Honda 400ex

User Manual: Honda 400ex

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CONTENTS

HOW TO USE THIS MANUAL

This service manual describes the service procedures
for the TRX400EX.

GENERAL INFORMATION
FRAMEIBODY PANELS/EXHAUST
SYSTEM

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 California 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 and 3 apply t o the whole motorcycle.
Section 2 describes procedures for removalfinstallation of components that may be required to perform
service described in the following sections.
Sections 4 through 18 describe parts of the motorcycle, grouped according to location.
Find the section you want on this page, then turn to
the table of contents on the first page of the section.

MAINTENANCE
LUBRICATION SYSTEM

aU
+

FUELSYSTEM
ENGINE REMOVAL/INSTALLATION

CYLINDER HEAD/VALVE

CYLINDER/PISTON

0
0

a
W

CLUTCH/GEARSHIFT LINKAGE

Most sections start with an assembly or system illustration, service information and troubleshooting for
the section. The subsequent pages give detailed procedures.

ALTERNATOR/STARTER CLUTCH

If you don't know the source of the trouble, go to section 20, Troubleshooting.

FRONT WHEEL/SUSPENSION/STEERING

CRANKCASEITRANSMISSIONI
CRANKSHAFT

"s
~
J
I

ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND
.... SPECIFICATIONS INCLUDED IN
THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT
THE TIME OF APPROVAL FOR PRINTING.
HONDA MOTOR CO., LTD. RESERVES THE
RIGHT TO MAKE CHANGES A T ANY TIME
WITHOUT NOTICE AND WITHOUT INCURRING
ANY OBLIGATION WHATEVER. NO PART OF
THIS PUBLICATION M A Y BE REPRODUCED
WITHOUT WRllTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE
ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON HONDA MOTORCYCLES, MOTOR
SCOOTERS OR ATVS.
~

REAR WHEEL/SUSPENSION
HYDRAULIC DISC BRAKE

HONDA MOTOR CO.. LTD
SERVICE PUBLICATIONS OFFICE

Date of Issue: September, 1998
0 HONDA MOTOR CO., LTD.

BATTERY/CHARGING SYSTEM
A

IGNITION SYSTEM

!YI

ELECTRIC STARTER

K
F

WIRING DIAGRAM
TROUBLESHOOTING
INDEX

SYMBOLS
The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to these symbols. it would be explained specifically in the t e x t without the use of the symbols.

Replace the part(s) with new one(s1 before assembly.

Use recommended engine oil, unless otherwise specified.

I
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1 : 1).

Use multi-purpose grease (Lithium based multi-purpose grease NLGl#2 or equivalent)

Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGl#2 or
equivalent).
Example: Molykote" BR-2 plus manufactured by Dow Corning, U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGl#2 or
equivalent).
Example: Molykotea G-n paste, manufactured by Dow Corning, U S A .
Honda Moly 60 (U.S.A. only)
Rocol ASP manufactured by Rocol Limited, U.K.
Rocol Paste manufactured by Sumico Lubricant, Japan

I -

Use silicone grease.

Apply a locking agent. Use a middle strength locking agent unless othelwise specified.

Apply sealant.
~

Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.

Use Fork or Suspension Fluid.

1. GENERAL INFORMATION
GENERAL SAFETY

1-1

LUBRICATION & SEAL POINTS

1-16

SERVICE RULES

1-2

CABLE & HARNESS ROUTING

1-18

MODEL IDENTIFICATION

1-3

EMISSION CONTROL SYSTEMS

1-23

SPECIFICATIONS

1-4

TORQUE VALUES

1-11

EMISSION CONTROL INFORMATION
LABEL

1-24

TOOLS

1-14

GENERAL SAFETY

CARBON MONOXIDE
If the engine must be running to do some work, make
sure the area is well ventilated. Never run the engine in
an enclosed area.

The exhaust contains poisonous carbon monoxide gas
that may cause loss of consciousness and may lead t o
death.
Run the engine in an open area or with an exhaust evacuation system in an enclosed area.

GASOLINE
Work in a well ventilated area. Keep cigarettes, flames
or sparks away from the work area or where gasoline is
stored.

USED ENGINE OIL

Used engine oil may cause skin cancer if repeatedly left
in contact with the skin for prolonged periods. Although
this is unlikely unless you handle used oil on a daily
basis, it is still advisable to thoroughly wash your hands
with soap and water as soon as possible after handling
used oil. KEEP OUT OF REACH OF CHILDREN.

BRAKE DUST
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.

Inhaled asbestos fibers have been found t o cause respiratorv disease and cancer.
Gasoline is extremely flammable and is explosive under
certain conditions. KEEP OUT OF REACH OF CHILDREN.

HOT COMPONENTS

Engine and exhaust system park become very hot and
remain hot for some time after the engine is run. Wear
insulated gloves or wait until the engine and exhaust
system have cooled before handling these parts.

BRAKE FLUID
CAUTION:
Spilling fluid on painted, plastic or rubber parts will
damage them. Place a clean shop towel over these
parts whenever the system is serviced. KEEP OUT OF
REACH OF CHILDREN.

1-1

GENERAL INFORMATION
BAlTERY HYDROGEN GAS 81ELECTROLYTE

The battery gives of explosive gases; keep sparks,
flames and cigarettes away. Provide adequate ventilation when charging or using t h e battery i n an
enclosed space.
The battery contains sulfuric acid (electrolytel.
Contact w i t h skin or eyes may cause severe burns.
Wearprotective clothing and a face shield.
- If electrolyte gets on your skin, flush w i t h water.
- If electrolyte gets i n your eyes, flush with water
for at least 15 minutes and call a physician, immediately.
Electrolyte is poisonous.
- I f swallowed, drink large quantities of wafer or
milk and follow with milk ofmagnesia or vegetable
oil and call a physician. KEEP OUT OF REACH OF
CHILDREN.

SERVICE RULES
1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that don't meet HONDAs
design specifications may cause damage to the motorcycle.
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English
fasteners.
4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling.
5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified.
6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
7. After reassembly, check all parts for proper installation and operation.
8. Route all electrical wires as show on pages 1-18 through 1-22, Cable &Harness routing.

1-2

GENERAL INFORMATION

MODEL IDENTIFICATION

VEHICLE IDENTIF'ICATION

NUMBER

The Vehicle Identification Number (VIN) i s located on the
left side frame down tube.

FRAME

The frame serial number is stamped o n the front side of
the frame.

The engine serial number is stamped on the lower left of
the crankcase.

The carburetor identification number is stamped on the left
side of the carburetor body.

ENGiNE SERIALNUMBER

COLOR LABEL

The color label is attached o n the frame crossmember
under the seat. When ordering color-coded parts, always
specify the designated color code.

1-3

GENERAL INFORMATION

SPECIFICATIONS
-

GENERAL
ITEM

SPECIFICATIONS

DIMENSIONS

Overall length
Overall width
Overall height
Wheelbase
Seat height
Footpeg height
Ground clearance
Dry weight
Curb weight
Maximum weight capacity

1,835 mm (72.2 in)
1,150 mm (45.3 in)
1,110 rnm (43.7 in)
1,230 mm (48.4 in)
810 mm (31.9 in)
353 mm (13.9 in)
110 mm (4.3 in)
170 kg (375 Ibs)
178 kg (392 Ibs)
110 kg (243 Ibs)

FRAME

Frame type
Front suspension
Front wheel travel
Rear suspension
Rear axle travel
Front tire size
Rear tire size
Front tire brand
Rear tire brand
Front brake
Rear brake
Caster angle
Camber angle
Trail length
Fuel tank capacity
Fuel tank reserve capacity

Double cradle
Double wish-bone
209 mm (8.2 in)
Swingarm
230 mm (9.1 in)
AT22 x 7-10
AT20 x 10-9
M/R 101 (Ohtsu)
M/R 501 (Ohtsu)
Hydraulic disc x 2
Hydraulic disc
6.5"
-0.8"
28 mm (1.1 in)
10 liters (2.6 US gal, 2.2 Imp gal)
1.6 liters (0.42 US gal, 3.52 Imp gal)

Cylinder arrangement
Bore and stroke
Displacement
Compression ratio
Valve train
Intake valve opens
closes
Exhaust valve opens
closes
Lubrication system
Oil pump type
Cooling system
Air filtration
Engine dry weight

Single cylinder, 15" inclined from vertical
85.0 x 70.0 mm (3.35 x 2.76 in)
397 cm3 (24.2 cu-in)
9.1 : 1
Silent multi-link chain driven SOHC with rocker arms
5" BTDC (at 1 mm lift)
40" ABDC (at 1 mm lift)
40" BBDC (at 1 mrn lift)
5" ATDC (at 1 mm lift)
Forced pressure (dry sump)
Trochoid
Air cooled
Oiled urethane foam
41.5 kn (91 Ibs)

ENGINE

1-4

**
**

GENERAL INFORMATION

GENERAL (Cont'd)

CARBURETOR

ITEM

SPECIFICATIONS

Carburetor type
Throttle bore

Piston valve
38 mm (1.5 in)

Clutch system
Clutch operation system
Transmission
Primary reduction
Final reduction
Gear ratio 1st
2nd
3rd
4th
5th
Gearshift pattern

Multi-plate, wet
Cable operating
Constant mesh, 5-speeds
2.826 (23/65)
2.533 (15/38)
2.916 (12/35)
1.937 (16/31)
1.473 (19/28)
1.181 (22/26)
1.000 (26/26)
Left foot oDerated return svstern. 1 - N - 2 - 3 - 4 - 5

Ignition system
Starting system
Charging system
Regulatortrectifier
Lighting system

ICM (Capacitive Discharge Ignition)
Electric starter motor
Single phase output alternator
Single phase full wave rectification
Battery

1-5

GENERAL INFORMATION
Unit: mm (in)

ITEM
Engine oil capacity

STANDARD

After draining

1.8 liters (1.9 US qt, 1.6 Imp qt)

After draininglfilter change

1.85 liters (1.95 US qt, 1.63 Imp qt)

After disassembly

2.2 liters (2.3 US qt, 1.9 Imp qt)

Recommended engine oil

Oil pump

SERVICE LIMIT

Honda GN4 or HP4 4-stroke oil or
equivalent motor oil
API service classification SF or SG
Viscosity: SAE 1OW-40 or 2OW-50
Tip clearance

0.15 (0.006)

Body clearance

0.15

- 0.22 (0.006 - 0.009)
0.02 - 0.09(0.001 - 0.004)

Side clearance

ITEM

0.12 10.005)

SPECIFICATIONS

Main jet

#148
3rd groove from top

Jet needle clip position
Pilot screw opening

See page 5-13

Float level

18.5 mm 10.73 in)

Idle speed

1,400 f 100 rpm

Throttle lever free play

Stem-to-guide clearance
-

Valve seat width
Valve spring

Free length

Cylinder head warpage

3-8mm(1/8-5/16in)

- 0.037
- 0.057

0.010

(0.0004 0.0015)

0.12 10.005)

0.14 (0.006)

INEX
Inner

(0.0012 - 0.0022)
1.0-1.1 (0.039-0.043)
37.19 (1.464)

Outer

44.20 (1.740)

0.030

2.0 (0.08)
36.3 11.43)
43.1 (1.70)
0.10 (0.004)

GENERAL INFORMATION

ITEM

STANDARD
85.000 - 85.010 (3.3465- 3.3468)

I.D.

Cylinder

85.10 (3.350)

Out of round
Taper
Warpage
Piston,

SERVICE LIMIT
0.05 (0.002)
0.05 (0.002)
0.10 (0.004)

Piston O.D. at 15 (0.6) from bottom

84.960 - 84.985 (3.3449 - 3.3459)

84.880 (3.3417)

Piston pin O.D.

19.994 - 20.000 (0.7872 - 0.7874)

19.964 (0.78601

Piston-to-piston pin clearance
Piston ring end gap

I
Piston ring-to-ring
groove clearance

TOP
Second

I 0.002 - 0.014 (0.0001 - 0.0006)
I 0.20 - 0.35 (0.008- 0.014)
I 0.35 - 0.50 (0.014- 0.020)

I 0.096 (0.0038)
1

0.50 (0.020)

0.65 10.026)

Oil (side rail)

0.20 - 0.70 (0.008 - 0.028)

0.90 (0.035)

TOP

0.030 - 0.065 (0.0012 - 0.0026)

0.14 (0.006)

Second

0.015 - 0.050 (0.0006 - 0.0020)

0.12 (0.005)

Cylinder-to-piston clearance

0.015 - 0.050 (0.0006 - 0.0020)

0.10 (0.004)

Connecting rod small end I.D.

- 20.041 (0.7882 - 0.7890)
0.020 - 0.047 10.0008 - 0.0019)

20.067 (0.7900)

20.020

Connectino rod-to-Diston Din clearance

ITEM
Clutch

STANDARD

Lever free play

10 - 20 (3/8 - 3/4)

Spring free length

52.64 (2.072)

Disc thickness

2.92 - 3.08 (0.1 15 - 0.121)

Outer I.D.
Outer guide

28.000-28.021 (1.1024- 1.1032)

I.D.

O.D.
Mainshafi O.D. at clutch outer w i d e

1 22.010 - 22.035 (0.8665 - 0.8675)
I

27.959-27.980 (1.1007- 1.1016)

21.959 - 21.980 (0.8645 - 0.8654)

ITEM
Starter driven gear boss O.D.

STANDARD
51.705

SERVICE LIMIT

50.0 (1.97)

Plate warpage

0.103 (0.OOAII

- 51.718 (2.0356 - 2.0361)

2.69 10.106)

I 0.15 (0.006)
1 28.04 (1.104)
I 22.05 (0.868)

I 27.90 (1.098)
I 21.91 (0.863)

SERVICE LIMIT
51.67 (2.034)

1-7

GENERAL INFORMATION

ITEM

STANDARD

SERVICE LIMIT

rransmission

:rankshaft

1-8

Runout

0.12 (0.005)

Big end side clearance

0.05 - 0.45 (0.002- 0.018)

0.6 (0.02)

Big end radial clearance

0.006- 0.018 (0.0002- 0.0007)

0.05(0.002)

ITEM

STANDARD

Minimum tire tread depth

I Standard

Cold tire pressure

Tie-rod distance between the ball joints

27 kPa 10.275 kaWcm2.. 4.0 osil
,
23 kPa (0.235kgf/cmz. 3.4 psi)
31 kPa (0.315kgf/cmz, 4.6 psi)
370.2 (14.57)

Toe

Toe-in: 17 f 15 (0.7f 0.6)

Shock absorber spring adiuster standard position

4th from softest Dosition

Minimum
Maximum

ITEM

STANDARD

Minimum tire tread depth
Cold tire pressure

Standard
Minimum
Maximum

27 kPa (0.275kgf/cm2, 4.0 psi)
23 kPa (0.235kgWcmz, 3.4 psi)
31 kPa 10.315kaWcm2. 4.6osil

Axle runout
Drive chain slack
Shock absorber spring installed length

30 - 40 (1-1/4
- 1-5/8)
231.5 (9.11)

SERVICE LIMIT

4.0(0.16)

SERVICE LIMIT

4.0 (0.16)

3.0 10.12)

- HYDRAULIC DISC BRAKE
ITEM

STANDARD
Front

DOT 4 brake fluid
2.8 - 3.2 (0.11 - 0.13)

Rear

3.8-4.2 (0.15-0.17)

Recommended brake fluid
Brake disc thickness
Brake disc runout
Master cylinder I.D.
Master piston O.D.
Caliper cylinder I.D.
Caliper piston O.D.

12.700 - 12.743(0.5000- 0.5017)
12.657- 12.684(0.4983- 0.4994)
33.960-34.010(1.3370- 1,3390)
33.895- 33.928 (1.3344- 1.3357)

SERVICE LIMIT

2.5(0.10)
3.5(0.14)
0.30 10.012)
12.75(0.502)
12.6510.498)
34.02(1.340)
33.8711.333)

1-9

r
Batten/

SPECIFICATIONS

ITEM

0.1 mA max.

Current leakage

13.0- 13.2 V

Fully charged

Voltage
(2OoC/68"F)

Charging current

_ _

Needs charaina

Below 12.3 V

0.9 A x 5 - 10 h

Normal
Quick

Alternator

4.0 A x 1.0 h

147 W/5,000 rpm

Capacity
Charaina coil resistance (2OoC/68"F)

0.1

ITEM
Spark plug

12 V - 8 A h

Capacity

- 1.0 n

SPECIFICATIONS

Standard

DPR8Z (NGK), X24GPR-U (DENSO)

For extended hiah weed ridina

DPR9Z (NGK), X27GPR-U (DENSO)
0.6 - 0.7 mrn (0.024 - 0.028 in)

Spark plug gap
Ignition coil primary peak voltage

100 V minimum

Ignition pulse generator peak voltage

0.7 V minimum

Exciter coil peak voltage

100 V minimum

lanition timina ("F" mark)

8" BTDC at idle

ITEM

STANDARD

Starter motor brush length

r
Bulbs

SPECIFICATIONS
12 v - 30/30w x 2

Headlight (High/low beam)
Taillight
Neutral indicator

1-10

8.5 (0.33)

12.5 (0.49)

ITEM

12V-5W

SERVICE LIMIT

12 v - 3.4 w

GENERAL INFORMATION

TORQUE VALUES
- STANDARD

TORQUE
N.m (kgf.m. Ibf4t)

FASTENER TYPE
5 mm bolt and nut
6 mm bolt and nut
8 mm bolt and nut
10 mm bolt and nut
12 mm bolt and nut

5 (0.5, 3.6)
10 (1.0,7)
22 (2.2, 16)
34 (3.5, 25)
54 (5.5, 40)

TORQUE
N.m (kgfm, Ibf4t)

FASTENER TYPE

5 mm screw
6 mm screw
6 mm flange bolt (8rnm head, small flange)

6 mm flange bolt (8 mm head, large flange)

6 mm flange bolt (10 mm head) and nut
8 mm flange bolt and nut
10 mm flange bolt and nut
Torque specifications listed below are for important fasteners.
Others should be tightened to standard torque values listed above.

NOTES: 1.
2.
3.
4.
5.
6.
-

4 (0.4, 2.9)
9 (0.9. 6.5)
9 (0.9. 6.5)

12 (1.2,9)

12 (1.2,9)
26 (2.7.20)
39 (4.0. 29)

Apply locking agent to the threads.
Apply oil to the threads and seating surface.
Apply grease to the threads and seating surface.
ALOC bolt. replace with a new one.
Castle nut: tighten to the specified torque and further tighten until its grooves align with the cotter pin hole,
Stake.

ENGINE
ITEM

THREAD
DIA. (mml

1
4

12
36
7
30
14
12
10
27
16

18 (1.8, 13)
15 (1.5, 11)
24 (2.4, 17)
8 (0.8, 5.8)
10 (1.0.7)
25 (2.5, 18)
20 (2.0. 14)
54 (5.5, 40)
20 (2.0. 14)

8
14
14
12
7

TORQUE
N.m 1kgf.m. IbfW

REMARKS

MAINTENANCE:
Spark plug
Valve adjusting hole cap
Valve adjusting lock nut
Crankshaft hole cap
Timing hole cap
Engine oil drain bolt (crankcase)
Engine oil drain bolt (oil tank)
Engine oil strainer screen (at oil tank)
Oil pipe joint flare nut
ZYLINDER HEADIVALVE:
Cylinder head cover bolt
Rocker arm shaft
Intake sub-rocker arm shaft
Exhaust sub-rocker arm shaft
Cam sprocket bolt
Cam tensioner plug
Cylinder head nut
:YLINDER/PISTON:
Cylinder bolt
Cylinder stud bolt
:LUTCH/GEARSHIFT LINKAGE:
Clutch center lock nut
Primary drive gear nut
Gearshift drum stopper arm pivot bolt
Gearshift spindle return spring pin
4LTERNATORISTARTER CLUTCH:
Flywheel bolt
Starter clutch bolt
Left crankcase cover stud bolt
Gearshift Dedal Dinch bolt

4
1
1
1
1
1

2
1
2
2
2
2
1
4

23 (2.3, 17)
27 (2.8, 20)
27 (2.8.20)
27 (2.8,20)
20 (2.0, 14)
4 (0.4, 2.9)
44 (4.5,33)

4
4

10
10

44 (4.5.33)
20 (2.0,33)

NOTE 2
oage 8-6

1
1
1
1

18
18
6
8

108 (11.0.80)
88 (9.0. 65)
12 (1.2,9)
24 (2.4, 17)

VOTE 2,6
VOTE 2

12
8
6
6

127 (13.0. 94)
30 (3.1.22)
10 (1.0.7)
20 (2.0, 14)

VOTE 2
VOTE 1

1
1

NOTE 1
VOTE 1
NOTE 1
NOTE 1
VOTE 2

1-1 1

- ENGINE (Cont'd)
ITEM

CRANKCASE/TRANSMlSSlON/CRANKSHAFT:
Mainshaft bearing setting plate bolt
LIGHTSISWITCHES
Neutral switch
.

QTY

THREAD
DIA. (mm)

N.m (kgf.m, IbfW

12 (1.2, 9)

13 (1.3,9)

0
"

THREAD
DIA. (mml

N.m (kgf.m, IbfW

4
4
2
2
2

10
8
8
8
6

42 (4.3.31)
30 (3.1, 22)
32 (3.3, 24)
23 (2.3, 17)
20 (2.0. 14)

4
2
1
1
4

8
4
8
8
12

21 (2.1, 15)
2 (0.2, 1.4)
18 (1.8, 13)
18 (1.8, 13)
54 (5.5,40)

1
1
4
1

10
10
8
10

74 (7.5,
54 (5.5,
26 (2.7,
74 (7.5,

2
3
2

10
4
5
10
14
8
10
10
12
12
10
14
8

39 (4.0, 29)
4 (0.4, 2.9)
2 (0.2, 1.4)
64 (6.5, 47)
59 (6.0, 43)
42 (4.3.31)
44 (4.5.33)
39 (4.0,29)
29 (3.0, 22)
54 (5.5, 40)
44 (4.5,33)
69 (7.0, 51)
32 (3.3, 24)

10
18
8
10
10
10
10
10
48
48
14
12

64 (6.5, 47)
137 (14.0, 101)
42 (4.3,31)
59 (6.0, 43)
44 (4.533)
59 (6.0, 43)
59 (6.0, 43)
59 (6.0, 43)
88 (9.0,65)
128 (13.0, 94)
108 (11.0,80)
59 (6.0,43)

FRAME
ITEM

WAME/BODY PANELS/EXHAUST SYSTEM:
Footpeg bracket bolt
Skid plate bolt
Muffler mounting bolt
Muffler band bolt
Exhaust pipe protector bolt
HAINTENANCE
Axle bearing holder pinch bolt
Front master cylinder reservoir cap screw
Parking brake arm lock nut
Rear master cylinder push rod lock nut
Tie-rod lock nut
iNGlNE REMOVALIINSTALLATION
Upper engine hanger nut
Front engine hanger nut
bolt
Lower engine hanger nut
:RONT WHEEL/SUSPENSION/STEERING
Handlebar lower holder nut
Throttle housing cover screw
Left handlebar switch housing screw
Front wheel nut
Front wheel hub nut
Front brake disc bolt
Shock absorber mounting nut
Upper and lower arm pivot nut
Upper and lower arm ball joint nut
Tie-rod ball joint lock nut
Tie-rod stud joint nut
Steering shaft end nut
Steering shaft holder bolt
3EAR WHEELISUSPENSION:
Rear wheel nut
Rear wheel hub nut
Rear brake disc bolt
Shock absorber mounting nut
Shock link-to-swingarm nut
Shock arm-to-frame nut
Shock arm-to-shock link nut
Final driven sprocket nut
Axle lock nut (outer)
(inner)
Swingarm pivot nut
Caliper stopper pin

2
6
4
8
4
4
4
1
2
8

2
4
2
1
1
1
4
1
1
1
1

TORQUE

REMARKS

NOTE 1

REMARKS

NOTE 4

54)
40)
20)
54)

NOTE 5
NOTE 4

NOTE 5

NOTE 3,5
NOTE 4

NOTE 1
NOTE 1
NOTE 1

GENERAL INFORMATION

ITEM
HYDRAULIC BRAKE:
Caliper bleed valve
Front brake caliper pad pin plug
Front brake caliper pad pin
Rear brake caliper pad pin
Brake hose oil bolt
Brake pipe joint nut
Front brake lever pivot bolt
nut
Rear master cylinder mounting bolt
Rear master cylinder reservoir hose joint screw
Front brake caliper slide pin
Front brake caliper bracket pin
Front brake caliper mounting bolt
Rear brake caliper slide pin
Rear brake caliper bracket pin
Rear brake caliper mounting bolt
Rear brake caliper parking brake base bolt
LIGHTSISWITCHES:
Headlight mounting bolt
DTHERS:
Sub-frame upper mounting bolt
Sub-frame lower mounting bolt

QTY

THREAD
D I A . ( ~ ~ )

3
4
4
2
4
2
1
1
2
1
2
2
2
1
1
2
2

8
10

8
10
10
6
6
6
4
8
8
8
8
8
8
8

6 (0.6, 4.3)
3 (0.3, 2.2)
18 11.8. 13)
18 (1.8, 13)
34 (3.5, 25)
17 (1.7, 12)
6 (0.6, 4.3)
6 (0.6, 4.3)
13 (1.3, 9)
2 (0.2,1.4)
23 (2.3, 17)
18(1.8, 13)
30 (3.1,22)
23 (2.3, 17)
18 (1.8, 13)
30 (3.1,22)
23 (2.3, 171

NOTE 4
NOTE 1

NOTE 4
NOTE 1
NOTE 4

4 (0.4, 2.9)

42 (4.3, 31)
54 (5.5, 40)

1-13

GENERAL INFORMATION

TOOLS
NOTES: 1. Equivalent commercially available in U.S.A.
2. Not available in U.S.A.
3. Alternative tool

DESCRIPTION

REF. SECTION

REMARKS

TOOL NUMBER

zarburetor float level gauge
Jniversal bearing puller
;ear holder
:lutch center holder
:lywheel holder
iotor puller

07401 -0010000
07631-0010000
07724-0010100
07724 - 0050002
07725 - 0040000
07733 - 0020001

iemover weight

07741 - 0010201

lalve guide driver, 5.5 mm
Sttachment. 32 x 35 mm
Wachment, 37 x 40 mm
Wachment, 42 x 47 mm
4ttachment. 52 x 55 mm
ittachment, 62 x 68 mm
ittachment, 72 x 75 mm
4ttachment. 24 x 26 mm
4ttachment. 35 mm I.D.
Pilot, 12 mm
Pilot, 15 mm
Pilot, 17 mm
"ilot, 20 mm
?lot, 25 mm
Wot, 30 mm
'ilot, 40 mm
Pilot, 22 mm
Bearing remover shaft
Bearing remover head, 15 mm
ittachment, 28 x 30 mm
Driver
Valve spring compressor
Valve seat cutter, 29 mm (EX 45")
Valve seat cutter, 35 mm (IN 45")
Flat cutter, 30 mm (EX 32")
Flat cutter, 35 mm (IN 32")
Interior cutter, 30 mm (INEX 60")
Cutler holder, 5.5 mm
Pilot screw wrench
Compression gauge attachment
Snap ring pliers
Lock nut wrench, 45 mm
Lock nut wrench, 56 mm

07742-0010100
07746-0010100
07746-0010200
07746-0010300
07746-0010400
07746 - 0010500
07746 - 0010600
07746 - 0010700
07746 - 0030400
07746 - 0040200
07746 - 0040300
07746 - 0040400
07746 - 0040500
07746-0040600
07746 - 0040700
07746-0040900
07746 - 0041000
07746-0050100
07746-0050400
07746- 1870100
07749-0010000
07757 - 0010000
07780 - 0010300
07780 - 0010400
07780 - 0012200
07780 - 0012300
07780-0014000
07781-0010101
07908-4220201
07908 - KK60000
07914 - SA50001
07916- 1870101
07916 - HA20000

Remover handle
Bearing remover, 17 mm
Bearing remover set, 15 mm
- bearing remover, 15 mm
-remover shaft
-remover head
-sliding weight

07936-3710100
07936-3710300
07936 - KClOOOO
07936 - KC10500
07936- KClOlOO
07936 - KC10200
07741 -0010201

Needle bearing remover

07946 - KA50000

1-14

NOTE 1
NOTE 2
NOTE 1
NOTE 1
NOTE 3
07933 - 3950000 (U.S.A. only)
NOTE 3:
07936 -371020A or 07936-3710200

NOTE 1

NOTE 1
NOTE 1
NOTE 3:
07916 - HA2010A (U.S.A. only)

NOTE 2

3
10

10
11
1
11.12
11.12
11.12
11
13
11
13
13
11
11,12
3, 11, 12, 13
12
11
11
13
11
12
12
9
9, 11, 12, 13
7
7
7
7
7
7
7
5
7
14
13
13
11
11
11

NOTE 2
NOTE 2
NOTE 3:
07936 - 371020A or 07936 - 3710201

GENERAL INFORMATION
~~

DESCRIPTION

TOOL NUMBER

Crankcase assembly tool
- assembly collar
- assemblv shaft

07965 - VMOOOOO
07965 - VMOOlOO
07965 - VM00200

-threaded adaptor

07965 - VM00300

Assembly collar
Valve guide reamer, 5.5 mm

07965 - VMOOlOO
07984 - 2000001

Spherical bearing driver

07HMF - HCOOlOO

Ball joint remover

07MAC - SLOO200

REMARKS
NOTE 2

REF. SECTION
11

NOTE 3:
07931 - ME4010B and
07931 - HB3020A
NOTE 3:
07931-KF00200
NOTE 3
07984 - 200000D (U.S.A. only)
NOTE 2
NOTE 3:07GAD - PH70100

