct a worn valve
seat.
NOTE
•
Follow the refacer manufacturer's operating instructions.
\--- 16
l'---
60 °
------�
___._�
_
I N : 07780 - 00 1 4000
(30 c/>)
EX: 07780 - 00 1 4 1 00
(37 . 5 c/>)
l }\
I N : 07780 - 00 1 2 1 00 (28 c/>)
EX: 07780 - 00 1 2300 (35 c/>)
I N : 07780 - 00 1 0200 (27 .5
EX: 07780 - 00 1 0400 ( 3 5
VALV E S EAT R E FAC I N G
32 '
</> )
</> )
( 1 ) R O U G H N ESS/I RREGULARITI ES
Use a 4 5 degree cutter t o remove any roughness o r irregulari
ties from the seat.
NOTE
•
Reface the seat with a 45 degree cutter when a valve guide
is replaced .
Use a 32 degree cutter to remove the top 1 /4 of the existing
valve seat material .
Use a 60 degree cutter to remove the bottom 1 /4 of the old
seat. Remove the cutter and i nspect the area you have
ref aced .
9- 1 3
CYLI N DER H EAD IVALVE
Install a 45 degree finish cutter and cut the seat to the proper
width . Make sure that all pitting and irregularities are removed .
Refinish if necessary .
Apply a thin coating of Prussia n Blue to the valve seat. Press
the valve through the valve guide and onto the seat to make a
clear pattern.
( 1 ) CONTACT TOO H I G H
NOTE
•
The location of the valve seat i n relation to the valve face is
very important for good sealing .
If the contact area is too high on the valve, the seat must be
lowered using a 32 degree flat cutter.
If the contact area is too low on the valve, the seat must be
raised using a 60 degree inner cutter.
Refinish the seat to specifications, using a 45 degree finish
cutter.
After cutting the seat, apply lapping compound to the valve
face, and lap the valve using light pressure.
After lapping, wash all residual compound off the cylinder
head and valve .
NOTE
•
Do not a llow lapping compound to enter the guides.
9- 1 4
( 1 ) CONTACT T O O LOW
CYLINDER H EAD/VALVE
CYLI N DE R H EAD ASSEM BLY
( 1 ) VALVE (4) RETAINER
I nstall the valve spring seats and new stem seals.
Lubricate each valve stem with m olybdenum disulfide oil and
i nsert the valve i nto the valve guide. Turn the valve slowly
while i nserting to avoid damaging the seals .
�
171
SPRING
j·/_· 11(.
SPR I N G ( 6 ) I N N E R
S EAT
SPR I N G
1" ·
( 5 ) COTTERS ?
Move the valves u p and down to check for smooth operation.
Install the valve springs with the tightly wound coils facing the
combustion chamber.
I nstall the spring retainers.
Compress the springs and i nstall the valve cotters.
CAUTION
•
To prevent loss of tension, do not compress the valve springs
more than necessary to install the valve cotters.
TOOL:
07757 - 00 1 0000 or
07957 - 329000 1
9- 1 5
Tap the valve stems gently with a soft hammer to firmly seat
the cotters .
NOTE
•
Support the cylinder head above the work bench surface to
prevent possible valve damage.
Apply locking agent to the threads of the sealing bolts and
tighten them, if removed.
CYLI N DER HEAD I NSTALLATION
I nstall the cam c h a i n g u i d e into the cylinder.
Make sure that the cam chain guide bosses are i n the grooves
of cylinder.
Clean the cylinder head surface of any gasket material .
I nstall the dowel pins and a new head gasket.
9- 1 6
CYLI N D E R H EA D IV ALVE
I nstall the carburetor insulator o n the cylinder head, aligning
the boss on the cylinder head with the slot in the insulator.
( 1 ) BOSS
(2)
SLOT
After '9 1 (Cal ifornia model only) :
I nstall the insulator bands align i n g the pins o n the insulator
bands with the slots o n the insulato rs as shown .
Tighten the band screws secu rely .
I nstall the cylinder head .
I nstall the 1 0 m m nut/washer, 8 m m nut/washer, 8 mm bolt/
washer and 6 mm bolt and tighten them in a crisscross pattern
i n 2 or 3 steps.
TORQUE :
1 0 mm
8 mm
8 mm
6 mm
nut:
bolt:
nut:
bolt:
48
23
23
10
N•m
N•m
N·m
N•m
(4.8
(2.3
(2.3
( 1 .0
kg-m,
kg·-m,
kg-m,
kg-m,
35 ft-lb)
1 7 ft-lbl
1 7 ft-lbl
7.2 ft-lbl
41
.
( 3 ) 8 m m BOLTS/WASHE
'88, '89:
RS!
..
( 1 ) SEALING WASH ERS
Check the oil pass pipe bolts and oil pass pipe for clogging or
bending.
.--
I nstall the oil pass pipe, new sealing washers, oil pass pipe
bolts and the pipe holder bolt.
Tighten the bolts .
TORQU E :
O i l pass pipe bolt:
7 mm: 1 0 N•m ( 1 .0 kg-m, 7 . 2 ft-lb)
8 mm: 23 N • m (2.3 kg-m, 1 7 ft-lb)
( 3 ) O I L PIPE
(2)
r
HOLDER
9- 1 7
I nstal l the following :
- cam chain tensioner with washers and bolts .
TORQUE: 1 0 N·m ( 1 . 0 kg-m , 7 . 2 ft-lbl
- camshaft ( page 9- 1 8 )
- camshaft holders ( page 9 - 1 9 )
- cylinder head cover (page 9-2 1 )
( 1 l CHAIN TEN SIONER
WASH ERS/SOLTS
-------�
.,_,� 'il!lltW'
CAMSHAFT I NSTALLATION
""""'
( 1 ) WAVE WASHERS
Apply m ol ybdenum disulfide oil to t h e rocker arm shafts .
I nstal l the ·ocker arms, rocker arm shafts and wave washers i n
t h e camshaft holders .
NOTE
•
I nstal l the wave washers in the proper position as show n .
Position the grooves in the rocker a r m shafts vertically, align
ing the bolt holes of the holder with the holes of the shafts .
Apply molybdenum disulfid e oil to the rocker a rm slipper faces .
F R O N T CYLI N D E R
NOTE
•
If the rear cylinder head has not been serviced, remove the
rear cylinder head cover and check the camshaft position as
follows:
Turn the crankshaft counterclockwise and align the " RT"
mark on the flywheel with the index mark on the timing
hole, then look for the identification mark on the camshaft
flange .
If the notch mark is facing up, turn the crankshaft counter
clockwise approximately 1 - 1 /8 turn (41 2° ) and begi n
instal l ation of t h e front camshaft.
If the notch mark faces down ( cannot be seen) , turn the
cra nkshaft cou nterclockwise approxi matel y 1 /8 turn
°
( 52 ) and beg i n insta l lation.
9- 1 8
, MoS2
( 1 ) G ROOVES
CYLI N D ER H EAD IV ALVE
Align the " FT" mark on the flywheel with the index mark on
the timing hol e .
N OTE
•
If the front and rear cylinder c a mshafts were removed, do
not confuse the m . Check the i dentification mark on the
neck of the camshaft flange.
I nstall the camshaft i n the cylinder h ead through the cam chain
and install the cam sprocket on the camshaft with the I N mark
facing inside .
With the notch mark on the camshaft flange facing up, align
the timing marks ( i ndex lines) on the cam sprocket with the top
of the cylinder head.
( 1 ) N OTCH
Place the cam chain on the sprocket.
Install the cam sprocket on the camshaft flange and recheck
that the timing marks (index lines) a l ign with the top of the cyl
inder head .
Align the cam sprocket bolt holes in the cam sprocket and
camshaft, install and tighten the cam sprocket bolt.
( 1 ) CAM SPROCKET BOLT
(2) HOLDER
TORQUE: 23 N · m (2.3 kg-m, 1 7 ft-lbl
T u rn the crankshaft cou nterclockwise one fu l l t u rn (360° )
. and insta l l the other sprocket b o lt .
°
T u rn the crankshaft counterclockwise one fu l l t u rn (360 ) .
a l i gning the "FT" mark with the i ndex mark, then check that
the tim ing marks on the cam sprocket a l ign with the to p of
the cy l ind er head .
9-19
CYLI NDER H EAD/VALVE
'88, '89:
I nstal l the dowel pins into the cylinder head .
I nstal l the holders, oil plate, 8 mm bolts, 8 m m nut and 6 mm
bolts .
After '89:
I nsta l l the dowel p ins into the cy linder head .
1 11sta l l the ho lders, o i l pipe 8 m m bo lts, 8 m m nuts and 6 mm
bo lts.
TORQU E :
'8 mm bolt: 23 N • m (2.3 kg-m, 1 7 ft-lb)
8 mm nut: 23 N•m (2.3 kg-m, 1 7 ft-lbl
6 mm bolt: 10 N • m ( 1 .0 kg-m, 7.2 ft-lb)
CAUTION
•
Note the direction of the camshaft end holder, install the flat
surface on the holder facing in.
After insta l l ing the front cy l inder camshaft, t u rn the crank
°
shaft counterclockw ise approximate ly 7 /8 t u rn ( 308 ) and
a l i gn the RT mark with the index on the t i m ing ho le, then
insta l l the rear cylinder camshaft.
Lubricate the cam lobes with fresh engine o i l .
If the cylinder head w a s removed from t h e engine in t h e frame,
instal l the following :
- radiator with upper radiator hose
- exhaust pipe
R E A R CYLI N D E R
NOTE
•
If. the front cylinder head was not serviced, remove the
front cylinder head cover and check the camshaft position
as follows:
Turn the crankshaft counterclockwise and align the "FT"
mark on the flywheel with the index mark on the timing
hole, then look for the identification mark on the camshaft
flange. If the notch mark is facing up, turn the crankshaft
countercl ockwise approx i mate l y 7/8 tu rn (308° ) a n d
begin insta l lat ion of the rear camshaft.
I f the camshaff notch mark faces down (cannot be seen) ,
t u rn the crankshaft co unterclockw i se appro x i mately
1 -7 /8 t u rn (668° ) and begin insta l lation.
9-20
After '89 :
C Y L I N D E R H EADNA L V E
Make sure that the " RT" ma�k on the flywheel aligns with the
index mark on the timing hole .
Place the camshaft into the correct position with the notch
mark on the camshaft flange facing up and install the cam
sprocket and camshaft holders using the same procedu re as
for the front cylinder.
Remove the 2 m m pin holding cam chain tensioner wedge A.
NOTE
•
•
Be careful not to let the 2 mm pin fal l i nto the crankcase .
Do not forget to remove the 2 m m pin before installing the
cylinder head cover.
CYLI N DE R H EAD COVE R I NSTALLATION
( 1 ) APPLY C ONTACT CEMENT
Clean the gasket and apply contact cement to the gasket
groove .
Apply sealant around the gasket.
Install the cylinder head cover, rubber washer, washer cover
and cylinder head cover bolts .
Tighten the cover bolts.
TORQUE: 1 0 N • m ( 1 .0 kg-m, 7 . 2 ft-lb)
�
'\\
( 1 ) R U BB ER
WASH E R
( 2 ) WASH E R
COVER
"\ (3) BOLT
CYLI NDER H EAD IV ALVE
I nstall the 0-ring on the water pipe with the tapered side facing
out and install the water pipe i nto the cylinder head .
Connect the water hose to the water pipe and i nstall the spark
plug caps.
I nstall the following parts :
- carburetors (page 4- 1 5)
- steering covers
Fill the cooling system (page 5-3)
' 2
9- 2
MEMO
CYLI N D ER/P IS TO N
1 0-0
10. CYLI N DE R/ P I STO N
S E RVIC E I N FO R M ATIO N
1 0- 1
P IS TO N R I N G I NS TALLATIO N
1 0- 5
TRO U BLES HOO T I N G
1 0- 1
PISTO N I NS TALLATIO N
1 0- 5
C Y LI N D E R
1 0- 2
C Y L I N D E R I NS TALLATIO N
1 0- 6
PIS TO N
1 0- 3
GEN ERAL
•
•
•
•
This section covers service of the cylinder and pisto n .
The front cyl inder/piston c a n b e serviced with t h e engine installed in the frame.
The engine must be removed to service to rear cylinder/piston.
To service the crankcase stud bolts, refer to page 1 1 - 1 5 .
Unit: mm ( i n )
STANDARD
SERVICE LIMIT
7 5 . 000 - 7 5 . 0 1 5 ( 2 . 9 5 2 8 - 2 . 9 5 3 3 )
75. 1 0 (2.957)
ITEM
Cylinder
Piston,
piston
rings
and piston
pin
I. D .
Warpage across top
Taper
--
0 . 1 0 ( 0 . 004)
--
0 . 06 ( 0 . 00 2 )
O ut-of-round
Piston ring-to-ring
g roove clearance
--
0 . 0 6 ( 0 . 00 2 )
Ring end gap
TOP
SECO N D
TOP
SECOND
OIL
0 . 0 1 5 - 0 . 0 4 5 ( 0 . 0006 - 0 . 00 1 8 )
0 . 1 0 ( 0 . 004)
0 . 0 1 5 - 0 . 0 4 5 ( 0 . 0006 - 0 . 00 1 8 )
0 . 1 0 ( 0 . 004)
0 . 1 0 - 0 . 30 ( 0 . 004 - 0 . 0 1 2 )
0 . 50 ( 0 . 020)
0 . 1 0 - 0 . 30 ( 0 . 004 - 0 . 0 1 2 )
0 . 50 ( 0 . 020)
0 . 20 - 0 . 7 0 ( 0 . 00 8 - 0 . 0 2 8 )
0 . 90 ( 0 . 0 3 5 )
Piston O . D .
7 4 . 9 6 5 - 7 4 . 9 90 ( 2 . 9 5 1 4 - 2 . 9 5 2 4 )
Piston pin bore
Connecting rod smal l end I . D .
1 8 . 0 0 2 - 1 8 . 008 ( 0 . 7 08 7 - 0 . 7 0 9 0 )
1 8 .05 (0. 7 1 1 )
1 8 . 0 1 6 - 1 8 . 034 ( 0 . 7 0 9 3 - 0 . 7 1 0 0 )
1 8.07 (0. 7 1 1 )
Piston pin O . D .
Piston-to-piston pin clearance
Cylinder-to-piston clearance
1 7 . 9 94 - 1 8 . 000 ( 0 . 7084 - 0 . 70 8 7 )
1 7 . 98 (0.708)
Piston pin-to-connecting rod
small end clearance
7 4 . 90 ( 2 . 94 9 )
0 . 00 2 - 0 . 0 1 4 ( 0 . 000 1 - 0 . 00 0 6 )
0 . 040 ( 0 . 00 1 6 )
0 . 0 1 0 - 0 . 0 5 0 ( 0 . 0004 - 0 . 00 2 0 )
0 . 1 0 ( 0 . 004)
0 . 0 1 6 - 0 . 040 ( 0 . 0006 - 0 . 00 1 6 )
0 . 060 ( 0 . 00 2 4 )
TROUBLESHOOTI NG
Low o r uneven compression
•
•
•
Worn cylinder or piston rings.
Leaking head gasket .
Incorrect valve timing.
Piston noise
•
•
Worn cylinder and piston.
Excessive carbon deposits .
Excessive smoke
•
•
•
Worn cylinder and piston rings.
Improperly insta lled piston rings.
Damaged piston or cylinder.
Overheating
•
Excessive carbon deposits on piston or combustion
chamber.
Faulty water p u m p .
1 0- 1
CYLI N D E R/PI STO N
CYLI N DER
R E M OVAL
NOTE
•
To service the rear cylinder/piston , first remove the engine
and then proceed with the common removal steps below.
- cylinder head cover (page 9 - 3 )
- cylinder head (page 9-8)
- gaskets, dowel pins, and cam chain guides.
Disconnect the water hose from the coolant connector.
Remove the clip and slide the cylinder joint collar toward
eigther the front or rear cylinder.
Remove the cylinder to be serviced .
Remove the cylinder gasket and dowel pins from the crank
case .
I N S PE CT I O N
Clean the top o f each cylinder thoroughly.
I nspect the cylinder walls for scratches and wear .
Measure and record t h e cylinder I . D . a t three levels in both an
X and Y axis . Take the maximum reading to determine the cyl
inder wear.
SERVICE LIMIT: 7 5 . 1 0 mm ( 2 . 9 5 7 in)
Calculate the piston-to-cylinder clearance . Take the maximum
reading to determine the clearance.
SERVICE LIMIT: 0. 1 0 mm (0.004 in)
Calculate the cylinder for taper at three levels i n an X and Y
axis. Take the maximum reading to determine the taper.
Calculate the cylinder for out-of-round at three levels in an X
and Y axis . Take the maximum reading to determine the out
of-roun d .
The cylinder must be rebored and an oversize piston fitted if
the service limits are exceeded.
The following oversize piston are available:
0.25 mm (0.01 0 in) and 0 . 50 mm (0. 020 in)
The cylinder must be rebored so that the clearance to a n over
size piston is 0. 0 1 0 - 0.050 mm (0. 0004 - 0 . 0020 in) .
1 0- 2
(1) IN
(3)
o�
�
TOP F""-....,.;;1;;;;�� X
( 2 ) EX
CYLI N D E R/PISTON
Inspect the cylinders for transverse warpage across the top.
NOTE
•
Measure warpage using a straight edge and feeler gauge as
shown .
SERVICE LIMIT: 0 . 1 0 mm (0.004 in)
P I STON
R E M OVAL
Place a shop towel i nto the crankcase and remove the piston
pin clips.
NOTE
•
Do not let the clips fall into the crankcase .
Push the piston pin out and remove the piston .
I N SPECTI O N
Clean the piston domes, ring lands and skirts .
Measure the piston ring-to-groove clearance .
SERVICE LIMIT:
Top :
0 . 1 0 mm (0.004 in)
Second : 0 . 1 0 mm (0.004 in)
If clearance is excessive, replace the piston ring.
Remove the piston rings and mark them to indicate the correct
cylinder and piston position for reassembly.
NOTE
•
Do not damage the piston rings when removing them.
1 0-3
CYLI N D ER/PISTON
I nsert the old piston ring into the proper ring groove and clean
the groove by rol l i n g the ring around the pistons
circumference .
Inspect the piston for cracks or other damage.
Measure the piston O . D .
NOTE
•
Take measurements 1 0 mm
9 0 ° to the piston pin hole.
(0.4
in) from the bottom , and
SERVICE LIMIT: 74.90 mm ( 2 . 949 in)
Calculate the piston-to-cylinder clearance by subtracting the
piston O . D . from the cylinder I . D . (page 1 0- 2 ) .
SERVICE LIMIT: 0.32 mm (0.0 1 3 in)
Measure the top and second piston ring end gaps : using a pis
ton , push the ring into the cyl inder squarely and make the mea
surement.
SERVICE LIMIT:
Top/Second : 0 . 50 mm (0.020 in)
Oil:
0 . 90 mm (0.035 in)
Measure each piston pin bore .
SERVICE LIMIT: 1 8 .05 mm (0. 7 1 1 in)
Measure each piston pin O . D .
SERVICE LIMIT: 1 7 . 98 mm (0. 708 in)
Calculate the piston pin-to-piston clearance .
SERVICE LIMIT: 0.40 mm (0.00 1 6 in)
1 0-4
CYLI N D E R/P ISTON
Measure the I . D . of the connectin g rod small end .
SERVICE LIMIT: 1 8 .07 mm (0. 7 1 1 in)
Calculate the piston pin-to-con n e cting rod clearance .
SERVICE LIMIT: 0.060 mm ( 0 . 0024 in)
Refer to section 1 1 for connecting rod replacement.
P I STON R I N G I NSTALLATION
NOTE
•
Insert the outside surface of the ring into the proper ring
groove and rol l around in the g roove to make sure that the
ring has a free fit around the p i ston ' s circumference.
Carefully install the piston rings o nto the piston with the mark
ings facing u p .
NOTE
•
Be careful not to damage the p i ston and piston rings during
assembly.
Stagger the ring end gaps
show n .
1 20 °
apart from each other as
NOTE
•
(7)
(7)
mm OR 20 mm OR
MORE
MORE
20
To install the oil ring, instal l t h e spacer first, then instal l the
side rails.
After installing the rings, check that they rotate freely without
sticking.
P I STON I N STALLATION
Place a shop towel into the cra n k case .
Coat the rod small end with molybdenum disulfide grease . As
semble the piston and connecting rod with the piston and
piston pin clips as shown .
NOTE
•
•
•
I nstall the pistons with the m a rk " I N " facing towards the
intake side .
After installing the piston pin c l ips, make sure that they are
seated properly and the end gaps are not aligned with the
cut-out in the piston.
Do not let the piston pin clips fall into the crankcase .
1 0- 5
CYLI N D E R/PISTON
CYLI N DER I NSTALLATION
Clean the cylinder gasket surface being careful not t o drop any
gasket material into the crankcase .
I nstall the dowel pins and new gasket.
Coat the cylinders piston rings/grooves and piston with oil .
Install the piston assembly into the cylinder from the top of the
crankcase while compressing the piston rings with your fin
gers.
Be sure each assembly is returned to its original position as
noted during remova l .
N OTE
Be careful not to damage the piston rings during assembly.
When the cylinder is halfway over the piston , route the cam
chain through the cylinder.
•
•
I nstal l a new 0-ring onto the cylinder joint and install the cylin
der joint collar by sliding the collar toward eigther cylinder.
I nstal l the clip securely.
Clean the cylinder gasket surface being careful not to drop any
gasket material .
NOTE
•
Avoid damaging the gasket surface .
Install the cam chain guide.
NOTE
•
•
Align the guide boss with the groove in the cylinder.
Make sure that the end of the guide is inserted into place in
the crankcase .
1 0- 6
CYLI N D ER/PISTON
I nstal l a new 0-ring into the connecting pipe and install and
tighten the connecting pipe mounting bolts, if the connecting
pipe was removed .
If only the water hose was removed , connect the hose with
clamp.
I nstal l the dowel pins and a new gasket .
I nstal l the cylinder heads and covers (Section 9 ) .
, (1) DOWEL PINS
\
1 0- 7
CRAN KSHAFT/TRANSM ISSION
'88 -'89 , ' 9 1 -' 9 5 :
20 - 30 N • m ( 2 . 0 - 3 . 0 kg-m, 1 4 - 22 ft-lb)
34 N·m (3.4 kg- m 2 5 ft-lb)
'
'88 -' 8 9 . ' 9 1 -' 9 5 :
30-50N · m (3 . 0-5 . Okg - m , 2 2 - 3 6ft- lb)
1 1 . CRAN KSHAFT/TRANSM I SSION
S E RVIC E I N FO R MATIO N
1 1 -1
C RA N KC A S E
1 1 -1 3
T RO U BLESHOOT I N G
1 1 -3
C RA N KCASE SEPARAT I O N
1 1 -4
TRAN S M I S S IO N ASS EMBLY I
I N STALLATIO N
1 1 -1 7
C RA N KS H AFT/CO N N EC T I N G RO D
1 1 -5
C RA N KC A S E ASSEM BLY
1 1 -1 9
T RA N S M I SSIO N
1 1 -1 1
G E N ERAL
•
•
•
•
To service the connecting rods, crankshaft, transmission and oil pump, the engine must be removed from the frame ( Sec
tion 6 ) .
A l l bearing i nserts are select fitted a n d are identified b y color code. Select replacement bearings from the code tables.
After instal l ing new bearings, recheck them with plastigauge to verify clearance.
Apply molybdenum disulfide g rease to the main journals and crankpins during assembly.
Before separating the crankcase, the following parts must be removed .
Section 9
Cylinder head cover
Water pipe
Camshaft holder
Cam chain and drive sproket
Section 1 0
O i l pass pipe
Cylinder joint collar
Water hose connecting pipe
Cam chain tensioner
Section
C a m chain guide
Crankshaft
Connecting rod
Transmission
O i l pump
9,
Section
9
NOTE
.
-
Camshaft
l
Section
-
The front cylinder camshaft and cylinder head
service c an be performed without removing
the engin e from the frame.
9
Cylinder head
Section 1 0
10
------
- C R A N KCASE _
SEPA RATIO N
Cylinder
Piston
+
Starter motor ( Section 1 7 )
R ight crankcase cover ( Section 7 )
- Clutch
- Gearshift linkage
- Primary drive gear
- Oil pipe
Left crankcase cover ( Section 8 )
- Flywheel
- Starter gears
1 1 -1
Ill
C RA N KS HAFT/TRAN S M I S S I O N
mm (in)
ITEM
Con
nectin
g rod big end side clearance
Cra n kshaft/
connecting rod Crankpin o i l clearance
Main journal oil clearance
Crankshaft ru nout
C1
Gear I . D .
Transmission
M 4 , M 2 , C3
Gear bushing O . D . C 1
M 4 , M 2 , C3
C1
Gear bushing I . D .
M2
C1
B ushing-toshaft clearance
M2
S hift fork/
fork-shaft
Gear-tobushing clearance
M4, M2
C 1 , C3
Cou ntershaft 0 . D .
Mainshaft 0 . D .
Backlash
C 1 bushing
M 2 bushing
1 st, 2 n d , 3rd
4th
Claw thickness
'88 , ' 89 , ' 9 1 -' 9 5 :
After'9 5 :
' 88 , ' 89 , ' 9 1 -' 9 5 :
Shaft O . D .