12.13
7
12

1-15

GENERAL INFORMATION

LUBRICATION & SEAL POINTS
-

ENGINE
LOCATION

MATERIAL

Camshaft journals and cam lobes
Rocker arm slipper surfaces
Sub-rocker arm slipper surfaces
Valve stem (valve guide sliding surface)
Clutch outer guide inner and outer surfaces
Piston pin outer surface
Connecting rod small end inner surface
Transmission gear rotating surfaces
Transmission gear shift fork grooves
Connecting rod big end bearing

Molybdenum oil solution
(a mixture of 112 engine oil
and 112 molybdenum
disulfide grease)

Rocker arm shaft sliding surfaces
Sub-rocker arm shaft sliding surfaces
Cam chain
Cylinder head nut threads and seating surfaces
Piston outer surface and piston pin hole
Piston rings
Cylinder bore
Cylinder bolt threads and seating surfaces (10 mm only)
Clutch arm spindle
Clutch lifter piece
Clutch disc lining
Clutch center lock nut threads and seating surface
Primary drive gear nut threads and seating surface
Flywheel bolt threads and seating surface
Transmission gear teeth
Shift fork shaft
Shift fork guide pins and inner surfaces
Shift drum grooves
Each bearing rotating area
Each O-ring whole surface
Each oil seal outer surface

Engine oil

Each oil seal lip

Multi-purpose grease

Rocker arm shaft threads
Sub-rocker arm shaft threads
Gearshift cam plate bolt threads
Left crankcase cover stud bolt threads
Alternator wire clamp bolt threads (inside left crankcase
cover)
Ignition pulse generator bolt threads
Mainshaft bearing setting plate bolt threads
Cam chain tensioner slider bolt threads
Cam sprocket bolt threads
Starter clutch bolt threads

Locking agent

Alternatorfignition pulse generator wire grommet seating
surface

Liquid sealant

1-16

REMARKS

Coating area (page 7-22)
Coating area (page 7-22)
Coating width: 6.5 mm 10.26
in) from ti[)

Coating width: 5 mm (0.2 in)

GENERAL INFORMATION

- FRAME
LOCATION

MATERIAL

Thronle cable end
Throttle lever pivot and dust seal lip
Brake lock cable end
Brake lock arm pivot
Front wheel hub dust seal lips
Steering shaft bushing inner surface
Steering shaft dust seal lips
Upper and lower arm pivot bearings
Upper and lower arm pivot dust seal lips
Shock arm and link bearings
Shock arm and link dust seal lips
Swingarm pivot bearings
Swingarm pivot dust seal lips
Rear brake pedal pivot
Rear brake pedal pivot dust seal lips
Rear axle bearing holder outer surface
Rear axle bearing holder dust seal lips
Rear brake caliper stay inner surface
Rear axle splines (brake disc and driven flange)
Rear axle outer lock nut stopper ring
Rear wheel hub nut threads and seating surfaces
Rear shock absorber upper needle bearing
Rear shock absorber dust seal lips
Front shock absorber lower bushings
Front shock absorber dust seal lips

Multi-purpose grease

Apply 1 g per each dust seal

Fill up 3 g per each bearing

Apply 3 g per each bearing

Apply 1 g per each dust seal

Molybdenum disulfide Daste

Air cleaner intake duct-to-housing mating surface

Engine oil

Throttle cable outer inside
Clutch cable outer inside
Brake lock cable outer inside

Cable lubricant

Handlebar grip
. . rubber inside

REMARKS

Honda Bond A or Honda
Hand Grip Cement (U.S.A.
only) or equivalent

Front brake lever-to-master piston contacting area
Front brake lever pivot
Rear brake master piston-to-push rod contacting area and
boot groove
Brake caliper pin bolt boots inside
Rear brake caliper parking brake shaft sliding surface

Silicone grease

Brake master piston and cups
Brake caliper piston and piston seals
Rear brake master cylinder hose joint O-ring
Rear brake caliper piston shaft O-ring

DOT 4 brake fluid

Clutch switch retainer screw
Rear axle outer and inner lock nut threads
Rear brake master cylinder hose joint screw threads

Locking agent

1-17

GENERAL INFORMATION

CABLE & HARNESS ROUTING

THROTTLE CABLE
BRAKE LOCK CABLE

ANDLEBAR SWITCH WIRE

BRAKE HOSE

CLUTCH CABLE

OIL TANK BREATHER
TUBE

NEUTRAL INDICATOR
CONNECTORS

EADLIGHT CONNECTOR
IGNITION SWITCH CONNECTORS

1-18

GENERAL INFORMATION

1-19

GENERAL INFORMATION

1-20

GENERAL INFORMATION

NEUTRAL SWITCH
WlRF

DIODE

CARBURETOR DRAIN TUBE

THROlTLE CABLE
CARBURETOR AIR VENT TUBE

FUEL TUBE

1-21

GENERAL INFORMATION

MASTER CYLINDER RESERVOIR HOSE

1-22

GENERAL INFORMATION

EMISSION CONTROL SYSTEMS
The California Air Resources Board (CARB) requires manufacturers to certify that their A N s comply with applicable exhaust
emissions standards during their useful life, when operated and maintained according to the instructions provided.

SOURCE OF EMISSIONS
The combustion process produces carbon monoxide and hydrocarbons. Controlling hydrocarbon emissions is very important
because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide
does not react in the same way, but it is toxic.
Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydrocarbons.

EXHAUST EMISSION CONTROL SYSTEM

The exhaust emission control system is composed of a lean carburetor setting, and no adjustments should be made except
idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcase emission control system.

CRANKCASE EMISSION CONTROL SYSTEM
The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere.
Blow-by gas is returned to the combustion chamber through the air cleaner and carburetor.
CARBURETOR

AIR CLEANER CONNECTING TUBE

AiRCLEANER

CRANKCASE BREATHER STORAGE TANK

e:FRESH AIR
-+: BLOW-BY GAS

NOISE EMISSION CONTROL SYSTEM

TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITE- US. federal law prohibits, or Canadian provincial laws
prohibit the following acts or the causing thereof: (11 The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the
purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; (2) the use of the vehicle
after such device or element of design has been removed or rendered inoperative by any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW
1. Removal of or puncturing of 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.

1-23

GENERAL INFORMATION

EMISSION CONTROL INFORMATION
LABEL
The Vehicle Emission Control Information Label is
attached o n the right side frame down tube.

1-24

VEHICLE EMISSION CONTROL
INFORMATION LABEL

2. FRAME/BODY PANELS/EXHAUST SYSTEM
SERVICE INFORMATION

2-1

FUEL TANK & HEAT PROTECTOR

2-4

TROUBLESHOOTING

2-1

FOOTPEG/MUD GUARD

2-5

SEAT/REAR FENDER

2-2

SKID PLATE

2-5

FRONT FENDER

2-2

EXHAUST SYSTEM

2-6

SIDE COVER

2-3

SERVICE INFORMATION
GENERAL

Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN.
Serious burns may result if the exhaust system is not allowed to cool beforecomponents are removed or serviced.

Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can
cause a fire or explosion.
This section covers removal and installation of the body panels, fuel tank and exhaust system.
Always replace the gaskets when removing the exhaust system.
* Always inspect the exhaust system for leaks after installation.
* Refer to section 18 for light and switch information.

TORQUE VALUES
Footpeg bracket bolt
Skid plate bolt (8 mm)
Muffler mounting bolt
Muffler band bolt
Exhaust pipe protector bolt

42
30
32
23
20

N m (4.3 kgfm,
N m (3.1 kgfm,
N m (3.3 kgfm,
N m (2.3 kgf.m,
N.m (2.0 kgfm,

31 Ibf4t)
22 IbfW
24 Ibf4t)
17 IbfW
14 IbfW

TROUBLESHOOTING
Excessive exhaust noise
* Broken exhaust system
Exhaust gas leaks

Poor performance
*
*
*

Deformed exhaust system
Exhaust gas leaks
Clogged muffler

2-1

FRAMElBODY PANELSlEXHAUST SYSTEM

SEAT/REAR FENDER

CAUTION:
The rear fender may be deformed if it contacts the
muffler while the exhaust system is hot.

REMOVAL
DO not allow the
assembly to
contact the
muffler when the
exhaust
svstem is hot.

Unlock the seat by turning the lock lever upward.
Raise the seatlfender assembly up and remove it.

INSTALLATION
SEAT/REAR FENDER
Install the seatlfender assembly by inserting the hook
between the screw and fuel tank and the prongs onto
the front mounting rubbers of the frame.
Push the seatlfender assembly forward and align the
mounting bosses with the rear mounting rubbers,
then press down to lock it.

LOCK LEVER

FRONT FENDER
MOUNTING RUBBERS
Gasoline is extremely flammable and is explosive
under certain conditions. KEEP OUT OF REACH OF
CHILDREN.

UPPERCOVER
REATHER TUBE

REMOVAL/INSTALLATION

TRIM CLIPS

FUEL FILL CAP

Remove the seatbear fender assembly.
Release the four trim clips by raising the center pin
and remove them.
Remove the breather tube and fuel fill cap.
Release the four tabs from the slits in the fender while
sliding the fuel tank upper cover rearward and remove
it.
TABS
Install the fuel fill cap.

2-2

SIDE COVER
REMOVAL/INSTALLATION

TABS

TRIM CLIP

Remove the seathear fender (page 2-2).
Remove the screw and two trim clips.
Release the side cover from the three tabs of the
front fender by sliding it forward and remove the side
cover.
When installing
the trim clips,
carefully align
the clip holes to
avoid damaging
the clip.

Installation is in the reverse order of removal.

TRIM dLlP

SCREW

2-3

FRAMElBODY PANELS/EXHAUST SYSTEM

FUEL TANK & HEAT PROTECTOR
REMOVAL/INSTALLATION

BOLTS

Remove the front fender (page 2-2).

FUELTANK

FUEL TANK
Turn the fuel valve OFF.
Disconnect the fuel tube from the fuel valve.
Unhook the mounting straps.
Remove the two mounting bolts and the fuel tank.

TANK UNDER HEAT PROTECTOR
Remove the carburetor air vent tube from the tube
holder in the heat protector.
Remove the clutch cable from the cable guide on the
protector.
Release the trim clip by raising the center pin and
remove it.
Remove the fuel tube from the protector rubber.
Remove the two mounting bolts.

GUIDE
AT PROTECTOR

Release the two tabs on the rear side of the protector
and remove the protector from the frame.
When installing
the trim clip,
carefullyalign
the clip holes to
avoid damaging
the clip.

Installation is in the reverse order of removal.

After installation, turn the fuel valve ON and check
the fuel line for leakage.
MOUNTING BOLT

- AIR VENTTUBE

2-4

TRIM CLIP

FRAMElBODY PANELSlEXHAUST SYSTEM

FOOTPEG/MUD GUARD
REMOVAL/INSTALLATION
Remove the five screws, nut and the mud guard.
Remove the washer bolt from the footpeg bottom and
the inner mud guard stay.
Remove the bolt and washer and the outer mud guard
stay from the stay hole in the footpeg.

y’

Remove the two socket bolts and washers and the
footpeg.
Installation is in the reverse order of removal.

TORQUE
Footpeg bracket bolt: 42 Nm 14.3 k g f m 31 IbfW

WASHEWBOLT
OUTER MUD GUARD STAY
INNER MUD GUARD ST
WASHER BOLT

SKIDPLATE
REMOVAL
Remove the five bolts and the skid plate from the
swingarm.

INSTALLATION
Hook the chain guard of the skid plate onto the
mounting boss on the swingarm, install the 6 mm bolt
and new four 8 mm bolts and tighten them.

TORQUE 8 mm bolt: 30 Nm 13.1 kgfm, 22 IbfW
-

SOCKET BOLTS

FRAME/BODY PANELSlEXHAUST SYSTEM

EXHAUST SYSTEM
REMOVAL
Do not service the exhaust system while it is hot.

Remove the seatkear fender (page 2-2).
MUFFLER
Loosen the muffler band bolts.
Remove the upper and lower muffler mounting bolts
and washers (between the muffler and frame).
Remove the muffler.
Remove the muffler gasket.
EXHAUST PIPE
Remove the joint nuts and the exhaust pipe.
Remove the joint gaskets.

I
GASKET&?

I
EXHAUST PIPE

MOUNTING BOLTS

INSTALLATION
Set the exhaust
pipe flange as
shown.

Install new joint and muffler gaskets.
Install the exhaust pipe and muffler in the reverse
order of removal by loosely tightening all fasteners.

EXHAUST PIPE FLANGE:

Tighten the joint nut first, then tighten the mounting
bolts and the band bolts.
TORQUE:
Muffler mounting bolt: 32 N.m (3.3 kgfm, 24 Ibf4t)
Muffler band bolt: 23 N m (2.3 kgfm, 17 Ibf.ft)
Exhaust pipe protector bolt: 20 N m (2.0 kgfm,
14 IbfW
View from front side:
After installation, inspect the exhaust system for leaks.

2-6

3. MAINTENANCE
SERVICE INFORMATION

3-1

DRIVE CHAIN SLIDER

3-14

MAINTENANCE SCHEDULE

3-3

BRAKE FLUID

3-14

FUEL LINE

3-4

BRAKE PADS WEAR

3-15

THROTTLE OPERATION

3-4

BRAKE SYSTEM

3-15

AIR CLEANER

3-5

SKID PLATE AND ENGINE GUARD

3-17

AIR CLEANER HOUSING DRAIN TUBE

3-6

CLUTCH SYSTEM

3-17

SPARK PLUG

3-6

SUSPENSION

3-18

VALVE CLEARANCE

3-7

SPARK ARRESTER

3-19

ENGINE OIL

3-9

NUTS, BOLTS, FASTENERS

3-19

ENGINE OIL FILTER

3-11

WHEELS/TIRES

3-19

ENGINE OIL STRAINER SCREEN
IN OIL TANK

STEERING SHAFT HOLDER BEARING

3-20

3-12

STEERING SYSTEM

3-20

ENGINE IDLE SPEED

3-12

DRIVE CHAIN

3-13

SERVICE INFORMATION
GENERAL

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. Run the engine in an open area or with an exhaust evacuation system in an enclosed area.

SPECIFICATIONS
ITEM

SPECIFICATIONS
3 - 8 mm (118 - 5/16 in1

Throttle lever free play
Spark plug

Standard

DPREZ (NGK), X24GPR-U (DENSO)

For extended high speed riding

DPR9Z (NGK), X27GPR-U (DENSO)
0.6 - 0.7 mm (0.024 - 0.028 in)

Spark plug gap
Valve clearance

Intake
Exhaust

Recommended engine oil

0.10 mm (0.004 in)
0.12 mm (0.005 in)
Honda GN4 or HP4 4-stroke oil or eauivalent motor oil
Viscosity: SAE IOW-40 or 2OW-50

After draining

Engine oil capacity

After drainingtfilter change

I
Engine idle speed

After disassemblv

1.8 liters (1.9 US qt, 1.6 Imp qt)
1.85 IiterS (1.95 US qt, 1.63 Imp qt)
2.2 liters (2.3US qt, 1.9 Imp qt)

1,400 f 100 rpm

3- 1

30 - 40 mm (1-114 - 1-5B in)

Drive chain slack

DOT 4 brake fluid

Recommended brake fluid

10 - 20 mm (318 - 314 in)

Clutch lever free play
Cold tire pressure
(FronffRear)

Standard

27 kPa (0.275 kgf/cm2,4.0 psi)

Minimum

23 kPa 10.235 kof/cm?.3.4 Dsil

Maximum

31 kPa (0.315 kgf/cmZ, 4.6 psi)
AT22 x 7-10

Tire size

Front

**
**

Rear

AT20 x 10-9

Front

M/R 101

Rear

M/R 501
1

4.0 mm (0.16 in)

Minimum tread depth (FronffRear)

Toe-in: 17 f 15 m m (0.7f 0.6 in)

Toe

TORQUE VALUES
Spark plug
Valve adjusting hole cap
Valve adjusting lock nut
Crankshaft hole cap
Timing hole cap
Engine oil drain bolt (crankcase)
Engine oil drain bolt (oil tank)
Engine oil strainer screen (at oil tank)
Oil pipe joint flare nut
Axle bearing holder pinch bolt
Front master cylinder reservoir cap screw
Parking brake arm lock nut
Rear master cylinder push rod lock nut
Tie-rod lock nut

3-2

18 N m (1.8 kgfm, 13 IbfW
15 N m (1.5 kgfm, 11 IbfW
24 N m (2.4 kgfm, 17 IbfW
8 N m (0.8 kgfm. 5.8 IbfW
10 N m (1.0 kgfm, 7 IbfW
25 N m (2.5 kgfm, 18 IbfW
20 N m (2.0 kgfm, 14 IbfW
54 N m (5.5 k g h , 40 IbfW
20 Nvn (2.0 kgfm. 14 IbfW
21 N m (2.1 kgfm, 15 IbfW
2 N m (0.2 kgfm, 1.4 IbfW
18 N m (1.8 kgfm, 13 IbfW
18 N.m (1.8 k g h , 13 IbfW
54 N m (5.5 k g h , 40 IbfW

MAINTENANCE

MAINTENANCE SCHEDULE
Perform the PRE-RIDE INSPECTION in the Owner's Manual at each scheduled maintenance period.

.-I: Inspect and Clean, Adjust, Lubricate or Replace if necessary.
C: Clean

R: Replace

A: Adjust

L: Lubricate

FREQUENCY

ITEMS

WHICHEVER
COMES FIRST

INITIAL
MAINTENANCE
100

150

1,000

2,000

NOTE

HOURS

100

200

STEERING SHAFT HOLDER
BEARING
STEERING SYSTEM

REGULAR
MAINTENANCE INTERVAL
600
1,200

I '
L

Refer to
paw

t
I
1

3-19

3-20
3-20
~

* ! Shouldbe serviced by your Honda dealer, unless the owner has proper tools and service data and is mechanicallv aualified.
** In the interest of safety, we recommend these items be serviced only by your Honda dealer.

NOTES 1. Service more frequently if the A N is ridden in dusty areas, sand or snow.
2. Service more frequently if the ATV is ridden in very wet or muddy conditions.
3. Replace every 2 years. Replacement requires mechanical skill.

3-3

MAINTENANCE

FUEL LINE
Remove the front fender (page 2-2).
Check the fuel line for deterioration, damage or leakage.
Replace the fuel line if necessary.

F U EL L

I~E

THROlTLE OPERATION
Check for any deterioration or damage to the throttle
cable. Check that the throttle lever for smooth operation. Check that the throttle opens and automatically
closes in all steering positions.

If the throttle lever does not return properly, lubricate
the throttle cable and overhaul and lubricate the
throttle housing.
For cable lubrication: Disconnect the throttle cable at
its upper end. Thoroughly lubricate the cable and its
pivot point with a commercially available cable lubricant or a light weight oil.
If the throttle lever still does not return properly,
replace the throttle cable.

Reusing a damaged or abnormally bent or kinked
throttle cable can prevent proper throttle slide
operation and may lead to a loss of throttle control
while riding.
With the engine idling, turn the handlebar all the way
to the right and left to ensure that the idle speed does
not change. If idle speed increases, check the throttle
lever free play and the throttle cable connection.
Measure the throttle lever free play at the tip of the
throttle lever.

THROITLE LEVER FREE PLAY: 3 8 mm
1118 - 5/16 in1

BOOT

LOCK NUT

Throttle lever free play can be adjusted at upper end
of the throttle cable.
Loosen the lock nut, turn the adjuster as required and
tighten the lock nut.
Install the rubber boot securely.

ADJUSTER

- -

MAINTENANCE

AIR CLEANER

RETAINING CLIPS

NOTE:
If the vehicle is used in dusty areas, sand or snow,
more freauent inwections are rewired.
Remove the seathear fender assembly (page 2-2).
Release the six retaining clips from the air cleaner
housing covet and remove the cover.

COVER

Loosen the air cleaner element band screw.
Remove the air cleaner element assembly from the
housing.

I
Remove the element band and the element core from
the air cleaner element.

SCREW
ELEMENT

Wash the element in non-flammable or high flash
point solvent such as kerosene.
Squeeze out the solvent thoroughly, and allow the
element to dry.

WASH

SQUEEZE OUT

3-5

MAINTENANCE
Apply approximately 20 g (0.7 oz) of Pro Honda Foam
Filter Oil or equivalent oil from the inside of the element.
Place the element into a plastic bag and spread the
oil evenly by hand.

PRO HONDA
FILTER

MA:

Install the element core into the air cleaner element
properly.
Install the element band onto the air cleaner element
and the element assembly over the connecting tube
flange in the housing securely.
Tighten the band screw.
Install the air cleaner housing cover and secure it
with the retaining clips.
Install the seathear fender assembly (page 2-2).

AIR C EANER HOUSING DRAIN TUBE
NOTE:
If the vehicle is used in very wet or muddy conditions, more frequent insDections are reauired.
Remove the drain tube from bottom of the air cleaner
housing to empty any deposits.
Install the drain tube securely.
\'

DRAIN TUBE

SPARK PLUG
Disconnect the spark plug cap and clean around the
spark plug base.
NOTE:
Clean around the spark plug base with compressed
air before removing the plug, and be sure that no
debris is allowed to enter the combustion chamber.
Remove the spark plug.

3-6

MAINTENANCE
Check the insulator for cracks or damage, and the
electrodes for wear, fouling or discoloration. Replace
the plug if necessary (recommended spark plug:
page 3-1).

CENTER ELECTRODE

INSULATOR

SIDE E L E C T R O ~

Clean the spark plug electrodes with a wire type
brush or special plug cleaner.
Check the gap between the center and side electrodes
with a wire-type feeler gauge. If necessary, adjust the
gap by bending the side electrode carefully.

SPARK PLUG G A P 0.6 0.7 mm (0.024- 0.028 in)
CAUTION:

To prevent damage to the cylinder head, hand-tighten
the spark plug before using a wench to tighten to the
specified torque.
Reinstall the spark plug in the cylinder head and
hand tighten, then torque to specification.

TORQUE 18 Nm 11.8 kgfm, 13 IbfW
Connect the spark plug cap,

VALVE CLEARANCE
NOTE:
Inspect and adjust the valve clearance while the
engine is cold (below 35"C, 95'F).
Remove the following:
- fuel tank and heat protector (page 2-4)
- timing hole cap and crankshaft hole cap
-valve adjusting hole caps.

3-7

MAINTENANCE
Rotate the crankshaft only counterclockwise to align
the T mark on the flywheel with the index notch in
the left crankcase cover.
Make sure the piston is TDC (Top Dead Center) on
the compression stroke.
This position can be obtained by confirming that
there is slack in the sub-rocker arm. If there is no
slack, it is because the piston is moving through the
exhaust stroke to TDC. Rotate the crankshaft one full
turn counterclockwise and match up the T mark
again.
CAUTION:

If the T mark is passed when trying to align it with the
index notch, rotate the crankshaft counterclockwise
again and align the T mark with the index notch. This
must be done to prevent the one-way decompressor
system from functioning and to obtain the correct
valve clearance.
Check the clearance of all valves by inserting a feeler
gauge between the adjusting screw and sub-rocker
arm.
NOTE:
When checking the clearance, slide the feeler gauge
from the inside out in the direction of the arrow.
VALVE CLEARANCES IN: 0.10 mm (0.004 in)
E X 0.12 mm (0.005 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.
TORQUE 24 N.m (2.4 kgfm, 17 Ibf4t)
After tightening the lock nut, recheck the valve clearance.

Coat new O-rings and install them into the grooves in
the adjusting hole caps.
Install the adjusting hole caps and tighten them.

TORQUE: 15 N.m (1.5 kgf.m, 11 IbfW
Coat new O-rings and install them onto the crankshaft hole cap and timing hole cap.
Install the caps and tighten them.

TORQUE:
Crankshaft hole cap: 8 N m (0.8 kgf.m, 5.8 Ibf4tl
Timing hole cap: 10 N.m 11.0 kgf.m, 7 Ibf.ft1
Install the heat protector and fuel tank (page 2-4),

3-8

MAINTENANCE

ENGINE OIL
Engine and exhaust system parts become very hot
and remain h o t for some time after the engine is run.
Wear insulated aloves.

LEVEL CHECK
NOTE:

Check the oil level after starting the engine and
allowing the oil to circulate through the engine
thoroughly. It is especially important on dry sump
engine, due to the comparatively large volume of
oil.
Do not snap the throttle while idling or the oil level
reading will be inaccurate.

FILLER HOLE

Place the vehicle on level ground.
Start the engine and let it idle for a 5 minutes. If the
air temperature is below 10°C (50"FL let the engine
idle for an additional 5 minutes (a total of 10 minutes).
Stop the engine.
After a few minutes, remove the oil filler capldipstick
from the oil tank and wipe it clean.
Check the oil level by inserting the oil filler/dipstick
into the oil filler hole without screwing it in.
The engine contains a sufficient amount of oil if the
oil level is between the upper and lower level marks
on the dipstick.

OIL VISCOSITIES

If the oil level is near or below the lower level mark,
and the recommended engine oil up to the upper
level mark.
RECOMMENDED ENGINE OIL
Honda GN4 or HP4 4-stroke oil or equivalent
motor oil
API service classification SF or SG
Viscosity: SAE 1OW-40 or 2OW-50

-20 -10

40
0

100 "F

30 40 "C

NOTE:
Other viscosities shown in the chart may be used
when the average temperature in your riding area is
within the indicated range.
Reinstall the filler capldipstick.

3-9

MAINTENANCE
A t Crankcase Oil Check Bolt

OIL CHECK BOLT AND SEALING WASHER

NOTE
The crankcase oil level check bolt is useful when
checking the lubrication; the oil pump adjusts the
oil level so that the crankcase is always kept at the
proper level. If this check shows otherwise, some
portion of the lubrication system is not working
properly.
* Do not check the oil level immediately after the
engine has been operated at high speeds. Make
sure that vehicle is on firm level ground while
idling. Allow the engine to idle for a few minutes
to stabilize the oil levels.
*

The crankcase oil level is correct if the oil is flush
with the bottom of the check bolt hole.

OIL CHANGE
CAUTION:
Used engine oil may cause skin cancer if repeatedly
left in contact with the skin for prolonged periods.
Although this is unlikely unless you handle used oil
on a daily basis, it is still advisable to thoroughly
wash your hands with soap and water as soon aspossible after handling used oil.
NOTE:
Change the oil with the engine warm to assure comDlete and raDid drainino.
Start the engine and let it idle for few minutes.
Stop the engine and remove the oil filler capldipstick.
Remove the oil tank and crankcase drain bolts with
the sealing washers and drain the engine oil.
After the oil has drained, install the drain bolts with
new sealing washers.

TORQUE:
Crankcase drain bolt 25 N.m (2.5 kgfm, 18 Mft)
Oil tank drain bolt: 20 N.m (2.0 k g f m , 14 IbfW
NOTE:

If maintenance is required for the oil tank oil
strainer screen, perform the maintenance on the
screen before filling the oil tank (page 3-12).
Pour in the engine oil after replacing the oil filter
(page 3-11).

\e*

DRAIN BOLT AND SEALING WASHER

3-1 0

MAINTENANCE
Pour the recommended oil (page 3-9)into the oil tank
up to the upper level mark on the dipstick.
NOTE:
~

The engine takes about 1.85 liters (1.95 US qt, 1.63
Imp qt) at oil and filter change. Because only a portion of that oil is held in the oil tank, you cannot add
the full amount initially.

OIL CAPACITY:
1.8 liters (1.9 US qt, 1.6 Imp qt)at draining
1.85 liters (1.95 US qt, 1.63 Imp qt) at draining/
filter change
2.2 liters (2.3 US qt, 1.9 Imp qt) at disassembly

FILLER CAPIDIPSTICK

Install the oil filler capldipstick.
Place the vehicle on firm level ground.
Start the engine and let it idle for a few minutes without snapping the throttle.
Stop the engine and add the recommended oil up to
the upper level mark on the dipstick.
Install the filler capldipstick.
Start the engine and recheck the oil level (page 3-91.
After replacing, make sure there are no oil leaks.

EhGlNE OIL FILTER

SPRING

Engine and exhaust system parts become very h o t
and remain hot for some time after the engine is run.
Wear insulated gloves.
Drain the engine oil (page 3-10).
Remove the following:

- cover bolts

- filter cover with O-ring
- oil filter
- spring.
Coat a new O-ring with engine oil and install it in the
cover groove.
Install the spring between the lugs and a new oil filter
with the “OUT-SIDE” mark facing out, then set the filter cover onto the filter and tighten the bolts securely.

CAUTION
installing the o i l filter backwards wi// resun in severe
engine damage.

Fill the engine and oil tank with the engine oil.

3-1 1

MAINTENANCE

-FLAR

ENGINE OIL STRAINER SCREEN IN OIL
TANK
Engine and exhaust system parts become very h o t
and remain h o t for some time after the engine is run.
Wear insulated gloves.
Drain the engine oil (page 3-10).
Disconnect the oil pipe from the lower side of the oil
tank by loosening the flare nut.

IL STRAINER SCR

Remove the oil strainer screen.
Wash the strainer screen thoroughly in high flash
point solvent until a l l accumulated dirt has been
removed.
Blow the screen dry with compressed air, or leave it in
a well ventilated place until the solvent has evaporated.
Before installing the strainer screen, it should be
examined closely for damage.

Coat a new O-ring with engine oil and install it onto
the oil strainer screen.
Install the strainer screen and tighten it.
TORQUE: 54 N.m (5.5 kgf.m, 40 Ibf+tl
Connect the oil pipe over the strainer by screwing the
flare nut. Tighten the flare nut.

TORQUE: 20 N.m (2.0 kgf.m, 14 Ibf4t)
Fill the engine and oil tank with the engine oil (page
3-10).

ENGINE IDLE SPEED

NOTE:

Inspect and adjust the idle speed after all other
engine maintenance items have been performed
and are within specifications.
* Engine must be warm for accurate adjustment.
Ten minutes of stop-and-ao riding is sufficient.
Warm up the engine, shift the transmission into neutral and place the vehicle on a level surface.
Checkthe idle speed and adjust by turning the throttle
stop screw as required.
IDLE SPEED 1,400

3-12

* 100 rpm

T H R O ~ L ESTOP SCREW

MAINTENANCE

DRIVE CHAIN
CHAIN SLACK INSPECTION
Never inspect and adjust the drive chain while the
engine is running.

Turn the ignition switch OFF, shift the transmission
into neutral.
Check the slack in the drive chain upper run midway
between the sprockets.

DRIVE

CAAIN

CHAIN SLACK 30 - 40 mm 11-1/4- 1-5/8 in1
BEARING HOLDER

ADJUSTMENT
Loosen the axle bearing holder pinch bolts.
Turn the axle bearing holder until the correct drive
chain slack is obtained, using the hex wrench in the
tool kit as shown.
Tighten the holder pinch bolts.

TORQUE 21 N.m (2.1 kgf.m, 15 IbfW
Recheck the drive chain slack and free wheel rotation.
If the chain slack is excessive when the bearing holder is turned fully rearward (the correct slack cannot
be obtained), replace the drive chain with a new one.
To replace the drive chain, remove the drive sprocket
cover (page 6-2) and swingarm (page 13-13).

PINCH BOLTS

:LEANING

S0F;T B

CLEANING AND INSPECTION
Clean the chain with a soft brush using a non-flammable or high flash point solvent and wipe it dry.
Be sure the chain has dried completely before lubricating.
Inspect the drive chain for possible damage or wear.
Replace any chain that has damaged rollers, loose fitting links, or otherwise appears unserviceable.
Installing a new chain on badly worn sprockets will
cause the new chain t o wear quickly. Inspect and
replace the sprockets as necessary.

LUBRICATION
Lubricate the drive chain with Pro Honda Chain Lube
or equivalent chain lubricant designed for specifically
for use on O-ring chains.
Some commercially available chain lubricants may
contain solvents which could damage the O-rings.
Wipe off the excess chain lube.

3-13

MAINTENANCE

SPROCKET INSPECTION

WORN

Inspect the drive and driven sprocket teeth for damage or wear. Replace if necessary.
Never use a worn chain on new sprockets. Both chain
and sprockets must be in good condition, or the new
replacement parts will wear rapidly.
Check the attachment bolt and nuts on the drive and
driven sprockets. If any are loose, torque them.

DRIVE CHAIN SLIDER
Check the drive chain slider for wear.
Replace the chain slider if it is worn to the bottom of
the wear limit groove.
Refer to section 13 for drive chain slider replacement.

BRAKE FLUID
CAUTION

Do not mix different types of fluid, as they are not
compatible with each other.

Do not allow foreign material to enter the system
SCREWS

when filling the reservoir.
Avoid spilling fluid on painted, plastic or rubber
parts. Place a rag over these parts whenever the
system is serviced.

SERVOIR CAP

NOTE:
When the fluid level is low, check the brake pads for
wear (page 3-17). A low fluid level may be due to wear
of the brake pads. If the brake pads are worn, the
caliper pistons are pushed out, and this accounts for
a low reservoir level.
If the brake pads are not worn and the fluid level i s
low, check entire system for leaks (page 3-17).

FRONT BRAKE
Turn the handlebar to the left side so that the reservoir is level and check the front brake reservoir level
through the sight glass.
If the level is near the "LOWER" level line, remove
the reservoir cap, set plate and diaphragm, and fill
the reservoir with DOT 4 brake fluid from a sealed
container to the casting ledge.
Install the diaphragm, set plate and reservoir cap and
tighten the cap screws.

TORQUE: 2 N.m (0.2 kgfm, 1.4 IbfW

3-14

LOWER LEVEL LINE

CASTING LEDGE

MAINTENANCE

REAR BRAKE

RESERVOIR CAP

Place the vehicle on a level surface.
Remove the seathear fender assembly (page 2-2).
Check the fluid level in the rear brake reservoir.
If the level is near the "LOWER" level line, remove
the reservoir cap, set plate and diaphragm, and fill
the reservoir with DOT 4 brake fluid from a sealed
container to the "UPPER" level line.
Install the diaphragm, set plate and reservoir cap.
Install the seatlrear fender assembly (page 2-21.

BRAKE PADS WEAR
Check the brake pad for wear.
Replace the brake pads if the wear limit indicator (lug
end) aligns with the reference plate.
Refer to page 14-5 for brake pad replacement.

Y?5

\{
[

REFERENCE PLATE

LUG

BRAKE SYSTEM
INSPECTION FOR AIR IN SYSTEM
Firmly apply the brake lever or pedal, and check that
no air has entered the system.

Refer to page 14-3 for air bleeding procedures.
Inspect the brake hoses and fittings for deterioration,
cracks. damaae
" or sians of leakage.
Tighten any loose fittings.
Replace hoses, pipes and fittings as required.

\
BRAKEHOS€

3-15

MAINTENANCE

BRAKE LOCK CABLE ADJUSTMENT
A lock cable
adjustment may
be required if the
parking brake
does not hold
the rear wheels
securely.

LOCK NUT

,ADJUSTING BOLT

Slide the dust cover off the lever bracket.
To adjust the clutch lever free play to more than 30

m m (1-1B in), loosen the lock nut at the clutch lever
and turn the adjuster all the way in.
Loosen the lock nut at the brake arm on the caliper
and turn the adjusting bolt clockwise until bolt resistance is felt. Then turn the adjusting bolt 118 turn
counterclockwise and tighten the lock nut while holding the adjusting bolt.

TORQUE 18 N.m (1.8 kgfm, 13 IbfW

1 ADJUSTER

Squeeze the clutch lever while pushing the brake lock
pin down until firm resistance is felt and measure the
brake lock cable free play at the end of the clutch
lever.

LOCK NUT

LOCK PN
!

FREE PLAY 25 - 30 mm (1 - 1.118 in)

25 - 30 mm (1 - 1-118 in)

To adjust the free play, loosen the lock nut and turn
the adjuster at the brake lock arm on the clutch lever
bracket.
Tighten the lock nut while holding the adjuster.
Adjust the clutch lever free play (page 3-19).

BRAKE PEDAL HEIGHT
Adjust the brake pedal to the desired height.
Loosen the lock nut and turn the push rod to obtain
the pedal height.
Tighten the lock nut after adjustment has been made.

TORQUE: 18 N m (1.8 kgfm, 13 Ibf.ft)

3-1 6

LOCK NUT

MAINTENANCE
If adjusting the brake pedal t o the lower position,
make sure that the clearance between the lower end
of the push rod and the brake pedal does not fall
below 1 mm (0.04 in).

ISPOSITION:

HIGHER POSITION:

If adjusting to the higher position, make sure that a
portion of the lower end of the push rod thread is visible inside the joint.
THREAD

PEDAL'

SKID PLATE, ENGINE GUARD
Check the skid plate and engine guard for cracks,
damage or looseness.
Tighten any loose fasteners. Replace the skid plate
and engine guard as required (page 2-5 and 6-3).

CLUTCH SYSTEM
Inspect the clutch cable f o r kinks or damage, and
lubricate the cable if necessary.

10 - 20 mm (3/8- 3/4 in)

Measure the clutch lever free play at the end of the
lever

FREE PLAY 10 20 m m 13/8

- 3/4 in1

Minor adjustments are made at the clutch lever.
Slide the dust cover off the lever bracket, loosen the
lock nut and turn the adjuster.
Tighten the lock nut securely.

\ (d

CAUTION

The adjuster mav be damaaed if it is DoSitiOned too
far out, leaving minimal thread engagement.

If the adjuster is threaded out neat its limit and the
correct free play cannot be obtained, turn the
adjuster all the way in and back out one turn.
Tighten the lock nut and make a major adjustment as
described following page.

ADJUSTER

3-1 7

MAINTENANCE
Major adjustments are made with the lower adjusting
nut at the engine.
Loosen the lock nut and turn the adjusting nut.
After adjustment is complete, tighten the lock nut
securely while holding the adjusting nut.
Check the clutch operation.
If the free play cannot be obtained, or the clutch slips
during test ride, disassemble and inspect the clutch
(section 91.

ADJUSTING NUT

SUSPENSION
For detailed
instructions On

Preloadand dampsenin% see
Owner's

. 1__

Loose, worn or damaged suspension parts impair
vehicle stability and control. Repair or replace any
damaged components before riding. Riding a ATV
with faulty suspension increases your risk of an accident and possible injury.

FRONT
Check the action of the shock absorbers by compressing them several times.
Check the entire shock absorber assembly for signs
of leaks, damage or loose fasteners.
Replace damaged components which cannot be
repaired.
Tighten all nuts and bolts.
Refer to section 12 for shock absorber service.

REAR
Check the action of the shock absorber by compressing it several times.
Check the entire shock absorber assembly for signs
of leaks, damage or loose fasteners.
Replace damaged components which cannot be
repaired.
Tighten all nuts and bolts.
Refer to section 13 for shock absorber and linkage
service.
I

Raise the rear wheel off the ground and support the
vehicle securely.
Check for worn swingarm bearings by grabbing the
swingarm and attempting to move the wheels side to
side.
Replace the bearings if any looseness is noted (section 13).

,
I

3-1 8

MAINTENANCE

SPARK ARRESTER

Wait until the exhaust system has cooled before
removing or installing the arrester. Touching the h o t
exhaust may result in severe burns.
Remove the three bolts and the spark arrester with
the gasket.

BOLTS

Use a brush to remove carbon deposits from the
screen mesh, being careful not to damage the screen
mesh.
The screen mesh must be free of breaks and holes.
Replace the spark arrester if necessary.
Install the spark arrester with a new gasket and tighten the bolts securely.

NUTS, BOLTS, FASTENERS
Check that all chassis nuts and bolts are tightened to
their correct torque values (page 1-11),
Check that all cotter pins, safety clips, hose clamps
and cable stays are in place and properly secured.

WHEELS/TIRES

Tirepressure
should be
checked when
the tires are
COLD.

Checkthe tire pressure with the tire pressure gauge.
RECOMMENDED TIRE PRESSURE (FrontlRear):
Standard:
27 kPa (0.275 kgf/cm2, 4.0 psi)
Minimum:
23 kPa (0.235 kgf/cm2, 3.4 psi)
Maximum:
31 kPa (0.315 kgf/cm2, 4.6 psi)
Check the tires for cuts, embedded nails, or other
damage.
Check the front and rear wheels for trueness (refer to
section 12 and 13).
Measure the tread depth at the center of the tires.
Replace the tires when the tread depth reaches the
following limits.

MINIMUM TREAD DEPTH (FrontlRear):
4.0 mm (0.16 in1

3-19

MAINTENANCE

STEERING SHAFT HOLDER BEARING
Make sure the
cables do not
interfere with the
rotation o f the
handlebar

Raise the front wheels off the ground and support the
vehicle securely.
Check that the handlebar moves freely from side to
side.
If the handlebar moves unevenly, binds, or has horizontal movement, inspect the steering shaft holder
bushing and bearings (section 12).

STEERING SYSTEM
Place the vehicle on level ground with the front
wheels facing straight ahead.
Mark the centers of the tires with chalk to indicate the
axle center height.
Align the gauge with the marks on the tires as
shown.
Check the readings on the gauge scales.
Slowly move the vehicle back until the wheels have
turned 180" so the marks on the tires are aligned with
the gauge height on the rear side.
Measure the toe on the rear pan of the tires at the
same points with no load on the vehicle.

TOE-IN: 17 f 15 mm (0.7 f 0.6 in)
NOTE:
Toe-in means the rear measurement is greater than
the front measurement.

TOE-'GAUGE

FRONT

REAR

When the toe i s out of specification, adjust it by
changing the length of the tie-rods equally by loosening the lock nuts and turning the tie-rods while holding the ball joints.
After adjusting each tie-rod, rotate both ball joints in
the same direction with the tie-rod axis until they
stop against the ball joint stud. Hold them in that
position and tighten the tie-rod lock nuts.

TORQUE 54 N.m 15.5 kgfm, 40 IbfW
After finally tightening the lock nuts, make sure the
ball joints operate properly by rotating the tie-rods,
to make sure both ball joints have equal play.

3-20

7E-ROD

MEMO

4-0

4. LUBRICATION SYSTEM
~

SERVICE INFORMATION

4-1

OIL PUMP &STRAINER

4-2

TROUBLESHOOTING

4-1

OIL COOLER 81OIL TANK

4-6

SERVICE INFORMATION
GENERAL
Used engine oil may cause skin cancer if repeatedly If& in contact with the skin forprolongedperiods. Although this is
unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and

water as soon as possible after handling used oil. KEEP OUT OF REACH OF CHILDREN.
-~

-.
-

This section covers service of the oil pump, oil stra'ner ('n crancasel and oil cooler.
For oil level check, oil change, oil filter replacement and oil strainer (at oil tank) cleaning, refer to section 3.
The service procedures in this section can be performed witn the engine installed in the frame.
When remov'ng ano instal ing the 0'1 pJmp Jse care not to allow dust or dirt 10 enter the eng'ne.
If any portion of the oil pump is worn beyond the specif'ed service I'mits. replace the oi pJmp as an assembly.
After 0 1 1 pLmp. oil cooler anoior oil p'pes has been installed, check [hat there are no oil leaks.

SPECIFICATIONS
ITEM
Engine oil capacity

STANDARD

After draining

1.8 liters (1.9 US qt, 1.6 Irnp qt)

After draining/filter change

1.85 liters (1.95

After disassembly

2.2 liters (2.3 US qt. 1.9 Irnp qt)

Honda GN4 or HP4 4-stroke oil or
equivalent motor oil
API service classification SE. SF or SG
Viscosity: SAE 1OW-40

Recommended engine oil

Oil DumD

SERVICE LIMIT

Tip clearance

0.15 (0.006)

1 0.15 - 0.22 (0.006 - 0.009)

Body clearance

US qt, 1.63 Imp qt)

0.20 (0.008)
0.25 (0.010)

TORQUE VALUES
Oil pipe joint flare nut
Oil pump assembly bolt

20 N m (2.0 kgfm, 14 IbfW
13 N m (1.3 kgfm, 9 Ibf-ft)

TROUBLESHOOTING

Oil level too low high oil consumption
Oil consumption
External oil leak
Worn piston rings or incorrect piston ring installation
* Worn cylinder
* Worn valve guide or stem seals
* Oil pump worn or damaged

Oil contamination
Oil or filter not changed often enough
* Worn piston rings or incorrect piston ring installation
* Worn valve guide or stem seals

4-1

LUBRICATION SYSTEM

OIL PUMP & STRAINER
REMOVAL
Remove the right crankcase cover (page 9-21,
Remove the clutch outer (page 9-5).
Remove the three mounting bolts and the oil pump.

Remove the gasket and two dowel pins.

RELIEF VALVE CHECK
Remove the following:

- cotter pin
- stopper plate
- spring

- valve

Check the spring and vah for

or damage.

Install the valve, spring and stopper plate into the oil
pump, then insert a new cotter pin from the pump
body side and secure it.

4-2

LUBRICATION SYSTEM

DISASSEMBLY
i

BOL

Remove the two bolts and separate the pump base
from the pump spacer.

Remove the following:
- drive pin
- thrust washer
- inner rotor
- outer rotor

WASH
Separate the pump body from the pump spacer.
Remove the following:
- pumpshaft
- drive pin
- dowel pins
- inner rotor
- outer rotor

SHAFT AND PIN

ROTORS

INSPECTION

PUMP BODY

PINS

PUMP SPACER

BODY SIDE:

NOTE:
Measure at several places and use the largest reading to compare the service limit. If any portion of the
oil pump is worn beyond the specified service limits,
replace the oil pump as an assembly.
Install the inner and outer rotors into the pump base
and pump body.
Install the DumD shaft with the drive pin into the
inner rotor and measure rotor tip clearance.

SERVICE LIMIT 0.20 mm 10.008 in1

4-3

LUBRICATION SYSTEM
.

Measure the pump body clearance.

.
-.--

BASE SIDE:

SERVICE LIMIT 0.25 mm 10.010 in)

' ii s;

I
!

Measure the pump side clearance.

BASE SIDE:

SERVICE LIMIT 0.12 mm (0.005 in)

OIL STRAINER CLEANING

Remove the bolt and pull the strainer out of the
crankcase.
Wash the strainer screen thoroughly in high flash
point solvent.
Before installing the oil strainer, it should be checked
for damage.
Install the oil strainer into the crankcase and tighten
the bolt securely.

4-4

LUBRICATION SYSTEM

ASSEMBLY
DOWEL PINS
PUMP BODY

DY OUTER ROTOR
BODY INNER ROTOR

PUMP SHAFT
PUMP SPACER
THRUST WASHER
RELIEF VALVE

STOPPER PLATE

BASE INNER ROTOR

Install the following into the pump body:
- outer rotor with the punch mark facing the pump
spacer
- inner rotor
- drive pin and shaft with the stepped end facing
pump body
- dowel pins
Assemble the pump body and spacer.

Install the following onto the pump shaft and into the
pump base.
- thrust washer
- drive pin
- outer rotor with the punch mark facing the pump
base
- inner rotor
Assemble the pump bodylspacer assembly and
pump base by aligning the drive pin with the slots in
the inner rotor.

BODY/SPACER

PUMP BASE

WASHER

ROTORS

4-5

LUBRICATION SYSTEM
BOLTS

Be sure that there are no gap between the mating
surfaces and tighten the two bolts.

TORQUE: 13 N.m (1.3 k9f.m. 9 IbfW

INSTALLATION
Install the two dowel pins and a new gasket.
i'

Set the pump assembly onto the crankcase and tighten the three bolts securely.
Install the clutch assembly (page 9-81,
Install the right crankcase cover (page 9-12).

OIL COOLER & OIL TANK
INSPECTION
Remove the front fender (page 2-2).
Check the oil cooler air passage for clogging or damage.
Check for any oil leakage from the oil cooler, oil tank
and pipe joints.

4-6

LUBRICATION SYSTEM

REMOVAL/INSTALLATlON
Drain the engine oil (page 3-9).

OIL COOLER
Disconnect the oil pipes from the oil cooler by
removing the joint bolts and remove the O-rings.

Remove the two mounting bolts and the oil cooler.
Replace the 0rings with new
ones and coat
them with
engine oil.

Installation is in the reverse order of removal

OIL TANK
Disconnect the oil tank breather tube.
Disconnect the oil pipes by loosening the flare nuts.
Remove the tank mounting bolts and the oil tank
from the mounting rubber.
Installation is in the reverse order of removal.

TOROUE: Flare nuts: 20 Nm (2.0 kgfm, 14 IbfW

OIL PIPES
Disconnect the oil pipes from the oil cooler and oil
tank (see above).
Disconnect the oil pipes from the engine by removing the bolts.
Remove the dowel pins and O-rings.
Check the oil pipes for clogging or damage.

-Replace the 0rings with new
ones and coat
them with
engine oil.

Installation is in the reverse order of removal.

4-7

FUEL SYSTEM

5-0

5. FUEL SYSTEM
SERVICE INFORMATION

5-1

CARBURETOR INSTALLATION

5-12

TROUBLESHOOTING

5-2

PILOT SCREW ADJUSTMENT

5-13

CARBURETOR REMOVAL

5-3

HIGH ALTITUDE ADJUSTMENT

5-14

CARBURETOR DISASSEMBLY/
INSPECTION

AIR CLEANER HOUSING

5-15

5-3

CARBURETOR ASSEMBLY

5-7

SERVICE INFORMATION
GENERAL

Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN.
If the engine must be running to do some work make sure the area is well-ventilated. Never run the engine in an
enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead
to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area.
Bending or twisting the control cable will impair smooth operation and could cause the cable to stick or bind, resulting in loss of vehicle control.
Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can
cause a fire or explosion.

NOTE:
If the vehicle is to be stored for more than one month, drain the float chamber. Fuel left in the float chamber may cause
clooaed iets. resultina in hard startina or Door driveabilitv.

For fuel tank removal and installation, see page 2-4.
Before disassembling the carburetor, place an approved fuel container under the carburetor, loosen the drain screw
and drain the carburetor.
After removing the carburetor, cover the intake port of the cylinder head with shop towel to prevent any foreign
material from dropping into the engine.
When disassembling the fuel system parts, note the locations of the O-rings. Replace them with new ones on
reassemblv.

5- 1

FUEL SYSTEM

SPECIFICATIONS
ITEM

SPECIFICATIONS

Carburetor identification number
________

QBlOA

Main jet

#I48
#38

Slow jet

3rd groove from top

Jet needle clip position

See page 5-13

Pilot screw opening
Float level

18.5 mm (0.73in)

Idle speed

1,400 f 100 rpm

3 - 8 mm (1/8- 5/16in)

Throttle lever free Dlav

TOOL
Carburetor float level gauge
Pilot screw wrench

07401 - 0010000
07908-4220201

TROUBLESHOOTING
Engine cranks but won't start
* No fuel in tank
* No fuel to carburetor
-Clogged fuel stainer
-Clogged fuel line
-Clogged fuel tank breather tube
* Too much fuel getting to the engine
-Clogged air cleaner
-Flooded carburetor
* Intake air leak
Contaminatedldeteriorated fuel
* Improper choke operation
* Improper throttle operation
* No spark at plug (faulty ignition system

Engine stalls, hard t o start, rough idling
Restricted fuel line
Fuel mixture too leanlrich
* Contaminated/ deteriorated fuel
Intake air leak
* Misadjusted idle speed
Misadjusted pilot screw
* Restricted fuel tank breather tube
* Clogged air cleaner
* Clogged slow circuit
* Starting enrichment valve close (ON)
Faulty ignition system (section 16)

Lean mixture
Clogged fuel jets
* Faulty float valve
* Float level too low
* Restricted fuel line
Clogged carburetor air vent tube
* Restricted fuel tank breather tube
* Intake air leak
* Faulty throttle valve
*

Rich mixture
* Starting enrichment valve close (ON)
Clogged air jets
* Faulty float valve
Float level too high
* Dirty air cleaner
Worn jet needle or needle jet

5-2

section 16)

Afterburn when engine braking is used
* Lean mixture in slow circuit
Faulty air cut-off valve
* Faulty ignition system (section 16)

Backfiring or misfiring during acceleration
Lean mixture
* Faulty ignition system (section 16)
Poor performance (driveability) and poor fuel economy
* Clogged fuel system
* Faulty ignition system (section 16)

FUEL SYSTEM

CARBURETOR REMOVAL
-_

AIR VENTTUBE

=
/

CARBURETOR

Remove the fuel tank (page 2-41.
Place and approved fuel container under the drain
tube. Loosen the drain screw and drain the carburetor.
Remove the air vent tube from the heat protector and
the fuel t u b e f r o m t h e heat protector rubber.
Disconnect the drain tube from the carburetor.
Loosen the connecting tube band and insulator band
screws.
Release the carburetor from the connecting tube and

BAND SCREW

Remove the t w o screws and the throttle linkage
cover.
Disconnect the throttle cable from the throttle drum.
Loosen the cable lock nut and remove the carburetor
from the cable outer.

CARBURETOR DISASSEMBLY/
INSPECTION
Disconnect the tubes from the carburetor body.
Remove the throttle stop screw stay attaching screw
and the throttle stop screw by turning counterclockwise.

AIR CUT-OFF VALVE
Remove the attaching screw and the air cut-off valve.
Remove the O-rings and joint pipe.

5-3

FUEL SYSTEM
Apply vacuum to the vacuum port.
The vacuum should maintained.
Air should not flow through the valve ports when the
vacuum is applied, and should flow when the vacuum is not applied.

THROTTLE VALVE

SCREWSAND

Remove the three screws, clamp and top cover.
Remove the O-ring from the body groove.

(

Remove the valve arm set screw and washer.
Pull the link arm shaft out of the carburetor body
while holding the throttle linkage.
Remove the return spring and the thrust washer.
Remove the throttle valve assembly from the carburetor body, being careful not to damage the jet needle.

Remove the two screws and valve arm.
Remove the jet needle.

LVE ARM

5-4

FUEL SYSTEM
Check the jet needle for stepped wear or damage.
Check the throttle valve for scoring, scratches or
damage.

‘
I
; cmE

ACCELERATOR PUMP
Remove the three screws while holding the accelerator pump cover.

Remove the pump cover, spring and the diaphragm,
being careful not to damage it.

I
I

SPRING

Visually check the following:
-diaphragm for deterioration or pin holes
-spring for deterioration
-diaphragm shaft for excessive wear or damage
-orifice in cover for clogging or restriction

uinrnnr

FLOAT AND JETS
Remove the four screws and the float chamber.

5-5

FUEL SYSTEM
Remove the baffle plate and the diaphragm shaft
boot.

BAFFLE PLATE

Check the boot for deterioration or damage.

'99- '00
After '00

Remove the float pin, float and float valve.

FLOAT

FLOATVALVE

Remove the float pin by gently tapping with a suitable
pin driver (O.D. 2 mml.
Check the float for damage or fuel in the float.

Check the float valve and valve seat for scoring,
scratches, clogging or damage.
Check the tip of the float valve, where it contacts the
valve seat, for stepped wear or contamination.
Check the operation of the float valve.

Remove the slow jet and main jet.
Loosen the lock nut and remove the needle jet holder
and needle jet.

CAUTION:
Handle the jets with care. They can easily be scored
or scratched.

Turn the pilot screw in and carefully count the number of turns until it seats lightly. Make a note of this
to use as a reference when reinstalling the pilot
screw.
CAUTION
Damage to the pilot screw seat will occur if the pilot
screw is tightened against the seat.

5-6

FUEL SYSTEM
Remove the pilot screw, spring, washer and O-ring.
Check each jet for wear or damage.
Check the pilot screw for wear or damage.
Clean the jets with cleaning solvent and blow open
with compressed air.

I
I

CARBURETOR CLEANING
Remove the following:

- air cut-off valve
- thronle valve

- accelerator pump

- main iet, needle iet holder, needle jet and slow jet
- pilot screw.

CAUTION:

Cleaning the air and fuel passages with a piece o f
wire will darnacre the carburetor body.
Blow open all air and fuel passages in the carburetor
body with compressed air.

CARBURETOR ASSEMBLY

THROTTLE VALVE ARM

AIR CUT-OFF VALVE

LINK ARM SHAFT

-2
$

FLOAT VALVE

THROTTLE LINK ARM
PLASTIC WASHER
PLANE WASHER
SPRING WASHER

THROTTLE VALVE

FLOAT CHAMBER

DRAIN SCREW
THROTTLE STOP SCREW

FLOAT CHAMBER CAP

PILOT SCREW

BAFFLE PLATE

5-7

FUEL SYSTEM

FLOAT AND JETS

Install the pilot screw with the spring, washer and a
new O-ring and return it to its original position as
noted during removal.
Perform the pilot screw adjustment if new pilot screw
is installed.

NEEDLEJET

CAUTION:

Damage t o the pilot screw seat will occur ifthe pilot
screw is tightened against the seat
Install the needle jet, needle jet holder and tighten
the lock nut. Install the main jet and slow jet.

CAUTION:
Handle the jets with care. They can easily be scored
or scratched.
'99- '00

Hang the float valve onto the float arm lip.
Install the float valve, float and float pin.

Affer '00 Install the float pin by gently tapping with a suitable pin

driver

(OD.2 mml as shown.

.
-_
0.5 f 0.3 mm
(0.02k0.01 in)

FLOAT LEVEL INSPECTION
NOTE:
*

Check the float level after checking the float valve,
valve seat and float.
Set the float level gauge so that it is perpendicular
to the float chamber face at the highest point of
the float.

With the float valve seated and the float arm just
touching the valve, measure the float level with the
float level gauge.

TOOL
Carburetor float level gauge

07401

BAFFLE PLATE

- 0010000

FLOAT LEVEL 18.5 mm (0.73 in)
The float cannot be adjusted.
Replace the float assembly if the float level is out of
specification.
Install the diaphragm shaft boot of the accelerator
pump until it is flush with the carburetor body.
Install the baffle plate by aligning its groove with the
lug on the carburetor body as shown.

5-8

FUEL SYSTEM

- .- -. . ...

i - l _

Install a new O-ring into the float chamber groove
securely.
Install the float chamber, being careful not to pinch
the boot and tighten the four screws.

ACCELERATOR PUMP
Insert the diaphragm shaft into the float chamber
through the boot and set the diaphragm rib into the
groove properly. To avoid damage to the boot, turn
the shaft slowly when inserting.

1
!
I

Place the spring onto diaphragm. Install and hold the
p u m p cover, being careful not t o pinch the
diaphragm and tighten the three screws.

THROlTLE VALVE
Install the needle clip onto the jet needle.

STANDARD CLIP POSITION: 3rd groove from top
Insert the jet needle into the throttle valve.

IEWS

Assemble the throttle valve and valve arm with the
two screws.
Install the throttle valve assembly into the carburetor
body, being careful not to damage the jet needle.

VALVE ARM

5-9

FUEL SYSTEM
Set the thrust washer between the valve arm and carburetor body (throttle drum side).
Insert the link arm shaft through the throttle link arm,
spring, carburetor body, washer and valve arm while
hanging the spring ends as shown.
Align the screw holes in the valve arm and shaft and
tighten the screw with the washer.
I

Make sure that the piston and butterfly throttle valves
are fully closed.
Make sure the clearance between the link arm shaft
and throttle link arm is 0.1 - 0.3 mm (0.004 - 0.012
in).
Adjust synchronization by opening or closing the slot
in the throttle link arm.

Install a new 0-rina into the groove in the carburetor
body.

Install the top cover an tighte the three screws with
the clamo.