After'9 5 :
Shift drum 0 . D . (at the left side journal)
Right and left shift
fork I . D .
2 4 . 000-24 . 02 1 ( 0 . 9449-0 . 94 5 7 )
2 8 . 000-2 8 . 02 1 ( 1 . 1 02 4- 1 . 1 03 2 )
2 3 . 9 59-23 . 980 ( 0 . 9433-0 . 944 1 )
2 7 . 9 59-2 7 . 980( 1 . 1 007- 1 . 1 0 1 6)
2 0 . 0 1 6-2 0 . 03 7 ( 0 . 7 880-0 ._7889)
2 5 . 000-2 5 . 02 1 ( 0 . 9843-0 . 9 8 5 1 )
0 . 02 3 -0 . 05 7 (0 . 0009-0 . 02 2 )
0 . 020-0 . 062 ( 0 . 0008-0 . 0024)
S E RV I C E LI M IT
0 . 30(0 . 00 1 )
0 . 07 ( 0 . 003)
0 . 06 (0 . 002)
0 . 05 ( 0 . 002)
2 3 . 94 (0 . 943)
2 8 . 04 (0 . 1 04)
2 4 . 94 (0 . 982)
2 7 . 94 ( 1 . 1 00)
2 0 . 06 ( 0 . 790)
2 5 . 04 (0 . 986)
0. 1 0 (0 . 004)
0. 1 0 (0 . 004)
0 . 002-0 . 062 ( 0 . 0008-0 . 0024)
0. 1 0 (0 . 004)
1 9 . 980- 1 9 . 99 3 ( 0 . 7 8 6 6-0 . 7 8 7 1 )
2 4 . 9 59-24 . 980(0 . 98 3 5 -0 . 9 8 2 6 )
1 . 02 1 -0 . 1 1 0 ( 0 . 0008-0 . 0043)
1 . 02 3 -0 . 1 1 7 ( 0 . 0009-0 . 0046)
5 . 93-6 . 00(0 . 2 3 3 -0 . 2 3 6 )
1 3 . 000- 1 3 . 0 1 8 ( 0 . 5 1 1 8-0 . 5 1 2 5 )
1 3 . 000- 1 3 . 02 1 ( 0 . 5 1 1 8-0 . 5 1 2 6 )
1 2 . 9 6 6 - 1 2 . 984(0 . 5 1 05-0 . 5 1 1 2 )
1 2 . 9 6 6- 1 2 . 984(0 , 5 1 05-0 . 5 1 1 2 )
1 1 . 9 6 6 - 1 1 . 984 ( 0 . 47 1 1 -0 . 47 1 8)
1 9 . 9 6 (0 . 786)
2 4 . 94 (0 . 982)
STAN DAR D
0 . 05-0 . 2 0 (0 . 002-0 . 008)
0 . 02 8 -0 . 05 2 (0 . 00 1 1 -0 . 0020)
0 . 02 5-0 . 04 1 (0 . 00 1 0-0 . 00 1 6 )
-
T O R Q U E VALU ES
Connecting rod bearing cap nut
Crankcase 8 mm stud bolt
1 0 mm stud bolt
34 N ·m ( 3 . 4 kg- m , 2 5 ft-lb)
20 - 30 N · m ( 2 . 0 - 3 . 0 kg-m, 1 4 - 2 2 ft-lb)
30 - 50 N ·m ( 3 . 0 - 5 . 0 kg-m, 2 2 - 36 ft-lb)
TOOLS
Special
Main bearing driver attachment
Bearing remover set
- remover handle
- remover weight
0 7 H M F - M M 90400
07936 - 3 7 1 000 1
07936 - 3 7 1 0 1 00
07936 - 3 7 1 0600
07741 - 00 1 020 1 or
07936 - 3 7 1 0200
Common
Driver
Attachment, 42
Pilot, 20 mm
Attachment, 52
Pilot, 22 mm
Pilot, 2 5 mm
1 1 -2
x
4 7 mm
x
55 mm
07749 - 00 1 0000
07 746 - 00 1 0300
077 46 - 0040 500
07746 - 00 1 0400
07 746 - 004 1 000
07746 - 0040600
U . S . A . Only
5 . 63 ( 0 . 2 2 2 )
1 3 . 04 (0 . 5 1 3)
1 3 . 04 (0 . 5 1 3)
1 2 . 9 0 (0 . 508)
1 2 . 9 5 (0 . 509)
1 1 . 94 (0 . 47 0)
CRA N K S HA FT/TRANSMISS I O N
TROU BLESHOOTI N G
Excessive noise
Crankshaft
- Worn main bearing
- Worn crankpin bearing
•
connecting rod
- Worn rod small end
- Worn crankpin bearing
•
Hard to shift
•
•
•
•
•
Shift
Shift
Shift
Shift
Shift
forks bent
fork shaft bent
spindle claw bent
drum cam grooves damaged
fork guide pin damaged
Transmission jumps out of gear
•
•
•
Gear dogs worn
Shift shaft bent
Shift forks bent
1 1 -3
CRANKS HAFT/TRANSMISSION
CRAN KCASE SEPARATION
Remove the engine from the frame ( Sectio n 6).
Refer to the service i nformation ( page 1 1 - 1 ) for the parts that
must be removed before the separating the crankcase .
Remove the oil pipe stay and cam chain tensioner set plate by
removing the bolts .
Remove the rear cam chain and cam chain drive sprocket.
Remove the bolt and cam chain tensioner set plate .
Remove the front cam chain from the crankshaft.
Remove the 8 mm bolts and 6 mm bolts from the left crank
case .
NOTE
•
•
2
Remove the bolts in a crisscross pattern in or 3 steps.
Loosen the 6 mm bolts first, then loosen the 8 mm bolts .
Remove the 8 m m bolts and 6 mm bolts from the right crank
case .
NOTE
•
•
2
Remove the bolts in a crisscross pattern in or 3 steps.
Loosen the 6 mm bolts first, then loosen the 8 mm bolts .
1 1 -4
•• •
CRANKS HAFT/TRA N S M I S S I O N
Place the left crankcase side down and separate the right
crankcase from the left crankcase while prying where indicat
ed at the point shown and tapping the cases at several loca
tions w ith a soft hammer.
Remove the dowel pins and clean the cran kcase halves of any
sealant materia l .
(1)
DOWEL PINS
.__
CRAN KSHAFT/CON N ECTI NG ROD
C RA N K S H A FT R E M OVAL
Remove the crankshaft from the left crankcase .
C RA N K S H A FT S I D E C L EARA N C E I N S PECTI O N
(1 l
FEELER GAUGE
Check t h e connecting rod side clearance with feeler gauge.
If either side clearance exceeds the service limit, replace the
connecting rod and recheck.
If still beyond the limit, replace the crankshaft.
I nspect the crankshaft for rough spots or damage.
1 1 -5
CRANKSHAFT/TRA N S M I S S I O N
C O N N ECTI N G R O D D I SA S S E M B LY
( 1 ) BEA R I N G CAPS
Remove the connecting rod bearing caps noting their loca
tions .
NOTE
•
Tap the side of the cap lightly if it is hard to remove .
CAUTION
•
Do not interchange the crankpin bearings. They must be in
stalled in their original positions or the correct bearing oil clear
ance may not be obtained resulting in engine damage.
•
C RA N K S H A FT R U N O U T I N S P ECTI O N
Place the crankshaft on a stand or V blocks .
Set a dial indicator on the main journals. Rotate the crankshaft
two revolutions and read the runout.
Actual runont is 1 /2 the tota l indicator read ing .
NOTE
•
The crankshaft cannot be repaired . Replace it if the journals
or crankpins are burnt, cracked, or if the runout is beyond
limits .
C O N N E CTI N G R O D B E A R I N G I N S P E CT I O N
Inspect the bearing insert� for damage or separation .
Clean all oil from the bearing inserts and crankpins.
( 2 1 SEPARATION
O I L C LEARA N C E I N S P ECTI O N
Put a piece o f plastigauge o n each crankpin avoiding the oil
hole .
I nstal l the bearing caps and rods on the correct crankpins, and
tighten them evenly.
TORQUE: 34 N • m (3.4 kg-m, 25 ft-lbl
NOTE
•
Do not rotate the crankshaft during inspectio n .
1 1 -6
( 1 ) PLASTI GAU G E
( 1 1 DAMA G E
CRAN KS HAFT/TRA N S M ISSION
Remove the caps and measure the compressed plastigauge at
its widest point on each crankpin to determine the oil clear
ance.
SERVICE LIMIT: 0.07 mm (0.003 i n )
I f the rod bearing clearance is beyond tolerance, select re
placement bearings.
C O N N E C T I N G ROD B EA R I N G S E LECT I O N
( 1 ) I . D . CODE N U M BER
Determine t h e connecting rod I . D . code number.
The code will be either a number 1 or 2 located on the rod in
the area shown.
Determine the corresponding crankpin O.D. code (or measure
the crankpin O . D . ) . The code will be either a letter A or B on
the crank weight.
C ross reference the crankpin and connecting rod codes to de
termine the replacement bearing color.
1\
C RANKPIN O . D . CODE
C O N N ECTI NG
R O D I.D. CODE
1
2
\
43.000 - 43 . 007 mm
( 1 . 6 9 29 - 1 . 6932 i n )
43.008 - 43 .0 1 6 m m
( 1 . 6932 - 1 .6935 i n )
A
3 9 . 982 3 9 . 990 mm
( 1 . 5 741 1 . 5 744 in)
c
( BROWN )
B
( B LACK)
B
39.97439.98 1 mm
( 1 . 57381 . 5741 in)
B
(BLACK)
A
( BLUE)
( 1 l O . D . CODE LETTERS
( 1 ) CRANKPIN BEAR I N G S
/
BEARING I NSERT THICKN ESS
A ( B L U E ) : 1 . 49 5 - 1 .499 mm (0.0589 - 0 .0590 i n )
B ( B LACK) : 1 .49 1 - 1 .495 mm (0.0587 - 0 . 0589 i n )
C ( BROWN ) : 1 .487 - 1 .49 1 mm (0.058 5 - 0. 0587 in)
1 1 -7
CRANKS HAFT/TRA N S M ISSION
M A I N BEAR I N G I N S PECTI O N
Measure the main journal O . D . and record it.
Measure the main journal bearing I . D . and record it.
Calculate the clearance between the main journal and the main
bearing .
If the oil clearance is beyond the service limit, select a replace
ment bearings as follows:
M A I N BEAR I N G S E LECTI O N
2
Determine the crankshaft main journal O . D . code. The code
will be either a number 1 or on the crank weight.
Determine the replacement main bearing.
Determine the corresponding main bearing I . D . code . The code
will be either a letter A or 8 on the crankcase .
1 1 -8
C RAN KSHAFT/TRAN S M ISSION
Choss replacement main bearings i n accordance with the table
below .
�
M A I N J O U RNAL
O . D . CODE
CASE I . D . C O D E
\
1
44. 9924 5 . 000 mm
( 1 . 7 7 1 31 . 77 1 7 i n )
48 . 9 90 - 49 . 000 mm
( 1 . 9 2 8 7 - 1 . 9 2 9 1 in)
49.000 - 49 .0 1 0 mm
( 1 . 9 2 9 1 - 1 . 92 9 5 i n )
A
B
c
( B ROWN )
B
( B LACK)
2
44. 984 44 . 9 9 1 mm
( 1 . 77 1 01 . 7 7 1 3 in)
B
( BLACK)
A
( BLU E)
BEARING I NSERT THICKNESS
A (BLU E ) : 2 . 003 - 2 . 0 1 3 mm ( 0 . 0789 - 0.0793 in)
B (BLACK) : 1 . 998 - 2 . 008 mm ( 0 . 0787 - 0 . 0 7 9 1 in)
C ( BROWN ) : 1 . 9 93 - 2 . 003 mm ( 0 . 0785 - 0.0789 in)
MAI N B EA R I N G R E P LA C E M E N T
Press the main bearing out of the crankcase using a hydraulic
press and special tools.
NOTE
•
Always use a press to remove the main bearing.
TOOLS :
Driver
07749 - 0 0 1 0000
Main bearing remover attachment 07HM F - MM90400
Mark a vertical line below each side of the bearing tab.
Apply molybdenum disulfide grease to the outer surface of the
main bearing.
(2) MARKS
(3) G ROOVE
Align the marks on the bearing w ith the groove in the bearing
hole, and press the main bearing i nto the crankcase .
CAUTION
•
Be careful not to damage the bearings.
TOOLS :
Driver
Main bearing driver attachment
07749 - 00 1 0000
07HMF - MM90400
(3) MAIN
BEARING
1 1 -9
CRAN KS HAFT/TRANSMISSION
C O N N ECTI N G R O D/ C RA N K S H A FT
S E L E CT I O N
If a connecting rod requires replacement, y o u should select a
rod with the same weight code as the original. But if that is
unavailable, you may use one of the others specified in the fol
lowing chart.
NOTE
The " 0 " mark in the table indicates that the matching is
possible in the crossed codes.
•
SELECTIO N TABLE
Front rod code
Rear rod code
A
B
c
A
B
c
*
0
0
0
0
0
0
0
* *
CAUTION
For selecting crankshaft weight:
Select "L " crankshaft weight, if the front rod and rear road
have code A ( •) .
Select "H" crankshaft weight, if the front rod and rear rod
have code C ( * *) .
Select crankshaft weight with no code, other than the above
two cases.
•
•
•
C O N N ECTI N G R O D A S S E M B LY
Install the bearing inserts on the rods and caps .
NOTE
•
•
Align the boss on the bearing with the groove in the rod or
cap.
Apply molbdenum disulfide grease to the bearing.
Install the connecting rods and caps on the crankpin. Be sure
each part is i nstalled i n its original position, as noted during re
mova l .
Tighten t h e bearing c a p nuts.
NOTE
•
•
Align the I . D . code on the cap and rod .
Tighten the nuts in two or more steps. After tightening,
check that the rods move freely without binding.
TORQUE : 34 N · m (3.4 kg-m, 25 ft-lbl
CRA N K S H A FT I N STALLAT I O N
Install t h e crankshaft in the left crankcase .
Install the dowel pins and assemble the crankcase .
1 1-10
( 2 ) CRANKSHAFT
WEIGHT CODE
( " L" or "H" or no mark)
( 1 ) Apply molybdenum disulfide g rease
C RAN KSHAFT/TRAN S M ISSION
TRANSM ISSION
( 1 ) MAI N
SHAFT
R EMO V A L
' 8 8 . '89 . ' 9 1 -'9 5 :
Remove the mainshaft, cou ntershaft, shift fork shaft and shift
drum as a n assembly.
After'9 5 :
Remove the shift fork shaft then remove the shift drum and
shift forks .
Remove the mainshaft and countershaft as a n assembly.
' 8 8 , '89 , ' 9 1 -' 9 5 :
Separate the shift fork/shaft, mainshaft a n d cou ntershaft
assemblies from each other:
( 2 .)
S H I FT FORK/
AFT
After'9 5 :
Separate the mainshaft and countershaft assemblies from
each other.
(3) COUNTERSHAFT
ASSEM BLY
D I SASS EMBLY/ I N SPECT I O N
Temporarily i nstall t h e mainshaft and countershaft t o the left
crankcase .
Measure the backlash of each gear.
STANDARD : 1 st, 2nd, 3rd
1 .02 1 - 0. 1 1 0 mm (0.0008 - 0.0043 in)
4th
1 .023 - 0. 1 1 7 mm (0.0009 - 0 . 0046 in)
' 8 8 , '89 , ' 9 1 -'9 5 :
Bend down the lock washer tabs and remove the bolt and lock
washer from the left shift fork.
Remove the shift fork shaft.
( 1 ) LOCK WASHER ( 2 ) BOLT
Disassemble the mainshaft and countershaft.
Remove the C4 gear by removing the stop rin g .
1 1 -1 1
C RAN KSHAFT/TRA N S M I S S I O N
I nspect the shift drum end for scoring, scratches, or evidence
of insufficient l ubrication . Check the shift drum grooves for
damage.
Measure the shift drum shaft O . D . at the left side journal.
SERVICE LIMIT: 1 1 . 94 m m (0.470 in)
Check the bearing inner and outer races for damage .
The bearing should turn smoothly and quietly.
I
1 2 1 S H I FT DRUM
Check the shift fork shaft for scratches, scoring or evidence of
insufficient lubrication .
Measure the shift fork shaft O . D .
S E RV I C E
LI M I T : '88 , '89 , '91 -'95 : 1 2 . 90mm (0 . 508 in)
After'95 : 1 2 . 95mm (0 . 509 in)
M easure the shift fork I. D. ( right and left) and the shift fork
claw thickness .
SERVICE LIMIT:
1 3 .04 m m (0 . 5 1 3 in)
I.D.:
CLAW THICKNESS: 5.63 mm (0. 222 in)
I nspect the shift drum and shift fork shaft journals for exessive
wear or damage .
Check the gear dogs, holes and teeth for excessive or
abnormal wear, or evidence of insufficient l ubrication .
Measure the I . D . of the following mainshaft countershaft at
C3, C 1 gears.
24.04 mm (0. 947 in)
SERVICE LIMITS : C 1 gear:
M2, M4, C3 gear: 28.04 mm ( 1 . 1 04 in)
1 1 -1 2
Measure the O . D . of the mainshaft following bushings:
SERVICE LIMITS :
M4 gear bushing :
C3 gear bushing :
M 2 gear bushing :
C1 gear bushing :
27 . 94
2 7 . 94
2 7 . 94
24. 94
mm
mm
mm
mm
( 1 . 1 00
( 1 . 1 00
( 1 . 1 00
( 0 .982
in)
in)
in)
in)
Calculate the clearance between each bushing and gear.
SERVICE LIMIT: 0. 1 0 mm (0.004 in)
Measure the I . D . of the M2 and C 1 bushings:
( 2 ) M 2 or C 1 BUSHING
or C3 BUSH I N G
SERVICE LIMITS :
M2 gear bushing : I . D . 2 5 . 04 mm (0.986 in)
C1 gear bushing : I . D . 24.06 mm (0. 790 in)
Measure the O . D . of the mainshaft and countershaft at the M 2
a n d C 1 bushings.
SERVICE LIMITS :
Mainshaft (at M2 gear bushing)
24. 90 mm (0.980 in)
Countershaft (at C 1 gear bushing)
1 9 .92 mm (0. 784 in)
(1)
2
Calculate the clearance between each bushing and shaft.
(2) C 1
Check the each shaft grooves for damage.
( 1 ) SNAP R I N G GROOVES
I
Replace if necessary .
( 2 ) LOCK A N D STOP
WASHER G ROOVES
+ +
t
( 3 ) SNAP RING
G ROOVE
t
(4) STOP
R I N G GROOVE
CRAN KCASE
BEA R I N G R E P LA C E M E N T
Turn the inner race of each bearin g with your finger. The bear
ings should turn smoothly and q uietly . Also check that the
bearing outer race fits tightly i n the crankcase.
Remove and discard the bearin g s if the races do not turn
smoothly, quietly, or if they fit l oosely i n the crankcase.
1 1 -1 3
CRAN KSHAFT/TRAN S M I S S I O N
Left crankcase
Remove the left mainshaft bearing using the special tools.
TOOLS:
Bearing remover set
- remover handle
- remover weight
07936 - 37 1 000 1 N ot
ava i lable i n U . S . A .
07936 - 37 1 0 1 00
07936 - 37 1 0600
0774 1 - 00 1 020 1 or
07936-37 1 0200
Drive the countershaft bearing and oil seal out of the crank
case .
I nstal l the new mainshaft bearing set plate on the left crank
case.
NOTE
•
Apply fresh engine oil to the new crankcase bearings before
installation .
I nstall t h e n e w bearings with t h e following tools.
TOOLS :
Left mainshaft bearing
Driver
Left countershaft bearing
Driver
Pilot, 25 mm
07749 - 00 1 0000
07746 - 00 1 0300
07749 - 00 1 0000
07746 - 00 1 0400
07746 - 0040600
I nstall a new countershaft oil sea l .
Check the gearshift spindle oil seal for wear or damage, re
place if necessary.
1 1-14
(1 )
BEARING
S ET
PLATE
Right crankcase
Remove the mainshaft bearing set plate and drive the counter
shaft bearing, mainshaft bearing and shift drum bearing out of
the crankcase .
TOOLS :
Right mainshaft bearing
Driver
Pilot, 22 mm
Right countershaft bearing
Driver
Pilot, 20 mm
07749 - 00 1 0000
07746 - 00 1 0400
07746 - 0041 000
07749 - 00 1 0000
07746 - 00 1 0300
07746 - 0040500
Apply a locking agent to the threads of the mainshaft bearing
set plate attaching bolt.
I nstall the set plate and tighten the bolt securely.
( 1 ) 1 0 mm STU D BOLT HOLES
I N SPECTI O N
Crankcase studs
'88 ' ' 8 9 ' ' 9 1 -'9 5 :
Check that the studs a re tight. I f any are loose, remove them ,
clean their threads with c ontact cleaner, then reinstall them
using Honda Anaerobic Thread Lock , o r equivalent.
(2) 8 mm STU D BOLT HOLE
After i nstalling, be sure to measure the distance from the top
of each stud to the crankcase surface .
( 1 ) 8 mm STU D BOLT
( 2 ) 1 0 mm STUD BOLT
Tighten the stud bolts to the specified torque.
TORQUE: 8 mm stud bolt:
20 - 30 N · m ( 2 . 0 - 3.0 kg-m, 1 4 - 22 ft-lb)
1 0 mm stud bolt:
3 0 - 50 N•m (3.0 - 5 .0 kg-m, 22- 36 ft-lb)
1 78 - 1 80 mm
( 7 .008 - 7 .087 in)
1 68 - 1 70 mm
( 6 . 6 1 4 - 6 . 693 i n )
1 1 -1 5
C RAN KS H A FT /TRAN S M ISSI O N
After'9 5 :
Check that the studs a re tight, I f any a re loose, remove them ,
clean their threads with contact cleaner, then reinstall them
apply engine oil to the threads .
NOTE
•
Install the studs with the flat side into the crankcase .
(1 )
FLAT SI DE
\�I=-=;1..1 �%,...
.--�
.. 1 1�1,
(2 ) B OSS S I DE
After installing , be sure to measure the distance from the top
of each stud to the crankcase surface as shown .
(1) 8
mm STU D BOLT
1 8 5- 1 8 7 mm
( 7 . 2 83-7 . 3 62
O I L J ET
Remove the oil jets from the front cylinder bore of the right and
left crankcase .
Check the 0-ring for fatique and damage .
1 1 -1 6
in)
(2) 1 0
mm STU D BOLT
1 68 - 1 70 mm
(6.6 1 4 - 6.693
in)
CRAN KSHAFT/TRA N S M ISSION
TRANSM I SSION ASSEM BLY I
I NSTALLATION
Apply molybdenum disulfide grease to the fol lowing.
- shift fork grooves
- inside and outside of the bushings
- outside of the spline bushings
( 51
C1 ( 36TI
(4) C2 (34T)
( 3 ) C3 ( 2 7TI
(6) MAINSHAFT
( 1 I COUNTERSHAFT
M4
( 1 0) M4 (29TI
(2)
C4
C O U NTERSHAFT
C3 C 2
C1
I nstal l the stopper ring and C4 gear onto the countershasft.
1 1 -1 7
C RAN KSHAFT/TRANSMISSION
I nstall the lock washer and stop washer, aligning bigger tabs of
the lock washer with bigger grooves of the stop washer in the
countershaft groove .
Turn the washers as shown to lock them on the nearest spline.
( 1 ) STOP
WASHER
I nstall the stop washer first, and then the lock washer for the
C3 gear.
Align and lock the washers using the procedure above.
I
Assemble the countershaft and mainshaft.
Check the gears for freedom of movement or rotation on the
shaft .
Check that the snap rings are seated in the grooves and align
their end gaps with the lands of the splines.
I
( 2 ) LOCK WASHER
' 8 8 , ' 89 , ' 9 1 -' 9 5 :
I nstall the left shift fork on t h e shaft with M R 1 mark facing the
groove on the shaft end and the bolt hole aligned with the
shaft hole.
( 1 ) MR1 MARK
( 2 ) G ROOVE
' 8 8 , ' 89 , ' 9 1 -' 9 5 :
Tighten the bolt with the lock washer a n d bend up the tabs of
the lock washer.
( 1 ) BOLT
( 2 ) TABS
1 1 -1 8
'88 . '89 . ' 9 1 -' 9 5 :
I nstall the right shift fork with the " R " mark o n the fork facing
up.
Assemble the mainshaft, countershaft, shift fork shaft and
shift drum.
I nstall them into the l eft crankcase as an assembly.
After'9 5 :
Assemble the mainshaft a n d countershaft .
I nstall them into the left cankcase as an assembly .
I nstall the shift forks into the shifter gear g rooves with the
markings facing up ( right crankcase side) .
I nstall the shift drum by aligning the shift fork guide pins wiht
the shift drum guide g rooves .
I nsert the shift fork shaft throug h the shift forks into the left
crankcase with the stepped end facing u p .
STE P P E D
EN D
CRAN KCASE ASSE M BLY
Apply sealant to the crankcase mating surfaces.
I nstall the dowel pins.
( 1 I DOW EL PINS
,
Assemble the right and left crankcases being careful to align
the dowel pins and shafts .
CAUTION
•
Do not force the crankcase halves together; if there is exessive
force required, something is wrong. Remove the right crank
case and check for misaligned parts.
1 1 -1 9
C RAN KSHAFT/TRANSMISSION
Apply oil to all crankcase bolts .
Instal l and tighten the right crankcase bolts i n a crisscross pat
tern in or 3 steps.
2
NOTE
•
Tighten the 8 mm bolts first, then tighten the 6 mm bolts.
2
I nstall and tighten the left crankcase bolts in a crisscross pat
tern in or 3 steps.
NOTE
•
Tighten the 8 mm bolts first, then tighten the 6 mm bolts .
I nstall the rear cam chain drive sprocket over the crankshaft,
aligning the extra-wide splines i n the sprocket and crankshaft.
Instal l the rear cam chain over the drive sprocket.
Install the oil pipe stay and cam chain tensioner set plate .
Tighten the bolt sercurely.
1 1 - 20
C RAN KS HAFT/TRA N S M ISSION
I nstal l the front cam chain over the front cam chain d rive
sprocket.
I nstall the cam chain tensioner set p l ate and tighten the bolt
securely.
I nstal l the rema1mng parts in the reverse order of removal
(page 1 1 - 1 ) .
1 1 -2 1
F R O NT W H E E L/ S U S P E N S I O N / STE E R I N G
After •g4 .
3 0 N · m (3 . 0 K g-m , 2 2 ft-lb )
1 05 N · m ( 1 0 . 5 Kg -m, 76 ft-lb)
2 3 N · m (2 . 3 K g-m , 1 7 ft-lb) �
2 2 N · m (2 . 2 K g-m , 1 6 ft-lb)
'88 , ' 8 9 ' ' 9 1 - . 93 • 2 7 N · m (2 . 7 K g-m , 2 0 ft-lb)
After ' 9 3 :. 3 1 N · m (3 . 1 K g-m , 22 ft-lb)
12-0
1 2. FRONT WH EEL/SUSP ENSION/STEER I NG
SERVICE I N F O RMATION
1 2- 1
FRONT W H EEL
1 2-6
TROU BLES H O O T I N G
1 2-2
FORK
1 2- 1 2
HAN D LEBAR
1 2-3
STEERING STEM
1 2- 1 9
SERV I CE I N FORMATION
•
•
•
•
•
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high
quality brake degreasing agent.
Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to clean brake
assemblies. Use an OSHA -approved vacuum cleaner or alternate method approved by OSHA, designed to minimize the hazard
caused by air borne asbestos fibers.
This section covers maintenance of the front wheel, fork and steering ste m . Refer to section 1 4 for front (hydraulic) brake
service .
Support the motorcycle using a hoist or a jack under the engine.
The VT600C uses leaf valve to the left .
ITE M
Axle ru nout
Front wheel rim runout
Fork spring free length
Radial
Axial
' 8 8 , ' 8 9 ' ' 9 1 -' 9 3 :
After' 93:
Fork tu be runout
'88.' 8 9 :
Fork flu id capacity
' 9 1 -' 9 3 :
After'93 :
R ight
'88.'89
Left
Fork fluid level
R ight
' 9 1 -'93
Left
After'9 3 :
STAN DAR D
S E RVICE LI M IT
-
0.2 m m (0.008 in)
2 . 0 m m ( 0.08 in)
2 . 0 mm (0.08 in)
299 mm ( 1 1 .8 in)
3 2 7 . 2 m m ( 1 2.9 i n )
0.2 m m ( 0.008 in)
-
-
3 0 5 m m ( 1 2 . 0 in)
333.9 m m ( 1 3. 1 in)
-
463 cc( 1 5.7 U S oz, 1 3.0 Imp oz)
468 cc( 1 5.8 US oz, 1 3.2 Imp oz)
449 cc( 1 6. 9 US oz, 1 5.8 Imp oz)
9 5.0 m m ( 3 .74 in)
93.0 mm(3.66 i n )
89.0 m m ( 3 . 5 0 in)
87.0 m m ( 3 .43 i n )
1 1 1 m m (4.4 in)
-
-
-
-
-
-
-
-
H andlebar mounting bolt
H andlebar upper holder bolt After ' 94 :
Clutch lever holder bolt
Brake m astercylinder holder bolt
Spokes
Brake disc mounting bolt
Front axle
Fork axle pinch bolt
Fork socket bolt
Fork top pinch bolt
Fork bottom pinch bolt
' 8 8 , ' 8 9 , ' 9 1 -' 9 3 :
B ra ke caliper mounting bolt
After ' 9 3 :
Steering bearing adjustment nut
Steering stem nut
23 N·m (2.3 kg·m, 17 ft-lb)
3 0 N · m ( 3 . 0 kg-m, 2 2 ft-lb)
1 2 N·m ( 1 . 2 kg-m, 9 ft-lb)
1 2 N·m ( 1 .2 kg-m, 9 ft-lb)
4 N·m (0.4 kg-m, 2.9 ft-lb)
40 N·m (4.0 kg-m, 29 ft-lb)
75 N·m ( 7 . 5 kg-m, 54 ft-lb)
22 N•m ( 2 . 2 kg-m, 1 6 ft-lb)
30 N•m ( 3 . 0 kg-m, 22 ft-lb)
1 1 N • m ( 1 . 1 kg-m, 8 ft-lb)
50 N • m ( 5 . 0 kg-m, 36 ft-lb)
2 7 N•m ( 2 . 7 kg-m, 20 ft-lb)
3 1 N· m ( 3 . 1 kg-m,2 2 ft-lb)
2 5 N • m ( 2 . 5 kg-m, 1 8 ft-lb)
1 05 N·m ( 1 0. 5 kg-m, 76 ft-lb)
1 2- 1
FRONT WHEEL/S U S P E N S I O N/STE E R I N G
T O O LS
Special
j
Spoke wrench
Bottom holder pipe
- holder attachment
- holder handle
07JMA - M R60 1 00 o r equivalent commercially available in U . S . A .
07930- KA50000
N ot available i n U . S . A .
07930- KA50 1 00
07930 - KA40200
Ball race remover
- driver attachment
- driver handle
07953 - MJ 1 0000
07953 - MJ 1 0 1 00 T
07953 - MJ 1 0200 J
Fork seal driver , 39mm
Steering stem socket
Steering stem driver
Bearing race remover
07 947 - 4630 1 00
079 1 6 - 37 1 0 1 00
07 946 - M BOOOOO
07946 - 37 1 0500
0 7 9 5 3- MJ 1 000A . 0 7 9 5 3- M J 1 000B o r
0 7 949 -37 1 000 1 a n d 0 7 7 4 6-00 1 0 1 00
Common
Driver
Pilot, 20 mm
Bearing remover head , 20 m m
Attachment, 52 x 55 m m
07 749 - 00 1 0000
07 746 - 00 1 0300
07 746 - 0040500
07 746 - 0050 1 00 -r-- Equivalent commercially available i n U . S . A .
07 746 - 0050600 _j
07 746 - 00 1 0400
TROUBLESHOOTI N G
Hard Steering
•
•
•
Steering bearing adjustment nut too tight
Faulty steering stem bearings
Insufficient air in front tire
Soft Suspension
•
•
Weak fork springs
I nsufficient fluid in fork legs
Hard Suspension
Steers to One Side or Does Not Track Straight
•
•
•
Bent fork legs
Bent front axle, wheel installed incorrectly
Unequal oil quantity i n each fork tube
•
•
Front Suspension Noise
•
Front Wheel Wobbling
•
•
•
•
•
Distorted rim
Worn front wheel bearings
Loose or broken spokes
Faulty tire
Axle or axle holder not tightened properly
1 2- 2
Fork oil level too high
Fork tube(s) bent or fork slider(s) damaged
•
•
Slider binding
Insufficient fluid in fork legs
Loose fork leg fasteners
FRONT WH EEL/SUSPENSION/STEERING
HAN DLEBAR
G R I P R E PLAC E M E N T
Remove t h e right handlebar switch screws a n d disconnect the
throttle cables from the throttle pipe.
Remove the grip end cap and right handlebar grip.
Remove the grip from the throttle pipe.
( 1 ) CEMMENT
Apply Honda Bond A or Honda Grip Cemment ( U . S . A . only) to
the inside surface of the throttle grip to the clean surface of
the throttle pipe. Wait 3 - 5 minutes and install the grip. Rotate
the grip for even application of the adhesive .
· �
Connect the throttle cables to the throttle pipe and i nstall the
right handlebar switch.
I nstall the grip end cap.
(3)
Remove the grip end cap and pull the grip off of the left handle
bar.
"() �
ROTTLE PIPE
( 2 ) G R I P END CAP
( 1 ) C E M M ENT
Apply Honda Bond A or Honda Grip Cemment ( U . S . A . only) to
inside surface of the left grip to the clean surface of the
handlebar. Wait 3 - 5 minutes and install the grip. Rotate 1:he
grip for even application of the adhesive.
NOTE
•
Allow the adhesive to d ry for a n hour before using . Check
for smooth throttle operation after the right grip is installed .
I nstall the grip end cap.
REMOVAL
Disconnect the clutch switch wires from the switch terminals.
- rear view mirror from the clutch lever holder
- clutch lever holder mounting bolts and holder
- left handlebar switch wire bands.
- left handlebar switch screws and switch
1 2-3
FRONT W H EEL/S USPENSION/STEERING
Disconnect the front brake light switch wires from the switch.
- rear view mirror from the master cylinder
- master cylinder holder mounting bolts and holder
- right handlebar switch wire bands
- right handlebar switch screws and switch
( 1 l BARKE LIGHT SWITCH
WIRE
Loosen the throttle cable lower adjusting nuts at the carbure
tors and disconnect the throttle cables from the throttle pipe.
Remove the handlebar mounting nuts, handlebar and rubber
seat from the fork bridge .
After '94 :
Remove the ha ndlebar upper holder bolts caps .
Remove the socket bolts , upper holders and handleba r .
Remove t h e n uts and handlebar lower holders .
R>/"1�------,
1 2-4
( 2 ) LOW E R
H O LD E R S
F R O N T WHEEL/SUSPENSIO N/STEERING
I N STA LLAT I O N
'88 , '89 , '9 1 -'94 :
I n stall the rubber seat into the fork bridge .
I n stall the washers and handlebar mounting n uts.
Tighten the nuts .
TO RQU E : 23 N · m ( 2.3 kg-m, 1 7 ft-lb )
After '94 :
I nstall the handlebar lower holders a n d tem porarily tighten
the n uts .
I nstal l the handlebar and upper holders with their pu nch marks
facing forward .
Tem porarily tighten the socket bolts .
Tig hten the lower holder nuts to the specified torque .
TO RQU E : 23 N • m ( 2 . 3 kg-m, 1 6 ft-lb)
( 1 ) LOWER H O L D E R N UTS
Loosen the u pper holder socket bolts a nd align the punch
m arks o n the handlebar with the splits of the handlebar
holders .
Tighten the forward bolts first, then tig hten the rear bolts .
T O R QU E : 3 0 N · m ( 3 . 0 kg-m , 22 ft-lb)
I nstal l the u pper holder bolt caps .
Install the left handlebar switch set collar on the upper switch
housing . Align the locating pin in the lower switch housing
w ith the hole in the handlebar.
Install the left handlebar switch attaching screws, and tighten
the forward screw first, then tighten the rear screw.
1 2- 5
FRONT WH EEL/S U S PE N S I O N/STE E R I N G
Install the clutch holder/lever and with the " U P" mark facing
up.
Align the end of the holder with the punch mark on the handle
. bar and tighten the upper bolt first then tighten the lower bolt.
TORQUE: 12 N·m ( 1 . 2 kg-m, 9 ft-lbl
Connect the clutch switch wires.
I nstall the right rea r view mirror in the holder.
Secure the wires with wire bands.
Apply grease to the throttle cable ends and connect the cables
to the throttle pipe.
I nstal l the right handlebar switch onto the handlebar, aligning
the locating pin with the hole in the handlebar.
I nstall the right handlebar switch screws and tighten the for
ward screw first, then tighten the rear screw.
I nstall the front brake master cylinder/holder with the " U P"
mark facing up.
Align the end of the holder with the punch mark on the handle
bar and tighten the upper bolt first, then tighten the lower bolt.
TORQU E : 12 N · m ( 1 . 2 kg-m, 9 ft-lbl
Connect the front brake light switch wires.
I nstal l the right rear-view mirror into the master cylinder/
holder.
Secure the wire with wire bands.
Adjust the following:
- throttle operation and free play (page 3 - 6 ) .
- clutch lever free play (page 3 - 1 8 ) .
1 2-6
FRONT WHEEL/S U S PE N S I O N /STEERING
FRONT WHEEL
R E M OVA L
Raise and support the motorcycle using a hoist or a jack u nder
the engine .
Remove the set screw and pull the speedometer cable out of
the speedometer gearbox .
t-
(
..
( 2 ) SET SCREW
Remove the axle pinch bolt caps, a n d bolts from the right front
fork leg .
Remove the axle and the front wheel.
NOTE
•
Do not operate the front brake lever after removing the
front wheel. To do so will cause difficulty in fitting the
brake disc between the brake pads.
Remove the side collar.
Remove the speedometer gearbox .
1 2- 7
FRONT W H E E L/SUSPEN S I O N/STEE R I N G
I N S P E CT I O N
e
(1 )
FRONT AXLE
AXLE
Set the axle in V blocks and measure the runout .
Actual ru nout is 1 /2 the tota l i n dicator reading .
-
SERVICE LIMIT: 0 . 2 mm (0 . 0 1 in)
�
e
WHEEL
Check the spokes and tighten any that are loose .
TORQU E : 4 N • m (0.4 kg-m, 2 . 9 ft-lbl
Check the rim runout by placing the wheel on a truing stand .
Then spin the wheel with hand, and read the runout using a
dial indicator.
SERVICE LIMITS :
RADIAL: 2 . 0 mm (0.08 in)
AXIAL: 2.0 mm (0.08 in)
(1)
CAUTION
•
Wheel balance directly affects the stability, handling and over
all safety of the motorcycle. A lways check balance when the
tire has been removed from the rim .
NOTE
•
•
For optimum balance, the tire balance mark (a paint dot on
the sidewall) must be located next to the valve stem.
Remount the tire if necessary .
\
\�a
(2)
Mount the front wheel in a inspection stand .
Spin the wheel, allow it to stop, and mark the lowest
(heaviest) part of the wheel with chalk. Do this two or three
times to verify the heaviest area.
If the wheel is balanced, it will not stop consistently i n the
same position.
1 2- 8
VALVE
BALANCE MARK
I
F R O N T W H EEL/S USPENSION/STEERING
To balance the wheel, i nstall wheel weights on the highest
side of the rim, the side opposite to the chalk marks. Add just
enough weight so the wheel will no longer stop i n the same po
sition when it is spun .
D o not a d d more than 70 grams.
"'( 1 ) WHEEL WEIGHT
e
WHEEL BEARING
Turn the inner race of each bearing with your finger.
The bearings should turn smoothly and quietly.
Also check that the bearing outer race fits tightly i n the hub.
Remove and discard the bearings if the races do not turn
smoothly, quietly, o r if they loosely in the hub.
( 1 ) WHEEL BEARING
B EA R I N G R E P LA C E M E N T
-
( 1 ) DUST SEALS
Remove the front wheel ( page 1 2-7) .
Remove the dust seal and retainer from the left side of the
wheel hub.
Remove the dust seal from the right side of the hub.
Remove the brake disc mounting bolts and disc.
1 2-9
FRONT WH E E L/S USPENSION/STE E R I N G
Drive out the wheel bearings and distance collar.
CAUTION
Never reuse old bearings.
•
TOOLS :
Bearing remover head, 20 mm
07746-005 0 1 0 0
07746-0050600
available i n U .S.A.
( 1 ) DRIVER
Drive in the new left bearing first until it seats.
I nstall the distance collar and drive in the right bearing.
N OTE
•
•
Install the bearings with the vendor markings facing the
outside. Be sure to drive the bearings i n squarely.
Always replace wheel bearings in pairs .
TOOLS :
Driver
Attachment, 42
Pilot, 20 mm
x
07749 - 00 1 0000
47 mm 07746 - 00 1 0300
07746 - 0040500
A S S E M B LY
•
Do not get get grease on the brake disc or stopping power will
be reduced.
-�
(1 1 l
(1 l
DISTAN C E COLLAR
'
__:::..c:o .
SIDE
CO LLAR
.
(9)
BEARI NG
(4)
(6)
1 2- 1 0
SPEEDOMETER
GEARBOX
f?�
SPEEDO
M ETER (5) WASHERS
G EAR
FRONT WH EEL/S U S PEN S I O N /STEERING
To replace the wheel;
Remove the tire and tube from the rim .
Place the rim and hub on the work bench and begin lacing with
new spokes from inside the hub.
Install the spokes with a space of six holes in between.
Measure the d istance ( B ) , and make a calculatio n .
(A)
7 0 . 8 mm ( 2 . 787 in) ( 8 ) + 2
Adjust the hub position so that the d ista n ce from the hub sur
face where the brake disc mounts to the side of rim is (A) .
Tighten the spokes in 2 or 3 progreassive steps.
=
TOOLS :
Spoke wrench :
-
07JMA - MR60 1 00 or
available in U . S .A.
TORQU E : 4 N•m (0.4 kg-m, 2 . 9 ft-lb)
Check the wheel runout (page 1 2-8) .
I nstall the tube and tire .
Coat the speedometer gear retainer with grease and install the
retainer i nto the wheel hub, aligning the tangs with the slots in
the hub.
Apply grease to the oil seal lip and instal l the oil seal over the
gear retainer.
Install the brake disc onto the wheel hub.
Apply a thread locking agent to the bolt threads and install and
tighten the bolts .
N OTE
•
Tighten the bolts in a crisscross pattern in 2 or 3 steps .
TORQUE : 40 N · m 14.0 kg-m, 29 ft-lb)
•
Do not get grease on the brake disc or stopping power will be
reduced.
Apply grease to the dust seal lips and install the seal on the
right side of the hub.
( 1 ) DUST SEAL
1 2- 1 1
FRONT WHEEL/SUSPENSIO N/STEERING
Apply grease to the speedometer gearbox and gear.
I nstall the speedometer gear and washers into the gearbox.
(1 I
G EAR BOX
I nstall the speedometer gearbox into the wheel hub, aligning
the tangs with the slots .
Clean the brake discs with a high quality degreasing agent.
I nstall the right side collar.
INSTALLATION
Place the front wheel between the front fork legs.
Fit the caliper over the brake disc, taking care not to damage
the brake pads.
Clean the axle and holder.
I nstall the axle through fork leg, the side collar, wheel hub and
speedometer gear box .
Set the speedometer gearbox tab under the tang on the left
fork slider.
t2 1 S�T SCREW
Tighten the front axle.
TORQUE: 75 N•m (7 . 5 kg-m, 54 ft-lbl
Tighten the fork pinch bolts .
TORQUE: 22 N·m (2.2 kg-m, 1 6 ft-lb)
I nstall the speedometer cable and set screw securely.
1 2- 1 2
FRONT W H EEL/S U S PENSION/STEERING
FORK
R E MOVAL
Remove the front wheel ( page 1 2 - 7 ) .
Remove the brake caliper mounting bolts and brake caliper.
Unhook the brake hose from the hook on the fender.
Tie the caliper to the handlebar so its weight does not pull on
the brake hose .
Pull the speedometer cable out of the cable holder on the fend
er.
Remove the front fender mounting bolts from the fork legs.
If the fork legs will be disassembled, loosen the fork cap bolts,
but do not remove them yet.
Q l il
Loosen the following bolts :
- turn signal mounting bolt
- fork top pinch bolt
- fork bottom pinch bolt
.
FO R KT O P P IN C H
BOLT
Pull the fork tubes out of the top bridge and steering stem.
(3)
( 2 ) TURN SIGNAL LIGHT
/
FORK BOTTO M PINCH BOLT . MOUNTING BOLT
1 2- 1 3
FRONT W H E E L/S U SPENSION/STE E R I N G
( 1 ) FORK CAP
D I SA S S E M BLY
Remove the fork cap bolt .
•
The cap bolts are under spring pressure. Take care when re
moving, and wear eye and face protection.
Remove the fork spring, seat washer and spacer.
Pour out the fork fluid by pumping the fork up and down sever
al times .
'\
\
Hold the fork slider in a vise with soft jaws or a shop towe l .
( 1 ) HOLDER HANDLE
CAUTION
•
Do not distort the fork slider in the vise.
I nstall the special tool i nto the fork tube and hold the piston,
then remove the socket bolt.
TOOLS :
Bottom holder pipe
- holder attachment
- bottom holder handle
07930-KA50000
N ot available i n U . S .A.
07930- KA5 0 1 00
07930- KA40200
Remove the dust seal and stop ring .
CAUTION
•
Be careful not to damage the fork tube.
1 2- 1 4
( 1 ) D U ST SEAL
FRONT W H E EL/S USPENS I O N/ST E E R I N G
I n quick successive motions, pull the fork tube out of the slid
er.
NOTE
•
The slider bushing that is pressed into the slider, and the
fork tube bushing on the end of the fork tube, must be
forced out.
Remove -th e oil lock piece from the fork slider.
Remove the piston and rebound spring from the fork tube.
Remove the oil seal, back-up ring and slider bushing from the
fork tube.
Do not remove the fork tube bushing until inspection
determines it is necessary ( page 1 2- 1 5 ) .
\
(4) BACK-U P RING (3) TUBE BUS H I NG
( 1 ) FO
I N S PE CT I O N
Fork spring
Measure the fork spring free lengt h .
S E RV I C E L I M IT: '88,'89 .' 9 1 -'93: 2 9 9 mm ( 1 1 .8 i n )
After'93:
333 . 9 mm ( 1 3 . 1 i n )
SPRI NG
•J\/"""fJ\J 'v'\I/lJJIIIIIIlf/1
Replace the spring if it is shorter than the service limit.
.
( 1 I FORK S L I D E R
Fork tube/slider/piston
( 2 ) FORK TUBE
�
Check the fork tube, fork slider and piston for score marks, ex
cessive or abnormal wear.
Replace any components which are worn or damaged .
Check the rebound spring for fatigue or damage.
. ,
(5)
��
!
REBO U N D
SPRING
(4) PISTON
\
•
'\(3) OIL LOCK PIECE
1 2- 1 5
FRONT W H E E L/SUSPEN S I O N/STEERING
Set the fork tube i n V blocks and read the ru nout.
Actual runout is 1 /2 the total indicator reading.
SERVICE LIMIT: 0 . 20 mm (0. 008 in)
Bushings
Visually inspect the slider and fork tube bushings.
Replace the bushings if there is excessive scoring or scratch
ing, or if the teflon is worn so that the copper surface a ppears
on more than 3/4 of the entire surface.
(11
BUSH I N G
Check the back-up ring; replace it if there is any distortion at
the points shown.
(21
.. ... ...
BACK-UP RING
~
(31 CHECK
PO INTS
(41 COPPER
SU RFACES
A S S E M BLY
(1 I
( 1 91
( 1 81
( 1 71
( 1 61
( 1 51
�
--_JJ
FORK TUBE CAP
'88 . '89 . ' 9 1 -'93 O N LY
0-RING
SPAC ER
SPR I N G SEAT
-----1/
(1 I
(61
(71
;:!
REBOU N D
SPRING
1 2- 1 6
�
.�
FORK SLIDER
LEAF
VALVE
""'==
�
�� ( 9 1 DRAIN BOLT
��
( 1 31
RIGHT FO RK TUBE
SLIDER BUSHING
( 3)
PISTON RING
PISTO N
(21
�>+--�-r l 5 1 BACK-UP RING
FORK SPRING
( 1 41
LEFT FORK TUBE
J.-- ( 1 01
( Except after'9 5)
@>
SOCKET BOLT
FORK TUBE
BUSH I N G
O I L LOCK PIECE
(1 1 I
( 1 21
CAUTION
•
•
The fork tube cannot be disassembled.
Do not interchange the right and left fork tube when in
stalling the fork tu be in th e fork slider.
FRONT WHEEL/S U S P E N S I O N /STEERING
I nstall the rebound spring i nto the fork tube.
I nstall a new postion ring i nto the piston groove .
Place the oil lock piece on the end of the piston and insert the
fork tube i nto the slider.
( 1 I OIL SEAL
(21 BACK-U P R I N G
/
PISTON
(61 SLIDER
BUSH I N G ( 5 ) TUBE BUSH I N G
I nstal l the special tools i nto the fork tube to hold the pis
ton,and i nstall and tighten the socket bolt.
TOOLS :
Bottom holder pipe
- holder attachment
- bottom holder handle
I
( 4 ) LOCK PIECE
( 2 1 BOTTO M HOLDER
HANDLE
(1 I HOLDER ATTACH MENT
�
07930- KA50000
N ot ava i l a ble i n U . S.A.
07930- KA50 1 00
N ot ava i lable i n U . S.A.
07930- KA40200
N ot ava i l able i n U . S.A.
Place the fork slider i n a vise with soft jaws or use a shop
towel. Apply a locking agent to the socket bolt and thread it
i nto the piston . Tighten w ith a 6 mm hex wrench .
( 1 l SOCKET
BOLT
,
.....
'
.....
'
'
NOTE
•
Temporarily install the fork sprin g and fork cap bolt to tight
en the socket bolt.