5-1 0

FUEL SYSTEM
Install the throttle stop screw with the washer and
spring by screwing it clockwise.
Secure the stay with the screw by aligning its hole
and boss.
Turn the throttle stop screw to align the butterfly
throttle valve with the edge of the outside by-pass
hole in the carburetor.

STAY

-h

SCREV

AIR CUT-OFF VALVE
Install new O-rings onto the air cut-off valve into the
joint pipe.
Install the joint pipe into the air cut-off valve with the
stepped side facing out (valve side).

Install the air cut-off valve and secure it with the screw.

i
J

Connect the vacuum, air vent and fuel tubes as shown.

TUBES

5-1 1

FUEL SYSTEM

CARBURETOR INSTALLATION
Install the throttle cable outer to the carburetor body
and connect the cable inner to the throttle drum.

T H R O T l L i- J Q U

Install the throttle linkage cover by aligning the tab
with the slit in the carburetor and secure it with the
two screws.

Install the carburetor into the insulator and connecting tube securely.
Align the lug on the carburetor with the groove in the
insulator and tighten the band screws.
Tighten the throttle cable lock nut.
Connect the drain tube to the carburetor.
Install the air vent tube into the heat protector.
Insert the fuel tube through the protector rubber.
Install the fuel tank (page 2-4).
Check the following:
- throttle operation (page 3-41
- engine idle speed (page 3-12)
Adjust the pilot screw if it was replaced (page 5-13).

5-1 2

PILOT SCREW ADJUSTMENT

IDLE DROP PROCEDURE
NOTE:

The pilot screw is factory pre-set and no adjustment
is necessary unless the pilot screw is replaced.
Use a tachometer with graduations of 50 rpm or
smaller that w i l l accurately indicate a 50 rpm
change.

1. Turn the pilot screw clockwise until it seats lightly,
then back it out to the specification given. This is
an initial setting prior to the final pilot screw
adjustment.

CAUTION:
Damage to the pilot screw seat will occur if the pilot
screw is tightened against the seat.

TOOL
Pilot screw wrench

07908-4220201

INITIAL OPENING: 2-1/4 turns out

2. Warm up the engine to operating temperature.
Stop and go riding for 10 minutes is sufficient.
3. Stop the engine and connect a tachometer according to the tachometer manufacturer’s instructions.
4. Start the engine and adjust the idle speed with the
throttle stop screw.
IDLE SPEED: 1.40

SCREW

THROTTLE STOP SCREW

100 rpm

5. Turn the pilot screw in or out slowly to obtain the
highest engine speed.
6. Lightly open the throttle 2 - 3 times, then adjust
the idle speed with the throttle stop screw.
7. Turn the pilot screw in gradually until the engine
speed drops by 50 rpm.
8. Turn the pilot screw out to the final opening.

FINAL OPENING: 1 turn out

9. Readjust the idle speed with the throttle stop screw.

5-13

HIGH ALTITUDE ADJUSTMENT
Below

Between
3,000 - 8,000 ft

Main jet
Pilot screw
oDeninq

1 turns in from

The carburetor must be adjusted for high altitude riding (between 3,000 - 8,000 ft/l,OOO - 2,500 m).

STANDARD SETTING: Below 5,000 ft 11,500 ml
HIGH ALTITUDE SETTING: Between 3,000 - 8,000 ft
(1.000 2,500 ml

The high altitude carburetor adjustment is performed
as follows:
Remove the carburetor (page 5-3) and the float chamber cap.
Replace the standard main jet with the high altitude

HIGH ALTITUDE MAIN JET #142
Check that the O-ring on the chamber cap is in good
condition and replace it with a new one if necessary.
Install the chamber cap and the carburetor.
Turn-in the pilot screw the specified number of turns
from the initial setting.

TOOL
Pilot screw wrench

07908-4220201

HIGH ALTITUDE PILOT SCREW OPENING:
1 turn in from initial opening
Start the engine and adjust the idle speed at high altitude to ensure proper high altitude operation.

If the engine must be running t o d o 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. Run the engine
in an open area or with an exhaust evacuation system
in an enclosed area.
CAUTION:
Sustained operation below 5,000 ft (1,500 ml with the
high altitude settings may cause engine overheating
and engine damage. Install the standard main jet
and screw out the pilot screw the specified number
of turns, when riding below 5,000 ft 11,500 ml.

STANDARD MAIN JET # 148
Pilot screw change for low altitude: 1 t u r n out

5-14

CHAbiatii wr

FUEL SYSTEM

AIR CLEANER HOUSING
REMOVAL/INSTALLATION
Remove the seat/rear fender assembly (page 2-2).
Disconnect the crankcase breather tube and remove
the crankcase breather storage tank f r o m the air
cleaner connecting tube.
Remove the mounting bolt.
Loosen the connecting tube band and intake duct
band screws.
Remove the air cleaner housing from the carburetor
and inlet duct.
Installation is in the reverse order of removal.
NOTE:
Apply oil t o the mating surface of the intake duct
and housing.
* When installing the crankcase breather storage
tank, align its tab with the connecting tube slit.
*

SCREW

AIR CLEANER HOUSING
SCREW

BREATHER TUBE

CRANKCASE BREATHER
STORAGE TANK

5-1 5

ENGINE REMOVAL/INSTALLATION

74 N.m 17.5 kgfm, 54 IbfW

26 N.m (i.7 kgfm. 20 Ibf+tl

6-0

6. ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION

6-1

ENGINE REMOVAL

6-2

ENGINE INSTALLATION

6-4

SERVICE INFORMATION
GENERAL
*
*
*

Afloor jack or other adjustable support is required to support and maneuver the engine.
When removing and installing the engine, tape the frame around the engine beforehand for frame protection.
The following components require engine removal for service:
-transmission (including shift fork, drum and shift spindle) (section 111
- crankshaft/balancer (section 11)
Other components can be serviced with the engine installed in the frame.

SPECIFICATIONS
ITEM
.

SPECIFICATIONS

Engine oil capacity

After draining

1.8 liters (1.9 US qt, 1.6 Imp qt)

After draining/filter change

1.85 liters (1.95

After disassembly

2.2 liters (2.3 US at, 1.9 IrnD at)

US qt.

1.63 Imp qt)

TORQUE VALUES

Upper engine hanger nut
Front engine hanger nut
bolt
Lower engine hanger nut
Swingarm pivot nut
Gearshift pedal pinch bolt

74 N.m (7.5 kgfvn, 54 Ibf+t)
54 N m (5.5 kgfm, 40 Ibf.ft)
26 N m (2.7 kgfm, 20 IbfW
74 N m (7.5 kgfm, 54 IbfW
108 N m (11.0 kgfm, 80 IbfW
20 N m (2.0 kgfm, 14 Ibf4t)

6- 1

ENGINE REMOVAL/INSTALLATION

ENGINE REMOVAL
Drain the engine oil (page 3-91
Remove the following:
-fuel tank and heat protector (page 2-41
-carburetor assembly (page 5-3)
-exhaust system (page 2-6).
Loosen the rear axle for maximum drive chain slack
(page 3-13).
Remove the two bolts, sprocket cover, sprocket protector and clamp.
Remove the fixing plate bolts.
Remove the fixing plate by aligning the splines of the
plate and countershaft.
Pull the drive sprocket off the countershaft and
remove the sprocket from the chain.
Remove the pinch bolt and the gearshift pedal.
T

Release the neutral switch wire from the clamp and
disconnect the connector.

Disconnect the alternator connectors and release the
wire from the wire band and clamp.

Disconnect the spark plug cap.
Disconnect the cylinder head breather tube.

ENGINE REMOVAL/INSTALLATION
Disconnect the starter motor cable by removing the
terminal nut.
Disconnect the crankcase breather tube from the
engine.
Release the brake lock cable from the cable guide by
removing the mounting bolt.

Loosen the clutch cable lock nut. Remove the holder
bolts and cable holder and disconnect the clutch
cable from the clutch arm.
Disconnect the oil pipes from the engine by removing the bolts. Remove the dowel pins and O-rings.
Remove the brake pedal (page 14-20).
Remove the two bolts and engine guard.

Support the engine w i t h a floor jack or other
adjustable support.

NOTE:
The jack height must be continually adjusted to
relieve stress for ease of bolt removal.
Remove the upper engine hanger nut, spacers and
bolt.

( 1

LNUT AND 501

Remove the front engine hanger nut, cable guide,
spacer and bolt.
Remove the front engine hanger bolts, pipe clamp
and hanger plates.
Remove the lower engine hanger nut, spacers and
bolt.

6-3

ENGINE REMOVAL/INSTALLATION
Remove the swingarm pivot nut and bolt.
Remove the engine out of the frame to the right.

-SWINGARM PIVOT BOLT'
ENGINE INSTALLATION
Install the engine into the frame from the right side in
the reverse order of removal.
NOTE:
*

.
*

Before installing, make sure that the pivot collars
are installed into the swingarm pivots.
Note the installation direction of the mounting
bolts and the position of the spacers.
The front hanger plates are identified by marks
them (R: right/l: left).
Install the swingarm pivot bolt and nut.
Install the lower engine hanger bolt, spacers (Left:
shorVRight: long) and nut.
Install the front engine hanger plate with the bolts
and clamp.
Install the front engine hanger bolt, spacer (right
side of the engine), guide and nut.
Install the upper engine hanger bolt, spacers (Left
shomight: long) and nut.

Tighten the nuts to the specified torque.

74 N m (7.5 kgfm, 54 1bf.h)

m (5.5 k g f m 40 IbfW

108 N m (11.0 k g f m 80 IbfW

74 N m (7.5 kgfm, 54 Ibf4t)

6-4

ENGINE REMOVAL/INSTALLATION
Install the removed parts from engine removal procedure (page 6-2 to 6-3) in the reverse order or removal.

TORQUE: Gearshift pedal pinch bolt:
20 N m 12.0 kgfm, 14 Ibf4t)

NOTE:
*

Route the wires, cables and tubes properly (page
1-18).
When installing the gearshift pedal, align the
punch marks on the pedal and spindle.
When installing the drive sprocket, install with the
"OUT SIDE" mark facing out. Set the fixing plate
into the countershaft groove and move it to align
the bolt holes in the plate and sprocket then tighten
the bolts.

Install the following:
- oilpipes (page 4-7)
- brake pedal (page 14-20)
-exhaust system (page 2-61
-carburetor assembly (page 5-12)
-fuel tank and heat protector (page 2-4)
Perform the following adjustments:

- drive chain (page 3-13)

-clutch cable (page 3-17)
- throttle cable (page 3-4)

Fill with engine oil (page 3-9).

6-5

CYLINDER HEAD/VALVE

17 IbfW
20

44 N m

, 2.9 Ibf.ft)

7-0

7. CYLINDER HEAD/VALVE
~

SERVICE INFORMATION

7-1

VALVE GUIDE REPLACEMENT

7-12

TROUBLESHOOTING

7-3

VALVE SEAT INSPECTION/REFACING

7-13

CYLINDER COMPRESSION

7-4

CYLINDER HEAD ASSEMBLY/
INSTALLATION

7-16

CAMSHAFT/CYLINDER HEAD COVER
INSTALLATION

7-18

CYLINDER HEAD COVER/CAMSHAFT
REMOVAL
CYLINDER HEAD REMOVAL/
DISASSEMBLY

7-4
7-9

SERVICE INFORMATION
GENERAL

This section covers service of the camshaft. rocker arms, cylinder head and valves. These parts can be serviced with
the engine installed in the frame.
* When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations.
Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before
inspection.
* Camshaft and lubricating oil is fed through oil passages in the cylinder head. Clean the oil passages before assembling cylinder head.
Pour clean engine oil into the oil pocket in the cylinder head during assembly to lubricate the camshaft.
* Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head. Do not
strike the head cover and cylinder head too hard during removal.

SPECIFICATIONS
Unit: mm (in)

ITEM

STANDARD
686- 883 kPa
(7.0 - 9.0 kgf/cm', 100 - 128 psi)

Cylinder compression at rpm

Valve clearance

Cam lobe height

Camshaft

0.10
.
. . in
,-.nna
.,

0.12 (0.005)

30.673-30.773 (1.2076- 1.2115)

30.57 (1.204)

30.468-30.568 (1.1995- 1.2035)

30.37 (1.196)

Runout

____

Rocker arm

IN
.. .

Shaft O.D.

SERVICE LIMIT

IN/EX

0.03 (0.001)

11,500- 11.518 (0.4528-0.4535)

11.53 (0.454)

11.466- 11.484 (0.4514-0.4521)

11.41 (0.449)

Sub-rocker arm

Valve,
valve guide

Valve stem O.D.

Valve spring

7- '1

CYLINDER HEADNALVE

TORQUE VALUES
Upper engine hanger nut
Cylinder head nut
Cam sprocket bolt
Cam chain tensioner plug
Rocker arm shaft
Sub-rocker arm shaft
Cylinder head cover bolt (8mm)
Spark plug

54 N.m (5.5 kgfm, 40 IbfW
44 N m (4.5 kgfm, 33 Ibf.ft) Apply oil to the threads and seating surface
20 N m (2.0 kgf.m, 14 IbfW Apply locking agent to the threads
4 N m (0.4 kgfm, 2.9 IbfW
27 N.m (2.8 kgfm, 20 IbfW Apply locking agent to the threads
27 N m (2.8 kgfm, 20 IbfW Apply locking agent to the threads
26 N m (2.7 kgfm, 20 IbfW
18 N.m (1.8 kgfm, 13 IbfW

TOOLS
Valve spring compressor
Valve guide driver, 5.5 mm
Valve guide reamer, 5.5 mm
Valve seat cutter, 35 mm (IN 45")
Valve seat cutter, 29 mm (EX 45")
Flat cutter, 35 mm (IN 32")
Flat cutter, 30 mm (EX 32")
Interior cutter, 30 mm (INIEX 60")
Compression gauge attachment
Cutter holder, 5.5 mm

07757 -0010000
07742- 0010100
07984 - 2000001 or 07984 - 200000D (U.S.A. only)
or equivalent commercially available in U.S.A.
077ao-ooi0400
07780-0010300
07780-0012300
07780-0012200
07780 - 0014000
07908 - KK60000
07781-0010101

TROUBLESHOOTING

Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing
top-end noise with a sounding rod or stethoscope.
If the performance is poor at low speeds, check for a white smoke in the crankcase breather tube. If the tube is smoky.
check for sized piston ring (section 8).

Compression too low, hard starting or poor performance
at low speed
Valves
- Incorrect valve adjustment
- Burned or bent valves
- Incorrect valve timing
-Broken valve spring
-Uneven valve seating
-Valve stuck open
Cylinder head
- Leaking or damaged cylinder head gasket
-Warped or cracked cylinder head
- Loose spark plug
Cylinderlpiston (section 8)

Compression too high
Excessive carbon build-up on piston head or combustion chamber
* Worn or damaged decornpressor system
Excessive smoke
Worn valve stem or valve guide
* Damaged stem seal
* Cylinderlpiston problem (section 8)

7-2

Excessive noise
Incorrect valve clearance
* Sticking valve or broken valve spring
* Excessive worn valve seat
Worn or damaged camshaft
* Worn or damaged rocker arm and/or shaft
* Worn rocker arm follower or valve stem end
Worn cam chain
* Worn or damaged cam chain tensioner
Worn cam sprocket teeth
Cylinderlpiston problem (section 8)

Rough idle
* ' Low cylinder compression

CYLINDER HEA WVALVE

CYLINDER COMPRESSION
Warm up the engine to normal operating temperature.
Stop the engine, disconnect the spark plug cap and
remove the spark plug.
Install the compression gauge with the gauge attachment into the spark plug hole.

TOOL
Compression gauge attachment 07908 KK60000 or
equivalent commercially available
in U S A .

Shift the transmission in neutral and open the choke
lever (OFF).
Open the throttle all the way and crank the engine
with the starter motor until the gauge reading stops
rising. The maximum reading is usually reached
within 4 - 7 seconds.
COMPRESSION PRESSURE
686 - 883 kPa (7.0 9.0 kgf/cm*, 100 128 psi)

NOTE:
Check that there is no leakage at the gauge connection,
Low compression can be caused by:
-blown cylinder head gasket
- improper valve adjustment
-valve leakage
- worn piston ring or cylinder
High compression can be caused by:

- carbon deposits in combustion chamber or on piston head

CYLINDER HEAD COVER/CAMSHAFT
REMOVAL
Remove the fuel tank under heat protector (page 2-4).
L

Remove the spark plug cap.
Disconnect the crankcase breather tube from the
head cover.

CYLINDER HEAD/VALVE
NUT

Remove the upper engine hanger nut, bolt and spacers.

Remove the timing hole cap, crankshaft hole cap and
valve adjusting hole caps (page 3-71,
The crankshaff
should be turned
only counterclockwise. This
must be done to
prevent the onewaydecornpressorsystern functioning

Rotate the crankshaft counterclockwise and align the
"T" mark on the flywheel with the index notch in the
left crankcase cover.
Make sure that the piston is a t TDC (Top Dead
Center) on the compression stroke.
The rocker arms should be loose.
If the rocker arms are tight, rotate the crankshaft
counterclockwise one full turn and realign the "T"
mark with the index notch.
..1

F~=.>-:;"T"

7,-7

,MARK:

Loosen the twelve 6 mm bolts and 8 mm bolt in a
crisscross pattern in 2 or 3 steps.
Remove the bolts and the cylinder head cover.

Remove the gasket and dowel pins.

7-4

CYLINDER HEADlVALVE

-_
~

Loosen the cam chain tensioner lifter plug.
Remove the t w o bolts, cam chain tensioner lifter and
gasket .

Becarefulnotto
let the sprocket
bolts fallinto the
crankcase,

TEN
___

Remove the cam sprocket bolt.
Rotate the crankshaft counterclockwise one turn and
remove the other cam sprocket bolt.

Remove the cam sprocket from the camshaft flange.
Attach a piece of wire to the cam chain t o prevent it
from falling into the crankcase.
Lift the camshaft and remove it.
Remove the cam sprocket from the cam chain.

i
I
i

,
I

Remove the plunger, spring and bearing setting pins,
being careful not to drop them into the crankcase.

7-5

CYLINDER HEAD/VALVE

CYLINDER HEAD COVER DISASSEMBLY
Hold the cylinder head cover securely and loosen the
sub-rocker arm shafts, being careful not to damage
the mating surface of the cylinder head cover.
Remove the shafts, sealing washers, sub-rocker arms
and wave washers.

Hold the cylinder head cover securely and loosen the
rocker arm shafts, being careful not to damage the
mating surface of the cylinder head cover.
Remove the shafts, sealing washers and rocker arms.

i
,

P
1

INSPECTION
CAMSHAFT
Check the cam and journal surfaces of the camshaft
for scoring, scratches or evidence of insufficient
lubrication.
Check the oil holes in the camshaft for clogging.
Turn the outer race of each bearing with your finger.
The bearings should turn smoothly and quietly.
Replace the bearing if the outer race does not turn
smoothly and quietly.

Measure the camshaft runout using a dial indicator.

SERVICE LIMIT: 0.03 mm (0.001 in1

7-6

CYLINDER HEAD/VALVE
Measure each cam lobe height,
SERVICE LIMIT I N 30.57 mm (1.204 in)
E X 30.37 mm (1.196 in)

ROCKER ARMlSHAFT
Check the rocker arms and shafts for wear or damage.
If the rocker arm slipper surface is worn or damaged,
check the camshaft cam lobe and oil passages.
Measure each rocker arm shaft O.D.
SERVICE LIMITS
Rocker arm shaft: 11.41 mm (0.449 in)
Sub-rocker arm shaft 6.92 mm (0.272 in)
Measure each rocker arm I.D.
SERVICE LIMITS:
Rocker arm: 11.53 mm (0.454 in)
Sub-rocker arm: 7.05 mm (0.278 in)
Subtract each rocker arm shaft O.D. from the corresponding rocker arm I.D. to obtain the rocker arm-toshaft clearance.
SERVICE LIMIT 0.10 mm (0.004 in)

DECOMPRESSOR DISASSEMBLY
Set the camshaft assembly onto the hydraulic press
by supporting the reverse decompressor cam flange.

Hold: REVERSE
DECOMPRESSOR
CAM

CAUTION

Do not support the assembly by the sprocket
flange. If will break or crack its flange.
When setting the camshafl assembly, take care
not to contact the support blocks against the cam
lobe or decompressor cam to avoid damaging
them when pressing.

Press the camshaft out of the sprocket flange.

DECOMPRESSOR CAM

7-7

CYLINDER HEAD/VALVE
Remove the following:
- thrust washer
- one-way clutch (clutch outer, rollers and springs)
- reverse decompressor cam
-stopper pin
- decompressor cam
- spring

RSE DECOMPRESSOF

ONE WAY CLUTCH

INSPECTION
Check the one-way clutch outer, rollers and springs
for wear or damage.
Check both cams for wear or damage.
Check the cam's sliding surface on the camshaft for
scoring or wear.

WASHER
CAM SPROCKET FLANGE

DECOMPRESSOR ASSEMBLY
DECOMPRESSOR CAM

CLUTCH OUTER

Lubricate the cams, one-way clutch and washer,
Install the spring into the camshaft hole, then install
the decompressor cam while holding the spring.
Assemble the reverse decompressor cam and clutch
outer with the stopper pin and install the assembly
onto the camshaft.
SPRING

Install the springs and rollers into the clutch outer
grooves as shown.

Install the thrust washer onto the clutch outer.

WASHER

Do notpress on Using a suitable tool (collar with 19 mm or more I.D.1,
the flange por- press the sprocket flange onto the camshaft by aligntion. It will break ing the wide groove with the wide tooth.
or crack.

SPROCKET FLANGE

7-8

DECOMPRESSOR
CAM

- - .----

CYLINDER HEAD REMOVAL/
DISASSEMBLY

r\,, ,..,-rn

CYLINDER HEAD/VALVE
I

I Ir A

Remove the following:
- exhaust system (page 2-6)
- carburetor (page 5-3)
- cylinder head cover and camshaft (page 7-3)
- spark plug
~

Remove the four cap nuts and washers, being careful
not to drop them into the crankcase.
Do not strike the Remove the cylinder head.
cylinder head too
hard.

DOWEL PINS

Remove the gasket and dowel pins.

v
-.

GASKI

Remove the three bolts and the carburetor insulator
from the cylinder head.
Remove the O-ring from the carburetor insulator.

Remove the valve spring cotters uslng the valve
spring compressor.

TOOL
Valve spring compressor

%CKRs

. \

07757-0010000

CAUTION
~

To prevent loss of tension, do not compress the
valve springs more than necessary to remove the
cotters.

\/ALVE SPRING COMPRESSOR

7-9

CYLINDER HEADNALVE
Remove the following:
- spring retainer
- inner and outer valve springs
-valve
- stem seal
- valve spring seat

NOTE:
Mark all parts during disassembly so they can be
Dlaced back in their original locations.

Remove the carbon deposits from the combustion
chamber and clean off the gasket surface, being careful not to damage the gasket and valve seat surfaces.

INSPECTION
CYLINDER HEAD
Check the spark plug hole and valve areas for cracks.
Check the cylinder head for warpage with a straight
edge and feeler gauge.

SERVICE LIMIT 0.10 mm (0.004 in)

VALVE SPRING
Measure the valve spring free length.

SERVICE LIMITS Inner: 36.3 mm 11.43 in)
Outer: 43.1 mm (1.70 in)

7-1 0

CTAM
-5

CYLINDER HEADlVALVE
VALVE STEMlVALVE GUIDE
Check that the valve moves smoothly in the guide.
Check the valve for bending, burning or abnormal
wear.
Measure each valve stem O.D. and record it.
SERVICE LIMITS: IN: 5.46 mm (0.215 in)
E X 5.44 mm 10.214 in)

Ream the valve guide to remove any carbon build-up
before measuring the guide.
Insert the reamer from the combustion chamber side
of the head and always rotate the reamer clockwise.
TOOL
Valve guide reamer, 5.5 mm

07984 2000001 or
07984 - 200000D
(U.S.A. only)

Measure each valve guide I.D. and record it.
SERVICE LIMIT 5.52 mrn (0.217 in)
Subtract each valve stem O.D. from the corresponding guide I.D. to obtain the stem-to-guide clearance.
SERVICE LIMITS IN: 0.12 mm (0.005 in)
E X 0.14 mrn (0.006 in)
If the stem-to-guide clearance exceeds the service
limit, determine if a new guide with standard dimensions would bring the clearance within tolerance.
If so, replace any guides as necessary and ream to fit.
If the stem-to-guide clearance exceeds the service
limit with a new guide, also replace the valve.

NOTE:
Inspect and reface the valve seats whenever the
valve guides are replaced (page 7-13).

7-1 1

CYLINDER HEAD/VALVE

VALVE GUIDE REPLACEMENT
Chill new valve guides in the freezer section of a
refrigerator for about an hour.
Heat the cylinder head to 130 - 140°C (275 - 290°F)
with a hot plate or oven. Do not heat the cylinder
head beyond 150" (300°F). Use temperature indicator
sticks, available from welding supply stores, to be
sure the cylinder head is heated to the proper temperature.

Wear heavy gloves to avoid burns when handling
the heated cy1;nder head.
ALV

CAUTION:

RIVER

Using a torch to heat the cylinder head may cause
warDage.
Support the cylinder head and drive the valve guides
out of the cylinder head from the combustion chamber side.

TOOL
Valve guide driver, 5.5 mm

07742- 0010100

Install new O-rings onto the new valve guides.
Drive the new valve guides in the cylinder head from
the camshaft side while the cylinder head is still heated.

TOOL
Valve guide driver, 5.5 mm

07742-0010100

Let the cylinder head cool to room temperature.

Ream the new valve guides.
Insert the reamer from the combustion chamber side
of the head and always rotate the reamer clockwise.

TOOL
Valve guide reamer, 5.5 mm

VALVE GUIDE REAMER'

07984 - 2000001 or
07984 - 200000D
(U.S.A. only)

NOTE:

Take care not to tilt or lean the reamer in the guide
while reaming.
Use cutting oil on the reamer during this operation.

Clean the cylinder head thoroughly to remove any
metal particles after reaming and reface the valve
seat (page 7-14).

7-12

&O-RING'

*a-*

CYLINDER HEADNALVE

VALVE SEAT INSPECTION/REFACING
INSPECTION
.~

Clean all intake and exhaust valves thoroughly t o
remove carbon deposits.
Apply a light coating of Prussian Blue t o each valve
seat.
Tap the valve against the valve seat several times
without rotating the valve, t o check for proper valve
seat contact.

Remove the valve and inspect the valve seat face.
The valve seat contact should be within the specified
width and even all around the circumference.

STANDARD: 1.0 1.1 mm (0.039 -0.043 in)
SERVICE LIMIT 2.0 mm (0.08 in)
If the valve seat width is not within specification,
reface the valve seat (page 7-14].

Inspect the valve seat face for:
Uneven seat width:
- Replace the valve and reface the valve seat.
Damaged face:
- Replace the valve and reface the valve seat.

DAMAGED FACE

UNEVEN SEAT
WIDTH

Contact area (too high o r t o o low)
- Reface the valve seat.

NOTE:
The valve cannot be ground. If the valve face is
b u r n e d o r b a d l y w o r n o r if it contacts t h e seat
unevenly, redace the valve

7-13

CYLINDER HEAD/VALVE
REFACING
NOTE:
*

Follow the refacing manufacturer's operating
instructions.
Be careful not to grind the seat more than necessary.

If the contact area is too high on the valve, the seat
must be lowered using a 32" flat cutter.
If the contact area is too low on the valve, the seat
must be raised using a 60" interior cutter.

CONTACT TOO HIGH

OLD SEAT
WIDTH

*
CONTACT TOO LOW

OLD SEAT
WIDTH

*
Using a 45" seat cutter, remove any roughness or
irregularities from the seat.

TOOLS
Valve seat cutter, 35 mm (IN1
Valve seat cutter, 29 mm (EX)
Cutter holder, 5.5 mm

ROUGHNESS

07780 0010400
07780 - 0010300
07781-0010101

or equivalent commercially available in U.S.A.

Using a 32" flat cutter, remove 114 of the existing
valve seat material.

TOOLS:
Flat cutter, 35 mm (IN)
Flat cutter, 30 mm (EX)
Cutter holder, 5.5 mm

\
07780-0012300
07780-0012200
07781-0010101

OLD SEAT WIDTH

or equivalent commercially available in U.S.A.

7-14

CYLINDER HEAD/VALVE

Using a 60" interior cutter, remove 114 of the existing
valve seat material.

TOOLS:
Interior cutter, 30 mm
Cutter holder, 5.5 mm

07780-0014000
07781 -0010101

or equivalent commercially available in U S A .

OLD SEAT WIDTH

Using a 45" seat cutter, cut the seat to the proper
width.
VALVE SEAT WIDTH: 1.0

1.0 - 1.1 mm
(0.039 - 0.043 in)

- 1.1 mm (0.039 - 0.043 in)

Make sure that a l l pitting and irregularities are
removed.

After cutting the seat, apply lapping compound to the
valve face, and lap the valve using light pressure.
CAUTION
Excessive lapping pressure may deform or damage the seat.
Change the angle of lapping tool frequently t o
prevent uneven seat wear.
Do n o t allow lapping compound t o enter the
guides.
After lapping, wash any residual compound off the
cylinder head and valve and recheck the seat contact.

7-15

CYLINDER HEAD/VALVE

CYLINDER HEAD ASSEMBLY/
INSTALLATION
-

@-SPRING

COTTER

Blow through the oil passage in the cylinder head
with compressed air.
Install the valve spring seats.
Install new stem seals.
Lubricate the valve stem sliding surface with molybdenum oil solution.
lnsett the valve into the guide while turning it slowly
to avoid damage to the stem seal.

i
r

>rKll\b b t A l

. ..-.
Install the inner and outer valve springs with the
tightly wound coils facing the combustion chamber.
Install the spring retainer.