TORQU E : 30 N·m (3.0 kg-m, 22 ft-lbl
Place the sl ider bushing over the fork tube until it rests on the
slider.
N OTE
•
Tape the upper edge of the fork tube to avoid damaging the
oil seal lip, while i nstalling the o i l sea l .
U s i n g a fork seal driver , drive t h e bushing into place .
I nstal l the back-up ring with the c hamfered side facing the
slider bushing.
Coat the oil seal lip with the recom mended fork oil.
D rive the oil seal i nto place using a fork seal driver.
I nstall the oil seal stop ring and the dust sea l .
TOOL:
Fork seal driver, 39mm
V
( 2 ) D U ST SEAL
d� Iv ( 3 ) STOP
RING
�� (4) O I L SEAL
�-
l
( 5 ) BACK-U P
RING
07947 - 4630 1 00
1 2- 1 7
FRONT WHEEL/S U S P E N S I O N/STEERING
Com press the fork leg and pour Honda Su spensio n F luid
SS-8 o r equ iva lent i nto the fork tube.
SPECI F I E D L E V E L :
'88, 89:
Right fork : 95.0 mm
Left for k : 93.0 mm
'91 -'93 : .
R ight fork : 89.0 m m
Left fork: 87.0 mm
After '93:
R i g ht and l eft forks :
r�
U
'
(1 )
O I L LEVEL
(3.74 in )
(3.36 i n )
LR
(3.50 in)
(3.43 i n)
1 1 1 m m (4 . 4 i n )
CAPAC I TY :
'88, '89: 463 cc ( 1 5.7 US oz , 1 3.0 I mp oz)
' 9 1 -'93 : 468 cc ( 1 5.8 U S oz, 1 3. 2 Imp oz )
After '93: 449 cc( 1 6 . 9 U S oz , 1 5.8 1 m p oz)
I nstal l the fork spring, washer and spacer into the fork tube.
'88 . '89 . ' 9 1 - '93 :
NOTE
•
l\Jt
. ·
Note the direction: the tightly wound coils should be at bot
tom .
�
( 1 )TI G HTLY WO U N D
C O I LS
t
r t'
r · r , t r .
' ' '' \I v
�J
11
V 'iJ 'v
J J111/(({(r �
:
. .
·
A Fter '93 :
N OT E
•
N ote the directio n :the tightly wound coils should be at top.
Loosely install the fork tube cap with a new 0-ring.
I N STA LLAT I O N
I nstall t h e fork tube, aligining its top e n d with the upper sur
face of the top bridge as show n .
Temporarily install a n d tighten the fork top pinch bolts and
turn signal mounting bolts .
:
; .:
1 2- 1 8
( 1 l 0-RING
(2) FORK TUBE CAP
.
. , �
,
FRONT WHEE L/S U S P E N S I O N/STEERING
I nstall and tighten the bottom pinch bolt.
TORQU E : 50 N · m (5.0 kg-m, 36 ft-lbl
Tighten the top pinch bolt.
TORQU E : 1 1 N·m ( 1 . 1 kg-m, 8 ft-lb)
I nstall the front fender and tighten the mounting bolts secure
ly.
,1
�"
(2)
�
M O U N T I N G BOLTS
Hook the brake hose onto the hose clip.
I nstal l the brake caliper with the mounting bolts .
Tighten the bolts to the Specified torque.
TORQU E : '88 . '89 . ' 9 1 - ' 9 3 ;
27 N•m ( 2 . 7 kg-m, 20 ft-lb)
After '93 :
3 1 N · m ( 3 . 1 kg-m , 22 ft-l b )
I nsert the speedometer cable through the fender holder.
1 2- 1 9
FRONT W H EEL/S U S P E N S I O N /STEER I N G
STEER I NG STEM
(2) SPEEDO
M ETER
R E M OVAL
Remove the fork legs and handlebar.
Disconnect the speedometer cable from the speedometer, and
the 6P black connector (see page 1 - 1 3 ) .
- speedometer from the fork bridge
- headlight from the headlight case
- headlight stay and mounting nuts, headlight stay and case
(4)
Remove the steering stem nut and washer.
STAY
(1 l
STE E R I N G
STEM
NUT
(1
) LOCK NUT
Remove the top bridge .
Remove the indicator panel and lights by removing the two
screws.
Straighten the lock washer tabs and remove the lock nut and
lock washer.
1 2-20
(2) LOCK WAS H E R
TABS
FRONT WHEEL/S U S P E N S I O N/STEERING
Loosen the steering head bearing adjustment nut.
TOOL: Steering stem socket
079 1 6 - 37 1 0 1 00
( 1 ) STEE R I N G
STEM
S O C K ET
Hold the steering stem by hand and remove the adjustment
nut, dust sea l , upper bearing inner race and upper bearing.
Remove the steering stem from the steering head .
Check the bearings and outer race for wear or damage .
Replace if necessary.
B EA R I N G R E PLAC E M E N T
( 9 ) LOWER B E A R I N G
�
( 1 0 ) L O W E R B EA R I N G I N N E R RACE
( 1 1 ) D U ST S E A L
1 2- 2 1
FRONT WH EEL/S U S P E N S I O N /STEERING
( 2 ) STEM
NUT
NOTE
•
Always replace the bearing and race as a set.
I nstal l the steering stem nut o n the top end of the steering
stem to protect the threads from damage.
Remove the lower i n ner race and dust seal using a punch or
d river.
Replace the dust seal with a new one whenever it is removed .
I
(3)
Remove the lower outer race using the special tools and a suit
able shaft.
TOOLS : Bearing race remover: 07946 - 37 1 0500
Remove the upper bearing outer race using the special tools.
TOOLS :
Ball race remover
- attachment
- driver handle
or
Attachment
07953 - MJ 1 0000
07953 - MJ 1 0 1 00
07953 - MJ 1 0200
J
N ot ava i l a b l e
in U . S . A .
0 7 9 5 3 - MJ 1 OOOA ,
07953 - MJ 1 0008 or
0 7 949-3 7 1 000 1 and
D river
Attachment, 32 X 35 m m 0 7746-00 1 0 1 00
Install a new dust seal over the steering stem.
Press a new lower bearing inner race onto the stem.
TOOL: Steering stem driver
07946 - MBOOOOO
Drive new upper and lower bearing outer races into the steer
ing head pipe .
TOOLS :
U pper bearing outer race :
Drive
07749 - 00 1 0000
07746 - 00 1 0300
Lower bearing outer race :
Driver
07749 - 00 1 0000
07746 - 00 1 0400
1 2-22
LOWER I N N E R R A C E
FRONT WH EEL/S USPEN S I O N /STE E R I N G
,,
I N STALLAT I O N
Pack t h e bearing cavities w i t h grease.
I nstall the lower bearing onto the stem.
Insert the stem i nto the steering head pipe and i nstall the upper
bearing, inner race, dust seal and steering bearing adjustment
n ut.
E R I N G B EA R I N G A DJ U ST M E N T
NUT
( 1 ) 1NNER RACE
... .
Apply e n g i n e o i l to the a d j u st m e n t n ut t h reads .
Tighten the steering bearing adjustment nut to the specified
torque.
TOOL: Steering stem socket
(1 I
t
STE E R I N G
STEM
SOCKET
0 79 1 6 - 37 1 0 1 00
TORQUE: 2 5 N·m ( 2 . 5 kg-m, 1 8 ft-lbl
Turn the steering stem back and forth five times to seat the
bearings.
Retighten the adjustment nut to the same torque.
Turn the steering stem to seat the bearings.
I nstall a new lock washer and bend the two opposite tabs
down into the grooves i n the adjustment nut.
( 1 I LOCK WA S H E R
(2) LOCK NUT
Install and finger tighten the lock n ut all the way.
Hold the bearing adjustment nut and further tighten the lock
nut, within 90 degrees, to align its g rooves with the tabs of the
lock washer.
Bend up the lock washer tabs i nto the grooves of the lock nut.
1 2-23
FRONT WH EEL/S U S PENS I O N /ST E E R I N G
I nstall the indicator panel with two screws.
I nstall the fork bridge then temporarily i nstal l the fork legs.
Tighten the steering stem nut.
TORQUE : 1 05 N • m ( 1 0 . 5 kg-m, 76 ft-lb)
Instal l the following parts:
- fork legs (page 1 2 - 1 8 ) .
- front wheel (page 1 2 - 1 2 ) .
Check the steering head bearing preload .
ST E E R I N G H EA D B EA R I N G P R E L O A D
Place a stand under the engine and raise the front wheel off
the groun d .
Position t h e steering stem t o the straight ahead position.
Hook a spring balance to the fork tube and measure the steer
ing head bearing preload .
NOTE
•
Make sure that there is no cable and wire harness interfer
ence.
The preload should be within 1 .0 - 1 . 5 kg ( 2 . 20 - 3 . 3 1 lb) for
right and left turns.
If the readings do not fall within the limits, lower the front
wheel on the ground and adjust the bearing adjustment nut.
After making sure the bearing preload , instal l the removed
parts in the reverse order of removal .
1 2 - 24
MEMO
REAR WHEEL/BRAKE/S U S PENSION
1 3-0
1 3. REAR WH EEL/ B RAK E/SUSP E NSION
SERVICE I N FO R M AT I O N
1 3- 1
BRAKE PEDAL
1 3- 1 0
T R O U BLESHOOTI N G
1 3-2
S H O C K ABSORBER
1 3- 1 1
REAR WH EEL
1 3- 3
SWINGARM
1 3- 1 4
R EAR BRAKE
1 3- 7
S EAT /REAR FENDER/S U B-FRA M E
1 3- 1 8
G E N ERAL
•
Support the motorcycle using a hoist or a jack under the engine.
CAUTION
Do not jack up the motorcycle using the oil filter.
•
•
•
•
•
•
Use only genuine Honda replacement fasteners for the rear suspension.
Note the i nstallation direction of the bolts.
A ny attempt to mount automobile tires on a motorcycle rim may cause the tire bead to separate from the rim with
enough explosive force to cause serious injury or death.
The rear shock absorber contains nitrogen under high pressure. Do not allow fire or heat near the shock absorber. Use only nitro
gen to pressurize the shock absorber. The use of an unstable gas can cause a tire or explosion resulting in serious energy.
Before disposal of the shock absorber, release the nitrogen by pressing the valve core. Then remove the valve from the shock ab
sorber.
assemblies. Use an OSHA -approved vacuum cleaner or alternate mothod approved by OSHA, designed to minimize the hazard
coused by airborne asbestos fibers.
S P E C I F I C AT I O N
Unit: mm (in)
ITEM
Rear wheel runout
STANDARD
SERVICE LIMIT
Radial
--
2 . 0 mm (0.08 in)
Axial
--
2 . 0 mm (0.08 in)
0 . 2 mm (0.01 in)
1 6 1 mm ( 6 . 3 in)
Rear axle runout
Rear brake drum I . D .
Rear brake lining thickness
Shock absorber spring free length
Rear suspension damper compression
--
1 60 mm ( 6 . 3 in)
5 mm (0. 2 in)
1 37 . 5 m m ( 5 . 4 1 in)
2 mm (0.08 in)
1 3 5 . 0 mm ( 5 . 3 1 in)
1 3 . 4 - 1 7 . 4 kg ( 2 9 . 5 4 - 3 8 . 36 lb)
1 3 . 3 kg ( 2 9 . 3 2 lb)
Spokes
Sprocket nut
Shock absorber mounting bolt
Swingarm pivot bolt
Rear axle
Damper rod lock nut
Brake torque rod nut
4 N•m (0.4 kg-m, 2.9 ft-lb)
65 N·m ( 6 . 5 kg-m, 4 7 ft-lb)
45 N•m (4. 5 kg-m, 33 ft-lb)
90 N•m ( 9 . 0 kg-m , 6 5 ft-lb)
90 N•m ( 9 . 0 kg-m, 6 5 ft-lb)
70 N·m (7.0 kg-m , 51 ft-lb)
27 N•m (2. 7 kg-m , 20 ft-lb)
1 3- 1
IIEI:f:l
..:I
REAR WHEEL/BRAKE/S USPEN S I O N
T O O LS
Special
Driver shaft
Spoke wrench
Attachment
Compressor screw
Snap ring pliers
07 946 - MJ00 1 00
07746 - 1 870 1 00
07JMA - M R60 1 00 or equivalent commercially
available i n U . S .A.
07G M E - 00 1 0000
07 J ME - M R 1 0 1 00
07G M E - 00 1 0 1 00
079 1 4 - 323000 1
Common
Bearing remover head , 1 7 mm
D river
Pilot, 1 7 mm
Pilot, 1 5 mm
Pilot, 22 mm
TROUBLESHOOTI NG
Wobble o r vibration i n motorcycle
Bent rim
Loose wheel bearing(s)
Loose or bent spokes
Damaged tire
Axle not tightened properly
Swingarm pivot bearing worn
Chain adjusters not adjusted equally
Bent frame or swingarm
Soft suspension
•
•
Weak spring
I mproper shock absorber spring preload
Hard suspension
•
•
•
•
I mproper shock absorber spring preload
Bent shock absorber rod
Swingarm pivot bearings damaged
Bent frame or swingarm
Suspension noise
•
•
Faulty rear damper
Loose fasteners
Poor brake performance
•
•
•
•
•
•
•
Improper brake adjustment
Worn brake shoes
Brake linings oily, greasy or dirty
Worn brake cam
Worn brake drum
Brake arm serrations improperly engaged
Brake shoes worn at cam contact area
:,,1 3-2
07 746 - 0050 1 OO or equivalent commercially
07 746 - 0050500
07749 - 00 1 0000
07 746 - 00 1 0300
077 46 - 0040400
07 746 - 00 1 0 1 00
07 746 - 0040300
07 746 - 004 1 000
J
R E A R W H EEL/BRAKE/S U S P E N S I O N
REAR WHEEL
REM OVAL ·
Support the motorcycle using a hoist or a jack under the en
gine.
CAUTION
•
Do not jack up the oil filter.
Loosen the drive chain adjusters on both sides of the swing
arm .
Remove the following parts :
- brake rod
- cotter pin, nut, seat washers and bolt from the torque rod
on the brake panel.
- Axle nut, adjuster collars, side collar and rear axle.
- drive chain from the drive sprocket
- rear wheel
- brake panel from the brake drum
I N S PE CT I O N
e
AXLE
Set the axle on V blocks and measure the runout.
e
WHEEL
Check the spokes and tighten any that are loose .
TORQUE : 4 N • m (0.4 kg-m, 2.9 ft-lbl
TOOL: Spoke wrench
07JMA - MR60 1 00 or
Check the rim runout by placing the wheel on a truing stan d .
S p i n t h e w h e e l h a n d and read t h e runout using a d i a l indicator.
SERVICE LIMITS:
RADIAL: 2.0 m m (0.08 in)
AXIAL: 2.0 mm (0.08 in)
e
WHEEL BEARING
Turn the i n ner race of each bearing with your finger.
The bearings should turn smoothly and quietly .
Also c h e c k that t h e bearing outer race fits tightly in t h e hub.
Remove a n d discard the bearings if the races do not turn
smoothly, q uietly, or if they fit loosely i n the hub.
NOTE
•
Replace wheel bearings i n pairs .
For bearin g replacement, see page 1 3-4.
e
WHEEL BALANCING
Refer to page 1 2- 7 .
NOTE
•
Do not add more than 70 grams of balancing weight to the
rear wheel
11 l WHEEL BEA RING
1 3- 3
REAR W H EEL/BRAKE/S USPENSION
S P R O C K ET/D R I V E N FLAN G E
D I SA S S E M B LY / I N S PECTI O N
Remove the wheel ( page 1 3-31 .
Remove the mounting nuts and separate the sprocket from the
flange .
Check the condition of the sprocket teeth .
Replace a worn or damaged sprocket.
NOTE
The d rive chain and d rive sprocket must also be inspected if
the driven sprocket is worn or damaged . Never instal l a new
drive chain on worn sprockets or a worn chain on new
sprockets . Both chain and sprocket must be i n good condi
tion or the new replacement chain or sprockets will wear
rapidly.
•
If driven flange the hub, drive it out by tapping it at several lo
cations with wood block.
Remove the dampers from the flange in the hub.
Remove the collar and dust seal from the flange .
D rive out the driven flange bearing, if necessary .
I nspect the dampers for deterioration.
Turn the inner race of the bearing with your finger.
The bearing should turn smoothly and quietly.
Also check that the outer race fits tightly in the flange .
Remove and discard the bearing if it does not turn smoothly
and quietly, or if the outer race fits loosely in the flange .
BEA R I N G R E PLAC E M E N T
Wheel bearing
Drive out the wheel bearings and the distance collar.
NOTE
•
If the bearings are removed , they must replaced .
TOOLS :
Bearing remover head, 1 7 mm
1 3-4
07746 - 0050 1 00
07746 - 0050500
( 1 1 GOOD
( 2 1 REPLACE
REAR WH EEL/BRAK E/S U S PENSION
First, drive in a new left wheel bearing until it is fully seated, in
stall the distance collar, then drive in a new right bearing.
TOOLS :
Driver
Attachment, 42
Pilot, 1 7 mm
x
47 mm
07749 - 00 1 0000
07746 - 00 1 0300
07746 - 0040400
NOTE
•
Drive the wheel bearings i n w ith the vendor mark facing
out.
Flange bearing
Drive out the bearing using a suitable tool.
Drive the new bearing in with its vendor mark facing out.
TOOLS :
Driver
Attachment, 42
Pilot, 1 7 mm
x
47 mm
07749 - 00 1 0000
07746 - 00 1 0300
07746 - 0040400
( 3 ) ATTACHM ENT
A S S E M B LY
-
-
(3) 0-RING
�j
A
( 1 1 1 BEARING
1 1 01 DAMPER RUBBER
/1
(4) DRIVEN SPROCKET
( 9 ) COLLAR
(8) FLANGE
( 7 ) NOISE ARRESTER
1 3- 5
REAR WH EEL/BRAKE/S U S P E N S I O N
Place the rim and hub on the work bench and begin lacing with
a new spoke from the hole of inside i n the hub.
Install the spoke with a space of two holes in between .
Measure the distance ( B ) , a n d make a calculation.
(A)
79 mm ( 3 . 1 1 0 in) ( B ) + 2
Adjust the hub position so that the distance from the hub right
end surface to the side of rim is (A) .
Tighten the spokes i n 2 or 3 progressive steps.
=
TOOL:
Spoke wrench
-
07JMA - MR60 1 00
available in U . S .A.
TORQUE : 4 N•m (0.4 kg-m, 2 . 9 ft-lb)
Check the wheel runout ( page 1 3-3) .
Install the tube and tire.
I nstall the collar in the driven flange bearing.
I nstall the damper rubbers on the flange and place flange i n the
hub.
Apply grease to a new 0-ring and i nstall it onto the flange
groove .
(2)
Apply grease to the dust seal lip and install it.
I nstall the driven sprocket, if removed, and a new seal .
Tighten t h e driven sprocket mounting nuts.
TORQU E : 65 N•m ( 6 . 5 kg-m, 47 ft-lb)
1 3-6
0-RING
REAR WH EEL/BRAKE/S USPENSION
I nstal l the axle collar.
· --=
I N STALLAT I O N
I nstall the brake panel on the wheel hub.
Position the rear wheel between i n swingarm and install the
drive chain over the driven sprocket.
Install the left side adjuster collar onto the rear axle and insert
the axle (from the left side) through the swingarm, wheel hub
and right side collar.
I nstall the adjuster collar and axle nut.
Tighten the axle nut lightly.
Adjust the drive chain ( page 3 - 1 3 ) .
Tighten the axle nut.
TORQUE: 90 N · m (9.0 kg-m, 65 ft-lbl
Connect the brake torque rod to the brake panel with bolt, seat
washer, washer and nut. (page 1 3-8 ) .
Tighten the nut.
TORQUE: 27 N • m (2. 7 kg-m, 20 ft-lbl
I nstall the cotter pin and bend back it securely.
Connect the brake rod to the brake arm and adjust the rear
brake pedal free play (page 3 - 1 6 ) .
R EAR BRAK E
I N S PECT I O N
Remove t h e rear w heel (page
1 3-3)
Remove the brake panel and measure the rear brake drum I . D.
SERVICE LIMIT: 1 6 1 mm ( 6 . 3 in)
Measure the rear brake lining thickness.
SERVICE LIMIT: 2 m m (0.08 in)
Replace the brake shoes if either one is thinner than the service
limit.
1 3- 7
REAR WHEEL/BRAKE/S USPENSION
D I SASS E M B LY
Remove the cotter pins and set plate .
(2)
COTTER PINS
Remove the brake shoes and springs from the brake panel .
NOTE
•
Mark the shoes to indicate their original positions before re
moving them.
Remove the following parts form the brake panel :
- bolt and brake arm
- indicator plate
- brake cam
- felt seal
A S S E M BLY
( 1 ) BOLT
(2)
I N D I CATOR
PLATE
(3) FELT SEAL
( 1 0) BRAKE
ARM
(9) BRAKE
PANEL
1 3-8
(8) SPRINGS
(4) BRAKE SHOES
�7(6)
(7) SET PLATE
COTTER PINS
REAR W H E E L/BRAKE/S USPENSION
( 1 ) BRAKE CAM
Apply grease to the brake anchor pins and brake cam. I nstall
the brake cam into the brake panel .
-
I nstall the felt seal.
Install the indicator plate on the brake cam aligning its tab with
cut-out on the brake cam .
Install the brake arm by aligning the punch marks on the arm
and cam.
I nstall and tighten the bolt.
(3)
Position the brake shoes in their original locations and install
the springs .
•
Grease on the brake linings will reduce stopping power.
Keep grease off of the brake linings. Wipe excess grease off the
cam and anchor pin.
I nstall the set plate and cotter pins, then bend back the pins.
I nstall the brake panel onto the wheel hub and install the rear
wheel (page 1 3-7 ) .
(4) SET PLATE
( 3 ) COTTER PI N� ( 2 ) SPRINGS
....
1 3-9
REAR WHE EL/BRAKE/S U S PE N S I O N
BRAKE PEDAL
R E M OVAL
Remove the foot peg bracket mounting bolts and washers .
Remove t h e brake pedal b y removing t h e cotter p i n , washer
and bolt.
I N STA LLAT I O N
Install the brake pedal in the reverse order o f removal .
NOTE
Note the locations of the washers .
(4)
BRAKE SHAFT ARM
( 1 ) BRAKE PEDAL ADJ U STER BOLT
( 2 ) DUST SEALS
-�
(5) PUNCH M A R K
(8) PIVOT CO LLAR
- ljiii@
1 3- 1 0
M I DDLE BRAKE ARM
NOTE
Align the punch mark on the brake shaft arm end with
the punch mark on the middle brake arm.
(7)
•
R EAR W H EEL/BRAK E/S USPEN S I O N
REAR SHOCK ABSORBER
REM OVAL
•
The rear shock absorber contains nitrogen under high pressure.
Do not allow fire or heat near the shock absorber.
Support the motorcycle using a hoist, or a jack under the en
gine.
Remove the follow i n g :
- seat, right and left s i d e cover
- rear ignition coil mounting bolts (page
- rear ignition coil stay mounting bolt
1 6- 5 )
Disconnect the fuel pump, fuel pump relay and turn signal
relay from the fuel pump stay .
Remove the fuel pump stay mounting bolt, nut and fuel pump
stay .
Remove t h e upper and lower shock absorber mounting bolts
and nuts then remove the shock absorber.
( 2 ) ATTACH M ENT
D I SA S S E M BLY
Set the spring preload adjuster to No. 1 position .
Compress the shock absorber with the compressor a n d attach
ment.
.;:f;:.'�:·�
'I
CAUTION
•
·,
Be sure the base is adjusted correctly for the shock spring seat
and the clevis pin is all the way in.
TOOLS :
Attachment
Compressor screw
07GME - 00 1 0000
07J ME - MR 1 0 1 00
07GME - 00 1 0 1 00
(1 )
No. 1 POSITION
11 1
Loosen the lock nut and remove the lower joint and nut.
Remove the com pressor and disassemble the shock absorber.
:::
J
INT
. �-
LOCK NUT
1 3- 1 1
REAR WHEEL/BRA K E/S U S PENSION
SPRING FREE LEN GTH
Measure the shock absorber spring free length .
SERVICE LIMIT: 1 35 . 0 mm ( 5 . 3 1 in)
Mark the damper rod at 1 0 mm below the case as show n .
Place the damper rod on a scale a n d measure t h e force re
quired to compress the damper to the 1 0 mm (0.4 i n ) mark.
COMPRESSION FORCE: 1 3 . 4 - 1 7 . 4 kg (29 . 54 - 38 . 36 1bl
If the force required is less than 1 3 . 3 kg ( 2 9 . 3 2 l b ) , gas is leak
ing.
Examine the damper rod and replace the damper unit if it is
bent or scored .
1 0 mm (0.4 i n )
Check the damper unit for oil leaks or other damage and the
damper rod for trueness .
Check the upper mount bushing for wear or damage .
S H O C K A B S O R B E R D I S POSAL PR O C E D U R E
Center punch the damper case t o mark a drilling point, a pproxi
mately 45 mm ( 1 . 8 in) from the mount top surface .
Wrap the damper unit inside a plastic bag and support the
damper unit upright i n a vise as shown.
Through the open end of the bag, insert a power drill with a
sharp 2 or 3 mm ( 5/64 - 1 /8 in) drill bit.
•
•
•
Do not use a dull drill bit which could cause a build-up of exces
sive heat and pressure inside the damper, leading to explosion
and severe personal injury.
The shock absorber contains nitrogen gas and oil under high
pressure. Do not drill any farther down the damper case than
the measurement given above, or you may drill into the oil
chamber; oil escaping under high pressure may cause serious
personal injury.
Always wear eye protection to avoid getting metal shavings in
your eyes when the gas pressure is released. The plastic bag is
only intended to shield you from the escaping gas.
Hold the bag around the drill motor and briefly run the drill
motor inside the bag; this will inflate the bag with air from the
motor and help keep the bag from getting caught in the bit
when you start.
1 3- 1 2
(3) D A M P E R U N I T
R EAR W H EEL/BRAKE/S U S PENSION
A S S E M B LY
( 1 ) DAMPER
�
( 2 ) SPRING
•
( 1 2 ) ADJU STER ADJUSTER
SEAT
(4) SPRING
( 5 1 LOWER
SPRING
SEAT
p
(3) U PPER SPRING
SEAT
a
l�Q
:\'
(B) PLUG
(7) LOWER JO I NT ( S) DRAI TU BE
( 1 01 STOPPER RUBBER
N
( 9 ) LOCK N UT
Install the following:
- stop rubber onto the damper rod
- spring a djuster seat and spring a djuster onto the damper so
that it rests in the softest position
- upper spring seat, spring (with the tightly wound end
upward and lower spring seat ) ,
- lock nut
LOCK NUT
Compress the spring with the compressor (07GME 00 1 0000)
and attachment (07 J M E - M R 1 0 1 00) .
Screw the lower joint onto the d a m per rod fully, hold it, and
tighten the lock nut.
TORQUE : 70 N·m (7 .0 kg-m, 51 ft-lb)
I N STA L LAT I O N
Install the rear shock absorber w ith the drain tube pointing
dow n .
Install a n d tighten the upper and lower mounting bolts and
nuts.
( 1 ) UPPER MOUNTING BOLT
TORQUE : 45 N·m (4. 5 kg-m, 33 ft-lb)
Route the drain tube into the tube guide in the swingarm .
Install the removed parts in the reverse order of removal .
Adjust t h e shock absorber spring preload b y turning the spring
adjuster, if necessary .
1 3- 1 3
REAR WH EEL/BRAKE/S U S P E N S I O N
SWI NGARM
R E M OVAL
Remove the rear wheel (page 1 3-3)
Remove the gearshift pedal mounting bolt from the foot peg .
( 1 I PEDAL
BOLT
Remove the drive sprocket cover.
Remove the drive sprocket bolts, set plate and drive sprocket.
Disconnect the gearshift arm from the gearshift spindle.
(i') DRIVE S � 2 )
�
COVER
BO LTS
!?W�, .
Remove the reserve tank from the frame ( page 5-9)
Remove the shock absorber lower mounting bolt and nut.
Remove the swingarm pivot bolt caps, pivot bolt and nut then
remove the swingarm from the frame .
D I SA S S E M B LY
Inspect the drive chain slider for wear or damage.
Replace it if necessary.
Inspect the drive chain for dirt or damage .
Clean or replace it if necessary ( page 3 - 1 4 )
- drive chain slider and chain cover
- dust seals and pivot collars
1 3- 1 4
( 1 I CHAIN COVER
REAR W H E E L/BRAKE/S U S PE N S I O N
I N S PECT I O N
I nspect the swingarm f o r deformation o r cracks.
Check the pivot bearings, collars and dust seals for wear or
damage.
\
'
'
(3) DUST
SEALS
Disassemble the drive chain cover and inspect the chain pro
tector for wear or damage, Replace if necessary .
\
'
(4) BEARINGS
( 1 ) CHAIN COVER
(2) PROTECTOR
P I VOT B E A R I N G R E PLAC E M E N T
Remove the dust seals from t h e right a n d left swingarm pivots .
Remove the snap ring from the right pivot.
TOOL: Snap ring pliers
079 1 4 - 323000 1
Drive the right pivot ball bearing out of the swingarm using a
hydraulic press and driver shaft.
TOOL: Driver shaft:
07946 - MJ00 1 00
1 3- 1 5
REAR WHEEL/ BRAKE/SUSPENSION
Drive the left needle bearing out of the swingarm .
TOOL: Driver shaft
07946 - MJ00 1 00
Carefully press new bearings into the swingarm pivots .
NOTE
•
I nstall the bearings with the marks facing out.
Right side ball bearing:
TOOLS :
Driver
Attachment, 32
Pilot, 1 5 mm
x
35 mm
07749 - 00 1 0000
07746 - 00 1 0 1 00
07746 - 0040300
Left side needle bearing:
TOOLS :
Driver
Attachment, 28
Pilot, 22 mm
Snap ring pliers
x
30 mm
07749 - 00 1 0000
07746 - 1 870 1 00
07746 - 0041 000
079 1 4 - 323000 1
I nstall the snap ring into the right pivot.
Apply grease to the new dust seal lips and install them , and
the collars i n the correct positions .
( 2 ) PIVOT COLLARS
1 3- 1 6
REAR WH EEL/BRAKE/S USPENSION
( 1 ) CHAIN COVER
A S S E M B LY / I N STA L LAT I O N
I nstall the chain slider a n d chain cover with protector .
(2) CHAIN SLIDER
I nstall t h e swingarm in t h e frame.
I nstall the swingarm pivot bolt and nut, and tighten the nut to
the specified torque.
TORQU E : 90 N · m ( 9 . 0 kg-m, 6 5 ft-lb)
I nstall the li·h ock absorber lower mounting bolt and nut.
TUr1\:.. � E : 45 N•m (4. 5 kg-m , 33 ft-lb)
I
I
I
I
( 1 ) PIVOT NUT
I nstall the following :
- swingarm pivot caps
- reserve tank (page 5-9)
- evapo rative e m iss i o n canister (California model only)
- drive sprocket with the drive chain
- gearshift arm
I nstall the drive sprocket cover and tighten the mounting bolt.
I nstall the gearshift pedal mounting bolt.
Apply grease to the gearshift pedal pivot collar refer to page
7-9.
Adjust the drive chain (page 3 - 1 3 ) and rear brake pedal free
play ( page 3 - 1 6 )
- rear wheel (page 1 3-7)
1 3- 1 7
REAR W H E E L/BRAKE/S U S P E N S I O N
SEAT/ R EAR FEN DER/SUB-FRAM E
R E M OVAL/ I N STA L LAT I O N
Remove the seat mounting socket bolts a n d unhook the seat
hooks from the frame, then remove the seat.
Remove the right and left side covers, pull out the prongs then
pull the cover down slowly to the release tabs .
Remove the fuel tank (page 4-3) and the rear fender mounting
bolts and Remove the tallight case mounting nuts .
Disconnect the right and left turn signal wire connectors, and
the rear brake light and licence light connectors.
Remove the rear fender from the main frame and sub-frame.
Remove the two sub-frame mounting bolts and two nuts, then
remove the sub-frame.
I nstall the removed parts i n the reverse order of remova l .
· ·- - - . .
( 2 ) SEAT
(3) RIGHT
SIDE
COVER
( 9 ) REAR
FENDER -----�·
(6) TAILLIGHT CASE
MOUNTING N UTS
( 7 ) SUB-FRA M E
MOUNTING
N UTS
1 3- 1 8
M E MO
HYDRA U LI C D I S C BRAKE
'88 , '89 , '9 1 -'93 :
1 . 5 N • m (0 . 1 5 kg-m , 1 . 1 ft-lb)
12
2 7 N · m ( 2 . 7 kg-m, 20 ft-lb)
1 4-0
N·m
( 1 .2
kg-m , 9 ft- l b )
14. HYDRAU LIC DISC BRAK E
After '93 :
1 2 N · m ( 1 .2 Kg-m,9 ft-lb )
7
�
3 5 N · m ( 3 . 5 Kg-m,2 5 ft-l b )
0 /:0
�
2 2 N · m (2 . 2 Kg-m, 1 6 ft-lb)
co go
() �
5 . 5 N · m(0.5
0
�
4 ft-lb )
�
1 2 N · m ( 1 .2 Kg-m,9 ft-lb)
3 1 N · m ( 3 . 1 Kg-m,22 ft-lb)
2.5 N · m (0.2 5 Kg-m, 1 .8 ft-lb)
1 4- 1
H Y D RA U LI C D I S K B R A K E
S ERVICE I N FORMATION
1 4- 2
BRAKE PAD/DISC
1 4- 5
TROU BLES H O OTI N G
1 4- 3
MASTER CYL I N D E R
1 4- 8
BRAKE F L U I D R EPLACEM ENT/
AIR BLEED I N G
BRAKE CALIPER
1 4-1 1
1 4- 4
G E N E RAL
•
•
•
•
•
•
•
•
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high
quality brake degreasing agent.
Use only DOT 4 brake fluid.
The brake caliper can be removed without disconnecting the hydraulic system.
Once the hydraulic system has been disassembled, or if the brakes feel spongy, the system must be bled.
Do not allow foreign material to enter the system when filling the reservoir.
Brake fluid will damage painted, plastic, and rubber parts. Whenever handling brake fluid, protect the painted, plastic and rubber
parts by covering them with a shop towel. If fluid does get on these parts, wipe it off immediately with a clean cloth.
A lways check brake operation before riding the motorcycle.
assemblies. Use an OSHA -approved vacuum cleaner or alternate method approved by OSHA, designed to minimize the hazard
caused by airborne asbestos fibers.
U n it: m m ( i n )
ITEM
Disc thickness
Disc runout
Master
cylinder
B rake
caliper
' 8 8,'89,
'9 1 -'93:
After ' 9 3:
' 88,'89,
' 9 1 -'93 :
After ' 9 3:
STAN DA R D
E R V I C E LI M IT
5.0(0.2 )
4.0(0. 1 6)
0.30(0.0 1 2 )
1 2 . 7 6 (0.502 )
1 2 . 6 5 (0.498 )
1 1 .05(0.43 5 )
1 0.94 5 ( 0.4309)
30.2 9 ( 1 . 1 93 )
3 0. 1 6 ( 1 . 1 87 )
2 7 .06 ( 1 .065 )
2 6.93 ( 1 .060)
-
I. D.
piston O.D.
I . D.
piston O.D.
cylinder I . D .
piston O.D.
cylinder I . D.
piston O.D.
1 2. 7 00- 1 2 .743 (0.5000-0. 50 1 7 )
1 2 . 6 5 7 - 1 2 .684(0.4983-0.4994)
1 1 .0- 1 1 .043 (0.433 1 -0.4348)
1 0.9 5 7-1 0.984(0.43 1 4-0.4324)
30.2 3 0-30.280( 1 . 1 902 - 1 . 1 92 1 )
30. 1 6 5-30. 1 9 8 ( 1 . 1 8 7 6- 1 . 1 8 8 9 )
2 7 .000-2 7 .050( 1 .0630- 1 .06 50)
2 6.93 5-2 6 . 9 6 8 ( 1 .604- 1 .06 1 7 )
T O R Q U E VA L U E S
Caliper mounting bolt
Brake hose oil bolt
Bleed valve
M aster cylinder holder bolt
Master cylinder cover screw
27 N • m ( 2 . 7 kg-m , 20 ft-lb)
30 N·m (3.0 kg-m, 22 ft-lb)
5 . 5 N · m (0. 5 5 kg-m, 4 ft-lb)
1 2 N·m ( 1 . 2 kg-m, 9 ft-lb)
1 . 5 N·m (0 . 1 5 kg-m, 1 . 1 ft-lb)
TOOL
Special
Snap ring pliers
1 4- 2
07 9 1 4 - 32 3000 1 or equivalent commercia lly
H Y D RA U L I C D I S C BRAKE
TROUBLESHOOTI N G
Brake lever soft o r spongy
•
•
•
•
A i r bubbles in hydra u l i c syste m .
Low f l u i d leve l .
H y d r a u l i c system l e a k i n g .
F a u lty dust s e a l or piston s e a l .
Brake lever too hard
•
•
•
Sticking pisto n ( s ) .
C logged hyd ra u l i c syste m .
Pads g l a zed or w o r n e x c e s s i ve l y .
Brake drag
•
•
H y d r a u l i c system stic k i n g .
Sti c k i n g piston ( s ) .
Brake grab o r pull t o one side
•
•
Pads conta m i n ated .
D i s c or wheel m i sa l ig n e d .
Brake chatter or squeal
•
•
•
•
Pad conta m i n ated .
Excessive d i s c r u n o u t .
C a l i p e r insta l l e d i n correct l y .
D i s c or w h e e l m i s a l i g n e d .
1 4-3
BRAKE FLU I D REPLACE M ENT/
AI R BLEEDI NG
CAUTION
Be careful not to allo w dust or water to enter the brake system
when filling the reservoir.
USE ONL Y D O T 4 BRAKE FL UID
Do not mix different types of fluid since they are not
compatible.
A void spilling fluid on painted surfaces. Place a rag over the
fuel tank whenever the system is serviced.
•
•
•
Check the fluid level with the fluid reservoir parallel to the
ground.
Remove the reservoir cover, set plate and diaphragm.
BRAKE F LU I D D RA I N I N G
Connect a bleed hose to the bleed valve.
Loosen the caliper bleed valve and pump the brake lever. Stop
operating the lever when fluid stops flowing out of the bleed
valve.
BRAKE FLU I D F I L L I N G /A I R B L E E D I N G
Close the bleed valve, fill the master cylinder with DOT 4 brake
fluid to the casting ledge level ( brake fluid upper level ) .
CAUTION
Do not mix different types of fluid since they are not
compatible.
Connect the commercially available brake bleeder to the
bleeder valve.
Pump the brake bleeder and loosen the bleed valve.
Add fluid when the fluid level in the reservoir is low.
Repeat above procedures until no air bubbles appear in the
plastic hose .
NOTE
•
If air is entering the bleeder from around the bleed valve
threads, seal the threads with teflon tape .
If a brake bleeder is not available, fill the system as follows:
Pump up the system pressure with the lever or pedal until
there are no air bubbles in the fluid flowing out of the reservoi r
hole a n d lever or pedal resistance is felt.
1 4-4
H Y D RAU LIC D I SC BRAKE
1 ) Squeeze the brake lever, then open the bleed valve 1 /2 turn
and close the valve.
NOTE
•
Do not release the brake lever (or pedal) u ntil the bleed
valve has been closed .
2) Release the brake lever slowly and wait several seconds
after it reaches the end of its travel.
Repeat steps 1 and 2 until bubbles cease to appear i n the fluid
at the end of the hose.
Tighten the bleed valve .
TORQUE : 5 . 5 N • m ( 0 . 5 5 kg-m, 4 ft-lbl
Close the bleed valve, fill the reservoir with the specified brake
fluid to the casting ledge leve l .
Reinstal l t h e diaphragm, set plate and cover.
•
A contaminated brake disc or pad reduces stopping po wer. Dis
card contaminated pads and clean a contaminated disc with a
high quality brake degreasing agent.
..
BRAKE PAD/DISC
F R O N T B RA K E PAD R E PLAC E M E N T
•
A contaminated brake disc or pad reduces stopping po wer. Dis
card contaminated pads and clean a contaminated disc with a
high quality brake degreasing agent.
NOTE
•
Always replace the brake pads i n pairs to assure even disc
pressure .
'88 , '89 , '9 1 -'93 :
Remove the pad pin plugs and loosen the pad pins.
Remove the caliper mounting bolts, then remove the brake cal
iper and bracket.
Pry one old pad agai nst the caliper with a screwdriver to push
the pistons i nto the caliper.
1 4- 5
HYDRA U L I C D IS C BRAKE
Pull the pad pins out of the caliper and remove the brake pads.
Position the pad spring in the caliper as show n .
I nstall new pads in the caliper.
NOTE
•
Always replace the brake pads in pairs to assure even disc
pressure .
I nstall the pad pins, first one pin, then the other, by pushing
the pads against the caliper to depress the pad spring .
Position the retainer spring i n the bracket .
Apply silicone grease to the caliper and bracket pin bolts .
I nstall the bracket .
1 4- 6
I nstal l the brake caliper over the disc, being careful not to
damage the pads, then tighten the caliper mounting bolt.
-
�
H Y D R A U LI C D I S C B RA K E
'
( 1 ) CALIPER MOUTING
BOLTS
TORQUE : 27 N·m (2. 7 kg-m, 20 ft-lbl
Tighten the pad pins and tighten the pad pin plugs securely.
NOTE
•
Operate the brake lever to seat the caliper pistons against
the pads.
After '93 :
Remove the pad pin plug and loosen the pad pin.
�(
.
. "
-l ·
f
.
f /, ( 1 ) PAD PI N
Pull the pad pin out of the caliper.
Remove the bra ke pads.
I nsert new outsid e pad and push the caliper piston in allow
clearance for installation of the new inside pad .
Instal l new inside pad.
Install the pad pin by pushing the pads against the caliper to
depress the pad spring.
Tighten the pad pin to the specified torque.
TO R Q U E : 1 8 N · m ( 1 . 8 Kg-m, 1 3 ft-lb)
I nstall a n d tig hten the pad pin plug to the specified torque.
TO R Q U E : 2 . 5 N · m(0.25 Kg-m, 1 .8 ft-l b)
1 4- 7
D I S C TH I C K N E S S
Measure the thickness of the d isc .
SERVICE LIMIT: 4.0 mm (0. 1 6 in)
BRA K E D I S C WA R PA G E
Measure the brake disc for warpage with a dial indicator as
shown.
SERVICE LIMIT: 0.30 m m (0.0 1 2 in)
MASTER CYLI N DER
R E M OVAL
Drain brake fluid from the hydraulic system .
Remove the rear view mirror from the master cylinder a n d dis
connect the brake light switch wires.
Disconnect the brake hose by removing the oil bolt and sealing
washers .
CAUTION
•
A void-spilling brake fluid on painted surfaces. Place a rag over
the fuel tank whenever the brake system is serviced.
N OTE
•
When removing the oil hose bolt, cover the end of the hose
to prevent contamination . Secure the hose to prevent fluid
from leaking out.
Remove the master cylinder holder bolts and holder, then
remove the master cylinder from the handlebar.
D I SA S S E M B LY
Remove the brake lever and brake light switch.
(1
) BRAKE LEVER
'
( 2 ) BRAKE LIGHT SWITCH
1 4-8
H Y D RA U LIC DISC BRAKE
( 1 ) SNAP R I N G
Remove the boot .
Remove the piston and spring by removing the snap ring .
TOOL:
Snap ring pliers
079 1 4 - 323000 1
available in U . S . A.
Clean the inside of the master cylinder, reservoir, spring and
piston with clean brake fluid .
( 2 ) BOOT
•
( 1 )SPRING
, .,.._
( 2 ) PISTON
I N SPECT I O N
Measure the master cylinder I . D .
S E RV I C E L I M IT: '88,'89,'9 1 -' 9 3 : 1 2. 7 6 m m (0. 502 in)
After'93:
1 1 .05 m m (0.435 i n )
Check the master cylinder for scores, scratches or nicks.
Measure the master piston O . D . at the shown position.
S E RV I C E L I M IT: '88,'89,'9 1 -'93: 1 2.65 m m (0.498 i n )
1 0. 945 m m (0.4309 in)
After'93:
Check the primary and secondary cups for damage before as
sembly.
AS S E M B LY
CAUTION
•
Handle the master cylinder piston, cylinder and spring as a set.
Coat all parts with clean brake fluid before assembly.
If the spring and seat were disassembled, assemble the wide
end of the spring on the seat .
Install the spring in the master cylinder with its seat facing in
side.
Instal l the piston.
CAUTION
•
When installing the piston, do not allo w the cup lips to turn
iside out.
1 4-9
HYDRA U L I C DISC BRAKE
I nstal l the snap ring using a snap ring pliers.
Install the boot .
(1 )
SNAP RING
CAUTION
•
Be certain that the snap ring is seated firmly in the groove.
TOOL:
Snap ring pliers
079 1 4 - 323000 1
available in U . S A .
�
.
( 2 ) BOOT
Install t h e brake lever a n d brake light switch.
I N STALLAT I O N
Set the master cylinder onto the handlebar with the holder
" U P" mark facing up.
Temporarily install the holder bolts. Align the slit of the master
cylinder with the punch mark on the handlebar.
Tighten the upper bolt first, then the lower bolt.
Connect the brake light switch wires to the switch terminals.
I nstall the rear view mirror.
Connect the brake hose with the oil bolt and two sealing wash
ers and tighten the oil bolt.
TORQU E : 30 N·m (3.0 kg � m. 22 ft-lb)
Fill the reservoir with DOT 4 brake fluid to the casting ledge
and bleed the brake system (page 1 4- 4) .
1 4- 1 0
I1 )
BRAKE LEVER
/
BRAKE CALl P E R
R E M OVAL
Place a clean container under the caliper and disconnect the
brake hose from the caliper by removing the oil bolt and sealing
washers.
CAUTION
•
A void spilling brake fluid on painted surfaces.
Remove the brake pads ( page 1 4- 5 ) .
D I SA S S E M BLY
- pad spring and pin bolt boot from the caliper
- retainer spring and pin bolt boot from the bracket
If necessary, apply compressed air to the caliper fluid inlet to
get the piston out. Place a shop rag under the caliper to cush
ion the piston when it is expelled . Use the air i n short spurts.
CAUTION
•
Do not bring the nozzle too close to th inlet.
Push the dust seals and piston seals in, lift them out and dis
card the m .
( 1 ) PISTON SEAL
NOTE
•
The seals must be replaced whenever they are removed.
Clean the seal grooves with clean brake fluid .
CAUTION
•
Be careful not to damage the piston sliding surfaces.
(2) DUST SEAL
I N S P ECTI O N
Check the pistons for scoring, scratches o r other faults.
Measure the piston O . D .
S E RV I C E LI M IT: '88,'89.'9 1 -'93: 30. 1 6 m m ( 1 . 1 87 i n )
26.93 m m ( 1 .060 in)
After'93:
Check the caliper cylinder for scoring, scratches or other
faults .
Measure the caliper cylinder I . D .
S E RV I C E L I M IT: '88.'89.'9 1 -'93: 30.29 m m ( 1 . 1 93 in)
27.06 m m ( 1 .065 in)
After'93:
1 4- 1 1
HYDRAULIC D I S C BRAKE
A S S E M BLY
Coat new piston seals and dust seals with clean brake fluid
and install them in the caliper.
I nstall the pistons anrJ i nstall them with the open ends toward
the pads.
( 2 ) D U ST SEALS
Instal l the pad spring on the caliper as show n .
Apply silicone grease t o t h e inside o f t h e boot, and instal l it.
(3) SILICONE
-�
( 1 ) RETAINE R
SPRING
I nstall the retainer spring as shown.
Apply silicone grease to the inside of the boot and install it.
I nstall the following:
- pads and pad pins to the caliper
- bracket to the caliper
I nstall the caliper assembly over the brake disc so that the disc
is positioned between the pads.
CAUTION
•
(2) SILICONE
Be careful not to damage the pads.
( 2 ) BOOT
I nstall and tighten the caliper mounting bolts .
TO R Q U E : '88,'89,'9 1 -'93: 27 N · m (2.7 Kg- m,20 ft-lb)
After'93:
3 1 N · m (3. 1 Kg- m,22 ft-lb)
Tighten the pad pins and i nstall and tighten the pad pin plugs.
Connect the brake hose to the caliper with the hose bolt and
two new sealing washers.
TORQU E: 30 N·m (3.0 kg-m, 22 ft-lb)
Bleed the air from the brake system (page 1 4-4) .
1 4- 1 2
-�
MEMO
BATTERY CHARG I N G SYSTEM
( 3 ) ST
SWITCH
MAIN FUSE
30A
1 5-0
1 5. BATTERY /CHARG I NG SYSTEM
' 8 8- ' 8 9 , ' 9 1 :
y
y
( 3 ) MAIN F U S E 30A
y
R/W
G
8 1 /G
(4) ALTER NATO R
81
81
81
( 1 ) R E G U LATO R/R E CTI F I E R
Y : Yellow
8 1 : Black
G : G reen
R : Red
W : White
After '9 1 :
y
y
y
( 3 ) M A I N F U S E 3 0A
G
(4) ALTER NATO R
( 1 ) R E G U LATO R/R ECTI F I E R
R/W
Y : Yellow
G : G reen
R : Red
W : white
1 5- 1
B ATTERY/ C H A R GING SYSTEM
S E RVI C E I N F O R M ATION
1 5-2
CHARG I N G SYSTEM
1 5- 7
TROUBLESHOOTING
1 5-3
REGU LATO R/RECT I F I E R
1 5- 8
BATTERY
1 5-4
ALTERNATOR
1 5-·9
G E N E RA L
•
•
•
•
•
•
•
•
•
The battery generates hydorogen gas which can be highly explosive. Do not smoke or allow flames or sparks near the battery,
expecially while charging it.
If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed. The ex
haust contains posisonous carbon monoxide gas that may cause loss of consciousness and, lead to death.
The following color codes are used throughout the electrical sections .
Bu = Blue
G = Green
Lg = Light Green
Bl
Black
Gr = Gray
0 = Orange
Br = Brown
Lb = Light Blue
P = Pink
R = Red
W = White
Y = Yellow
Slow charge the battery whenever possible, quick charging should be an emergency procedure only.