TIGH"

WOL
COIL
Combustion chamber

7-16

511

CYLINDER HEADlVALVE
Grease the cotters to ease
insfallation.

Install the valve spring cotters using the valve spring
compressor.

TOOL
Valve spring compressor

07757-0010000

CAUTION:
To prevent loss of tension, do n o t compress the
valve springs more than necessary t o install the cotters.

Support the cylinder head so that the valve heads
will not contact anything that cause damage.
Tap the valve stems gently with two plastic hammers
as shown to seat the cotters firmly.

Coat a new O-ring with oil and install it into the
groove in the carburetor insulator.
Install the carburetor insulator onto the cylinder head
and tighten the three bolts securely.

Clean the cylinder mating surface.
Make sure that the cam chain guide bosses are positioned in the cylinder grooves.
Install the dowel pins and a new gasket.

7-17

CYLINDER HEADWALVE
Route the cam cnain tnrough the cylhoer head and
instal. the cylinoer head onto the cylinder.
Apply oil to the cylinder head nut threads and seating
surfaces.
Install the cylinder head nuts with the washers and
tighten them in a crisscross pattern in 2 or 3 steps.
Note the position of the large washer.

CYLlhDER HEAD
\

CAP

NuTs-a

TOROUE: 44 Nm (4.5 kgfm, 33 IbfW
Install and tighten the spark plug.

TOROUE: 18 N.rn (1.8 kgfm, 13 Ibf4t)
Install the following:
-camshaft and cylinder head cover
- carburetor (page 5-12)
- exhaust system (page 2-6)

CAMSHAFTKYLINDER HEAD COVER
INSTALLATION
Lubricate the camshah bearing with oil.
Install the camshafl bearings with the sealed side of
the sprocket side bearing facing out.
Apply molybdenum oil solution to the cam lobes and
journal.

Install the bearing setting pins, spring and plunger,
being careful not to drop them into the crankcase.

!ARK:

7-18

CYLINDER HEADNALVE
Install the cam sprocket onto the cam chain so that
the index lines on the sprocket with the upper surface
of the cylinder head.

F
I

Install the camshaft onto the cylinder head through
cam sprocket.
Install the cam sprocket onto the camshaft flange
securely.
Make sure that the index lines on the cam sprocket
with the upper surface of the cylinder head when the
"T" mark on the flywheel is aligned with the index
notch in the left crankcase cover.

Apply locking agent to the cam sprocket bolt threads.
A l i g n the b o l t holes i n the cam sprocket and
camshaft flange and install the cam sprocket bolt.
The crankshaft
should be turned
only counterclockwise. This
must be done to
prevent the oneway decompressor system functioning.

Turn the crankshaft counterclockwise one turn and
install the remaining cam sprocket bolt.
Tighten the INDEX LINE side bolt first.

TORQUE: 20 Nm 12.0 kgfm, 14 IbfW
Turn the crankshaft counterclockwise one turn and
tighten the other cam sprocket bolt t o the same
toque.

\Align
c . . . (when
~
aligning

rioicii aiiu

IIWTK,

CAM CHAIN TENSIONER LIFTER
INSTALLATION
Remove the cam chain tensioner lifter plug and 0ring.
Check the lifter operation:
- The tensloner shaft should not go into the body
when it is pushed.
- When it is turned clockwlse with a screwdriver, the
tensioner shaft should be pulled into the body.
The shaft springs out of the body as soon as the
screwdriver is released.

k
1

7-19

CYLINDER HEAD/VALVE
Make a tensioner shaft stopper tool of a thin piece of
steel (0.8 m m thick) using the diagram.

Turn the tensioner shaft clockwise with the stopper
tool to retract the tensioner, then insert the stopper
fully to hold the tensioner in the fully retracted position.

Install a new gasket onto the cam chain tensioner
lifter.
Install the tensioner lifter onto the cylinder and tighten
the two mounting bolt securely.
Remove the stopper tool from the tensioner lifter.
Coat a new O-ring with oil and install it into the tensioner lifter groove.
Install and tighten the tensioner lifter plug.

TORQUE: 4 Nm (0.4 kgfm, 2.9 Ibf4t)

Make sure that the index lines on the cam sprocket
with the upper surface of the cylinder head when the
"T" mark on the flywheel is aligned with the index
notch in the left crankcase cover.

7-20

CYLINDER HEAD/VALVE
CYLINDER HEAD COVER ASSEMBLY

SUB-ROCKER ARM "A"/
COPPER WWAVE
ASHT
WASHER
EXHAUST SUB-ROCKER ARM SHAFTS

R. IN. ROCKER ARM
L, EX, ROCKER ARM

R,EX.
ROCKER ARM
MRAR , R / n
I

COPPER WASHERS
ROCKER ARM "IN"/
WAVE WASHER

SUB-ROCKER ARM "IN"/

..-Y.,LI.

\AlA\lE 1 A I A C U E R

COPPER
WASHERS

IN AKE SUB-ROCKER
ARM SHAFTS

.-.

Clean the threads of each rocker arm shaftthoroughly.

- -

Apply engine oil to the rocker arm and shaft sliding
surfaces.

7-21

CYLINDER HEAD/VALVE
Install the rocker arms in the cylinder head cover as
shown.

Install the rocker arm shafts with new sealing washers.
Apply locking agent to the 2 - 3 threads of the rocker
arm shafts and tighten the shafts.

5i7 y-"
WASHER

TORQUE: 27 N m 12.8 kgfm. 20 Ibf4t)

Install the sub-rocker arms and wave washers in the
cylinder head cover as shown, noting each identification mark as shown.

-\/"
"

Install the sub-rocker arm shafts with new sealing
.
washers.
Apply locking agent to the 2 - 3 threads of the subrocker arm shafts and tighten the shafts.

TORQUE: 27 Nm (2.8 kgfm, 20 IbfW

7-22

5 - 7,

IN "

CYLINDER HEAD/VALVE
CYLINDER HEAD COVER INSTALLATION
Apply molybdenum oil solution to the slipper surfaces
of the rocker arms and sub-rocker arms.

Clean the mating surfaces of the cylinder head and
head cover.
Pour engine oil into the oil pocket in the cylinder head.

The crankshaff
shouldbe turned
only
counterclockwise.
This must be
done to prevent
the one-way
decompressor
system
functioning.

Rotate the crankshaft counterclockwise and align the
"T" mark on the flywheel with the index notch in the
left crankcase cover so that the cam lobes are facing
down.

\
._
Install the dowel pins and a new gasket

CYLINDER HEADlVALVE
Install the valve adjusting hole caps.
Install the cylinder head cover onto the cylinder head.
Install the 8 mm and 6 rnrn cylinder head cover bolts
and tighten them in a crisscross pattern i n 2 or 3
steps.
TORQUE: 8 mm bolt: 23 Nm (2.3k g f m 17 IbfW

Install the spacers, upper engine hanger bolt and nut,
and tighten the nut.
TORQUE: 54 Nm (5.5 k g f m 40 IbfW

Connect the crankcase breather tube to the cylinder
head cover.
Install the spark plug cap.
Check the valve clearances and adjust if necessary
(page 3-7).

7-24

MEMO

CYLINDER/PISTON

44 N m (4.5 kgfm, 33 Ibf.ft)

8-0

8. CYLINDER/PISTON
SERVICE INFORMATION

8-1

CYLINDER/PISTON REMOVAL

8-3

TROUBLESHOOTING

8-2

PlSTONlCYLlNDER INSTALLATION

a-7

SERVICE INFORMATION
GENERAL

The cylinder and piston can be serviced with the engine installed in the frame.
Take care not to damage the cylinder wall and piston.
Do not damage mating surfaces by using a screwdriver when removing the cylinder.
Camshaft lubricating oil is fed through the oil passage in the cylinder. Clean the oil passage before installing the
cylinder.

SPECIFICATIONS
Unit: mm (in)

ITEM
Cylinder

I.D.

SERVICE LIMIT

STANDARD

85.000 - 85.010 (3.3465- 3.3468)

85.10(3.350)

Piston,
piston pin, piston ring

Cylinder-to-piston clearance
Connecting rod small end I.D.
Connecting rod-to-piston pin clearance

0.015 - 0.050 (0.0006- 0.0020)
20.020 - 20.041 (0.7882- 0.7890)
0.020- 0.047lO.0008- 0.0019)

0.10(0.004)
20.067 (0.7900)
0.103(0.0041)

TORQUE VALUES
Cylinder bolt (10 mm)
Cylinder stud bolt

44 N m (4.5kgfm, 33 IbfW
20 N m (2.0 k g f m 14 IbfW

Apply oil to the threads and seating surface

8- 1

CYLINDER/PISTON

TROUBLESHOOTING
Compression too low, hard starting or poor performance
at low speed
* Leaking cylinder head gasket
* Worn. stuck or broken piston ring
Worn or damaged cylinder and piston

Compression too high, overheating or knocking
Excessive carbon built-up on piston head or combustion
chamber

Excessive smoke
Worn cylinder, piston or piston rings
* Improper installation of piston rings
* Scored or scratched piston or cylinder wall

Abnormal noise
Worn piston pin or piston pin hole
* Worn connecting rod small end
* Worn cylinder, piston or piston rings

8-2

CYLINDER/PISTON

CYLINDER/PISTON REMOVAL
CYLINDER REMOVAL
Remove the cylinder head (section 7).
Remove the two 6 mm cylinder bolts.

Do not strike the
cylinder too hard
and do not damage the mating
surface with a
screwdriver.

Remove the cam chain guide (front).
Remove the four 10 mm cylinder bolts and washers.
Remove the cylinder.

Remove the gasket and dowel pins.

PISTON REMOVAL
Place a clean shop towel over the crankcase to prevent the clip from falling into the crankcase.
Remove the piston pin clips with the pliers.
Push the piston pin out of the piston and connecting
rod, and remove the piston.

CVLINDER/PISTON
PISTON

Spread each piston ring and remove it by lifting up at
a point opposite the gap.

),*

”

CAUTION:
Do not damage the piston ring by spreading the
ends too far.

Clean carbon deposits from the piston.
CAUTION
Clean carbon deposits from the ring grooves with a
ring that wi// be discarded. Never use a wire brush; if
wi// scratch the groove.

INSPECTION
CYLINDER
Inspect the cylinder bore for scratch or wear.
Measure the cylinder I.D. at three levels in an X and Y
axis.
Take the maximum reading to determine the cylinder
wear.

SERVICE LIMIT 85.10 mm 13.350 in)
Calculate the cylinder-to-piston clearance.
Refer to page 8-5 for measurement of the piston O.D.

SERVICE LIMIT 0.10 mm (0.004 in1
Calculate the cylinder taper and out-of-round at three
levels in an X and Y axis. Take the maximum reading
to determine the taper and out-of round.

SERVICE LIMITS Taper: 0.05 mm (0.020 in1
Out-of-round:0.05 mm 10.020 in)

I
TOP

The cylinder must be rebored and an oversize piston
fitted if the service limits are exceeded.
The 0.25 mm (0.010 in) and 0.50 mm (0.020 in) oversize pistons are available.
The cylinder must be rebored so that the clearance
for an oversize piston is 0.015 - 0.050 mm (0.0006 0.0020 in).

8-4

’’-

BOTOM

CYLINDER/PISTON

Check the top of the cylinder for warpage with a
straight edge and feeler gauge across the studs and
bolt holes as shown.

SERVICE LIMIT 0.10 mm (0.004 in)

PlSTONlPlSTON RING
Inspect the piston rings for movement by rotating the
rings. The rings should be able t o move in their
grooves without catching.

Push the ring until the outer surface of the piston ring
is nearly flush with the piston and measure the ringto-ring groove clearance.

SERVICE LIMITS: Top: 0.14 mm (0.006 in)
Second: 0.12 mrn (0.005 in)

Insert each piston ring into the bottom of the cylinder
squarely using the piston.
Measure the ring end gap.

SERVICE LIMITS Top: 0.50 mm (0.020 in)
Second: 0.65 mm (0.026 in)
Oil (side rail): 0.9 mm (0.04 in1

Measure the piston pin O.D. 90" to the piston pin
hole and at point 15 mm (0.6 in) from bottom of the
piston skirt.

SERVICE LIMIT 84.880 mm (3.3417 in)
Compare this measurement against the maximum
cylinder I.D. measurement and calculate the pistonto-cylinder clearance (page 8-4).

8-5

CYLINDER/PISTON
- a

Measure piston pin hole I.D. in an X and Y axis. Take
the maximum reading to determine the I.D.

SERVICE LIMIT 20.060 mm (0.7898 in)

I _

Measure the piston pin O.D. at three points.

SERVICE LIMIT: 19.964 mm (0.7860 in)
Calculate the piston-to-piston pin clearance.

SERVICE LIMIT 0.096 mm (0.0038 in1

Measure the connecting rod small end I.D.

SERVICE LIMIT: 20.067 mm (0.7900 in)
Calculate the connecting rod-to-piston pin clearance.

SERVICE LIMIT: 0.103 mm (0.0041 in)

CYLINDER STUD BOLT REPLACEMENT
Remove the stud bolts from the cylinder
Install new stud bolts in their proper positions and
tighten them.
A 10 x 92 mm stud bolt
6: 10 x 60 mm stud bolt
C: 10 x 73 mm stud bolt

TORQUE 20 N.m 12.0 kgf.m, 14 IbfW
After installation, measure the stud height from the
cylinder surface.

SPECIFIED HEIGHT: A 81.5 k 0.5 mm (3.21 k 0.02 in)
B 49.5 k 0.5 mm (1.95 f 0.02 in1
C: 62.5 k 0.5 mm (2.46 0.02 in)

Adjust the stud height if necessary.

8-6

CYLINDER/PISTON

PISTON/CYLINDER INSTALLATION
PISTON RING INSTALLATION

D TOPRING

Carefully install the piston rings into the piston ring
grooves with the markings facing up.

SECOND RING

CAUTION:

OIL RING

Be careful not to damage the piston and rings during
installafion.
NOTE:

Do not confuse the top and second rings.
To install the oil ring, install the spacer first, then
install the side rails.

Stagger the piston ring end gaps 120" degrees apart
from each other.
Stagger the side rail end gaps as shown.
MARK
/

20 mm (08 in) OR MORE

OIL RING

20 mm (0.8 in) OR MORE

PISTON INSTALLATION
Place a clean shop towel over the crankcase to prevent the clip from falling into the crankcase.
Apply molybdenum oil solution to the piston pin
outer surface and connecting rod inner surface.
Install the piston with the "IN" mark toward the
intake side and insert the piston pin through the piston and connecting rod.
Install new piston pin clips into the grooves of the
piston pin hole.

8-7

CYLINDER/PISTON

NOTE:
Make sure that the piston pin clips are seated
securely.
Do not align the piston pin clip end gap with the
piston cutout.

CYLINDER INSTALLATION
Clean the gasket surfaces of the cylinder and crankcase thoroughly, being careful not to damage it, and
careful not to allow gasket material into the crankcase.

Install the dowel pins and a new gasket

Coat a new O-ring with oil and install it into the
groove in the cylinder bottom.

8-8

CYLINDER/PISTON
Apply oil to the cylinder wall, piston and piston ring
outer surfaces.

Route the cam chain through the cylinder and install
the cylinder over the piston while compressing the
piston rings with your fingers.

CAUTION:
Be careful not to damage the piston rings and cylinder wall.

Apply oil t o the 10 mm cylinder bolt threads and
seating surfaces and install them with the washers.
Tighten the bolts in a crisscross pattern in 2 or 3
steps.

TORQUE: 44 Nm (4.5 kgfm, 33 Ibf+tl
Install the 6 mm cylinder bolts and tighten them
securely.
Install the cam chain guide into the cylinder and
crankcase, aligning the bosses with the grooves in
the cylinder.
Install the cylinder head (section 7).
p.

---

-//

6 rnrn BOLTS

8-9

CLUTCHlGEARSHlFT LINKAGE

108 N m (1

9-0

9. CLUTCH/GEARSHIFT LINKAGE
L

SERVICE INFORMATION

9-1

PRIMARY DRIVE GEAR

9-10

TROUBLESHOOTING

9-2

GEARSHIFT LINKAGE

9-1 1

RIGHT CRANKCASE COVER REMOVAL

9-3

CLUTCH

9-5

RIGHT CRANKCASE COVER
INSTALLATION

9-12

SERVICE INFORMATION
GENERAL

The clutch and gearshift linkage can be serviced with the engine installed in the frame.
Engine oil viscosity and level and the use of oil additives have an effect on clutch operation. Oil additives of any kind
are specifically not recommended. When the clutch does not disengage or the motorcycle creeps with the clutch disengaged, inspect the engine oil and oil level before servicing the clutch system.
* The crankcase must be separated when the transmission, shift drum and shift forks require service (section 11).
*

SPECIFICATIONS
Unit: mm (in)

TORQUE VALUES
Clutch center lock nut

108 N m (11.0 kgfm, 80 I b f W

Primary drive gear nut
Gearshift drum stopper arm bolt

88 N m (9.0 kgfm, 65 I b f W
12 N m (1.2 kgfm, 9 IbfW

Apply oil to the threads and seating surface.
Stake.
Apply oil t o the threads and seating surface.

TOOLS
._

Driver
Attachment, 28 x 30 mm
Pilot, 17 mm
Clutch center holder
Gear holder

07749-0010000
07746- 1870100
07746-0040400
07724 - 0050002 or equivalent commercially available in U S A ,
07724- 0010100 not available in U.S.A.

9- 1

CLUTCH/GEARSHIFT LINKAGE

TROUBLESHOOTING
Clutch lever too hard
* Damaged, kinked or dirty clutch cable
Improperly routed clutch cable
Damaged clutch lifter mechanism
Faulty clutch lifter plate bearing

---

Clutch will not disengage or motorcycle creeps with
clutch disengaged
* Too much clutch lever free play
* Warped clutch plates
Faulty clutch lifter
* Improper oil viscosity or oil additive used

Clutch slips
No clutch lever free play
* Clutch lifter sticking
* Worn clutch discs
Weak clutch springs
Oil additive used
Hard to shift
* Improper clutch operation
Incorrect engine oil viscosity
* Incorrect clutch adjustment
* Bent or damaged gearshift spindle
Damaged gearshift cam
Bent fork shaft or damaged shift forks and shift drum
(section 11)

Transmission jumps out of gear
Broken shift drum stopper arm
Weak or broken shift linkage return springs
Worn or damaged gearshift cam
* Bent fork shaft or worn shift forks and shift drum
(section 11)
Worn gear dogs or slots (section 11)

9-2

CLUTCHlGEARSHlFT LINKAGE

RIGHT CRANKCASE COVER REMOVAL

-1

I IETFR A R M

PAR1 E

- I - - - - -

Drain the engine oil (page 3-10),
Remove the rear brake pedal (page 14-20).
Remove the two bolts and clutch cable holder, and
disconnect the clutch cable from the clutch lifter arm.

Remove the bolts, oil pipes O-rings and dowel pins
from the right crankcase cover.

Remove the right crankcase cover bolts.

Theclutch lifter
spindle is
engaged with
the clutch lifter
piece inside the
right crankcase
cover.

Remove the right crankcase cover while turning the
clutch lifter arm counterclockwise to disengage the
lifter arm spindle from the lifter piece.

9-3

CLUTCHlGEARSHlFT LINKAGE
DOWEL-PINS

Remove the gasket and dowel pins.

Remove the O-ring and oil pump driven sprocket from
the oil pump.

CLUTCH LIFTER ARM

RETUR

Remove the clutch lifter arm and return spring from
the right crankcase cover.
Check the lifter arm spindle for wear or damage.
Check the return spring for fatigue or damage.

LIFTER ARM

Check the spindle dust seal and needle bearings for
wear or damage.
Replace any faulty parts.

BEARING

9-4

CLUTCHlGEARSHlFT LINKAGE

CLUTCH
DISASSEMBLY
Remove the right crankcase cover (page 9-3).
Loosen the clutch spring bolts in a crisscross p2w-m
in several steps.
Remove the bolts and springs.

Remove the pressure plate and lifter piece.
Remove the clutch discs and plates.

Be carefulnor to
damage the
mainshaff
threads.

Unstake the clutch center lock nut.

Hold the clutch center with the special tool and
remove the clutch center lock nut.

TOOL:
Clutch center holder

07724 - 0050002 or
equivalent
commercially
available in U S A .

9-5

CLUTCH/GEARSHIFT LINKAGE
Remove the lock washer, plain washer and clutch
center.

Remove the thrust washer, clutch outer and clutch
outer guide.

BEARING

INSPECTION
LIFTER BEARING
Turn the inner race of the lifter bearing with your finger.
The bearing should turn smoothly and quietly.
Also check that the outer race of the bearing fits
tightly in the pressure plate.
Replace the bearing if the inner race does not turn
smoothly, quietly, or if the outer race fits loosely in
the pressure plate.
Drive the bearing out of the pressure plate.
Drive a new bearing into the plate with its mark side
facing up.

TOOLS
Driver
Attachment, 28 x 30 mm
Pilot, 17 rnrn

07749-0010000
07746 - 1870100
07746-0040400

CLUTCH SPRING
Replace the

Measure the clutch spring free length.

clutch springs as
a set.

9-6

SERVICE LIMIT 50.0 mm 11.97 in)

CLUTCH/GEARSHIFT LINKAGE
-

CLUTCH DISC

Replace the
clutch discs and
plates as a set.

Check the clutch discs for signs of scoring or discoloration.
Measure the clutch disc thickness.

SERVICE LIMIT 2.69 mm 10.106 in)

CLUTCH PLATE
Replace the
clutchdiscsand
plares as a set

Check the plates for discoloration.
Check the plate warpage o n a surface plate using a
feeler gauge.

SERVICE LIMIT 0.15 mm 10.006 in)

CLUTCH CENTER
Check the clutch center and pressure plate for nicks,
indentations or abnormal wear made by the plates.

CLUTCH OUTER/OUTER GUIDE

Check the primary driven gear teeth for wear or damage.
Check the slots in the clutch outer for nicks, indentation or abnormal wear made by the clutch discs.
Measure the clutch outer 1.0.

SERVICE LIMIT: 28.04 mm (1.104 in)
Measure the clutch outer guide I.D.and O.D.

SERVICE LIMITS: I.D.: 22.05 mm 10.868 in1
O.D.: 27.90 mm (1.098 in)

9-7

CLUTCH/GEARSHlFT LINKAGE
MAINSHAFT
Measure the mainshaft O.D. a t the clutch outer guide.

SERVICE LIMIT 21.91 m m (0.863 in1

ASSEMBLY
Coat the clutch outer guide with molybdenum oil
solution and install it onto the mainshaft with the
flange side facing the crankcase.

Install the clutch outer and thrust washer.

Install the clutch center and plain washer.

9-8

CLUTCHlGEARSHlFT LINKAGE
Install the lock washer with the "OUTSIDE" mark facing out.

Apply oil to the threads and seating surface of a new
clutch center lock nut and install it onto the mainshaft.
Hold the clutch center with the special tool and tighten
the lock nut.

TOOL
Clutch center holder

07724-0050002or
equivalent
commercially
available in U S A .

TORQUE: 108 N.m (11.0 k g f m 80 IbfW

Becarefulnotto
damage the
mainshaft
threads.

Install the
out-side clutch
disc tabs into the
shallow slots in
the clutch outer.

Stake the clutch center lock nut into the mainshaft
groove.

Coat the clutch discs with clean engine oil.
Install the seven clutch discs and six plates alternately,
starting with the disc.

DISCS

9-9

CLUTCHlGEARSHlFT LINKAGE
Apply oil to the clutch lifter piece whole surface and
lifter bearing.
Install the clutch lifter piece and pressure plate.
Install the clutch springs and bolts.
Tighten the bolts in a crisscross pattern in several
steps.
Install the right crankcase cover (page 9-12).

PRIMARY DRIVE GEAR
REMOVAL
Remove the right crankcase cover (page 9-3).
Disassemble the clutch to the clutch center thrust
washer (page 9-5).
Install the special tool between the primary drive and
driven gear as shown, loosen the primary drive gear
nut.

TOOL
Gear holder

07724- 0010100
not available in
U.S.A.

Remove the clutch outer.
Remove the primary drive gear nut, washer, oil pump
drive gear and primary drive gear from the crankshaft.

INSTALLATION
Install the primary drive gear onto the crankshaft by
aligning the wide groove with the wide tooth.
Install the oil pump drive gear with the "OUT" mark
facing out by aligning the wide groove with the wide
tooth.

9-1 0

CLUTCH/GEARSHIFT LINKAGE
Apply oil to the primary drive gear nut threads and
seating surface.
Install the washer and primary drive gear nut.

Remove the oil pump (page 4-21.
Install the clutch outer onto the mainshaft.
Install the special tool between the primary drive and
driven gears as shown and tighten the primary drive
gear nut.

TOOL
Gear holder

07724 -0010100
not available in
USA.

TORQUE 88 N m (9.0 kgfm, 65 Ibf.ft)
Assemble the clutch (page 9-81.
Install the oil pump (page 4-61.
Install the right crankcase cover (page 9-12).

GEARSHIFT LINKAGE
NOTE:
For gearshift spindle service, refer to section 11

REMOVAL
Remove the right crankcase cover (page 9-3).
Remove the bolt and gearshift cam plate,
Remove the bolt, stopper arm, washer and return
spring.
Remove the dowel pin from the shift drum.
Check the gearshift cam and stopper arm for wear or
damage.
Check the stopper arm return spring for fatigue or
damage.

INSTALLATION
Install the dowel pin into the shift drum.
Install the return spring, washer (between the arm and
spring), stopper arm and bolt, and tighten the bolt.

TORQUE: 12 Nm (1.2 k g f m , 9 Ibf.ft)

9-1 1

ALTERNATOR/STARTER CLUTCH

kgfm.

10-0

10. ALTERNATOR/STARTER CLUTCH
-

SERVICE INFORMATION

10-1

FLYWHEEL REMOVAL

10-5

TROUBLESHOOTING

10-1

STARTER CLUTCH

10-6

ALTERNATOR STATOR

10-2

FLYWHEEL INSTALLATION

10-8

ITEM

STANDARD

SERVICE LIMIT

TORQUE VALUES
Flywheel bolt
Starter clutch bolt
Left crankcase stud bolt

127 N m (13.0 kgf.m, 94 Ibf.ft)
30 N.m (3.1 kgf.m, 22 IbfW
10 N m (1.0 kgf.m, 7 IbfW

Apply oil to the threads and seating surface.
Apply locking agent to the threads.

TOOLS
Flywheel holder
Rotor puller

07725 - 0040000 or equivalent commercially available in U.S.A.
07733 - 0020001 or 07933 - 3950000 (U.S.A. only)

TROUBLESHOOTING

Starter motor turns, but engine does not turn
Faulty starter clutch
Damaged starter idle and reduction gears

10-1

ALTERNATOR/STARTER CLUTCH

ALTERNATOR STATOR
LEFT CRANKCASE COVER REMOVAL
Remove the four bolts and the starter idle gear cover.

Remove the gasket and dowel pins.
Remove the spacer, starter idle gear and shaft from
the left crankcase cover.

Remove the seatlrear fender (page 2-2).
Disconnect the alternator connectors.

Remove the pinch bolt and gearshift pedal from the
gearshift spindle.

10-2

ALTERNATOR/STARTER CLUTCH

Remove the nut, seven bolts and the left crankcase
cover.

Remove the gasket and dowel pins.
Remove the starter reduction gear shaft and gear.

,GROMMET

STATOR REMOVAL/INSTALLATION
Remove the bolt and wire clamp.
Remove the two ignition pulse generator bolts and
wire clamp.
Remove the three stator bolts.
Remove the wire grommet and statorlignition pulse
generator assembly from the left crankcase cover.
Install the statorlignition pulse generator assembly
onto the left crankcase cover.
Apply sealant to the wire grommet seating surface
and install it into the cover groove properly.

s...... .

BOLTS

GENERATOR

Install the stator bolts and tighten them securely.
Apply locking agent to the ignition pulse generator
bolt threads.
Install the wire clamp onto the ignition pulse generator and tighten the two bolts securely.
Apply locking agent to the wire clamp bolt threads.
Install the wire clamp and tighten the bolt securely.

10-3

ALTERNATOR/STARTER CLUTCH

LEFT CRANKCASE COVER
INSTALLATION
Install the starter reduction gear and shaft.
Coat a new O-ring with oil and install it into the
starter motor groove.

...

Install the dowel pins and a new gasket

Install the left crankcase cover, being careful not to
pinch the neutral switch wire.
Install the nut and seven bolts, and tighten them
securely.

Install the gearshift pedal onto the gearshift spindle,
aligning the punch marks on the pedal and spindle.
Install the gearshift pedal pinch bolt and tighten it.
TOROUE: 20 N m (2.0 kgfm, 14 Ibf4t)

10-4

ALTERNATORlSTARTER CLUTCH
Route the alternator wire properly (page 1-18).
Connect the alternator connectors.
L

Install the seatlrear fender (page 2-21.

Install the starter idle gear shaft, gear and spacer in
the left crankcase cover.
Install the dowel pins and a new gasket.

3
Install the starter idle gear cover and tighten the four
bolts securely.

r-CF.
i

FLYW HEEL R EMOVAL
Remove the left crankcase cover (page 10-2).
I

Hold the flywheel with the special tool and loosen the
flywheel bolt.

r"'

TOOL
Flywheel holder

07725-0040000or
equivalent commercially
available in U S A .

Remove the flywheel bolt and special washer.

10-5

ALTERNATOR/STARTER CLUTCH
Remove the flywheel using the special tool.

TOOL
Rotor puller

07733- 0020001or
07933 3950000
[U.S.A. only)

Remove the 3.7 mm washer and starter drive gear.

Remove the needle bearing, spacer anu woooruff
key.