Remove the battery from the motorcycle for charging.
The battery on this motorcycle is a sealed type . Do not remove the filler hole caps even during charging. Do not use a non
maintenance free battery as a replacement.
All charging system components can be checked on the motorcycle.
When i nspecting the charging system , check the system components and circuits step-by-step according to the trouble
shooting chart on the next page.
Alternator removal is described in Section 8.
STANDARD
ITEM
Battery
Capacity
Voltage at 20 ° C ( 68 ° F)
Fully cahrged
Needs charging
Charging current
Charging time
1 2 V - 8 AH
1 3.0- 1 3.2 v
1 2.3 v
0.8 amperes
1 0 Hr
Regulator/rectifier
Type
Three-phase/ful l-wave
Alternator
Regulated voltage
Charging coil resistance at 20 ° C (68 ° F)
1 4 - 1 5 V/4, 000 rpm
0. 1 - 1 . 0 0
Output
0 . 345 kw/5,000 rpm
Charging start rpm
1 ,000
TO O LS
Digital multitester ( KOWAl
or
Circuit tester ( SANWA)
or
Circuit tester ( K OWAl
1 5-2
0 7 4 1 1 - 0020000 or KS-AHM-32-003 ( U . S . A . only)
07 308 - 002000 1
TH-5H
±
1 00 rpm
BATTERYI CHARG I N G SYSTEM
TROU BLESHOOTI NG
I
ABNORMAL
Measure the battery leakage (page 1 5- 7 ) .
Check the regulator/rectifier resistances between each regulator/rectifier terminals (page
1 5- 8 )
NORMAL
.
Short circuit in wire
harness
ABNORMAL ----+ • Faulty ignition
switch
NORMAL
I
Check for an overcharged battery (page 1 5-8 ) .
J
NOT OVE CHARG E D
I
L.
ABNORMAL
I
REG U LATED
.
Faulty regulator/
rectifier
Fault y battery
Measure the voltage between the R/W (+) and G
NO VOLTAGE
with terminals (-) of the regu lator/rectifier 4P t-------_. • Open or short circuit in wire harness
• Loose connecotor
Black connector. (wire harness side) (page 1 5-8 )
BATTERY VOLT AGE C O M ES
+
Disconnect the 3P connector of the regulator/
rectifier, check the alternator stator coil
resitances ( page 1 5-8)
1..._
STA N DARD
Loose 3P connector
_. .
_______
ABNORMAL
Faulty stator coil
...___________.,.
Check the regulator/recrifier resistan ces be
tween each regulator/rectifier terminal ( page
ABNORMAL
t-------.... •
1 5- 8 ) .
Faulty regulator/
rectifier
NORMAL
'"-------•
· Faulty battery
1 5-3
BATTE RY/CHARG I N G SYSTEM
BATTERY
R E M OVAL
CAUTIO N
•
D o not remove the battery while exhaust pipe is hot.
Remove the right side cove r .
U n hook t h e fuse box from t h e battery case cove r .
Remove t h e battery case cover by removi ng t h e bolts .
( 1 ) BATTE RY
CASE
COVER
·
�-......:..)�.:t:::;;;.::::...u-1 21 s o LT s -
Remove the left side cove r .
( 1 ) N EGATIVE
TERMINAL
Disconnect t h e battery negative terminal lead from t h e battery
fi rst , then disconnect the positive terminal lead .
Pull the battery out of the battery case .
--\ ',
2:,L.)� - - "
_.._ _
�
v v< r\\ -\ \\
(2) POSITIVE "'TER M I NAL
\
I N STALLATION
P l a c e the battery i nto the case and connect the battery posi
tive cable to the battery fi rst from the rig ht side, then connect
the negative cable from the left side .
Coat the battery term i n a l with clean g rease .
I nsta ll the battery case cover by hooking the tab on the cover
to the hook on the case .
I nsta ll and tighten the cover m o u nting bolts .
I nstall the fuse box onto the battery case cover .
I nstall the ru bber covers in the seq uence as shown .
I nstal l the right and left side covers .
R oute the battery cables as shown on the battery caution
la bel .
CAUTI O N
WIRING
1 5-4
AS
SHOWN
BELOW
BAlTERY/CHARG I N G SYSTEM
VO LTAGE I N S PECTI O N
I
R emove the right a n d left side covers .
Remove the battery case cove r .
M easu re the battery voltage using a digital multimete r .
VO LTAG E : Fully charged : 1 3 . 0- 1 3 . 2V
U nder charged : Below 1 2 . 3V
TOO L :
Digital multimeter
0741 1 -0020000 ( KOWA)
KS-A H M -32-003 ( U . S. A. only)
(1\ BATTERY
BATTERY TESTI N G
N OTE
Always clear the work a rea of flammable materials such as
gasoline, brake flu i d , electrolyte , or cloth towels when
operating the tester , the heat generated by the tester may
cause a fire .
•
R emove the battery (page 15-4) .
Secu rely con nect the tester's p ositive ( + ) cable first, then
connect the negative ( - ) cable .
N OTE
For accu rate test result, be s u re the tester's cables and
clamps a re in good working condition and that a secu re
connection can be made at the battery .
•
Set the tem pe ratu re switch to " H I G H" o r " LOW" depending
o n the ambient tem pe ratu re .
~
� ©©©00@ @ 0
M-
LJ
LIM
HIGH:
6 0 ° F ( 1 5 ° C ) o r higher
LOW:
6 0 ° F ( 1 5.° C ) or lower
LJ
Push in the appropriate test b utton for th ree secon d and read
the condition of the battery on the mete r .
N OTE
Be sure you 've selected the test butto n of 5 . 5 Ah-9Ah .
For the first check, DO N OT charge the battery before
testing-test it is an "as is" condition .
�
lQoOOOO@ @ O
Test B utton s
1 5- 5
BATTERY/CHARG I N G SYSTEM
CAUTIO N
To avoid damaging the tester, only test betteries with an
amperage rating of less than 30A .
Tester damage can result from overheating when :
- The test button in pushed in for more than three seconds.
YELLOW
(- 1 )
RED
(-3, -2)
G RE E N
(+ 1 ' +2, +3)
- The tester is used without being allowed to cool for at
least one minute when testing more than one battery.
- Move than ten consecutive tests are performed without
allowing at least a 30- minute cool-down period.
N OTE
The result of a test on the meter scale is relative to the amp .
hour rating of the battery . Any BATTERY R EA D I N G I N
T H E G R EE N ZO N E I S O K . B atteries should only b e char
ged if they register in the YELLOW o r R E D zone .
•
BATTERY C H AR G I N G
N OTE
B e sure the a rea a round the charger is well ventilated , clear
of flammable materials, and free from heat, humidity,
water and dust .
Clean the battery terminals and position the battery as far
away from the charger as the leads will permit .
D o not place batteries below the charger-gases from the
battery may corrode and damage the charger.
D o not place batteries on top of the charger. B e sure the air
vents a re not blocked .
•
•
•
•
1 . Tu rn the Power Switch to the O F F position .
2 . Set the battery Amp . H r . Selector Switch for the size of
the battery being charged .
3 . Set the Timer to theposition indicated by the Honda
Battery Tester ; R E D-3 , R E D-2 or YELLOW- 1 . If you a re
charging a new battery , set the switch to the N EW BATT
position .
4 . Attach the clam ps to the battery terminals-R E D to Posi
tive, B LACK to N egative .
BATTERY A M P H R .
SELECTOR SWITCH
� . ... .
5.5 10 1.0
3 . • ••
Connect the battery cables only when the Power Switch is
OFF.
Connect the battery cables only when the Power Switch is O F F .
Connecting the cables with the Power Switch can pro
duce a spark which could ignite or explode the battery.
1 5- 6
··�
\11)
.. .
.
Set the a ppropriate a m p . hour ratin g .
BATTE RY/CHARG I N G SYSTEM
Turn the Power Switch to the O N position .
6 . When the timer reaches the "Trickle" position , the charg
ing cycle is complete . Turn the Power Switch OFF a n d
disc o n n ect t h e cla m ps .
5.
N OTE
The c h a rger will automatically switch to the Trickle mode
after the set charging time has elapsed .
•
7.
Retest the battery using the Honda Battery Tester a n d
rech a rg e i f necessary using t h e above steps .
N OTE
For accurate test results, let the battery cool for at least ten
m i nutes o r u ntil gassing subsid es after charging .
•
CHARG I NG SYSTEM
N OTE
When i nspectin g the charging system , check the system
components and lines step-by-step according to the
tro ubleshootin g o n page 1 5-2 .
Measurin g circuits with a large capacity that exceeds the
capacity of the tester may cause damage to the tester .
Before starting each test, set t h e tester a t the high capacity
range first, then g radually down to low capacity ranges i n
order that y o u have t h e correct range a n d d o not damage
the tester .
When measuri n g small capacity circuits, keep the ignition
switch off . If the switch is suddenly turned on d u ring a
test, the tester fuse ·may blow .
•
•
•
(1 )
BATTERY
NEGATIVE TERM INAL
LEAKAG E I N S PECTIO N
Check the battery a mpere leakage before making the regulat
ed ampere inspection .
Turn the ignition switch off and d i sco n n ect the battery nega
tive cable from the battery .
Connect the tester between the negative cable and the nega
tive battery terminal .
The voltag e should i n dicate less than 0 . 1 rnA with the ignition
switch off.
( 2 1 BATTERY
N EGATIVE
CABLE
LEAKAG E AM P E R ES : 0 . 1 mA max.
1 5- 7
BATTERY/ C HA R GING SYSTEM
R E G U LATED V O LTAG E I N S P E CT I O N
N OTE
•
Be sure the battery is i n good condition before performing
this test .
Warm up the engine to normal operating temperature .
Stop the engine, a n d connect the voltmeter a s shown .
Start the engine a n d allow i t to idle, then increase the engine
speed gradually.
The voltage should be controlled to 1 4. 3 - 1 5 . 1 V at 5,000
rpm .
CAUTION
•
Be careful not to let the battery positive cable contact the frame
while testing.
REGULATOR/ RECTI Fl ER
I N S PECT I O N
Remove the left side cover.
Disconnect the 3P (WHITE) and 4P ( BLACK) regulator/rectifier
connectors .
Check the connectors for loose or corroded terminals.
If the regulated voltage reading was out of specification,
check the circuits between the connector terminals (wire
harness side and alternator side) following the chart below .
TER M I NALS
STANDARDS
Red/White (+) and Green (-)
Yellow and Yellow
Battery voltage should come
0 . 1 - 1 . 0 0 (20° C/68 ° F)
ITEM
Battery charging line
Alternator coil line
Check the resistances between the leads with an ohmmeter. If
the resistance is out of the specifications, replace the regulator
rectifier.
�
e
NOTE
•
•
•
•
Red/White
Use a SANWA [SP- 1 0Dl or [TH-5Hl tester or KOWA D I G I
TAL VOLTO M ETER (074 1 1 - 0020000 ) .
The reg ulator/rectifier has a semi-co nducto r . If a d ifferent
tester is used , the results will be out of specification .
You ' ll get a false reading if your finger touches the tester
probe .
If the pointer of the tester fails to swing to zero when the
adjusting knob is turned fully clockwise or counter
clockwise, replace the battery in the tester.
Range
Tester
SP- 1 0D
TH-5H
15- 8
KO
RX 1 00
U n it : KO
'88-'89 , '9 1
G reen
Red/White
�
5 "' 30
4.2
Yellow
Yellow
Yellow
4.2
4.2
G reen
00
-----00
Yellow
00
1 "' 20
�
Yellow
00
1 "' 20
00
00
00
------
00
00
00
e
Red/White
Yellow
Yellow
Yellow
G reen
00
1 "'
20
00
00
-----U n it: KO
After '9 1 :
�
Yellow
Red/White
-----0.5- 1 0
0.5- 1 0
0.5- 1 0
0. 7 - 1 5
Yellow
Yellow
Yellow
G reen
00
00
00
00
00
00
00
00
00
�
00
------
00
00
0.5- 1 0
0.5- 1 0
�
0.5- 1 0
00
----
B ATT E R Y/ C HA R GIN G SYST E M
ALTERNATOR
I N S P ECTI O N
NOTE
•
It is not necessary to remove the stator coil to make this
test.
Disconnect the alternator 3P (WHITE) connector.
M easure the resistance between the yellow wire terminals and
check for no continuity between each terminal and ground.
STANDARD: 0 . 1 - 1 . 0
0
Replace the stator if the resistance is out of specification or if
there is continuity between each yellow wire terminal and
ground ( page 1 5 - 8 ) .
1 5- 9
I G N I T I O N SYST E M
ENGINE STOP SWITCH
(4) MAIN
FUSE
( 5 ) IGN ITION
SWITCH
( 1 1 ) NEUTRAL
SWITCH
A FTE R '93 ;
( 1 4) S I D E STAN D SWITCH
1 6-0
(6) REAR I G N ITION
( 1 2 ) I G N ITI O N
COIL
CONTR O L M O D U LE
1 6 . I G N I T I O N SYST EM
'88 , '89
r---- B I/W
---�B I
R/BI -o
( 1 ) ENGINE
STOP
SWITCH
(5) I G N I T I O N ( 4 ) M A I N
(2) SUB
FUSE
10 A
SWITCH
FUSE
30 A
e
( 1 3 ) S I D E STA N D
SWITCH
( 3 ) BATT E RY
1 2 V BAH
G/W
B l : Black
Y : Yellow
B u : Blue
G : G reen
R : Red
W : White
Lg : Light G re e n
( 1 2 ) TO
FUEL CUT
R E LAY
y
� �
( 9 ) FRONT
�
( 1 2 ) I G N ITION
CONTRO L
M O D U LE
( 1 0) REAR
11
-
>-
-
( 7 ) I G N IT I O N C O I L
11
-
( 9 ) FRONT
( 1 0) REAR
( 1 4 ) I G N ITION P U L S E G E N E R A T O R
-
AFTER '89 :
.---- B I/W
---�B I
( 1 ) ENGINE
STOP
SWITCH
R/BI-o
( 5 ) I G N I T I O N (4) M A I N
(2) SUB
FUSE
10 A
SWITCH
( 1 3 ) S I D E STA N D
SWITCH
e
( 3 ) BATT E R Y
1 2 V BAH
G /W
G
FUSE
30 A
B l : Black
Y : Yellow
Bu : B l u e
G : G reen
R : Red
W : White
Lg : Light G reen
-::
( 1 2 ) TO
FUEL C U T
R E LAY
Bl
a:
::J >
aJ -
� �
( 9 ) FRONT
11
-
-
( 7 ) I G N ITION COIL
>: �
�
>-
G/W
G Y
:J
aJ
� Bu �
( 1 2 ) I G N ITI ON
CONTROL
M O D U LE
( 1 0) REAR
11
-
-
1 6- 1
I G N I TIO N S Y ST E M
S E RVIC E I N FO R MATIO N
1 6- 2
I G N I T IO N P U LS E G E N E R ATO R
1 6- 6
TRO U BLES HOO T I N G
1 6- 3
S I D E STAND SWITCH
1 6- 7
I G N I T IO N CO N T RO L MO D U LE
I N S P E CT IO N
1 6_ 4
I G N ITIO N T I M I N G
1 6- 8
I G N ITIO N CO I L
1 6- 5
•
If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in on enclosed area.
G E N ERAL
• Ignition timing cannot be adjusted since the ignition control module is non-adjustable.lf ignition timing is incorrect.check
the system inspectio n and replace any faulty parts.
• For spark plug gap inspectio n and adjustment procedu re,see page 3-8.
• For alternator removal and i nstallation,see sectio n 8.
• For ignition pulse generator removal and installation,see page 7 - 1 1 .
• When i nspecti n g the i g n ition system,check the system components a n d li nes step-by-step according to the tro u ble
shooting on next page.
• Each pair of the spark plugs( Front and Rear) has its own ignition circu it.
• To test the neutral switch,refer to section 1 8.
ITEM
STAN DARDS (20° C/68 ° F)
N I PP O N D E N SO
NGK
S p a r k plug
X24EPR-U9
DPR8EA-9
0.8-0.9
S p a r k plug
I g nition t i m i n g
I n it i a l ( F m a r k )
I g n ition c o i l
resistance
Pri m a ry
Secondary
6.2
g e n e rator
With p l u g w i re
BTDC/i d l e
1 9 . 8 - 24 . 2
4 50 - 550
C o i l resistance
TOOLS
Tester
1 6-2
kO
n
F ( 2 ) - R ( 1 ) 308 °
Firing order
D i g it a l m u ltitester ( KOWAl
or
C i rc u i t tester (SANWA)
or
C i rc u it tester (KOWAl
(0.03 - 0.04
1 .89- 2.32 n
2 3 . 5 5 - 30 . 4 5 kO
Without p l u g w i re
Ignition pulse
mm
074 1 1 - 0020000
07 308 - 0020000
TH-5H
or
J
KS-AH M-32-003 ( U . S . A .
N ot available in U .S.A.
only)
in)
I G N ITI O N SYSTEM
TROU BLESHOOTI N G
When performing a spark test, keep open flames or sparks away from the work area.
•
No spark at one spark plug
•
•
Faulty spark plug
Faulty spark plug wire
No spark at all plugs
1 . Check the i g n ition contro l m od u le connectors for loose contact.
ABNORMAL
NORMAL
2 . Measure voltage betWeen the B l ( + )and G (-)/
between the B u/Y( + )a n d G (-)/between Y
( + )and G (-)of the ignition control module 6 P
connector. B attery voltag e should appear
with the ignition switch ON and engine stop
switch at R U N .
•
Faulty
Fuel cut relay (page 1 8-9)
• Fuel pump (page 1 8- 1 0)
Open circuit in wire harness
•
,.-
•
ABNORMAL
NORMAL
•
(page 20- 1 )
Faulty
• Side stand switch ( page 1 6-6)
• Neutral switch ( page 1 8- 1 1 )
• Short circuit in wire harness
�
NORMAL
3- 1 . C h e c k the i g n it i o n p u lse g e n e rato r resistances at the ignition control module 4P
connector( page 1 6-4).
loose connectors .
3-2. Check the ignition pulse generator( page
1 6- 6 ) .
ABNORMAL
NORMAL
•
•
l
Open or short circuit
in wire harness
loose connectors
•
�
ABNORMAL
�
ABNORMAL
Faulty pulse gener
ator
No spark at either spark group ( Front or Rear) - (CHECK WRONG SPARK GROUP)
A_L_--1� · Faulty ignition coil
B_N_O_R_M
1 . Check the ignition secondary coil resistance 1--- A
_
_
• Faulty spark plug wire
( page 1 6-4) .
-
� NORMAL
O_R_M_A_L
2- 1 . Check the ignition primary coil resistance at 1---A_B_N_
the ignition control module 6 P connector
( page 1 6-4) .
�r
__
1
NORMAL
•
NORMAL
•
}
l
2-2. Check the ignition coil (page 1 6-4) .
loose connectors
in wire harness
•
•
\
Faulty ignition coil
Open circuit in wire
harness
I
3-2. Check the ignition pu lse generator( page
3- 1 . C h e c k the i g n it i o n p u lse g e n erator resist- I -ABNORMAL
-.!
6 -_6)
1_
ances at the ignition control module 4P con - - --- -- L____ ,.:-. ________....-________�
nector(page 1 6- 4).
ABNORMAL
NORMAL
•
NORMAL
•
4. Exchange the ignition coil and try the spark
test.
GOOD JUMP
r------t� '·
l
in wire harness
loose connectors.
•
�
Faulty ignition pulse
generator
Faulty ignition coil
1 6-3
I G N ITION SYSTEM
I G N ITION CONTROL MODULE
I N S P ECTION
Remove the left side cover and connector plate .
N OTE
•
Check the system components and lines step-by-step ac
cording to the troubleshooting chart on page 1 6-3.
Disconnect the ignition control module connectors and check
them for loose o r corroded termi nals.
Measure the resistance between connector terminals using
the following chart.
<6P CONN ECTOR>
ITEM
TERMI NALS
81
( Rear) Bu!Y and
81
Ignition primary coil
Y and
( Front)
D C power supply circuit line
(+) and G (- ) , Bu/Y (+) and G ( - ) , Y (+) and G
(-) with the ignition switch " O N " and engine stop
switch " R U N "
81
STANDARD ( 2 0 ° C/68 ° F)
1 . 89 - 2 . 3 2
(}
Battery voltage should come.
< 4 P C O N N ECTOR>
ITEM
TERMINALS
I g n ition pulse generator coil
W/Y and Y ( Front) W/Bu and Bu ( Rear)
Each terminal and body ground
I G N ITION COI L
I N S PECTI O N
Remove the fuel tank ( page 4-3) a n d crankcase breather tank.
Measure the primary coil resistance of the front ignition coil in
the frame.
Remove the right side cover and rear ignition coil and measure
the primary coil resistance.
Checking for continuity between the primary terminals.
STANDARD : 1 .89 - 2 .32
0
(20 ° C/68 ° F)
Disconnect the spark plug caps from the plugs and measure
the secondary coil resistance with the spark plug caps in place.
STANDARD : 23 . 5 5 - 30.45
1 6 -4
kO
(20° C/68 ° F)
STANDARD ( 2 0 ° C/68 ° F)
450 - 550 (}
NO CONTI N U ITY
I G N ITION SYSTEM
If the resistance is out of range, remove the spark plug wires
and measure the resistance between the secondary coil termi
nals.
STAN DARD : 1 9 . 8 - 24 . 2
kO
(20° C/68 ° F)
R E PLAC E M E N T
Rear ignition coil
Remove the right side cover.
Disconnect the fuse connectors and starter relay switch from
the case .
Front ignition coil
Remove the fuel tank ( page 4-3 ) .
Remove the crankcase breather tank from the frame.
1)
CRAN KCASE
BR EATH E R
TA N K
•
Remove the ignition coil mounting bolts and disconnect the
primary terminals from the coils.
Remove the spark plug caps from the spark plugs.
Install the new ignition coil in the reverse order of the removal .
NOTE
•
Connect the primary wire terminals properly.
Front coi l : black terminal - black/white wire
green terminal - yellow/blue wire
Rear coi l : black terminal - black/white wire
green termina l - blue/yellow wire
1 6- 5
r(i')
IGN ITIO N S YSTEM
I G N ITION P U LS E G E N ERATOR
I N S PECT I O N
G E N E RATO R C O N
"
NOTE
•
It is not necessary to remove the ignition pu lse generator to
make this i nspection.
Remove the left steering cover.
Disconnect the ignition pulse generator 4P connector
(WH ITE) .
M easure the resistan ces between the white/yellow a n d yellow
wires(front ignition pulse generator) and white/blue and blue
wires( rear ignition pulse generator)
STAN DAR D :
450 - 550
0
(20° C/68 ° F)
For ignition pulse generator replacement, refer to section 8 .
SIDE STA N D SWITCH
I N SPECT I O N
'88 , '89 , '9 1 -'93 :
Re move the seat a n d left side cove r . D i s c o n n ect the 2 P
( G reen) c o n n e ctor a n d t h e G reen/White w i r e .
C h e c k the conti n u ity between e a c h term i n a l of t h e s i d e sta n d
switch .
SIDE STAND DOWN (RELEASED)
Side sta n d
position
Term i n a l s
Tester
Reading
S i d e stand up
(pushed )
-ignition circuit
open
G ree n/White to Green
Y e l l o w / B l a c k to G reen
N o conti n u ity
C o nti n u ity
Side sta nd down
( released)
-ig nition circuit
closed
G re e n/White to G reen
Y e l l o w / B l a c k to G re e n
Conti n u ity
N o conti n u ity
rO
0
<,.)
�
( 1 1 TO
WA R N I N G
LIGHT
(21 TO
SPARK U N I T
-. Y/BI
--GIW
I
,..()
( 1 ) TO
WA R N I N G
LIGHT
II
.,.
G
1 6- 6
S I D E STA N D U P ( PU S H E D )
( 2 ) TO -- Y/BI
SPARK U N I T
--- G/W
()-
9-
I
·�
G
I G N IT I O N S Y ST E M
After '93 :
Disconnect the side stand 3 P g reen connector and check for
conti n u ity between each terminals as shown below.
There should be continuity between the 0-0 positions on the
conti n u ity chart.
G reen/White Yellow/ B lack
Side sta n d
down
Side stan d
up
()
0
G reen
-o
0
( 1 ) D OWN
( 1 ) B O LT
R E M OVAL/ I N STA L LATI O N
Remove t h e left side cover.
Discon nect the side stand 3 P g reen connector.
Remove the side stand switch mounting bolt,setting plate,
washer a n d side stand switch.
I nstall the switch in the reverse order of removal.
N OTE
•
Align the switch pin with the side stan d h ole.Aiign the
switch g ro ove with the setting plate tang and align the
setting plate solt with the side stand return spring holding
pin.
TO R Q U E :
Side stand switch mounting bolt : 9 N · m (0 . 9 kg-m , 7 ft-lb)
R oute the side stand switch wire properly.
I G N ITION TI M I NG
NOTE
The ignition control module system is factory pre-set and
can not be adjusted.lgnition tim i n g inspectio n procedures
a re g iven to inspect the fu nction of the ignition control
module com ponents.
Con nect the timing light to the other spark plug wire if you
see that the ignition timing is i ncorrect,and you might be
able to see the timing is correct.
•
Warm up the engine to operating temperature.
Remove the timing inspection hole cap on the right crankcase
cover.
r
Connect the timing light to the front spark plug wire.
1 6-7
I G N ITION SYSTEM
The timing is correct if the " F" mark aligns with the index
mark on the right crankcase cover at idle for each cylinder.
Raise the engine rpm and the " F " mark should begin to rotate
counterclockwise for each cylinder.
If the ignition timing is incorrect, make a system inspection
( page 1 6-3) and replace any faulty parts .
(1 l
"F" MARK
(2) I NDEX
MARK
1 6-8
MEMO
ELECTRIC S TARTER
( 8 ) CLUTCH
SWITCH
I
I
I
I
I
I
I
I
I
(7) D I O D E
A FT E R '93 ;
( 1 2)
( 1 4)
S I D E STAN D SWITCH
·- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
( 1 l M A I N FUSE
30A
(4)
( 2 l BATT E R Y
( 1 2)
STARTER RELAY
SWITCH
1 2 V 8AH
STARTER
RELAY
SWITCH
SIDE
STAND
SWITC H
( 5 ) I G N ITI O N
C O NT R O L
M O D U LE
DOWN
I
Lg/R
(8) CLUTCH SWITCH
-=-
B l : Black
Y : Yellow
G: G reen
R: Red
W: White
Lg : Light green
I
G/W
G
( 6 ) N EUTRAL
(7) CLUTCH D I O D E
SWITCH
G/R--+------+-t-+-1 L g/R_...�-a-R--o'--o-- R t BI---<f\...J>-- BI ----o
I G N ITION ( 1 0 } S U B- F U S E ( 9 ) STARTER
SWITCH
1 OA
SWITCH
'------ Y t R·--------'
(1 1 )
1 7 -0
1 7. ELECTR IC STARTER
S ERV I C E I N FO RMATIO N
1 7- 1
STARTER RELAY SWITCH
1 7-6
T RO U B L E S HOOTING
1 7- 1
C L UTC H D IO D E
1 7-7
STARTER MOTO R
1 7-3
G E N E RA L
• T h e starter motor a n d i g mt1 o n p u l s e g e n e rator c a n be removed with the e n g i n e i n t h e f r a m e .
• To i ns p e ct t h e i g n it i o n p u l s e ge nerator, r e f e r to Secti o n 1 6 .
• Refer to secti o n 8 for starter c l utch removal a n d i n sta l l at i o n .
SPEC I F I CATI O N
Unit: m m (in)
ITEM
S t a rter m o t o r b r u s h le ngth
STA N DA R D
SERVICE LIMIT
1 2 . 5 (0.49)
6.5 (0.26)
TRO U BLESHOOTI NG
N OT E
•
•
T h e starter motor s h o u l d turn w hen t h e tra n s m i s s i o n is i n neutral a n d the c l u t c h d i seng aged .
C h e c k f o r t h e f o l l o w i n g before t r o u b l e s hooting the syste m .
- B l o w n m a i n ( 3 0 A ) or s u b ( 1 O A ) f u s e .
- Loose battery a n d starter motor c a b l e s .
- D i s c h a rg e d batte ry .
Starter motor does not turn
1 -1
.
"CLICK"
H EA R D
C h e c k the starter relay s w it c h for operati o n . Y o u s h o u l d h e a r the r e l a y " C LI C K "
w h e n t h e starte r switch button is depr e s s e d . ( pa g e 1 7 - 6 )
_I
I
1 - 2 . A p p l y battery voltage t o t h e starter motor
d i rectly a n d check the operati o n .
TURNS
•
" C L I C K " NOT H E A R D
.
A B N O R M AL
2. Check t h e n e u t r a l i n d icator for f u n cti o n .
.
.
N O R MAL
3.
.
N O V O LTAGE
C h e c k t h e starter r e l a y s w i t c h v o l t a g e
( page 1 7-6)
.
BATTERY
V O LTA G E C O M E S
4 . C h e c k t h e starter r e l a y switch f o r c o n t i n u ity
( p age 1 7 - 7 )
N ORMAL
.
.
.
I
ABN ORMAL
J
Loose c a b l e s
Fau lty sta rter relay
switch ( page 1 7 - 6 )
.
J
I
DOES NOT TURN
Fau lty sta rter motor
( page 1 7 - 3 )
F a u lty neutral s w itch ( p age 1 8 - 1 1 )
Loose neutral s w itch connectors
Fau lty i g n it i o n s w itch ( p age 1 8 - 6 )
.
Loose c l u t c h d i o d e con nector
F a u lty starter relay sw itch ( page 1 7 - 6 )
Fau lty cl utch d i o d e ( page 1 7 - 7 )
Open or s h o rt c i rcuit in w i re harness
.
F a u lty st a rter relay switch
.
Loose starter rela y switch c o n n e ctor
1 7- 1
ELECTRIC S TARTER
The starter motor can turn i n the neutral position, but should not turn except with the gear selector i n neutral , the side stand
up and the cluth lever pulled in.
BATTERY VOLT
AGE M EASURED
Measure the Voltage between the Green/White
t-------+!J Check the clutch switch ( page
(+) and Green (-) terminals of the side stand
connector (wire harness side ) .
There should b e battery voltage .
N O VOLTAG E
(or too l ittle voltage)
Check the side stand switch ( page
1 6- 5 )
Starter motor turns engine slowly
•
•
•
Low specific gravity
Excessive resistance i n circuit
Binding in starter motor
Starter motor turns, but engine does not turn
•
•
Faulty starter clutch
Faulty starter motor gears
Starter motor and engine turns, but engine does not start
•
•
Engine problems
- Low compression
- Fouled spark plugs
1 7-2
1 8-1 1 )
.
I
ELECTRIC STARTER
STARTER MOTOR
R E M OVAL
•
With the ignition switch OFF, remove the negative cable at the
battery before servicing the starter motor.
Remove the rubber cap and disconnect the starter motor
cable.
Remove the motor mounting bolts .
Remove the motor from the left side.
D I S A S S E M B LY
(1 l
(4) REAR COVER
FRONT COVER
Remove the following components :
- motor case screws.
- front and rear covers.
- armature .
�
NOTE
•
Record the location and number of shims.
( 2 ) CASE
I N S P ECT I O N
Measure each brush length .
Check for continuity from the cable terminal to the motor case
and from the cable termina to the brush wire ( black) .
(1
CONTINU ITY
CABLE TERMINAL-MOTOR CASE
N O CONTI N U ITY : NORMAL
CABLE TERMI NAL-BRUSH ( B LACK WIRE)
C O N T I N U ITY: NORMAL
Disassemble the brush holder if necessary .
1 7-3
ELECTRIC STARTER
I nspect the commutator bars for discoloration .
Bars discolored in pairs indicate grounded armature coils.
(1 l
C O M M UTATOR
Check for continuity between pairs of commutator bars .
There should be continuity .
Check for continuity between individual commutator bars and
the armature shaft.
There should be no continuity .
Check the front cover oil seal for wear or fatigue.
(1 )
O I L SEAL
(2) FRONT COVER
1 7 -4
ELECTRIC STARTER
A S S E M B LY
( 2 ) CASE
(5)
BRUSH HOLDER
(7)
(4)
( 1 0) 0-RI N G
( 1 3) S H I M S
( 1 ) FRONT COVER
0-RING
SHIMS
�,�
( 1 2 ) N UTS
( 1 0) CABLE TERM I NAL AND BRUSHES
( 9 ) REAR COVER
Set the brushes on the brush holder.
Align the starter motor case notch with the brush holder tab .
I nstall the a rmature i n t h e case.
Set the brush springs.
Install the rear shims in the same location and number when
disassembled .
Install the 0-ring on the case.
Install the rear cover, aligning its slot with the brush holder pin.
(3) SLOT
1 7-5
ELECTRIC STARTER
(2)
I nstall the front shims in the same location and number when
disassembled .
FRONT
COVER
Instal l the 0-ring on the case .
I nstall the lock washer, aligning its tabs with the slots of the
front cover.
Apply grease to the dust seal and instal l the front cover.
(5) LOCK WASHER
(3)
0-RING
Align i ndex marks of the front cover, case and rear cover as
shown.
Instal l and tighten the starter motor case screws and apply oil
to the 0-ring and install it on the front cover.
(3)
REAR COVER
(2)
0-RING
I N STALLATI O N
I nstall the starter motor in the engine.
I nstall and tighten the motor mounting bolts securely.
NOTE
•
Install the ground cable with one mounting bolt as show n .
Connect t h e motor cable t o t h e motor terminal a n d install the
rubber cap over the terminal.
Connect the battery negative cable .
STARTER RELAY SWITCH
O P E RATI O N I N S PECT I O N
Depress t h e starte switch button with the ignition switch O N .
The c o i l is normal if the starter relay switch clicks.
V O LTA G E I N S PE CT I O N
If you don ' t hear t h e switch "CLI C K " , disconnect t h e switch
connector.
Shift the transmission into neutral and turn the ignition switch
ON.
Measure t h e voltage between the yellow/red (+) a n d green/red
(-) wires of the relay connector as you press the starter.
The tester should show battery voltage. If it does not, make
the following continuity inspection.
1 7-6
�T
t
OR
ELECTRIC STARTER
C O N T I N U I TY I N S P E C T I O N
Remove the starter relay switc h .
Connect an ohmmeter t o t h e switch large terminals.
Connect a fully charged 1 2 V battery positive wire to the start
er relay switch Yellow/Red wire terminal, and the battery neg
ative wire to the G reen/Red wire terminal.
There should be continuity while the battery is connected to
the terminals, and no continuity when the battery is discon
nected .
CLUTCH DIODE
R E M OVAL
Remove the clutch diode from the wire harness.
I N S P ECTI O N
Check for continuity with a n ohmmeter.
Connect the positive probe to the (+) terminal and the negative
probe to the (-) terminal of the diode.
There should be continuity, then reverse the probes, there
should be no continuity .
N OTE
•
The test results shown above are for a positive ground ohm
meter and the opposite results will be obtained when a neg
ative ground ohmmeter is used .
( 1 ) CONTI N U ITY
1 7- 7
MEMO
1 8. LI GHTS/ M ETER/SWITCH ES
S E RVI C E I N FO R MATIO N
1 8- 1
F U E L P U MP RELAY
1 8-9
T RO U BL ES HOO T I N G
1 8-2
F U E L P U MP
1 8- 1 0
H EA D L I G H T
1 8-3
O I L P R ESS U R E SWITCH
1 8- 1 0
B U L B R EP LA C E M ENT
1 8-4
N E UTRAL SWITCH
1 8- 1 1
SP E E DO M ET E R
1 8-4
BRAKE L I G H T SWITCH
1 8- 1 1
I G N ITIO N SWITCH
1 8-6
CLUTCH SWITCH
1 8- 1 1
H A N D L EBAR S WITCH ES
1 8- 7
TURN S I G NAL R E LAY
1 8- 1 2
T H E R MO STAT I C SWITCH
1 8-8
HO RN
1 8- 1 2
COO LA N T T E MP ERATURE I N D I CATO R
1 8-8
•
•
Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area with the engine stopped.
Do not smoke or allo w flames or sparks in the work area or where gasoline is stored.
G E N E RA L
•
•
•
•
Some wires have different colored bands around them near the connector. These are connected to other wires which cor
respond to the band color.
A l l p last i c co nnecto rs have lock ing tabs that must be released befo re d isco nnect i ng, and must be a l igned and fu l ly engaged
when reco nnect i ng.
To isolate an electrical failure, check the continuity of the electrical path through the part. A continuity check can usually
be made without removing the part from the motorcycle. Simply disconnect the wires and connect a continuity tester or
volt-ohmmeter to the terminals o r connections.
A contin u ity tester is useful when checking to find out whether or not there is an electrical connection between the two
points . An ohmmeter is needed to measure the resistance of a circuit, such as when there is a specific coil resistance in
volved , o r when checking for high resistance caused by corroded connections.
S P E C I F I C ATI O N S
headlight
Brake/ta i l l ight
Turn signal lights
12 V
60 W/55
1 2 V 32/3
cp
W
( 2 7/8 W)
1 2 V 32/3 cp ( 2 3/8 W)
1 2 V 32 cp ( 2 3 W)
Front
Rear
License light
Indicator lights
12 V 4
2
2
cp
turn signal
1 2 V 1 .7 W
neutral
1 2 V 1 .7 W
high beem
1 2 V 1 .7 W
M eter light
Main fuse
x
x
1 2 v 3.4 w
30 A
Sub-fuse
'88, '89
After '89
F uel pu m p f low capacity
1 0 A x 6, 1 5A x 1
1 0 A x 3, 1 5A x 1
800 cc ( 0.76 USqt, 0.70 l mpqt)
TO R Q U E V A L U E S
Radiator thermostatic switch
Oil pressure switch
Ignition switch mounting bolt
1 8 N•m
1 2 N·m
1 1 N·m
(1 .8
(1 .2
(1 .1
kg-m, 1 3 ft-lb)
kg-m, 9 ft-lb) - Apply sealant to the threads
kg-m , 8 ft-lb) - Shear bolt
1 8- 1
LIG HTS/METER/S W I TC H ES
TROUBLESHOOTI NG
N o Lights Come O n When Ignition Switch I s Turned O N :
•
•
•
•
•
•
Bulb at fault or burned out
Faulty switch
Wiring to that component has open circuit
Fuse blown
Wiring loose, broken, or at fault
Battery dead or disconnected
All Lights Come O n , but Dimly, when Ignition Switch I s
Turned ON:
•
•
Headlight Beam Does Not Shift When HI-LO Switch Is Op
erated:
•
•
•
1 8-2
Battery voltage low
Faulty bulb
Beam filament burned out
Faulty dimmer switch
Wiring loose, broken, or at fault
L I G HTS/M ETER/SWITC H ES
H EADLIGHT
I
I
I
I
R E M OVAL/ I N STALLAT I O N
Remove the two screws a n d headlight.
•
Disconnect the headlight connector and remove the rubber
protector.
Remove the headlight retainer clip and replace the headlight
bulb.
(1 )
RETAINER CLIP
(2)
HALOGEN BULB
CAUTION
•
•
•
•
•
This motorcycle is equipped with a halogen headlight bulb.
Do not put finger prints on the headlight bulb, they may create
hot spots on the hulb.
If you touch the bulb with your bare hands, clean it with a cloth
moistened with alcohol to prevent its early failure.
Do not try to replace the bulb or clean the headlight with the
light ON.
After replacing the bulb, install the rubber boot tightly against
the unit.
NOTE
•
Instal l the rubber protector with the top mark facing u p .
I nstall t h e headlight in t h e reverse order of removal .
1 8-3
LIG HTS/M ETER/SWITC H ES
BULB REPLACE M E NT
NOTE
•
See page
1 8- 5
for speedometer bulb replacement.
T U R N S I G NAL LIGHT
Remove the turn signal lens attaching screws.
While pushing i n , turn the bulb counterclockwise to remove .
Replace the bulb, if desired .
I nstall i n the reverse order of removal .
NOTE
•
Seat the rubber packing properly.
B R A K E/TA I L L I G H T
Remove the taillight lens attaching screws .
While pushing i n , turn the bulb cou nterclockwise to remove .
I nstall i n the reverse order of removal .
N OTE
•
Seat the rubber packing properly.
LICENSE LIGHT
Remove the bolts and license light case mounting nuts .
Replace the bulb with a new one.
SPEEDOM ETER
R E M OVAL
Disconnect the speedometer cable from the meter.
Remove the steering covers and disconnect the speedometer
connector (6P Black) .
Remove the speedometer stay mounting bolts and meter from
the fork bridge .
1 8-4
(1 l
S P E E D O M ET E R
CABLE
B U L B R E PLAC E M E N T
Remove t h e trip-meter knob b y removing the attaching screw .
Romove the speedomater cover mounting screws and cover.
Replace the meter bulb with new one.
( 5 ) SPEEDOMETER
(3)
STAY
( 2 ) MOUNTI NG
SCREWS
(8) 6P BLACK
CON NECTOR
( 1 ) 0-RI N G
( 1 0) SPEEDOMETER
CABLE
( 9 ) SPEEDOM ETER
COVER
Assemble the removed parts in the reverse order of disassem
bly
( 1 ) SPEEDO
M ETER
WIRE
Route the speedometer wire as shown and instal l and tighten
the mounting screws.
I N STA L LAT I O N
I nstall the speedometer i n the reverse order o f remova l .
1 8- 5
I N D I CATO R PAN E L B U L B R E PLAC E M E N T
Remove the indicator bulbs from the indicator panel, b y first
pulling out each bulb and socket together.
I G N ITION SWITCH
I N S PECTI O N
Remove the seat and right side cover.
Disconnect the ignition switch 4P White and 2P Black connec
tor.
Check for continuity between the ignition switch connector
terminals in each switch position .
Continuity should exsist between the color coded wires in
each chart below.
'88, '89:
BAT
ON
OFF
0
p
0
COLOR
R
IG
�
FAN
-o
TL1
0
TL2
p
-o
-o
R/BI
Bu/0
Br/W
Br
Y/BI
After '89:
R E PLAC E M E N T
( 2 ) MOUNTING RUBBER
Remove t h e ignition switch cover b y removing t h e bolt.
Remove the shear bolt heads using a drill then remove the
switch (cylinder) .
Install the new switch and new shear bolts .
Tighten the shear bolts u ntil the head twist off.
(1 )
1 8- 6
HOLDER
LIGHTS / M ETER/S WITC H ES
HAN DLEBAR SWITCHES
(1
) LEFT HANDLEBAR
SWITCH
The handlebar switches (dimmer, turn signals, horn, starter,
engine stop, etc . ) must be replaced as assemblies.
Remove the steering covers.
L E FT H A N D L E B A R SWITCH
Disconnect the left handlebar switch connector (9P White) .
And check for continuity between the terminals.
Contin uity should exsit between the color coded wires in each
chart.
Dimmer Switch
------Lo
(N)
Hi
Color code
H L2
0
Hi
Lo
-o
�
�
0
-o
Bu/W
Bu
w
R
L
�
Turn Signal Switch
' 8 8 . ' 89 . '9 1 :
------RIGHT
N
w
0---
--o
0
Color code
Gr
Lb
Horn Button
'88 . '89 . '9 1 :
Released
D epressed
Color code
0
�
LEFT
------
TL1
PR
PL
-o
�
-o
0
-o
0
B r/BI
0/W
�
Lb/W
Turn Signal Switch
After '91 :
After '9 1 :
Ho1
Ho2
0
-o
W/G
Lg
------
Released
Depressed
Color code
Ho1
Ho2
0
-o
BI/Br
Lg
R I G H T H A N D L E B A R SWITC H
------
R I G HT
N
LEFT
Coler code
w
0
R
L
TL
0
().
0
Gr
Lb
PL
PR
.()
-o
�
{)
0
-o
0
B r/ B I
Lb/W
0/W
Disconnect the right handlebar switch connector (9P Red) and
check for continuity between the terminals .
Continuity should exist between the color coded wires as indi
cated in each chart.
After '93 :
'88 . '89 . '9 1 -'93 :
------
IG1
ST
Pushed
�
�
Color code
Bl
Y/R
Released
Engine Stop Switch
'88 , '89 , ' 9 1 -'93 :
------
IG1
Color code
Bl
RUN
OFF
0
HL
HL1
0
--o
�
R � leased
Bu/W
Pushed
Color code
BI/R
IG2
ST
0
{)
81/W
Y/ R
IG,
I G2
BI/G
B I /W
HL
H L1
BI/R
B u /W
0
After '93:
IG2
-o
BI/W
-------
RUN
OFF
Color code
1 8-7
LIG HTS/ M ET ER/SWITC H ES
THERMOSTATIC SWITCH
I N S P E CT I O N
T h e the rmostati c switch senses t h e temperature o f t h e r a d i a
tor coolant a n d s i g n a l s t h e f a n moto r . The motor c o m e s i nto
action at 9 8 ° - 1 0 2 ° C ( 2 08 ° - 2 1 6 ° F ) a n d stops at b e l o w
9 3 ° - 9 7 ° C ( 1 9 9 ° - 2Q1 ° F ) .
Before testing c h e c k the c o o l a n t level at warm-up the e n g i n e
to operating temperature .
If the fan does not t u r n , d i s c o n n ect the connectors from t h e
thermostatic s w itch a n d j u m p the term i n a l s using a j u m p e r
w i r e . T u r n t h e i g n it i o n s w itch O N .
I f the fan turns, replace t h e thermostatic switc h .
If t h e f a n does n o t start test t h e f a n moto r : D i sconn ect t h e f a n
motor connecto r . ( 2 P B l a c k ) at t h e l eft steering h e a d c o n n e c
tor h o l d e r .
Check for battery b o l t a g e b e t w e e n the b l ue/black w i re a n d
g r o u n d with the i g n it i o n s w itch O N .
I f there i s n o voltage, c h e c k the su b-fuse ( 1 0 A ) . o r loose ter
m i n a l s or connector, o r an o p e n c i r c u it
Suspend the therm ostati c switch i n a p a n of coolant ( 50 - 50
m i xture) a n d c h e c k the tempe ratures at w h i c h the s w itch
opens a n d closes .
M a ke s u re that there is no conti n u ity at room temperat u re a n d
t h e n g r a d u a l l y r a i s e the c o o l a nt temperature . The switch
s h o u l d show c o n t i n u ity ( c l o s e ) at 9 3 ° - 9 7 ° C ( 1 9 9 ° 207 ° F ) .
N OTE
o
o
o
Keep the temperature for 3 m i n utes to confirm cont i n u it y .
A s u d d e n c h a n g e of t e m p e rature w i l l c a u se error tempera
ture reading between the thermometer a n d switc h .
Do not let the s w itch or thermo meter touch the pan as it w i l l
g i ve a false read i n g .
I m merse the s w itch i n c o o l a n t u p to its thread s .
I nsta l l a n e w 0 - r i n g on t h e switc h .
A p p l y sea l a nt t o t h e switch thread a n d i n sta l l i t .
T i g hten the s w i t c h to the s p e c i f i e d torq u e .
TORQUE: 1 8 N • m ( 1 .8 kg-m, 1 3
ft-l b )
NOTE
o
Do not over tig hten t h e sw itch .
COOLANT TEM P E RATU RE I N DICATOR
SYSTEM I N S P E C T I O N
R e m ove the horn .
Disconnect the sensor w i re from the thermosensor a n d s h o rt it
to ground using a j u m pe r w i r e .
T u r n t h e ignition s w i t c h O N .
T h e temperature i n d icator l i g h t s h o u l d come o n . I f the i n d i c a
tor l i ght d o e s n o t c o m e o n , c h e c k the su b-fuse ( 1 0 A ) a n d
w i res f o r a loose c o n n ection o r a n o p e n c i rcuit; if n o rm a l , re
p l a c e the meter with a new one .
1 8-8
( 1 ) T H E R M O M ET E R
[]]
0
( 2 ) T H E R M OSTAT I C
SWITCH
L I G HTS/ M ETER/SWITC H ES
(1)
TH ERMOS E N S O R I N S PECTI O N
D r a i n the coo l a nt from t h e t h e r m ostat housing by removing
the d r a i n bolt i n t h e h o u s i n g .
D i sconn ect the w i re from t h e t h e rmosensor a n d remove the
thermosenso r .
Suspend t h e thermosensor i n o i l o v e r a he ater a n d measure the
resistance thro u g h t h e sensor as the o i l heats u p .
Temperatur ( ° C/ ° F )
50/ 1 2 2
Resista nce ({})
1 53 . 9
80/ 1 7 6
51 .9
1 20/248
T H E R M O M ET E R
m
Q
1 6. 1
Wear gloves and eye protection.
NOTE
•
•
O i l must be u s e d as the h e ated l i q u i d to check the f u n ction
a bove 1 00 ° C ( 2 1 2 ° F ) .
You w i l l get f a l s e rea d i n g s if either the sensor or
thermometer touches t h e p a n .
R e p l a ce t h e sensor if i t is o u t o f s pecifications by more t h a n
1 0 % a t a n y temperature l i sted .
A p p l y sea l a n t to t h e threads of t h e thermosensor a n d tig hten it
i n the thermostat h o u s i n g .
NOTE
•
Keep the c l e a r n a c e of 3 - 4 mm ( 0 . 1 - 0 . 2 i n ) betw een the
case and the t h e rmosensor threads e n d s .
C o n nect the w i r e to t h e thermose nsor.
FU EL PUM P R E LAY
•
conditions. Work in a well ventilated area. Do not smoke or
allow flames or sparks in the your work area or where gasoline
is stored.
Remove the seat a n d right s i d e cover.
Check the sub-fuse ( 1 0 A ) .
Re move the r e l a y from t h e rubber b racket a n d check the re l a y
c o n n e ctor term i n a l s for l o o s e n e s s and co rrosi o n .
Inspect as follows :
D i s con nect t h e c o n n e ctor a n d test the w i res on the m a i n har
ness side .
ITEM
STA N DA R D
Between Bl ( + ) a n d b o d y g r o u n d ( - )
w ith the i g n it i o n s w itch " O N "
Battery voltage
s h o u l d come .