,_SPAEL

?" '*c

"." -.r r

STARTER CLUTCH
REMOVAL
Remove the flywheel (page 10-5).
Remove the starter driven gear while turning it counterclockwise.
Remove the washer.

DRIVEN GEAR
Hold the flywheel with the special tool and remove
the starter clutch bolts.

TOOL
Flywheel holder

07725-0040000

FLYWHEEL

Remove the starter clutch assembly from the flywheel.
Remove t h e sprag clutch f r o m t h e starter clutch
outer.

10-6

ALTERNATOWSTARTER CLUTCH

INSPECTION

b m i i r i i n N GFAR

im F GFAR

Check the starter idle gear and reduction gear for
wear or damage.

SPRAG ri (ITCH

Check the starter clutch outer and sprag clutch for
abnormal wear or damage.

Check the starter driven gear teeth for wear or damage.
Measure the starter driven gear boss O.D.

SERVICE LIMIT 51.67 mm (2.034 in)

INSTALLATION

_ .

Install the sprag clutch into the starter clutch outer
with the flange side facing the flywheel side.

SPR

10-7

ALTERNATOR/STARTER CLUTCH
Apply locking agent t o the starter clutch bolt threads.
Install the starter clutch assembly onto the flywheel
and install the bolts.
Hold the flywheel with the special tool and tighten
the bolts.

TOOL
Flywheel holder

07725-0040000or
equivalent commercially
available in U S A .

TORQUE: 30 N.m (3.1 kgf.m, 22 Ibf.ft)

7RIVENGEAR

Install the starter driven gear with the washer while
turning it counterclockwise.

Make sure that the starter driven gear turns counterclockwise smoothly and does not turn clockwise.
Install the flywheel.

Fl fWHEEL INSTALLATION
Lubricate the needle bearing with oil.
Install the 5.6 m m spacer and needle bearing onto the
crankshaft.

Clean any oil from the tapered portions of the crankshaft and flywheel.

Install the woodruff key in the crankshaft key groove.

Install the starter drive gear.

lnsta I the flvwhcel on tne crankshaft, aligning tne
kcy way mitn rhe woodruff key.
ii.

10-8

ALTERNATORlSTARTER CLUTCH

Apply oil to the flywheel bolt threads and seating surface, and install the special washer and bolt.
Hold the flywheel with the special tool and tighten
the bolt.

TOOL
Flywheel holder

07725-0040000or
equivalent commercially
available in U.S.A.

TORQUE: 127 N m 113.0 kgfm, 94 Ibf4t)
Install the left crankcase cover (page 10-41,

10-9

CRANKCASE/TRANSMISSION/CRANKSHAFT

11-0

11. CRANKCASE/TRANSMISSION/CRANKSHAFT
SERVICE- INFORMATION

11-1

CRANKSHAFTlBALANCER

TROUBLESHOOTING

11-2

CRANKCASE BEARING REPLACEMENT 11-12

CRANKCASE SEPARATION

11-3

CRANKCASE ASSEMBLY

TRANSMISSION

11-4

11-9
11-15

SERVICE INFORMATI0 N
GENERAL

The crankcase halves must be separated to service the transmission and crankshaft. To service these parts, the
engine must be removed from the frame (section 6).
Be careful not to damage the crankcase mating surfaces when servicing.

SPECIFICATIONS
Unit: mm lin
~

ITEM
Shift fork

I.D.
Claw thickness
Shaft O.D.

SERVICE LIMIT

STANDARD
13.000- 13.021 (0.5118-0.5126)
5.93 - 6.00 (0.233 - 0.236)
~
_
_
12.966- 12.984 (0.5105-0.5112)

13.05 10.514)

5.5 (0.22)

12.90 (0.508)

Transmission

Crankshaft

TORQUE VALUES
Mainshaft bearing setting plate bolt
Gearshift spindle return spring pin bolt

12 N m (1.2 kgfm. 9 IbfW
24 N m 12.4 kgfm, 17 IbfW

Apply locking agent to the threads

11-1

CRANKCASEITRANSMISSIONlCRANKSHAFT

TOOLS
Bearing remover set, 15 mm

- bearing remover, 15 mm
- remover shaft
- remover head
- sliding weight
Bearing remover, 17 mm
Remover handle
Remover weight
Driver
Attachment, 32 x 35 mm
Attachment, 37 x 40 mm
Attachment, 42 x 47 mm
Attachment, 52 x 55 mm
Attachment, 72 x 75 mm
Pilot, 12 mm
Pilot, 15 mm
Pilot, 17 mm
Pilot, 22 mm
Pilot, 25 mm
Pilot, 30 mm
Universal bearing puller
Crankcase assembly tool
- assembly collar
-assembly shaft
-threaded adaptor

07936- KCIOOOO not available in U.S.A.
07936 - KC10500
07936- KClOlOO not available in U S A .
07936 - KC10200 not available in U.S.A.
07741 -0010201 or 07936-371020A or 07936-3710200
07936 - 3710300
07936- 3710100
07741-0010201or07936-371020Aor07936-3710200
07749 - 0010000
07746-0010100
07746-0010200
07746 - 0010300
07746 - 0010400
07746 - 0010600
07746-0040200
07746-0040300
07746 - 0040400
07746-0041000
07746 - 0040600
07746-0040700
07631 - 0010000 or equivalent commercially available in U.S.A.
07965 - VMOOOOO not available in U.S.A.
07965 - VMOOIOO
07965 -VM00200 or 07931 - ME4010B and 07931 - HB3020A
07965-VM00300or07931-KF00200

TROUBLESHOOTING
Excessive engine noise
Worn, seized or chipped transmission gears
* Worn transmission bearing
* Worn or damaged connecting rod bearings
* Worn crankshaft main journal bearing
Worn connecting rod small end
Worn balancer bearing
Improper balancer installation
*

-.
--

Transmission jumps out of gear
Worn gear dogs or dog holes
Worn shift drum guide groove
Worn shift fork guide pin
* Worn gear shifter groove
Worn shift fork
* Bent shift fork shaft

Hard to shift
Damaged shift fork
* Bent shift fork shaft
* Damaged shift fork guide pin
Damaged shift drum guide groove
Abnormal vibration
* Improper balancer timing

11-2

CRANKCASEITRANSMISSIONICRANKSHAFT

CRANKCASE SEPARATION

-11_

TENSiONER SLIDER

Remove the following:
-engine (section 6)
-cylinder head (section 7)
-cylinder and piston (section 8)
- clutch, gearshift linkage, primary drive gear
(section 9)
-oil pump (section 41
- flywheel (section 101
-starter motor (section 18)
- bolt, tensioner sliderlcollar and washer
- cam chain
- cam chain drive sprocket

- tworight crankcase bolts

-3

Loosen the eleven left crankcase bolts in a crisscross
pattern in 2 or 3 steps and remove them.

Place the crankcase assembly with the left side down.
Remove the right crankcase from the left crankcase
while tapping them a t several locations with a soft
hammer.
i

CAUTION:
Do not pry the crankcase apart with a screwdriver.

11-3

CRANKCASElTRANSMlSSlONlCRANKSHAFT
Remove the gasket and dowel pins.

GASKET

TRANSMISSION
DISASSEMBLY
Separate the crankcase (page 11-3).
Pull the gearshift plate away from the shift drum and
remove the gearshift spindle.

Pull the shift fork shaft out of the left crankcase and
shift forks.
Remove the shift forks and shift drum.

Remove the mainshaft and countershaft assembly as
a set.
Disassemble the mainshaft and countershaft.

11-4

FORK SHAF

-rr?:
-1

CRANKCASE/TR ANSMISSION/CRANKSH AFT
"

INSPECTION
GEAR/BUSHING/SHAFT
Check the gear dogs and teeth for abnormal wear or
damage.
Measure the gear I.D.

SERVICE LIMITS: M 4 25.08 mm (0.987 in1
M5: 25.06 mm (0.987 in)
C1: 23.07 mm (0.908 in)
C2, C3: 28.08 mm (1.106 in1
Measure the gear bushing O.D.

SERVICE LIMITS: M4, M5: 24.90 mm (0.980 in1
C1: 22.90 mm 10.902 in1
C2. c3: 27.94 mm (1.100 in1
Calculate the gear-to-bushing clearance.

SERVICE LIMIT 0.10 mm (0.004 in)
Measure the gear bushing I.D.

SERVICE LIMITS: M 4 22.10 mm (0.870 in1
C1: 20.80 mm (0.791 in1
C2, C3: 25.06 mm (0.987 in1
Check the mainshaft and countershaft for abnormal
wear or damage.
Measure the malnshaft O.D. at the M4 gear.

SERVICE LIMIT 21.92 mm (0.863 in)
Measure the countershaft O.D. at the C1, C2 and C3
gears.

SERVICE LIMITS At C1: 19.94 mm (0.785 in)
At C2, C 3 24.92 mm (0.981 in1

I
I

Calculate the gear bushing-to-shaft clearance.

SERVICE LIMIT 0.10 mm 10.004 in)

SHIFT DRUM
Check the shift drum guide grooves for abnormal
wear or damage.
Check the shift drum journals for scoring, scratches
or evidence of insufficient lubrication.

11-5

CRANKCASE/TRANSMISSION/CRANKSHAm

. .- .
SHIFT FORK
Check the shift fork guide pins for abnormal wear or
damage.
Measure the shift fork 1.D

SERVICE LIMIT 13.05 mm (0.514 in)
Measure the shift fork claw thickness.

SERVICE LIMIT 5.5 m m (0.22 in)

SHIFT FORK SHAFT
Check the shift fork shaft for damage or bending
Measure the shift fork shaft O.D.

SERVICE LIMIT 12.90 mm (0.508 in)

GEARSHIFT SPINDLE
Check the gearshift plate for wear or damage.
Check the return spring and reset spring for fatigue
or damage.

ASSEMBLY
7ING
Clean all parts in solvent and dry them thoroughly.
Apply molybdenum oil solution to the gear teeth,
sliding surface, shifter grooves and bushings.
Assemble the mainshaft and countershaft.

CORRECT

INCORRECT

NOTE:
Always install the thrust washer and snap ring
with the chamfered (rolled) edge facing away from
the thrust load.
* Install the snap ring so that its end gap aligns with
the groove in the splines.
Make sure that the snap ring is fully seated in the
shaft groove after installing it.

11-6

SNAP RING

CRANKCASE/TRANSMISSION/CRANKSHAFT
MAINSHAFT

THRUST WASHER
SPLINE WASHER

SPLINE WASHER
M 4 GEAR (22T)
M4 GEAR BUSHING
THRUST WASHER
WASHER AND SNAP RING DIRECTION:

MAINSHAFT (Ml: 12T)

THRUST
WASHER

C3 GEAR BUSING
C3 GEAR (28T)
SPLINE WASHER

\
COUNTERSHAFT
WASHER AND SNAP RING DIRECTION:

THRUST WAS HER

C1 GEAR BUSHING

T
I
THRUST WASHER
~

C1 GEAR (35T)

: Gear and bushing rotating

shift fork grooves

11-7

CRANKCASE/TRANSMISSION/CRANKSHAFT
Check the gears for freedom of movement or rotation
on the shaft.
Engage the mainshaft and countershaft gears.

Be sure to install
the thrust
washers.

If removed, insall thecrankshaftbalancer (page 11-11),
Apply oil to the countershaft oil seal lip.
Install the mainshaft and countershaft assemblies as
a set into the left crankcase.

NOTE:
Each shift fork has an identification mark; L for the
left fork, C for the center fork and R for the right fork.

Coat the shift forks with oil.
Install the shift forks into i ! gear shi !r grooves
with their identification marks facing u p (right
crankcase side).
Apply oil to the shift drum guide pin grooves and
journals.
Install the shift drum and insert the shift fork guide
pins into the shift drum guide pin grooves.

11-8

CRANKCASE/TRANSMISSION/CRANKSH AFT
Coat the shift fork shaft with oil.
Install the shift fork shaft through the shift forks and
into the left crankcase.

FORK

Apply oil to the gearshift spindle oil seal lip

Install the gearshift spindle by aligning the return
spring ends with the spring pin bolt while pulling the
gearshift plate.
Engage the gearshift plate with the shift drum.

. ,

Assemble the crankcase halves (page 11-14),

CRANKSHAFT/BALANCER
REMOVAL
Separate the crankcase (page 11-31,
Remove the transmission (page 11-4)
Remove the crankshaft and balancer from the left
crankcase using a hydraulic press while holding
them.

CAUTION

Be careful not t o damage the crankcase mating surface and crankshaft assembly.

11-9

CRANKCASE/TRANSMlSSlON/CRANKSHAFT
If the left crankshaft bearing is left on the crankshaft,
remove it using the bearing puller with a suitable
protector.

TOOL
Universal bearing puller

UhlVERSAL BEARING

07631 0010000 or
equivalent commercially
available in U.S.A.

NOTE:
Always replace the left crankshaft bearing with a new
one when the crankshaft is removed.
PROTECTOR

INSPECTION
CRANKSHAFT

Set the crankshaft as shown and measure the runout
using a dial indicator.
SERVICE LIMIT 0.12 mm 10.005 in1

6 mm-

Measure the side clearance between the connecting
rod big end and crank weight with a feeler gauge.
SERVICE LIMIT 0.6 mm 10.02 in)

Measure the radial clearance at the connecting rod
big end in an X and Y directions.
SERVICE LIMIT: 0.05 mm (0.002 in)

11-10

-8 mm

CRANKCASE/TRANSMISSION/CRANKSHAFT
BALANCER
Check the balancer gear for wear or damage.

INSTALLATION
Apply oil to a new crankshaft bearing.
Drive the crankshaft bearing into the left crankcase
with the marking side facing up.

TOOLS
Driver
Attachment, 72 x 75 mm
Pilot. 30 mm

07749-0010000
07746 - 0010600
07746-0040700

Engage the balancer and crankshaft by aligning the
index lines on the balancer drive and driven gears as
shown, and install the crankshaft and balancer
together into the left crankcase.

11-11

CRANKCASElTRANSMlSSlONlCRANKSHAFT
Assemble the special tools onto the crankshah.
Draw tne crankshatt into the bearing 'nner race.
TOOLS:
Crankcase assembly tool
-Assembly collar
Assembly shaft

- Threaded adaptor

-/ROD

cob.

07965 - VMOOOOO
not available in U.S.A.
07965 VMOOlOO
07965 - VM00200 or
07931 - ME40100 and
07931 HB3020A
07965 VM00300 or
07931 - KF00200

\
:OLLAR

CAUTION:
~

Be careful n o t t o let the connecting r o d press against
the crankcase mating surface while drawing the
crankshaft.

After drawing the crankshaft in, make sure that the
index lines on the crank weight and balancer weight
are aligned.
Install the transmission (page 11-7).
Assemble the crankcase halves (page 11-14).

CRANKCASE BEARING REPLACEMENT
RIGHT CRANKCASE BEARING
Remove the balancer bearing with the special tools.
TOOLS:
Bearing remover set, 15 mm

- Bearing remover, 15 mm

- Remover, 15 mm
- Remover shaft

- Sliding weight

07936 KClOOOO
not available in U.S.A.
07936 - KC10500
07936 - KC10200
not available in U.S.A.
07936 KClOlOO
not available in U.S.A.

07741 - 0010201 or
07936 - 371020A or

ii
.1

BEARING REMOVEFi'
-

07936-3710200
Remove the two bolts and mainshaft bearing setting
plate.
Drive the crankshaft, mainshaft and countershaft
bearings out of the right crankcase.
Remove the countershaft oil seal.

11-12

CRANKCASElTRANSMlSSlONlCRANKSHAFT
Apply oil to new bearings.
Drive the mainshaft, crankshaft and balancer bearings in with the marking side facing up using the special tools.

TOOLS:
Mainshaft bearing:
Driver
Attachment, 42 x 47 mm
Pilot, 22 mm

07749 0010000
07746-0010300
07746 - 0041000

Crankshaft bearing:
Driver
Attachment, 72 x 75 mm
Pilot, 30 mm

07749 0010000
07746-0010600
07746-0040700

Balancer bearing:
Driver
Attachment, 37 x 40 mm
Pilot, 15 mm

07749 0010000
07746-0010200
07746-0040300

AND-PILOT

Drive a new countershaft oil seal in using a suitable
24 mm socket.
Drive the countershaft bearing in with the sealed side
facing down using the special tools.

TOOLS:
Driver
Attachment, 42 x 47 mm
Pilot. 17 mm

07749-0010000
07746-0010300
07746-0040400
lll~i

Apply locking agent to the mainshaft bearing setting
plate bolt threads.
Install the setting plate and tighten the bolts.

. .

TORQUE: 12 N.m 11.2 kgf.m, 9 IbfW
Be sure to align the
notch in the
couniershafl oil seal
with ihe crankcase
passage.

LEFT CRANKCASE

Remove the countershaft and gearshift spindle oil
seals.
i

Use 24 mm socket or suitable tool.

11-13

CRANKCASElTRANSMlSSlONICRANKSHAFT
Remove the mainshaft bearing using the special
tools.
TOOLS:
Mainshaft bearing:
Bearing remover, 17 mm
Remover handle
Sliding weight

07936-3710300
07936-3710100
07741-0010201or
07936 - 371020A or
07936-3710200

Heat the crankcase 80°C (176°F)evenly using a heat
gun and remove the balancer bearing.

Always wear insulated gloves when handling the
crankcase after it has been heated.

IVER

CAUTION:

L..

Do n o t use a torch to heat the case; it may cause
waroina.
Apply oil to new bearings.
Drive the countershaft and balancer bearings in with
the marking side facing up using the special tools.
TOOLS
Countershaft bearing:
Driver
Attachment, 52 x 55 mm
Pilot, 25 mm

07749 0010000
07746 - 0010400
07746 - 0040600

Balancer bearing:
Driver
Attachment, 32 x 35 mm
Pilot, 12 mm

07749-0010000
07746-0010100
07746-0040200

ATrACH M E

Drive the mainshaft bearing in with the sealed side
facing down using the special tools.

TOOLS:
Driver
Attachment, 37 x 40 mm
Pilot, 17 mm

07749-0010000
07746-0010200
07746 0040400

Install new countershaft and gearshift spindle oil
seals.
Install the crankshaft (page 11-10),
Install the transmission (page 11-7).
Assemble the crankcase halves (page 11-14).

11-14

CRANKCASE/TRANSMlSSlON/CRANKSHAFT

CRANKCASE ASSEMBLY

Clean the left and right crankcase mating surfaces
thoroughly, being careful not to damage them.
Install the dowel pins and a new gasket.

Make sure a l l t h e p a r t s are i n s t a l l e d in t h e left
crankcase.
Install the right crankcase over the left crankcase.

..-*..-

,.. ..

Install the left crankcase bolts and tighten them i n a
crisscross pattern in 2 or 3 steps.

Install and tighten the right crankcase bolts.

11-15

CRANKCASEITRANSMISSIONlCRANKSHAFT
Install the cam chain drive sprocket onto the crankshaft, b y aligning the wide groove w i t h the wide
tooth.

Install the cam chain onto the drive sprocket and
through the crankcase.

;TENSIONER

Apply locking agent to the cam chain tensioner bolt
threads.
Install the washer (between the crankcase and slider),
tensioner sliderlcollar and bolt, and tighten the bolt
securely.
Install the following:
-primary drive gear, clutch, gearshift linkage (section 9)
- piston and cylinder (section 8)
- cylinder head (section 7)
oil pump (section 4)
- flywheel(section 10)
- starter motor (section 18)
- engine (section 6 )
~

11-16

i WASHER;COLLA&OLT .

MEMO

FRONT WHEELlSUSPENSlONlSTEERlNG

39 N m (4.0kgfm,

44 N m (4.5 kgfm,

42 N m (4.3 kgfm, 31 1bf.e

9 N m (3.0kgf.m,

33 IbfW

64 N m (6.5 kgfm, 47 Ibf.ft)

12-0

12. FRONT WHEEL/SUSPENSION/STEERING
-

SERVICE INFORMATION

12-1

TIRES

12-9

TROUBLESHOOTING

12-2

SUSPENSION ARM

12-12

HANDLEBAR

12-3

FRONT SHOCK ABSORBER

12-16

THROTTLE HOUSING

12-5

STEERING SHAFT AND TIE-ROD

12-17

FRONT WHEEL AND HUB

12-6

SERVICE INFORMATION
GENERAL
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc
with a high qualify brake degreasing agent

ITEM

STANDARD

Minimum tire tread depth
Cold tire pressure

SERVICE LIMIT
4.0 (0.16)

Standard

27 kPa (0.275 kgf/cmZ, 4.0 psi)

Minimum

23 kPa (0.235 kgf/cm2, 3.4 psi)

Maximum

31 kPa (0.315 kgf/cm2, 4.6 psi)

Tie-rod distance between the ball joints

370.2 (14.57)

Toe

17 f 15 (0.7 f 0.6)

Shock absorber sDrina adiuster standard nosition

4th from softest nosition

TORQUE VALUES

Handlebar lower holder nut
Throttle housing cover screw
Left handlebar switch housing screw
Front wheel nut
Front wheel hub nut
Front brake disc bolt
Shock absorber mounting nut
Upper and lower arm pivot nut
Upper and lower arm ball joint nut
Tie-rod ball joint lock nut
Tie-rod stud joint nut
Steering shaft end nut
Steering shaft holder bolt

39 N m (4.0 kgfm, 29 I b f W
4 N m (0.4 kgfm, 2.9 IbfW
2 N m (0.2 kgfm, 1.4 IbfW
64 N.m (6.5 kgfm, 47 I b f W
59 N.m (6.0 kgfm, 43 Ibf+t)
42 N m (4.3 kgfm, 31 Ibf.ft)
44 N m (4.5 kgfm, 33 Ibf.ft)
39 N m (4.0 kgfm. 29 I b f W
29 N m (3.0 kgfm, 22 Ibf+t)
54 N m (5.5 kgfm. 40 I b f W
44 N-m (4.5 kgfm, 33 IbfW
69 N.m (7.0 kgfm, 51 Ibf4t)
32 N m (3.3 kgfm, 24 IbfW

Castle nut
ALOC bolt

Castle nut

12-1

FRONT WHEEL/SUSPENSION/STEERlNG

TOOLS
Driver
Attachment, 32 x 35 mm
Attachment, 37 x 40 mm
Attachment, 42 x 47 mm
Pilot, 15 mm
Pilot, 17 mm
Pilot, 20 mm
Bearing remover shaft
Bearing remover head, 15 mm
Assembly collar
Ball joint remover
Spherical bearing driver

07749-0010000
07746 - 0010100
07746 - 0010200
07746-0010300
07746 - 0040300
07746 - 0040400
07746 - 0040500
07746 - 0050100
07746 - 0050400
07965 - VMOOlOO
07MAC - SLOO200
07HMF - HCOOlOO not available in U.S.A. or 07GAD . PH70100

TROUBLESHOOTING

Hard steering
Steering shaft holder too tight
Damaged steering shaft bearinglbushing
* Insufficient tire pressure

Soft suspension
Weak shock absorber spring
Faulty shock absorber damper
* Loose front suspension fasteners

Steers one side or does not track straight
* Incorrect wheel alignment
Unequal tire pressure
Bent tie-rod, suspension arm or frame
Worn or damaged wheel hub bearings
Weak shock absorber

Hard suspension
Bent shock absorber damper rod
Improperly installed suspension arms
* Faulty suspension arm spherical bearings

.
--

Front wheel wobbling
Bent rim
Worn or damaged wheel hub bearings
* Faulty tire
Wheel hub not tightened properly

12-2

Front suspension noise
Binding suspension link
Loose front susuension fasteners

FRONT WHEEL/SUSPENSlON/STEERlNG

HANDLEBAR
REMOVAL
c

Remove the fuel tank breather tube from the handlebar cover.
Remove the handlebar cover attaching bolt, being
careful not to let the bolt fall into the steering shaft.
Remove the cover by releasing its ends off the handlebar carefully.

Remove the wire bands.

Remove the two screws, holder and throttle housing.
Remove the two bolts, holder and master cylinder.

Slide the boot off the clutch lever bracket.

BANDS

MASTER
CYLINDER

LEVER BRACKET

THROTLE HOUSING

SWITCH

RETAINER

Remove the screw and clutch switch retainer.
Remove the clutch switch out of the clutch lever
bracket and disconnect the connectors,
Remove the two bolts, holder and clutch lever bracket.
Remove the two screws and handlebar switch housing.

SWITCH HOUSING

COF~NECTORS'

12-3

FRONT WHEEL/SUSPENSION/STEERlNG
Remove the screw and grip end.
Remove the handlebar grip.

GRIP END

HANDLEBAR GdlP

Remove the four bolts and the upper holders:
Remove the handlebar from the lower holders.

PUNCH MARKS

INSTALLATION
Place the handlebar onto the lower holders and align
the punch mark on the handlebar with the top of the
lower holder.
Install the upper holders with the punch marks facing
forward. Install the four bolts and tighten the forward
bolts first, then tighten the rear bolts.

I HANI~LEBAR

U&ER HOLDERS

GRIP END

Apply Honda Bond A or Honda Hand Grip Cement
(U.S.A. only) to the inside surface of the handlebar
grip and to the clean surface of the handlebar.
Wait 3 - 5 minutes and install the grip. Rotate the
grip for even application of the adhesive.
NOTE:
Allow the adhesive to dry for an hour before using.
Install the grip end with the screw securely by aligning the flats.

Install the handlebar switch housing by aligning its
locating pin with the hole in the handlebar.
Install the t w o attaching screws and tighten the
upper screw first, then tighten the lower screw.
TORQUE: 2 Nm (0.2 kgfm, 1.4 1bf.h)

12-4

SWITCH

FRONT WHEELISUSPENSIONISTEERING
Install the clutch lever bracket and holder with the
"UP" mark facing up.
Align the slit of the lever bracket with the punch mark
on the handlebar, and tighten the upper bolt first,
then the lower bolt.
Connect the clutch switch to the connectors and
install it into the clutch lever bracket.
Secure the switch with the retainer and a new screw.
Cover the bracket with the boot securely.
MARK

Install the master cylinder and holder with the "UP"
mark facing up.
Align the slit of the master cylinder with the punch
mark on the handlebar, and tighten the upper bolt
first. then the lower bolt.

BOLTS

CONNECTORS

MASTER CYLINDER

"UP" MARK

Install the throttle housing and holder against the
master cylinder.
Align the lug on the throttle housing with the slit of
the master cylinder, and tighten the forward screw
first, then the rear screw.

THROTTLE HOUSING

Secure the handlebar switch wire with the wire
bands (page 1-18).
Install the handlebar cover and breather tube in the
reverse order of removal.

THROTTLE HOUSING

COVER

DISASSEMBLY
Remove the three attaching screws and the throttle
housing cover.
Remove the gasket.

GASKET

12-5

FRONT WHEELISUSPENSIONISTEERING
Slide the boot off the throttle cable adjuster
Loosen the cable adjuster.
Bend down the lock washer tab and remove the pivot
nut, lock washer, throttle arm and return spring, then
the throttle lever with the plastic washer.
Disconnect the throttle cable from the throttle arm.
Remove the dust seal from the housing bottom.

ASSEMBLY
Apply grease to the thronle lever pivot in the housing.
Coat a new dust seal lip with grease and install it into
the housing until it is fully seated.
Connect the cable to the throttle arm.
Insert the throttle lever with the washer into the
housing and install the throttle arm with the spring
over the throttle lever pivot by aligning the flat surfaces.
Install a new lock washer and the pivot nut.
Tighten the pivot nut and bend up the washer tab
against the nut.
Install the housing cover with a new gasket and tighten
the three screws.

TORQUE: 4 Nm 10.4 kgfm, 2.9 IbfW
Adjust the throttle lever free play (page 3-41,

FRONT WHEEL AND HUB
WHEEL REMOVAL
Loosen the wheel nuts
Place the support block under the frame to raise the
front wheel off the ground.
Remove the nuts and wheel.

HUB DISASSEMBLY
CAUTION:
Support the caliper so that it does not hang from the
brake hose. Do not twist or bend the brake hose.
Remove the following:
-two mounting bolts and brake caliper
- brake hose from the clamp
- bolt and disc guard
Y

CALIPER

12-6

FRONT WHEEL/SUSPENSlON/STEERlNG

- cotter pin
- hub nut
- wheel hubldisc

:"-I
IT

-three bolts and brake disc
- side collars

- dust seals.

DUST SE
Turn the inner race of each bearing with your finger.
The bearings should turn smoothly and quietly. Also
check that the bearing outer race fits tightly in the
hub.
Replace the
bearings in
pairs.

Remove and discard the bearings if the races do not
turn smoothly and quietly or if they fit loosely in the
hub.

Install the bearing remover head into the bearing.
From opposite side, install the bearing remover shaft
and drive the bearing out of the wheel hub.
Remove the distance collar and drive out the other
bearing.

TOOLS
Bearing remover shaft
Bearing remover head, 15 mm

07746 -0050100
07746 0050400

NOTE
Replace the wheel bearings in pairs. Do not reuse old
bearings.

12-7

FRONT WHEEL/SUSPENSION/STEERING
HUB ASSEMBLY

DRIVER
/

Drive in a new inner bearing (brake disc side1 squarely
with the marking side facing up until it IS fully seated.
Install the distance collar with the large dia. facing
the inner bearing.
Drive in a new outer bearing squarely with the marking side facing up until it is fully seated.

TOOLS
Inner bearing (disc side):
Driver
Attachment. 42 x 47 mm
Pilot, 20 mm
Outer bearing (wheel sideJ:
Driver
Attachment, 32 x 35 mm
Pilot, 15 mm

07749 0010000
07746 0010300
07746-0040500

ATTACHMENT AND PILOT

07749-0010000
07746 0010100
07746-0040300

Do not get grease on the brake disc or stopping
power will be reduced.

Install the brake disc with the stamp facing up (away
from the hub).
Install new disc bolts and tighten them in 2 - 3 steps.

TORQUE: 42 Nm (4.3 kgfm, 31 Ibf4tl
Apply grease to new dust seal lips.
Install the dust seals into the wheel hub until they are
flush with the hub surface.

TOOLS:
Disc side:
Assembly collar
Wheel side:
Attachment, 32 x 35 mm

Qm
**
DUSl

\
DISC

i l ~ f i ~ a

07965 - VMOOlOO
07746 - 0010100

Install the side collars.
Install the wheel hubldisc onto the knuckle and the
hub nut.
Tighten the hub nut to the specified torque and further tighten it until its grooves align with the cotter
pin hole.

TORQUE: 59 N

(6.0 kgfm, 43 Ibf4t)

Install a new cotter pin.
Secure the brake hose with the clamp on the knuckle.
Install the brake caliper with new mounting bolts and
tighten them.

TORQUE: 30 N m 13.1 kgfm, 22 Ibf4tJ
Install the disc guard and tighten the bolt.
x

12-8

BOLTS

FRONT WHEEL/SUSPENSION/STEERlNG

WHEEL INSTALLATION
Install the wheel onto the hub with the tire valve facing out and the arrow mark facing in the normal
rotating direction.

NOTE:
Do not interchange the left and right tires.
Install the wheel nuts with the tapered side facing
inward and tighten them.

TORQUE: 64 N.m (6.5 kgfm, 47 Ibftt)

TIRE.‘VALVE

TIRES
REMOVAL
NOTE:

This service requires the Universal Bead Breaker
(GN-AH-958-661).
Remove and install the tire from the r i m side
omosite the valve stem.

Remove the core from the valve stem.

CAUTION
Use of the bead breaker tool is required for tire
removal.
Do not damage the bead seating area of the rim.
Use Coats 220 Tire Changer or equivalent t o
remove the tire from the rim. If a tire changer is
not available, tire irons may be used, but take
care not to scratch the wheel.
Install the blade for 9/11” rims onto the breaker arm
assembly.

CAUTION:
Use of an improper size blade may result in damage
to the rim, tire or b/ade.

PRESS BLOCK

BLADE

12-9

FRONT WHEEL/SUSPENSION/STEERlNG
Place the proper size adaptor onto the threaded shaft
and then put the wheel over the threaded shaft and
adaptor.
Lube the bead area with water, pressing down on the
tire sidewalllbead area in several places to allow the
water to run into and around the bead. Also lube area
where the breaker arm will contact the sidewall of the
tire.

Use only water as a lubricant removing or mounting
tires. Soap or some mounting lubricants may leave a
slippery residue which can cause the tire to shift on
the rim and lose air pressure during riding.
While holding the breaker arm assembly a t an
approximate 45" position, insert the blade of the
breaker arm between the tire and rim. Push the
breaker arm inward and downward until it is in the
horizontal position with its press block in contact
with the rim.
Only one white nylon button is used for the wheels
on the TRX400EX. The button must be ground across
the rounded surface to within 1.5 mm of the center
hole. Install the button on the right side of the press
head (as viewed when installed on tire).
With the breaker arm in the horizontal position, place
the breaker press head assembly over the breaker arm
press block. Make sure the press head bolt is backed
out all the way and then position the nylon button on
the press head against the inside edge of the rim.
Insert the threaded shaft through the appropriate
hole in the breaker press head assembly. When
installing the press head block onto the breaker arm,
you may have to rotate the press head assembly to
draw the blade fully under the wheel rim. Then,
straighten the press headlbreaker arm assembly and
tighten the lever nut until both ends of the breaker
press head assembly are in firm contact with the rim.
Tighten the press head bolt until the reference mark
on the press block is aligned with the top edge of the
press head. Do not tighten past this reference mark.
If the rest of the bead cannot be pushed down into
the center of the rim by hand, loosen the press head
bolt and the lever nut.
Rotate the breaker arm assembly and breaker press
head assembly 118 t o 114 the circumference of the
rim.
Tighten the lever nut and then tighten the press head
bolt as described.
Repeat this procedure as necessary until the remainder of the bead can be pushed down into the center
of the rim.
Assemble the Universal Bead Breaker on the other
side of the wheel and break the bead following the
same procedures.
Remove the tire from the rim using a tire changer
machine of tire irons and rim protectors.
Remove tire from rim that has the smallest shoulder
area to simplify removal.

12-10

BREAKER ARM ASSEMBLY
\

ADAPTER

THREADED SHAFT

WHITE NYLON BUTTON:

'RESS HEAD BOLT

TOP EDGE OF

RIM BEAD BLOCKS

FRONT WHEELlSUSPENSlONlSTEERlNG

TIRE REPAIR
NOTE:
Use the manufacturer’s instructions for the tire repair
kit you are using. If your kit does not have instructions, use the procedures provided here.
Check the tire for puncturing objects.
Chalk mark the punctured area and remove the puncturing object.
Inspect and measure the injury.
Tire repairs for injuries lager than 15 mm (518 in)
should be a section repair.
Section repairs should be done by a professional tire
repair shop.
If the injury is smaller than 15 mm (5/8in). proceed
with the repair as described here.
Install a rubber plug into the injury as follows:
Apply a cement to a plug inserting needle and work
the needle into the injury to clean and lubricate it.
Do this three times.
Do not let the cement dry.

Insert and center a rubber plug through the eye of
the inserting needle.

Becarefulnotto

push the plug all
the way into the
tire to prevent it
from falling
inside.

Apply cement to the rubber plug.
Push the inserting needle with plug into the injury
until the plug is slightly above the tire.
Twist the needle and remove it from the tire; the plug
will stay in the tire.
Trim the plug 6 mm (114 in) above the tire surface.
Repeat the above procedure if the puncture is large.
Do not use more than two plugs per injury.
Allow the repair to dry. Drying time will vary with air
temperature. Refer to the tire repair kit manufacturer’s recommendations.
Inflate the tire and test the seal by dabbing a small
amount of cement around the plug. Escaping air will
cause a bubble in the cement. If there is leakage,
remove the tire (page 12-7) and apply a cold patch to
the inside of the tire as described.
If a plug has been inserted, trim it even with the inner
tire surface.
Temporarily place a rubber patch that is at least twice
the size of the puncture over the injury. Make a mark
around the patch, slightly larger than the patch itself.
Rough the area marked inside the tire with a tire
buffer or a wire brush. Clean the rubber dust from
the buffed area.

12-1 1

FRONT WHEELISUSPENSIONISTEERING
Apply cement over the area marked and allow it to
dry.
Remove the lining from the patch and center it over
the injury.
Press the patch against the injury using a special
rolIe r.
NOTE:
*

Allow cement to dry until tacky before applying
patch.
Do not touch the cement with dirty or greasy
hands.

ASSEMBLY
Install the tire onto the rim, where the rim shoulder
width is the narrowest, to simplify installation.

fl-

Clean the rim bead seat and flanges.
Apply clean water to the rim flanges, bead seat and
base.

Use only water as a lubricant removing or mounting
tires. Soap or some mounting lubricants may leave a
slippery residue which w n cause the tire to shift on
the rim and lose air pressure during riding.

Front tire:
Reartire:

Install the valve core in the valve stem.
Install the front tire with the arrow mark facing in the
normal rotating direction.
Install the rear tire with the “OUT SIDE” facing the
tire valve.
Inflate the tire to seat the tire bead.

FRONT TIRE:

RIGHT

LEFT

Deflate the tire. Wait 1 hour and inflate the tire to the
specified pressure.
Check for air leaks and install the valve cap.
COLD TIRE PRESSURE lFront/Rear):
Standard: 27 kPa 10.275 kgflcm’, 4.0 psi)
Minimum: 23 kPa 10.235 kciflcmz. 3.4 osil
Maximum: 31 kPa 10.315 kgflcmz, 4.6psil

SUSPENSION ARM
REMOVAL
Remove the wheel hub (page 12-61.
Remove the tie-rod from the knuckle (page 12-17).
Remove the cotter pins from the upper and lower
arm ball joint studs.
Remove the joint nuts, clamp and washer,

12-12

TIRE CALVE

FRONT WHEEL/SUSPENSION/STEERlNG
rz--

_.______^,,r^

Release the ball joints of the upper and lower arms
off the knuckle, using the special tool according to
the following instructions.

TOOL
Ball joint remover

07MAC - SLOOZOO

Apply grease to the ball joint remover at the point
shown.
This will ease installation of the tool and prevent
damage to the pressure bolt threads.
Insert the jaws carefully. making sure that you do not
damage the ball joint boot.
Adjust the jaw spacing by turning the pressure bolt.

Apply grease here

PRESSURE BOLT

,c
I
,

NOTE:

If necessary, apply penetrating type lubricant t o
loosen the ball joint.

Once the tool is in place, turn the adjusting bolt as
necessary to make the jaws parallel.
Then hand-tighten the pressure bolt and recheck the
jaws to make sure they are still parallel.

PRESSURE BOLT

Tighten the pressure bolt with a wrench until the ball
joint stud pops loose.
Remove the knuckle from the upper and lower arms.

L
ADJUSTING BOLT

Remove the following:
- four bolts and carry pipe

12-13

FRONT WHEEL/SUSPENSION/STEERlNG

- bolt and brake hose clamp from the upper arm
- upper arm pivot nuts, bolts and upper arm
-shock absorber lower mounting nut and bolt
- lower arm pivot nuts, bolts and lower arm

Remove the pivot collars and dust seals.

INSPECTION
Check the pivot collars, dust seals and spherical bearings for wear or damage.

Inspect the ball joint rubber for tears of other damage
by moving the ball joint studs.
It should move freely and smoothly

12-14

FRONT WHEELlSUSPENSlONlSTEERlNG

PIVOT BEARING REPLACEMENT
Remove the stopper rings.
Press the spherical bearing out of the arm pivot.

TOOL
Spherical bearing driver

07HMF - HCOOlOO
not available in
U.S.A. or
O7GAD - PH70100

Install a new stopper ring into the groove in the arm
pivot properly.
Press a new bearing into the arm pivot until it contacts the stopper ring, using the same tool.
Install a new stopper ring into the opposite side
groove.
NOTE:
Spherical bearing case is split as part of manufacturing
process.

BEARING DRIVER

BEARING

STOPPER RING

INSTALLATION
Pack 3 g (0.1
shown.

02)

of grease into each arm pivot as

COLLARS

Coat new dust seal lips with grease and install them
into the arm pivots until they are flush with the pivot
ends.
Install the pivot collars into the dust seals.

Install the following:

- upper and lower

arm with pivot bolts from front
side
- pivot nuts
- shock absorber lower mounting bolt and nut
-brake hose clamp with bolt

TORQUE:
Upperllower arm: 39 Nm (4.0 kgfm, 29 IbfW
Shock absorber: 44 Nm (4.5 kgfm, 33 Ibf.ft)

12-15

FRONT WHEEL/SUSPENSlON/STEERING
-carry

pipe with four bolts

Install the knuckle onto the upper and lower arms
with the joint nuts, washer and clamp.
Tighten each nut to the specified torque and further
tighten until its grooves align with the cotter pin hole.

TORQUE: 29 N m (3.0 kgfm, 22 IbfW
Install new cotter pins.
Install the following:
- tie-rod into knuckle (page 12-7)
- wheel hub and front wheel (page 12-81,

COTTER F'INS

Adjust the toe (page 3-22).

WAS HER

FRONT SHOCK ABSORBER
REMOVAL
i

Support the vehicle with a support block to raise the
front wheels off the ground.
Support the lower arm and remove the upperllower
mounting nuts, bolts and shock absorber.

INSPECTION

TOLLAR

Remove the lower pivot collar and dust seals.
Check the pivot collar and dust seals for wear or
damage.

DUST SEALS

12-16

FRONT WHEEL/SUSPENSION/STEERlNG
Check the bushings for wear or damage.
Check the damper unit for leakage or other damage.
Replace the shock absorber assembly if necessary.

INSTALLATION
Apply molybdenum disulfide paste to the lower
bushing of the shock absorber.
Coat new dust seal lips with molybdenum disuifide
paste and install them into the lower pivot.
Install the lower pivot collar.

Install the shock absorber with the mounting bolts
from front side.

BER

install the mounting nuts and tighten them.
TORQUE: Upper/Lower: 44 N.m (4.5 kgf.m, 33 1bf.W

STEERING SHAFT AND TIE-ROD
REMOVAL
When removing
the tie-rod only,
itcan be
removed without
removingthe
front fender.

Remove the front fender (page 2-21,
Release the cables and wire harness from the cable
guide.
Remove the bolt and brake hose clamp from the
steering shaft holder.
Remove the handlebar lower holder nuts, washers
and the handlebar assembly from the steering shaft.
CAUTION:

Do not twist or bend the brake hose and pipe.
Remove the two bolts and the steering shaft holders.

12-17

FRONT WHEELlSUSPENSlONlSTEERlNG
Remove the cotter pins f r o m the tie-rod ball joint
studs.
Remove the joint nuts by holding the joint stud flat
surfaces.
Remove the tie-rods from the knuckles and steering
shaft.

Remove the cotter p n and tne steering shaft end nut
Remove the steerlng snaft and shaft co lar from tne
frame.

I
i

INSPECTION
Inspect the tie-rod for distortion or damage.
Inspect the ball joint rubbers for tears of other damage by moving the ball joint studs.
They should move freely and smoothly.

Check the steering shaft bushing for wear or damage.

. .

12-18

FRONT WHEEL/SUSPENSION/STEERlNG
Check the steering shaft for distortion or damage.

Turn the inner race of each bearing with your finger.
The bearing should turn smoothly and quietly. Also
check that the bearing outer race fits tightly in the
frame.
Remove and discard the bearing if the race do not
turn smoothly and quietly, if it fits loosely in the
frame.

BEARING REPLACEMENT
Remove the dust seals
Remove the snap ring.
Drive the steering shaft bearing out of the frame.

TOOLS:
Driver
Attachment, 32 x 35 mm

07749 0010000
07746 - 0010100

Drive in a new bearing squarely with the marking
side facing up until it is fully seated.

TOOLS:
Driver
Attachment, 37 x 40 mm
Pilot, 17 mm

07749-0010000
07746-0010200
07746 - 0040400

Install the snap ring into the groove properly.
Coat new dust seals with grease and install them
until they are flush with the frame edge.

BEARING

FRONT WHEELISUSPENSIONISTEERING
TIE-ROD ASSEMBLY

c., .

When the tie-rod ball joints will be replaced, install
the ball joints and lock nuts as shown.

Adjust the tie-rod length so that the distance between
each lock nut and thread end is 6.5 mm (0.26 in). (A
difference between both ends distances is 3 mm (0.1
in) max.
Tighten these
nuts after
installing the tierod into the
knuckle and
steering shaft.

Temporarily tighten the lock nuts while the ball joints
position are 180" from each other.

INSTALLATION

6.5 rnm

6.5 rnm
(0.26 in)

STEERING

Apply grease to the shaft bushing inner surface.
Install the shaft bushing onto the steering shaft with
the "UP" mark facing up.
Install the steering shaft into the shaft bearing.

-5Ai
BUSHING

Install the shaft holders with the two bolts as shown.
Tighten the holder bolts.
TORQUE: 32 N m 13.3 kgfm, 24 Ibf4t)

Install the shaft collar into the dust seal.
Install the end nut and tighten it.
TORQUE: 69 N m 17.0 kgfm, 51 Ibf4t)
Install a new cotter pin.

12-20

FRONT WHEELlSUSPENSlONlSTEERlNG
Install the tie-roo into the steer ng shaft and knuckles
with the flat lwrench holding point1 side facing the
knuckle.
Install the joint nuts and tighten them by holding the
joint stud flat surfaces.

--.

, ..

TORQUE 44 N.m 14.5 kgf.m, 33 IbfW
If the ball joints were replaced, tighten the lock nuts
following procedure:
Rotate both ball joints with the tie-rod axis until they
stop against the ball joint studs. Hold them in that
position and tighten the ball joint lock nuts.

NUT

TORQUE: 54 N m 15.5 kgfm, 40 Ibf4t)

HANDLE-

Install new cotter pins into the tie-rod ball joint studs.

CAUTION:

Do not twist or bend the brake hose and pipe.
Route the wire
andcableproperlylpage 1-18),

Install the handlebar assembly onto the steering
shaft with the lower holder nuts and washers.
Tighten the nuts.

TORQUE: 39 Nm 14.0 kgf.m, 29 IbfW
Install the cables and wire harness into the guide on
the shaft holder.
Install the brake hose onto steering shaft holder with
the clamp bolt.

Adjust the toe (page 3-20).
Install the front fender (page 2-2).

12-21

REAR WHEEL/SUSPENSION

59 N.m (6.0 kgfm, 43 Ibf4tl

I
137 N m (14.0 kgfm, 101 IbfW

108 N m (11.0 kgf.m, 80 Ibf4t)

64 N.m (6.5 kgf.m. 47 Ibf.ft)

13-0

13. REAR WHEEL/SUSPENSION
~

SERVICE INFORMATION

13-1

REAR SHOCK ABSORBER

13-9

TROUBLESHOOTING

13-2

SHOCK LINKAGE

13-11

REAR WHEEL

13-3

SWINGARM

13-13

REAR AXLE

13-3

SERVICE INFORMATION
GENERAL
A contaminated brake disc or Dad reduces stODpino
Discard contaminated Dads and clean a contaminated
. . _ Dower.
.
disc with a high quality brake degreasing agent.
The shock absorber contains nitrogen under high pressure. Do not allow fire or heat near the shock absorber.
Before disposal o f the shock absorber, release the nitrogen b y pressing the valve core. Then remove the valve from
the shock absorber reservoir.

A jack or other support is required to support the vehicle.
When using the lock nut wrench for the axle lock nuts, use a deflecting beam type torque wrench 20 inches long. The
lock nut wrench increases the torque wrench's leverage, so the torque wrench reading will be less than the torque
actually applied to the lock nut. The specification given is the actual torque applied to the lock nut, not the reading on
the torque wrench. Do not overtighten the lock nut. The specification later in the text gives both actual and indicated.
Refer to section 12 for tire information.
Refer to section 3 for drive chain information.
Refer to section 14 for brake system information.

SPECIFICATIONS
Unit: mm (in)

STANDARD

ITEM

SERVICE LIMIT

I 4.0 (0.16)
Minim um
Maximum
Axle runout
Drive chain slack
Shock absorber spring installed length

I 23 kPa (0.235 kgf/cm2, 3.4 psi)
I

31 kPa (0.315 kgf/cm', 4.6 psi)

30-40(1-1/4-1-5/8)

1 231.5 (9.11)

I 3.0

10.12)

TORQUE VALUES
Rear wheel nut
Rear wheel hub nut
Shock absorber mounting nut
Shock link-to-swingarm nut
Shock arm-to-frame nut
Shock arm-to-shock link nut
Final driven sprocket nut
Axle lock nut (outer)
(inner)
Swingarm pivot nut
Caliper stopper pin

64 N m (6.5 kgfm. 47 IbfW
137 N m (14.0 kgfm. 101 IbfW
Apply grease to the threads and seating surface/Castle nut
59 N m (6.0 kgfm, 43 Ibf.ft)
44 N m (4.5 kgfm, 33 IbfW
59 N m (6.0 kgfm, 43 IbfW
59 N m (6.0 kgfm, 43 IbfW
59 N m (6.0 kgfm, 43 Ibf.ft)
88 N m (9.0 kgfm, 65 IbfW
Apply locking agent to the threads
Apply locking agent to the threads
128 N m (13.0 kgfm, 94 IbfW
108 N m (11.0 k g f m 80 IbfW
Apply locking agent to the threads
59 N m (6.0 kgfm. 43 IbfW

13-1

REAR WHEEL/SUSPENSION

TOOLS
Driver
Attachment, 24 x 26 mm
Attachment, 62 x 66 mm
Attachment, 35 mm I.D.
Pilot, 17 mm
Pilot, 40 mm
Lock nut wrench, 56 mm
Lock nut wrench, 45 mm
Needle bearing remover
Assembly collar

07749 - 0010000
07746 - 0010700
07746 - 0010500
07746 - 0030400
07746-0040400
07746 - 0040900
07916 - HA20000 or 07916- HA2010A (U.S.A. only)
07916- 1870101 or equivalent commercially available in U.S.A.
07946 - KA50000
07965 - VMOOIOO

TROUBLESHOOTING
Rear wheel wobbling
Bent rim
Worn or damaged rear axle bearings
* Faulty rear tire
Axle fastener not tightened properly
* Faulty swingarm pivot bearings
*
*

Rear wheel turns hard
Faulty rear axle bearings
Bent rear axle
* Rear brake drag
* Drive chain too tight

Soft suspension
*
*

Weak shock absorber spring
Incorrect suspension adjustment
Oil leakage from damper unit

Hard suspension
Incorrect suspension adjustment
Damaged rear suspension pivot bearings
Bent damper rod

*
*

Rear suspension noise
Faulty rear shock absorber
* Loose rear suspension fasteners
* Worn rear suspension pivot bearings

13-2

REAR WHEELlSUSPENSlON

REAR WHEEL
REMOVAL
Loosen the wheel nuts.
Supporr the vehicle with a support block to raise the
rear wheels off the ground.
Remove the nuts and wheel.
For tire removallinstallation and repair, refer to section 12.

INSTALLATION
Install the tire onto the hub with the tire valve facing
out.
Install the wheel nuts with the tapered side facing
inward and tighten them.

TAPERED SIDE

TORQUE: 64 Nm 16.5 k g f m 47 IbfW

REAR AXLE

INNER LOC

REMOVAL
i

CAUTION:
Suooort the caliDer so that it does not hang from the
brake hose. Do n o t twist or bend the brakehose.
Remove the rear brake caliper (page 14-6).

i
~

-1_

Thelocknuts
has left hand
threads

Loosen the axle inner lock nut while holding the
outer lock nut, using the special tools.

-.- -.

I
(

OUTER LOCK NUT

TOOLS
Lock nut wrench, 56 mm

Lock nut wrench, 45 mm

07916 - HA20000 or
07916- HA2010A
(U.S.A. only)
07916 - 1870101 or
equivalent commercially
available in U S A .

Loosen the outer lock nut until the stopper ring can
be removed, using same tool.
Remove the stopper ring from the axle groove.

13-3

REAR WHEELlSUSPENSlON
Remove the wheels (page 13-31,

NUT

Remove the cotter pin and the hub nut.
Remove the right wheel hub.

Remove the stopper ring, outer and inner lock nuts
from the axle.
Remove the skid plate (page 2-5).
Remove the brake disclhub by sliding it outward.
Remove the O-ring from the inside of the disc hub.

‘STOPPER RING
Loosen the rear axle for maximum drive chain slack
(page 3-13).
Remove the drive chain from the driven sprocket.
If the sprocket must be replaced, remove the four
nuts, bolts and the driven sprocket.

Install the
ni 31 , the right end c
! axle to
prevent the threads from beingdamage.
Remove the axle by driving the axle out of the bearing holder in the swingarm, using a rubber mallet.

13-4

REAR WHEELlSUSPENSlON
Remove the O-ring.
Remove the nuts, bolts and driven sprocket.

SPROCKET
Remove the snap ring from the bearing holder.
Remove the caliper stay and stopper bushing.
Remove the O-rings from the bearing holder and stay
groove.

\
SNAP KING
Remove the axle bearing holder to the left by tapping
it lightlyfrom the right side.
Remove the 0-rings from the holder grooves.
Remove the dust seals.

INSPECTION
Set the axle in V-blocks and measure the axle runout
with a dial indicator.
Actual runout is 112 the total indicator reading.

SERVICE LIMIT 3.0 mm (0.12in1

13-5

REAR WHEEL/SUSPENSION
Turn the inner race of each bearing with your finger.
The bearings should turn smoothly and quietly. Also
check that the bearing outer race fits tightly in the
holder.
Replace the axle
bearings in
osirs.

Remove and discard the bearings if the races do not
turn smoothly and quietly or if they fit loosely in the
holder.

INSTALLATION
STOPPER BUSHING
I

' RING

0-~NGS
BOLTS

DRIVEN SPROCKET

REAR WHEELlSUSPENSlON
Drive in a new right bearing (brake disc side) squarely
with the marking side facing up until it is fully seated.
Install the distance collar.
Drive in a new left bearing squarely with the marking
side facing up until it is fully seated.

TOOLS
Driver
Attachment, 62 x 68 mm
Pilot, 40 mm

07749-0010000
07746-0010500
07746-0040900

ATTACHMENTAND PILOT
a

Clean the bearing holder outer surface and the
swingarm inner surface.

Coat new O-rings with oil and install them into the
grooves in the bearing holder.
Apply grease to the bearing holder outer surface.
Install the bearing holder into the swingarm until it is
fully seated, being careful not to damage the O-rings.

Coat new O-rings with oil and install them into the
caliper stay groove and onto the bearing holder.
Install the bushing onto the stopper bolt.
Apply grease to the inner surface of the caliper stay
and install the stay onto the bearing holder and bushing.
Install the snap ring into the bearing holder gropve
with the "OUT SIDE" facing out to secure the caliper
stay.

Pack 1 g (0.04 oz) of grease into each new dust seal
lip cavity.
Install the dust seals until they are flush with the
bearing holder

STAY

13-7

REAR WHEELlSUSPENSlON
Install the driven sprocket with the chamfered side of
the bolt holes facing in.
Coat a new O-ring with oil and install
driven sprocket flange and axle.

between the

'ROCKET

Install the axle into the swingarm through the drive
chain until it is fully seated. Install the chain over the
driven sprocket.

Coat a new O-ring with oil and install it into the
groove in the disc hub.
Apply grease to the disc hub splines.
Install the brake disclhub onto the axle with the
stamp facing out.
Install the inner and outer lock nuts onto the axle.
Install the stopper ring but do not install it into the
ring groove yet.

Apply grease t o the hub nut threads and seating surface.
Install the wheel hub and hub nut onto the axle.
Tighten the hub nut to the specified torque and further tighten it until its grooves align with the cotter
pin hole.

TORQUE: 137 N.m (14.0 kgfm, 101 IbfW
Install a new cotter pin.
Install the wheels (page 13-3).

COTTER PIN'

Q
$
*

13-8

REAR WHEELlSUSPENSlON

Thelocknuts
haslen-hand
threads.

Turn the outer lock nut clockwise until the stopper
ring groove is covered with the outer lock nut and
apply locking agent to the lock bolt threads as shown.
Turn the outer lock nut counterclockwise until the
ring groove is visible and install the stopper ring into
the groove.
Apply grease to the stopper ring (outer lock nut seating surface) and turn the outer lock nut to seat it
against the stopper ring.
Tighten the outer lock nut.
TOOL
Lock nut wrench, 45 mm

Refer to torque
wrench reading
mformation on
page 13-1
"SERVICE
INFORMATION".

07916 - 1870101 or
equivalent commercially
available in U.S.A.

UTER LOCK NUT

TORQUE: Actual: 88 Nm (9.0 kgf.m, 65 Ibf4t)
Indicated: 79 N.m (8.1 kgf.m, 59 IbfW
Apply locking agent to the inner lock nut area of the
lock bolt threads.
Tighten the inner lock nut while holding the outer
lock nut.
TOOLS
Lock nut wrench, 56 mm

Lock nut wrench, 45 mm

07916 - HA20000 or
07916 - HA2010A
(U.S.A. only)
07916 1870101 or
equivalent commercially
available in U.S.A.

WRENCH

TORQUE: Actual: 128 N.m (13.0 kgf.m, 94 Ibf4tl
Indicated: 115 N.m (11.7 kgf.m.85 Ibf4t)
Tighten the driven sprocket nuts if the sprocket was
removed.
TORQUE 59 N.m (6.0 k9f.m. 43 IbfW
Install the brake caliper (page 14-6).
Install the skid plate (page 2-5).
Adjust the drive chain slack (page 3-13)

REAR SHOCK ABSORBER
REMOVAL
Remove the seatlrear fender (page 2-21.
Support the vehicle with a support block to raise the
rear wheels off the ground.
Support the swingarm and remove the mounting
nuts, bolts and the shock absorber.

INSPECTION
Becarefulnot to
lose the needle
rollers o f the
bearing.

Remove the upper pivot collar and check the needle
bearing, pivot collar and dust seals for wear or damage.
Checkthe damper unit for leakage or other damage.
Replace the shock absorber assembly if necessary.

13-9

REAR WHEEL/SUSPENSION

BEARING REPLACEMENT
Remove the dust seals.
Press the needle bearing out of the shock absorber.

TOOL
Needle bearing remover

Press the mark-

ing side of the
bearing.

07946 KA50000

Apply grease to new needle bearing rollers.
Carefully press the needle bearina into the shock
absorber until the depth from the outer surface is 5.5
mm (022 in).

TOOLS:
Driver
Attachment, 24 x 26 mm
Pilot, 17 mm

DRYER

07749 0010000
07746 - 0010700
07746 - 0040400

Make sure that the need e rollers are in positJon.

"I /

Apply grease to new dust seal lips and install them
into the upper pivot until they are seated against the
needle bearing.
Install the pivot collar.

'PIVOT

INSTALLATION
Set the shock absorber onto the shock link and into
the frame and install the mounting bolts from the
right side.
Install the mounting nuts and tighten them.

TORQUE: Upper/Lower: 59 Nm 16.0 kgf.m, 43 Ibf.ft)
Install the seathear fender (page 2-2).

13-10

COLLAR

REAR WHEELlSUSPENSlON

SHOCK LINKAGE

REMOVAL
i

NOTE:
The linkage can be serviced with the skid plate
installed, although it is easier to service if the skid
plate is removed (page 2-51,
Support the vehicle with a support block to raise the
rear wheels off the ground.