Y /Bu wire bet w e e n the p u m p
relay a n d s p a r k u n it
C O N T I N U I TY
BI/Bu wire betwe e n the p u m p
re l a y and fuel p u m p
C O N T I N U ITY
1 8-9
L I G H TS / M ETER/SWITC H ES
FU EL PUM P
S Y S T E M I N S P ECTI O N
Turn the ignition switch O F F a n d remove the seat and discon
nect the fuel pump wire connectors and temporarily connect
the balck and black/blue wire teminals at the main harness
connector with a jumper wire.
Disconnect the fuel outlet tube at the fuel pump and connect a
fuel tabe or equivalent to the pump outlet line.
Hold a graduated beaker under the pump outlet line.
•
conditions. Work in a well ventilated area. Do not smoke or
allow flammes or sparks in your work area or where gasoline is
stored.
Turn the ignition switch on and let fuel flow into the beaker for
5 seconds, then turn the ignition switch off .
M u ltiply the amount in the beaker by 1 2 to determine the fuel
pump flow capacity per minute .
FUEL PUMP FLOW CAPACITY :
800 cc (0. 76 US qt 0. 70 Imp qt)
min . /minute
O I L P R ESSU RE SWITCH
Make sure that the oil pressure warning light comes on with
the ignition switch " O N " .
I f the light does not come on, inspect a s follows:
Remove the drive sprocket cover ( Page 1 3- 1 4) .
Disconnect the oil pressure switch wire from the switch by re
moving the terminal screw.
Short it to ground using a jumper wire . Turn the ignition switch
"ON".
The oil pressure warning l ight should come on.
If the light does not come on, check the bulb, sub-fuse
a n d wires f o r a loose connection or an open circuit.
( 1 0 AI
Start the engine and make sure that the light goes out. If the
light does not go out, check the oil pressure (page 2 -5) .
If the oil pressure is normal, replace the oil pressure switch
( page 2 -5) .
1 8- 1 0
!I�
( 1 ) O I L PRESS � R E SWITC �
-
LIGHTS/METER/SWITC H ES
N EUTRAL SWITCH
I N S P E CT I O N
Remove t h e left side cover a n d disconnect the 2P ( Black) con
nector.
Check the neutral switch for continuity between the light
green/red connector and body gro u n d .
There s h o u l d b e contin uity between t h e l ight green/red con
nector and body ground .
There should be continuity with the transmission i n neutral and
no continuity with the transmission in any gear.
If there is no continuity i n neutral , remove the drive sprocket
cover (page 1 3- 1 4) and check the wire connection for an open
circuit.
BRAK E LI GHT SWITCH
F R O N T I N S P E CT I O N
Disconnect the front brake light switch connectors and check
for contin u ity between the switch terminals.
There should be continuity with the front brake applied, and no
continu ity with the brake release d .
Replace t h e switch i f necessary .
R E A R I N S P ECTI O N
Disconnect the rear brake light switch connector and check for
contin u ity between the terminals.
There should be continuity with the rear brake applied and no
continuity with the rear brake released .
Replace the rea r brake light switch , if necessary .
CLUTCH SWITCH
I N SPECTI O N
Disconnect the clutch switch wire connectors.
Check for continuity between the switch terminals.
There should be continuity with the clutch applied and no con
tinuity with the clutch released .
\
Replace the clutch switch if necessary.
1 8- 1 1
LIG HTS/ M ET E R/SWITC H ES
TU RN SIG NAL RELAY
Remove the seat, then remove the turn signal relay from the
rubber bracket .
Check the turn signal circuit for proper connections before
making this test.
Connect each terminal as indicated below :
D . C . 1 2 V Positive ( + )
White/G ree n :
G reen :
D . C . 1 2 V Negatvie (-)
Turn signal wire of one side; connect the
G ray:
other side to ground (frame ) .
Check for correct lighting ON a n d
OFF.
If the turn signal relay fails this test, replace it.
HORN
Disconnect the wire connectors from the horn a n d connect a
1 2 V battery to the horn wire terminals. The horn is normal if it
sounds.
1 8- 1 2
1 9. WI R I N G DIAG RAM
·as. ·as:
0
0
......
�i
CD
I
HHn ·
a:
:::&
I
N
l!:d::
.
·� ��,:�
u
9··
;•
·
:;:
w.: F:,�
�
1!:.��
�
·�� r-�· '··�··
.
0
···
..,.,
.
�
l!:.j !
<
H ·"'ii
"''
:�
i
I
r---- A
,!.I! 9
ss
LS_ � I•A
z� � �•
--:- · ·��·
lM 0
IIIII
'" C>t-•
�
•
I
�
·A
!
! ...
. ..
a
�
!!i!
!III
II
�
!1/18
�h\
...
"'
6
��=
��
�
· -
�
""'·
�
··
.... ..
� � r::�
��r-·
�+ �g�::
g
I
I
�
il !
-
;
;
�
!I
I
�
'
�
:
r-_.,.
,
�
m
.
0 .
d
�
� 10:
� '"
�:
= a]
-�
•o
r-- • -<38= g =
•
•
•
•
· U D:l2
2� �
��
�·· i
�,. ·
.
=- �
��
·�:
i
'2
__r-:•::
.,.-c=.,.
-ill�� .��
�
i
....�
lb .'-c:l<>-"
�� . . .. . .
�
-
'-ii
'"1
�-il:m
�
1
:
��
�
�
.,.
-�
.,.,
· -
11
l<
• •--c::J<>-• =
, J
..
g �
•
I
�
'"ii=
F·
=5:i"i t=
-�!� ==
�
I
-g
i
I
3
.
I
'WI
�-·
J
L = � :; . '1 "! = ; .J .
a
•
�
�
"�
I
II
�;=
·I·!)
III
0
0
•
!If•
J
...,
-,
K�
§
•
w
�
-
__c=._;=
I
....,
-
��O · �
J
· ·-
.
..
! uo
. ..
.
�==
AI!J
��
�
�-11 1
re -
�
J!r-
-
! ...
lil.�
.._
... fi!�=
;
-
- -a -
.
-
''"
" •r-II•J.
r-- ll iAala
r-- .a�•
111• i! t::".,!'l�"
..., ��
...- r"'�-:-=
·18
.c. �9
Ul
r ....
�
!:
;
r--:
..
.
t--
..
i�� m.,)It-0�
�·�·
·a
�� . ·
I•
_ .. ..
:�
'@""
�� --�
'-- t-- "''
r-
•
'
�-
, .
�:==�
- :J
C@c:·
··
l
._ !=:� I�
�[]F=
!!;�!:
..
�
.
� :o
r--- •r•..
'',:
�:=
"� u · :@: · a
d
� ;
I��
�- �
�;=�-��
.,._
C.,
e
0
CW)
0
0
. ... dl "' • •
1d
•d
II
-
· l2 l
-� �
.
.
-
I
I
I
�
t
1 9- 1
W I R ING D I AGRAM
=
=
toCD
=
>
I
•
N
=
�
=
=
I
oil
�
li
i
1 9- 2
I
��
- �
�
1:
I
t
�
W I RING D I A G R A M
'92 , '93 ;
I
�
il
:;; !:!
I
I
I
3
t)§
:.
�
�
I
�
i
�
��
�
�
iii
�
I
!:2
;
�
L
�
�
1 9- 3
W I R IN G DIAGRAM
After '93 :
1 9-4
20. TROUBLESHOOTI NG
E N G I N E DO ES NOT START O R I S
H A R D TO START
20- 1
POO R PERFO R MANCE AT H I G H
SPEED
20-4
E N G I N E LACKS PO W E R
20-2
POO R H A N D L I N G
20-4
PO O R PERFO RM A N C E AT LOW A N D
IDLE SPEEDS
20-3
E N G I N E DOES NOT START OR IS HARD TO START
POSSIBLE CAUSE
1 . Check fuel flow to carburetor
REAC H I N G CARBURETOR
2. Perform spark test
SPARK
1
3 . Test cylinder compression
C O M PRESSION NORMAL
4.
l
l
Sta
by fol lowing no,mal pmcedu"
E N G I N E DOES NOT FIRE
5 . Sta
N OT REAC H I N G CARBU RETO R ---·•
•
•
•
•
•
•
Fuel tank empty
Clogged fuel line or fuel filter
Sticking float valve
Faulty fuel pump
Faulty fuel pump relay
Clogged fuel tank vent hole
Loose or disconnected fuel pump
relay wire
WEAK OR NO SPARK ------• ·• GO TO PAG E 1 6-2
WET PLUG ------ ·• Mixture too rich
• Carburetor flooded
• Carburetor choke on, or partially
closed
• Cylinder flooded
• Air cleaner dirty
LOW COMPRESSION ------+ •
•
•
•
•
•
•
Improper valve clearance (too small )
Valve stuck open
Worn cylinder and piston rings
Damaged cylinder head gasket
Seized valve
Improper valve timing
I mproper valve and seat contact
Carburetor incorrectly adjusted
I ntake pipe leaking
Improper ignition timing
( Faulty spark u nit or pulse gener
ator)
• Fuel contaminated
E N G I N E STARTS BUT STOPS ---• •
•
•
•
with choke applied
20- 1
TROUBLESHOOTING
E N G I N E LACKS POWER
POSSIBLE CAUSE
1.
Raise wheels off ground and spin
by hand
WHEELS SPIN FREELY
2.
�
Check tire pressure
PRESS U R E NORMAL
3.
+
Check for clutch slippage
C LUTCH ENGAGED PROPERLY
4.
�
Accelerate lightly
E N G I N E SPEED I N C REASES
5.
Check ignition timing
CORRECT
6.
t
Check valve clearance
CORRECT
7.
+
Test cylinder compression
NORMAL
8.
j
Check carburetor for clogging
N OT CLOGGED
9.
t
Check spark plug condition
NOT FOULED OR DISCOLORED
t
1 0 . Check oil level and condition
CORRECT
1
20-2
WHEELS DO NOT SPIN FREE LY --- ·
•
•
•
•
Brake dragging
Worn or damaged wheel bearings
Wheel bearing needs lubrication
Drive chain too tight
Axle nut excessively tight
PRESSURE LOW--------1� · Punctured tire
• Faulty tire valve
CLUTCH SLIPS --------. •
•
•
•
Faulty clutch l ifter system
Worn clutch disc/plate
Warped clutch disc/plate
Weak clutch spring
E N G I N E SPEED DOES NOT I N C REASE -·
•
•
•
•
•
•
•
Carburetor choke closed
Clogged air cleaner
Restricted fuel flow
Clogged muffler
Clogged fuel cap vent hole
Faulty fuel pump
Faulty fuel pump relay
Loose , broken or shorted , wire or
connection of pump relay
INCORRECT ----------..... •
•
F a u lty i g n it i o n c o ntrol m o d u l e
F a u lty i g n it i o n p u lse g e n e rator
INCORRECT ----------..... • I mproper valve adjustment
• Worn valve seat
TOO LOW ------ ·•
•
•
•
•
•
Valve stuck open
Worn cylinder and piston rings
Leaking head gasket
I mproper valve timing
Seized valve
I mproper valve and seat contact
CLOGGED ------· Carburetor not serviced frequently
enough
FOU LED OR D I SCOLORED----___,� ·· Plugs not serviced frequently
enough
• Wrong heat range
I N C O RRECT--------• • Oil level too high
• Oil level too low
Contaminated oil
TROUBLESH OOTI N G
POSSIBLE CAUSE
1 1 . Remove cylinder head cover and
inspect lubrication
VALVE TRAI N LUBRICATED
PROPERLY
•
1 2 . Check for engine overheating
NOT OVERH EATI N G
1 3 . Accelerate o r r u n a t h i g h speed
VALVE TRAIN NOT LUBRICATED --••
•
PROPERLY
•
•
Clogged oil passage
Clogged oil control orifice
Contaminated oil
Faulty oil pump
OVERHEATING --------___,� . Coolant level low
• Fan motor not working
(thermostatic switch)
• Thermostat stuck closed
• Excessive carbon build-up in combustion chamber
• Use of poor quality fuel
• Clutch slipping
• Lean fuel mixture
ENGINE KNOCKS
___
_____
Worn piston and cylinder
• Wrong type of fuel
• Excessive carbon build-up in com
bustion chamber
• Ignition timing too advanced
_.. ,.
E N G I N E DOES NOT KNOCK
( Fa u lty i g n ition control m o d u l e )
• Lean f u e l mixture
POOR P ERFORMANCE AT LOW AND I DLE SPEEDS
POSSIBLE CAUSE
.
1 Check ignition timing and valve
clearance
CORRECT
+
2. Check carburetor pilot screw
adjustment
I NCORRECT
_________
I mproper valve clearance
• Improper ignition timing
- Faulty i g n it i o n control m o d u l e
___,� .
- F a u lty i g n it i o n p u lse g e n e rator
I N CO RRECT -------___,� . See Fuel System, Section
4
CORRECT
•
3 . Check for leaking intake pipe
NO LEAKAG E
4.
+
Perform the spark test
GOOD SPARK
LEAKING ------ · Loose carburetor
• Damaged insulator
WEAK OR I NTERM ITTENT SPARK-· Faulty, carbon or wet fouled spark
plug
• GO TO PAG E 1 6-2
20-3
TRO U BLESH OOTI N G
POOR PE RFORMANCE AT H IGH SPEED
POSSIBLE CAUSE
1.
Check i g n ition t i m i n g a n d v a l v e
clearance
I N C O R R E C T -------__,� .
•
C O R R ECT
•
2 . D i s c o n n ect fuel l i n e at c a r b u retor
F U E L FLOW R E ST R I CT E D
____
__,�.
•
F U E L F LOWS F R E E LY
1
•
•
•
3 . Remove carbu retors a n d c h e c k for
clogged jets
I m p roper
I m p roper
- F a u lty
- F a u lty
valve clearance
i g n it i o n t i m i n g
i g n it i o n c o ntrol m o d u l e
i g n it i o n p u lse g e n e rator
Clogged fuel l i n e
Clogged fuel c a p vent h o l e
Clogged f u e l v a l v e
Fau lty fuel p u m p o r relay
Clogged fuel filter
C L O G G E D ------- ·
Clogged jets
I N C O R R E C T --------� ·
C a m s h aft not i n s t a l l e d properly
W E A K ------- ·
Fau lty v a l v e s p r i n g
NO C L O G G E D J ETS
4 . Check
t
alve t i m i n g
C O R RECT
•
5 . Check valve spring tension
POOR HA N DL I N G ---- C h e c k t i r e pressure
POSSIBLE CAUSE
1 . I f steering is heavy ----- ·
•
•
2. If either wheel i s w o b b l i n g ---- ·
•
•
•
•
•
3. If the motorcycle pulls to o n e side ------- ·
•
•
•
•
20-4
Bea r i n g adjustment nut too tight
D a m a g e d ste e r i n g h e a d bearings
Bent stee r i n g stem
Excessive w h e e l b e a r i n g p l a y
Bent rim(s)
I m p roperly i n st a l l e d w h e e l h u b ( s )
S w i n g a r m p ivot b e a r i n g s
excessively w o r n
Bent frame or s w i n g a rm
Loose s w i n g a r m p i vot bolt
I n co rrect d rive c h a i n adjustment
Front a n d r e a r w h e e l s not a l i g n e d
Bent fork legs
Bent swingarm
B e n t fra m e
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Alternator/Starter Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8- 1
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-9
Battery/Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-2
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-4
Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4- 1 1
Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 5
Replacement/Air Bleeding
.
1 4-4
Brake Light Switch . .
.
. .
1 8- 1 1
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 7
Brake Pad/Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4-5
Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 - 1 0
Shoe/Pad Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 6
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 6
Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-4
Cable & Harness Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 0
Camshaft Installation . . . . . . . .
s- ·1 8
Removal .
. . . .
.
. ..
9- 4
Carburetor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1 0
3-7
Choke . .
.
.
4-6
D isassembly .
.
.
.. .
Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 1
I n stallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1 5
Removal .
..
. .
.
4-6
Separation/ Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1 3
Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 0
Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-7
Clutch/Gearshift Linkage . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7- 1
Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7-7
I nstallation .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8- 1 1
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 8
Control Cable Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 1 2
Coolant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3
Temperatu re Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-8
Coolant/Reserve Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9
Cooling System
.
.
.
.. . .
. . . 3- 1 2 , 5 - 1
Crankcase
. ... .
.
.
1 1 -1 3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 - 1 9
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8
Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 -4
Crankshaft/Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 - 1
Crankshaft/Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 -5
Cylinder Head/Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9- 1
Cylinder/Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0- 1
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0-2
Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 2
Cylinder Head
.
...
.
9-8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 1 5
Cylinder Head Cover Installation . . . . . . . . . . . . . . . . . . . . . . . 9-2 1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3
Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 1 6
I nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0-6
D rive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3
Electric Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 - 1
Emission Control I nformation Labels . . . . . . . . . . . . . . . . . . . 1 -22
Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2 1
Engine Removal/Installation . .
. .
6 1
6-5
Engine I nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4
Engine Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
.
. . . . . . . . . . . . . . .
.
. .
. . . . . . . . . . . . . .
. . . . . . . . .
. . . .
. . . . . . . .
. . . . . . .
.
.
.
.
.
.
. .
.
. . . . . . . . . . . .
. .
.
. .
. . .
.
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . .
. . . . . . . .
. . .
.
.
. . .
. . . . .
. . . . . . . . . . . . . . . .
. . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . .
. . . . . . . . . . . . .
. .
. . .
.
.
. . . . . . . . . . . . . . . .
. . . . . . . . . . . .
. .
. . . . . . . .
. . . .
.
.
.
.
.
.
.
.
.
. .
.
. . .
. . . . . . .
. . . . . . . . . . . .
.
.
. . . . . . .
. . . . . .
. . . . .
. . . . .. .
.
.
. . . . .
. . .
. . . . . . . . . . . . . . . . . . . . .
.
.
. .
.
.
.
.
.
. . . . . . .
. . . . . . . . . . . .
. . . . .
. . . . . . . . . . . . . . . . . . . .
.
.
.
.
.
.
. . . . . . . . .
. .
. . . . . . . . . . . . . . . .
-
2 1 . I N DEX
Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EVAP Carburetor Air Vent Control Valve I nspectio n
(California m o d e l o n ly) . . . . . . . .
.
..
Evaporative Emission Control System . . . . . . . . . . . . . . . . .
Evaporative Emission Purge Control Valve Inspection
(California model only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel I nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fork . . . . . . . . . . :
. ..
...
Front Wheel/Suspension/Steering . . . . . . . . . . . . . . . . . . . . . .
Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line
.
. .
.....
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay
. . ...
.
. .; . . . . . . . .
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .. . . . . . . .. . . . . . . . . . . .
Gearshift Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General I nformation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety
.
.
..
H andlebar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aim
.
.
.
.
High Altitude Adjustment ( U . S . A . Only) . . . . . . . . .
Horn
Hydraulic Disc Brake . . ; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Control Module Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Pulse Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coil
.
.
. .
.
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Left Crankcase Cover I nstallation . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lights/Meter/Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sched u le ' 8 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Schedule ' 8 9 , ' 9 1 -'93 : . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sched ule After '93 : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model ldentifiction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Neutral Switch
. .
.
.
N uts, Bolts, Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O i l Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Check
. .
.
. . .
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pilot Screw Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ring I nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary Drive Gear
. .
...
Radiator Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator/Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Wheel/Brake/Suspension . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake
.
. . .
Wheel
. . .
.
. . .
Regulator/Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
.
.
.
. . . .
. . . .
. .
. . . . .
. . . . .
. . . . . . . .
.
.
.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .
. . . . . .
.
.
.
. . . . . . . .
. . .
.
. . . . . . . . .
. . .
. . . .
. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . .
. . . . . . . .
. . .
..
. .
.
. . . . . . .
. . . . . . . . . . . . . . .
. . . . . . .
. . . . . . . . . . . . . . . . . .
.
.
.
. . . . . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . . . .
. .
. . . . . .
. . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
. .
.
. . . .
. . . . . . . . .
. . . . . . . . . . . .
. .
. . . . . . . . . . . . . . . . . . . . . . .
.
.
.
.
.
.
.
. . . . .
. .
. . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . -· .
. . .
.
.
. . . . .
.
. . . . . .
. . . . . . . . . . . . . . . . . . .
.
. . . .
.
.
.
.
.
.
.
. . . .
. .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
.
.
. . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
.
. . . .
.
. . . . .
.
. .
. . . . . . . . . . .
. . . . . . . . . .
.
. .
.
2-4
6-3
4- 1 7
3- 1 3
4- 1 6
8-5
8-3
1 2- 1 3
1 2- 1
1 2-7
4- 1
3-6
1 8- 1 0
1 8-9
4-3
7-8
1 -1
1 -1
1 2-4
1 8-7
1 8-3
3-1 8
4- 1 6
1 8- 1 2
1 4- 1
1 6-4
1 6-6
1 6-2
1 6-4
1 8-6
1 6-6
8-6
8-2
1 8- 1
2- 1
2- 1 2
3- 1
3-3
3-4
3-5
1 4-8
1 -2
1 8- 1 1
3-20
2- 5
2- 5
1 8- 1 0
2-6
4- 1 5
1 0-3
1 0-5
1 0-5
7-1 1
3-1 1
5-5
1 3- 1
1 3-7
1 3-3
1 5- 8
21 -1
I N D EX
Right Crankcase Cover Installation .
7-1 4
7-3
Removal
. .. . . . .. .
.
. .
Seat/Rear Fender/Sub-frame
1 3- 1 8
Service I nformation
Alternator/Starter Clutch . . . . . . . . . . . . . . . . . . . . . . . .
8- 1
Battery/Charging System . . . . . . . . . . . . . . . . . . . . . . . . 1 5-2
Clutch/Gearshift Linkage . .. .. .. .. .. .. .. .. .. .. .. . .
7- 1
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5- 1
Crankshaft/Transmission . . . . . . . . . . . . . . . . . . . . . . . 1 1 - 1
Cylinder Head/Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1
Cylinder/Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0- 1
Electric Starter . . . .
. .. .
.
1 7- 1
Engine Removal/Installation . . . . . . . . . . . . . . . . . . . .
6-2
Front Wheel/Suspension/Steering
. . . . . 1 2- 2
Fuel System .
.. . . . .
. . ..
4- 1
Hydraulic Disc Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4- 2
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6- 2
Lights/Meter/Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8- 1
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2- 2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3- 1
Rear Wheel/Brake/Suspension . . . . . . . . . . . . . . . . . 1 3- 1
Service Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . 1 3- 1 1
Side Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 9
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6-6
Spark Plugs .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .
3- 8
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 -3
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-4
Starter Clutch . .
... .... .. ..
.. . .
8-4
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7-3
Relay Switch .
.. . ..
.
1 7-6
Steering Head Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 2 1
Stem .
. .
. . . . . . . . . . . . . . . . . . . . . . . . 1 2- 20
Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 9
Swingarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3- 1 4
System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3
Thermostatic Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-8
Throttle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6
Tools
1 -8
Torque Values
...........................................
1 -5
Transmission . . .
.........
.. . ...........
1 1 -1 1
Assembly/Installation . . .
. .... . ..... 1 1 -1 7
Troubleshooting
Battery/Charging System . . . . . . . . . . . . . . . . . . . . . . . . 1 5-3
Clutch/Gearshift Linkage . . . . . . . . . . .
7-2
Cooling System . . .. .. .. .. .. .. .. . . .. . . .. .. .. .. .. . . . .
5- 1
Crankshaft/Transmission . . . . . . . . . . . . . . . . . . . . . . . . 1 1 -3
Cylinder Head/Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2
Cylinder/Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0- 1
Electric Starter .
.
.. ..
. . . 1 7- 1
Front Wheel/Suspension/Steering . . . . . . . . . . . . 1 2- 3
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4- 3
Hydraulic Disc Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4-2
Ignition System .. .. . . . . . . .. . . . . . . . . .. . . . . . . . . . . .. . . 1 6-2
Lights/Meter/Switches . . . . . . . . . . . . . . . . . . . . . . . . .. . 1 8-2
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2
Rear Wheel/Brake/Suspension . . . . .. . . . . . . . . .. 1 3-2
Turn Signal Relay . . .
. . .
.
. . 1 8- 1 2
.
. . . . . . . .
.
.
. . .
. .
. .
.
. . . . . . . . . . . . . . . . . . .
. . . . .
. . . . .
.
. . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.
.
Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guide Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat l nspection/Refacing . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheels/Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .
.
. .
. .
3-8
9- 1 1
9- 1 2
5-7
3- 20
1 9- 1
.
. .
.
. . .
. . . . . . . .
. .
. .
. . . . . .
. . . . . . . . .
. .
. . . . .
. . . . . . . .
.
.
.
. .
. . . . . . . .
. .
.
.
.
. .
. . . . . . . .
.
. .
.
.
.
.
.
.
.
.
. . . . . . . .
.
.
.
. . . . . . . . . . . . . . .
. . . . .
.
. . . . . . .
.
.
. . .
. . . . . . . . . . . . . . . .
. .
. . . .
. . . . . .
.
.
. . . . . . . . .
. . .
.
. .
.
. .
.
. .
.
.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . .
. . .
. . . .
. . . . . . .
. . . . .
. . . . .
.
.
. . .
. . . .
. . .
. .
. . .
.
. . .
.
. . .
. . .
.
. . . .
. .
.
. . .
. . . . . . . . . .
. . . . . . . .
. .
. . . . .
. .
. .
.
. .
..
..
..
..
. .
2 1 -2
. . . . . . . . . . . . .
. .
. .
. . . . . . . .
. . . . . . .
.
(278)

VLX VT600 88-89 91-96 Service Manual

Transcription

Similar documents

Tool Catalog