Support the swingarm and remove the following:
-shock absorber lower mounting nut and bolt
-shock arm-to-shock link nut and bolt
-shock link-to-swlngarm nut and bolt
-shock link and washer
-shock arm-to-frame nut and bolt
-shock arm

?
-

INSPECTION
Becarefulnotto
lose the needle
rollers of the
bearing.

Remove the pivot collars and check the needle bearings, pivot collars and dust seals for wear or damage.

BEARING REPLACEMENT

NEEDLE BEARING
REMOVER

Remove the dust seals.
Press the needle bearing out of the shock arm and
shock link.

TOOLS:
Needle bearing remover
Assembly collar

07946 KA50000
07965 - VMOOIOO

COLLAR

/
13-1 I

REAR WHEEL/SUSPENSION

Press the marking side of the
bearing

Apply grease to new needle bearing rollers.
Carefully press the needle bearing into the shock arm
and shock link until the depth from the outer surface
is 5.5 mm (0.22 in).

TOOLS:
Driver
Attachment, 24 x 26 mm
Pilot, 17 mm

07749 - 0010000
07746-0010700
07746-0040400

p'iiACHMENTAND
*PILOT

Make sure that the needle rollers are in position.
Apply grease to new dust seal lips and install them
into the pivots until they are seated against the needle bearings.
Install the pivot collars.

INSTALLATION
Note the installation of the pivot
bolts. All bolts
are installed
from the right
side.

Install the shock arm into the frame with the "UP"
mark facing up and the bolt and nut.

-.StiOCJ.

install the shock link over the shock arm and into the
swingarm with the washer (left side of the shock
link), bolts and nuts.
Connect the shock absorber to the shock link with the
bolt and nut.
Tighten the linkage and shock absorber mounting nuts.

TORQUE:
Shock arm-to-frame: 59 N m (6.0 kgfm, 43 Ibf4t)
Shock arm-to-shock l i n k
59 N m (6.0 kgfm, 43 Ibf4tl
Shock link-to-swingarm:
44 N m 14.5 kgfm, 33 IbfW
Shock absorber mounting:
59 N m (6.0 kgfm, 43 Ibf4t)

13-12

A?M

\ -

7
n
0

sc,

)CK ARM

REAR WHEEL/SUSPENSION

SWINGARM

CLAr

REMOVAL
Remove the rear axle (page 13-31,

Support the swingarm and remove the following:
-screw and brake hose clamp
- bolt and brake hosellock cable clamp
-shock absorber lower mounting nut and bolt
-shock link-to-swingarm nut and bolt

- swingarm pivot nut and bolt
- swingarm from the frame

-dust seal caps and outer dust seals
-under cover and chain slider if necessary.

INSPECTION
Becarefulnot to
lose the needle
rollers of the
bearing.

Remove the pivot collars and check the needle bearings, pivot collars and dust seals for wear or damage.

\
INNER DUST
/
SLIDER

I
COLLARS

BEARING REPLACEMENT
Remove the inner dust seals.
Press the needle bearing and thrust bushing out of
the swingarm.

TOOLS:
Needle bearing remover
Attachment, 35 mm I.D.

EDLE BEAR1
nti v i u v t n

07946 - KA50000
07746-0030400

I.+---

A n A C H MEF

13-13

REAR WHEEL/SUSPENSION

Press the
marking side of
the bearing.

NEEDLE BEARING

Apply grease to new needle bearing rollers.
Carefully press the needle bearing and thrust bushing into the swingarm pivot until the bushing is fully
seated.

TOOL
Needle bearing remover

RFhfln\/FR

SHlNG

07946 - KA50000

\RING
/

Pack grease into new inner dust seal lip cavities.
Install the inner dust seals until they are flush with
the pivot surfaces.
Install the pivot collars.

INSTALLATION

Instail the slider
with the wear
limit groove facing up, aligning
its slit with the
lug.

Install the following if they are removed:
-under cover with the bolt
-chain slider with the bolts and collars
Pack grease into new outer dust seal lip cavities.
Install the outer dust seals onto the swingarm pivots
and the seal caps over the dust seal securely.
Set the swingarm into the frame, take care to prevent
removing the dust seal caps, and install the pivot bolt
from the right side.
Install the pivot nut and tighten it.

JPIVOT'BOLTAND NJT

TORQUE: 108 N.m (11.0 kgfm, 80 Ibf.ft)

BOLTS AND NUTS

Connect the shock link to the swingarm and the
shock absorber to the shock arm by inserting the
pivot bolts from the right side.
Install the nuts and tighten them.

TORQUE:
Shock link-to-swingarm:
44 Nm (4.5kgfm, 33 Ibf.ftl
Shock absorber mounting:
59 N.m (6.0 kgfm, 43 Ibf4tl

SHOCI: LINK'

-_I_

13-14

ABSORBER
-

REAR WHEELlSUSPENSlON
Install the brake hoselcable clamp with the bolt t o
secure the brake lock cable.
Install the brake hose clamp with the screw.

SCREW/
CLAMP

Install the rear axle (page 13-6).

’ BRAKE HOSE

LOCK CABLE

13-15

HYDRAULIC DISC BRAKE

34 N m (3.5 kgfm, 25 IbfW

34 N m (3.5 kgfm, 25 Ibf.ft)

14-0

14. HYDRAULIC DISC BRAKE
SERVICE INFORMATION

14-1

FRONT BRAKE CALIPER

14-10

TROUBLESHOOTING

14-2

REAR MASTER CYLINDER

14-13

REAR BRAKE CALIPER

14-16

BRAKE PEDAL

14-20

BRAKE FLUID REPLACEMENT/
AIR BLEEDING
BRAKE PAD/DISC

14-3
14-5

FRONT MASTER CYLINDER

14-7

SERVICE INFORMATION
GENERAL
L

A confarninafed brake disc or p a d reduces stopping power. Diswrd contaminatedpads and clean a contaminated disc
with a high quality brake degreasing agent.

ITEM
Recommended brake fluid
Brake disc thickness

STANDARD
DOT 4 brake fluid

Front

Brake disc runout
Master cylinder ID.
Master piston O.D.
Caliper cylinder I.D.
Caliper piston O.D.

Caliper bleed valve
Front brake caliper pad pin plug
Front brake caliper pad pin
Rear brake caliper pad pin
Brake hose oil bolt
Brake pipe joint nut
Front brake lever pivot bolt
nut
Rear master cylinder mounting bolt
Rear master cylinder reservoir hose joint screw
Front brake caliper slide pin
Front brake caliper bracket pin
Front brake caliper mounting bolt
Rear brake caliper slide pin
Rear brake caliper bracket pin
Rear brake caliper mounting bolt
Rear brake caliper parking brake base bolt

2.8-3.2(0.11-0.13)
3.8-4.2(0.15-0.17)

Rear

12.700-12.743(0.5000-0.5017)
12.657- 12.684(0.4983- 0.4994)
33.960-34.010(1.3370-1.3390)
33.895- 33.928(1.3344-1.3357)

6 N m (0.6 kgfm, 4.3 IbfW
3 N m (0.3kgfm, 2.2 IbfW
18 N m (1.8k g f m 13 IbfW
18 N m (1.8kgfm, 13 IbfW
34 N m (3.5kgfm, 25 Ibf.ft)
17 N m (1.7kgf.m, 12 IbfW
6 N.m (0.6kgfm, 4.3 IbfW
6 N m (0.6 kgfm, 4.3 Ibf4t)
13 N m (1.3kgfm, 9 Ibf4t)
2 N m (0.2kgfm, 1.4 Ibf.ft)
23 N m (2.3kgfm, 17 Ibf.ft)
18 N m (1.8kgfm, 13 IbfW
30 N m (3.1 kgfm, 22 IbfW
23 N m (2.3kgfm, 17 IbfW
18 N m (1.8kgfm, 13 Ibf-ft)
30 N m 13.1 kgfm, 22 IbfW
23 N.m (2.3k g f m 17 IbfW

SERVICE LIMIT
2.5 (0.10)
3.5 (0.14)
0.30 (0.012)
12.75(C1.502)
12.65(C1.498)
34.02(11.3401
33.87(1:ssSl

:m
-

ALOC bolt
Apply locking agent to the threads

ALOC bolt
Apply locking agent to the threads
ALOC bolt
Apply locking agent to the threads

14-1

HYDRAULIC DISC BRAKE

TOOL
Snap ring pliers

TROUBLESHOOTING
Brake leverlpedal soft or spongy
Air in hydraulic system
Leaking hydraulic system
Contaminated brake padldisc
Worn caliper piston seals
* Worn master cylinder piston cups
Worn brake padldisc
Contaminated caliper
Contaminated master cylinder
* Caliper not sliding properly
Low brake fluid level
* Clogged fluid passage
Warpedldeformed brake disc
* Stickinglworn caliper piston
Stickinglworn master piston
Bent brake leverlpedal

--*

Brake leverlpedal hard
Clogged/restricted hydraulic system
Stickinglworn caliper piston
Stickinglworn master piston
* Caliper not sliding properly
Bent brake leverlpedal

Brake grab or pull one side
* Misaligned disc or wheel
* Contaminated brake padldisc
* Warpedldeformed brake disc
Caliper not sliding properly

Brake drag
Contaminated brake padldisc
* Badly worm brake pad/disc
* Warpedldeformed brake disc
* Caliper not sliding properly
* Cloggedlrestricted fluid passage
Sticking caliper piston
* Misaligned disc

14-2

07914- SA50001

HYDRAULIC DISC BRAKE

BRAKE FLUID REPLACEMENT/
AIR BLEEDING
A contaminated brake disc or pad reduces stopping
power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing
agent.
CAUTION

Do not allow foreign material to enter the system
when filling the reservoir.
Avoid spilling fluid on painted, plastic or rubber
parts. Place a rag over these parts whenever the
system is serviced.
Use onlv DOT 4 brake fluid from a sealed container.
Do not mix different types of fluid. They are not
compatible.

BRAKE FLUID DRAINING
Remove the reservoir cap, set plate and diaphragm
(page 3-14 for front, page 3-15 for rear).
Connect the bleed tube to the bleed valve.
Loosen the bleed valve and pump the brake lever or
pedal until no more fluid flows out of the bleed valve.

1
--.,
~

-- -

.BLEtL; .t:i,.,,-Vt.

BRAKE FLUID FILLING/BLEEDING
Close the bleed valve.
Fill the reservoir with DOT 4 brake fluid from a sealed
container.
Connect a commercially available brake bleeder to
the bleed valve.
Pumo the brake bleeder and loosen the bleed valve.
Add brake fluid when the fluid level in the reservoir is
low.

NOTE:
*

Check the fluid level often while bleeding the
brake to prevent air from being pumped into the
system.
When using a brake bleeding tool, follow the man.
ufacturer's oDerating instructions.

14-3

HYDRAULIC DISC BRAKE

not appear in the bleed tube.
NOTE:
~~

If air is entering the bleeder from around the bleed
valve threads, seal the threads with teflon tape.
Close the bleed valve and operate the brake lever or
pedal. If it still feels spongy, bleed the system again.

R
If a brake bleeder is not available. use the following
procedure:
Pump up the system pressure with the brake lever or
pedal until lever or pedal resistance is felt.

Connect a bleed tube to the bleed valve and bleed
the system as follows:
1. Squeeze the brake lever or depress the brake
pedal, open the bleed valve 114 turn and then
close it.
NOTE:

Do not release the brake lever or pedal until the
bleed valve has been closed.
2. Release the brake lever or pedal slowly and wait
several seconds after it reaches the end of its travel.

Repeat the steps 1 and 2 until air bubbles do not
appear in the bleed tube.
Tighten the bleed valve.

TORQUE: 6 N m 10.6 kgfm, 4.3 Ibf4t)
Fill the reservoir to the upper level line with DOT 4
brake fluid from a sealed container.
Install the diaphragm, set plate and reservoir cap
(page 3-14 for front, page 3-15 for rear).

14-4

HYDRAULIC DISC BRAKE

BRAKE PAD/DISC
FRONT BRAKE PAD REPLACEMENT
Always replace
the brake pads in
pairs to ensure
even discpressure.

Remove the front wheel (page 12-6).
Remove the pad pin plugs and loosen the pad pins.
Release the brake hose from the clamp.
Remove the mounting bolts and front brake caliper.

Push the caliper piston all the way in to allow installation of new brake pads.
NOTE:
Check the brake fluid level in the brake reservoir as
this operation causes the level to rise.
Pull the pad pins out of the caliper body while pushing in the pads against the pad spring.
Remove the brake pads.

Make sure that the pad spring is in position as
shown.
Install new brake pads into the caliper body with the
shim facing toward the piston.
Install the pad pins by pushing in the pads against
the pad spring to align the pad pin holes in the pads
and caliper body.

Install the front brake caliper so the disc is positioned
between the pads, being careful not to damage the
pads.
Install new mounting bolts and tighten them.

TORQUE: 30 N.m (3.1 kgf.m, 22 Ibf4t)
Secure the brake hose with the clamp.
Tighten the pad pins.

TORQUE: 18 N.m (1.8 kgfm, 13 IbfW
Install the pad pin plugs and tighten them.

TORQUE 3 N.m 10.3 kgf.m, 2.2 IbfW
Operate the brake lever to seat the caliper piston
against the pads.

14-5

HYDRAULIC DISC BRAKE

REAR BRAKE PAD REPLACEMENT
Alwaysreplace
the brake pads in
pairs to ensure
even discpressure.

Straighten the lock plate tabs and loosen the pad
pins.
Remove the mounting bolts and rear brake caliper.

Push the caliper piston all the way in to allow installation of new brake pads.
NOTE:
Check the brake fluid level in the brake reservoir as
this operation causes the level to rise.
Pull the pad pins out of the caliper body with the lock
plate while pushing in the pads against the pad
spring.
Remove the brake pads.

Make sure that the pad spring is in position as
shown.
Install new brake pads into the caliper body with the
shim facing toward the piston.
Install the pad pins with a new lock plate by pushing
in the pads against the pad spring to align the pad
pin holes in the pads and caliper body.

I
1

Install the rear brake caliper so the disc is positioned
between the pads, being careful not to damage the
pads.
Install new mounting bolts and tighten them.
TORQUE: 30 Nm (3.1 kgf.m, 22 Ibf4t)
Tighten the pad pins.

TOROUE: 18 Nm (1.8 kgfm, 13 IbfW
Bend up the lock plate tabs against the pad pins.
Operate the brake pedal to seat the caliper piston
against the pads.

14-6

HYDRAULIC DISC BRAKE

BRAKE DISC INSPECTION

Visually inspect the disc for damage or cracks.
Measure the brake disc thickness at several points.

SERVICE LIMIT Front: 2.5 mm (0.10 in1
Rear: 3.5 mm (0.14 in)

Replace the brake disc if the smallest measurement IS
less than service limit.

Check the brake disc for warpage.

SERVICE LIMIT 0.30 mm 10.012 in)
Check the bearing for excessive play, if the warpage
exceeds the service limit.
Replace the brake disc if the bearings are normal.

FRONT MASTER CYLINDER

MASTER CYLINDER

CAUTION:

Avoid spilling fluid on painted, plastic or rubber
park. Place a rag over these parts whenever the
system is serviced.
When removing the oil bolt, cover the end of the
hose to prevent contamination.

DISASSEMBLY
Drain the brake fluid from the front brake hydraulic
system (page 14-3).
Disconnect the brake hose from the master cylinder
by removing the oil bolt and sealing washers.

BRAKE HOSE

HOLDER

I LEVER

Remove the master cylinder holder bolts, holder and
the master cylinder.
Remove the following:
- pivot nut, bolt and brake lever
- piston boot

14-7

HYDRAULIC DISC BRAKE
-snap ring

SNAP RING

TOOL
Snap ring pliers

07914

- SA50001

- master piston
-spring
Clean the master cylinder, reservoir and master piston in clean brake fluid.

INSPECTION
Check the piston cups for wear, deterioration or damage.
Checkthe spring for damage.
Check the master cylinder and piston for scoring,
scratches or damage.
Measure the master cylinder I.D.

SERVICE LIMIT 12.75 mm (0.502 in1
Measure the master piston O.D.

SERVICE LIMIT: 12.65 mm (0.498 in1

ASSEMBLY
MASTER CYLINDER

BOLT

HYDRAULIC DISC BRAKE
Coat the master piston and piston cups with clean
brake fluid.
Install the spring onto the master piston.
Install the sorina
.
I and master Diston into the master
cylinder.

CAUTION:

. .

Do not allow the oiston CUD lim to turn inside out.

PISTON

Install the snap ring into the groove in the master
cylinder, using the special tool.

TOOL
Snap ring pliers

07914 SA50001

CAUTION:
Be certain the snap ring is firmly seated in the
groove.
Install the boot into the master cylinder and the
groove in the piston.
Apply silicone grease to the brake lever contacting
surface of the piston.
Apply silicone grease to the brake lever pivot.
Install the brake lever and pivot bolt, and tighten it.

BOLT AND NUT

BOOT

TORQUE: 6 N m (0.6 kgfm, 4.3 IbfW
Install the pivot nut and tighten it.

TORQUE: 6 Nm (0.6 kgfm, 4.3 Ibf4tl

Install the master cylinder and holder with the "UP"
mark facing up.
Align the end of the master cylinder with the punch
mark on the handlebar, and tighten the upper bolt
first, then tighten the lower bolt.
Connect the brake hose to the master cylinder with
the oil bolt and new sealing washers by aligning the
hose joint with the stopper groove.
Tighten the oil bolt.

TORQUE: 34 Nm (3.5 kgfm, 25 IbfW

Fill and bleed the front brake hydraulic system (page
14-3).

PUNCH M ARK

"UP" MARK

14-9

HYDRAULIC DISC BRAKE

FRONT BRAKE CALIPER
CAUTION
Avoid spilling fluid on painted, plastic or rubber
parts. Place a rag over these parts whenever the system is serviced.

DISASSEMBLY

Remove the front wheel (page 12-61.
Drain the brake fluid from the front brake hydraulic
system (page 14-3).

I
/L

OIL RO! i

Disconnect the brake hose from the front brake
caliper by removing the oil bolt and sealing washers.
Remove the dust plug and loosen the caliper slide
pin.

'LUG AND SLIDE PIN

BOOTS

Removethe brake pads (page 14-5).
Loosen the slide pin and remove the following:
-caliper bracket and washer
- pad spring
-slide pin and boots

WASHER

Place the shop towel over the piston.
Position the caliper body with the piston down and
apply small squirts of air pressure to the fluid inlet to
remove the piston.

Do not use high pressure air or bring the nozzle too
close to the inlet.

Push the dust seal and piston seal
out.

in and lift them

CAUTION:
Be careful not to damage the piston sliding surface.
Clean the seal grooves, caliper cylinder and piston
with clean brake fluid.

14-10

HYDRAULIC DISC BRAKE

INSPECTION
Check the caliper cylinder and piston f o r scoring,
scratches or damage.
Measure the caliper cylinder I.D.

SERVICE LIMIT: 34.02 mm (1.340 in)
Measure the caliper piston O.D.

SERVICE LIMIT 33.87 mm (1.333 in1

ASSEMBLY
BLEED VALVE

PAD PIN PLUGS

CALIPER BODY

PISTON SEAL

CALIPER BRACKET

WEAR REFERENCE PLATE

WASHER

BRACKET PIN

Coat new piston seal and dust seal with clean brake
fluid and install them into the seal grooves in the
caliper.
Coat the caliper piston w i t h clean brake fluid and
install it into the caliper cylinder with the opening
toward the caliper body.

14-1 I

HYDRAULIC DISC BRAKE
Install the pad spring as shown.

If the pin boots are hard or deteriorated, replace
them with new ones.
Install the bracket pin boot into the caliper body and
pack silicone grease to the inside of the boot.
Apply silicone grease to the grease groove in the
slide pin.
Install the slide pin boot and the slide pin so the boot
ribs properly align with the grooves in the caliper
body and slide pin.

Install the caliper bracket over the caliper body with
the spring washer (between the slide pin and bracket)
and thread the slide pin into the bracket, being careful not to damage the pin boot.
Make sure that the boots are seated securely into the
pin grooves.

Install the brake pads (page 14-5).
Tighten the slide pin and install the dust plug.

TORQUE: 23 N m (2.3 kgfm, 17 IbfW
Connect the brake hose to the brake caliper with the
oil bolt and new sealing washers, and tighten the oil
bolt by aligning the hose joint with the stopper
groove.

TORQUE: 34 Nm (3.5 kgfm, 25 Ibf.ft)
Fill and bleed the front brake hydraulic system (page
14-3).

Install the front wheel (page 12-91,

14-12

HYDRAULIC DISC BRAKE

REAR MASTER CYLINDER

CAUTION:
Avoid spilling fluid on painted, plastic or rubber
parts. Place a rag over these parts whenever the
system is serviced.
When removing the oil bolt, cover the end of the
hose to prevent contamination.

DISASSEMBLY
Drain the brake fluid from the rear brake hydraulic
system (page 14-3).
Disconnect the push rod from the brake pedal by
removing the cotter pin and joint pin.
Disconnect the brake hose from the master cylinder
by removing the oil bolt and sealing washers.
Remove the master cylinder mounting bolts.

Disconnect the reservoir hose joint from the master
cylinder by removing the joint screw.
Remove the O-ring.

Remove the boot from the master cylinder.
Remove the snap ring and push rod using the special
tool.

TOOL
Snap ring pliers

07914 SA50001

Remove the master piston and spring.
Clean the master cylinder and master piston in clean
brake fluid.

14-13

HYDRAULIC DISC BRAKE

INSPECTION

Check the piston cups for wear, deterioration or damage.
Check the spring for damage.
Check the master cylinder and piston for scoring,
scratches or damage.
Measure the maser cylinder I.D.
SERVICE LIMIT 12.75 mm 10.502 in)
Measure the master piston O.D.
SERVICE LIMIT 12.65 mm 10.498 in1

ASSEMBLY
MASTER CYLINDER
I

PUSH ROD

L
SPRING

Coat the master piston and piston cups with clean
brake fluid
Install the spring onto the master piston.
Install the spring and master piston into the master
cylinder.

TER PISTON

OD
CAUTION:
Do not allow the piston cup lips to turn inside out.

Apply silicone grease to the push rod contacting area
of the master piston and the boot groove in the push
rod.

14-14

HYDRAULIC DISC BRAKE

Install the push rod into the master cylinder and the
snap ring into the groove in the master cylinder,
using the special tool.
TOOL
Snap ring pliers

07914

- SA50001

CAUTION:

Be certain the snap ring is firmly seated in the
groove.
Install the piston boot into the master cylinder and
the groove in the push rod.

\SNAP RING
PLIERS

If the push rod joint is reinstalled, adjust the push rod
length so that the distance from the center of the
master cylinder lower mounting hole to the center of
the ioint Din hole is 80 mm (3.1 in).
Tighten the lock nut.
Adjust the brake pedal height if necessary (page 316).

80 mm (3.1 in)

-1

Coat a new O-ring with brake fluid and install it onto
the hose joint
Apply locking agent to the joint screw threads.
Connect the reservoir hose joint to the master cylinder and secure it with the joint screw.
TORQUE: 2 Nm (0.2 kgf.m, 1.4 Ibf.ft)

Install the master cylinder with new mounting bolts
and tighten them.
TORQUE 13 Nm 11.3 k g f m 9 IbfW
Connect the brake hose to the master cylinder with
the oil bolt and new sealing washers, and tighten the
oil bolt.
TORQUE: 34 Nm (3.5 kgfm, 25 IbfW

14-15

HYDRAULIC DISC BRAKE
Connect the push rod t o the brake pedal with the
joint pin and secure it with a new cotter pin.
Fill and bleed the rear hydraulic system (page 14-3).

REAR BRAKE CALIPER
CAUTION:
~

Avoid spilling fluid on painted, plastic or rubber
parts. Place a rag over these parts whenever the system is serviced.

DISASSEMBLY
Drain the brake fluid from the rear brake hydraulic
system (page 14-3).
Loosen the lock nut and remove the adjusting bolt
and brake arm. Disconnect the brake lock cable from
the brake arm and remove it from the cable stay.

ADJUSTING
BOLT

Remove the two bolts and parking brake base.
Remove the O-ring.
Disconnect the brake hose from the rear brake caliper
by removing the oil bolt and sealing washers.
Loosen the caliper slide pin,
Remove the brake pads (page 14-6).

Loosen the slide pin and remove the following:
-caliper bracket and washer
- pad spring
-slide pin and boots
-caliper piston

14-16

HYDRAULIC DISC BRAKE
CAUTION:
Be careful not to damage the piston sliding surface.
c

Push the dust seal and piston seal in and lift them
out.
Remove the O-ring.
Clean the seal grooves, caliper cylinder and piston
with clean brake fluid.

INSPECTION
CABLE LOCK BRAKE
Remove the shaft boot and the brake shaft.
Check the shaft and base threads for wear or damage.

HYDRAULIC BRAKE
Check the caliper cylinder and piston for scoring,
scratches or damage.
Measure the caliper cylinder I.D.

SERVICE LIMIT 34.02 mm (1.340 in)
Measure the caliper piston O.D.

SERVICE LIMIT 33.87 mm (1.333 in)

14-17

HYDRAULIC DISC BRAKE

ASSEMBLY

WASHER
CALIPER BRACKET

WASHER

SLIDE PIN
OTS

BRAKE PADS
IM

PISTON SEAL
DUSTSEAL

SZN
BOOT

PAD SPRING

WEAR REFERENCE PLATE

-RING

PARKING BRAKE BASE

BRAKE SHAFT
-BOOT

BLEED VALVE
LOCK NU?

ADJUSTING BOLT

Coat a new O-ring with clean brake fluid and install it
into the caliper.
Coat new piston seal and dust seal with clean brake
fluid and install them into the seal grooves.
Coat the caliper piston with clean brake fluid and
install it into the caliper cylinder.

**
&
O-RING
Install the pad spring as shown.
If the pin boots are hard or deteriorated, replace
them with new ones.

Install the bracket pin boot into the caliper body and
pack silicone grease to the inside of the boot.
Apply silicone grease to the grease groove in the
slide pin.
Install the slide pin boots and the slide pin so the
boot ribs properly align with the grooves in the
caliper body and slide pin.

SPRING

14-18

HYDRAULIC DISC BRAKE
Install the caliper bracket over the caliper body with
the spring washer (between the slide pin and bracket)
and thread the slide pin into the bracket, being careful not to damage the pin boot.

Make sure that the boots are seated securely into the
pin grooves.

Install the brake pads (page 14-61,

SLIDE PIN

Tighten the slide pin.

TORQUE 23 N.m 12.3 kgf.m, 17 IbfW
Connect the brake hose to the brake caliper with the
oil bolt and new sealing washers, and tighten the oil
bolt.

TORQUE: 34 N.m (3.5 kgf.m, 25 IbfW
Fill and bleed the rear brake hydraulic system (page
14-3).

The brake shaft
has left-hand
threads.

Apply silicone grease to the brake shaft outer surface.
Position the shaft so that its punch mark is within the
reference marks on the base and thread it.
Screw the shaft in fully and make sure that the punch
mark is within the reference marks.
If the shaft boot is hard or deteriorated, replace it
with new one. Install the boot over the brake base
and into the shaft groove properly.

Instal, a new O-ring into the base groove and rhe
brake base onto the ca iper body w'th the two bolts.

TORQUE: 23 N.m 12.3 kgf.m. 17 IbfW

14-19

HYDRAULIC DISC BRAKE
Apply grease to the lock cable end.
Install the lock cable into the stay and connect it to
the brake arm.
Turn the brake shaft clockwise approximately 90"
from fully seated position and install the brake arm
onto the brake shaft by aligning the punch marks on
the arm and shaft.

Loosely install the lock nut and adjusting bolt.
Adjust the lock cable free play (page 3-16).

ADJUS
BOLT

BRAKE PEDAL
REMOVAL
Disconnect the push rod from the brake pedal by
removing the cotter pin and joint pin.
Remove the return spring from the pedal.
Remove the cotter pin, washer and the brake pedal.

3TTER PIN

INSTALLATION
Coat new dust seal lips with grease and install them
into the pedal pivot in the frame.
Apply grease to the pedal pivot groove and install the
pedal.

14-20

\
JO

HYDRAULIC DISC BRAKE
Secure the pedal with the washer and cotter pin.
Hook the return spring to the pedal.
Connect the push rod to the pedal with the joint Din
and secure the joint pin with a new cotter pin.

a$*

COTTERPIN

14-21

BAlTERY/CHARGING SYSTEM

"r$ r

FUSE (15A)

BI : Black
R : Red

15-0

G : Green
P : Pink

15. BATTERY/CHARGING SYSTEM
~~

SERVICE INFORMATION

15-1

CHARGING SYSTEM INSPECTION

15-5

TROUBLESHOOTING

15-3

REGULATOR/RECTIFIER

15-6

BAlTERY

15-4

ALTERNATOR CHARGING COIL

15-7

SERVICE INFORMATION
..~

GENERAL
*

The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when
charging.
The battery contains sulfuric acid felectrolvte/. Contact with skin or eyes may cause severe burns. Wear protective
clothing and a face shield.
If electrolyte gets on your skin, flush with water.
If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately.
Electrolyte is poisonous.
If swallowed, drink large quantifjes of water or milk and follow with milk of magnesia or vegetable oil and call a
phvsician. KEEP OUT OF REACH OF CHILDREN.

. Always turn off the ignition switch before disconnecting any electrical component.
CAUTION:
~~

Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is ON and current is present.
*
*

For extended storage, remove the battery, give it a full charge, and store it in a cool, dry place.
For a battery remaining in a stored vehicle, disconnect the negative battery cable from the battery.

NOTE:
The maintenance free battery must be replaced when it reaches the end of its service life.

CAUTION:
The batterv cam shouldnot be removed. AttemRting t o remove the sealins caps from the cells mav damaue the batten/.
~

The battery can he damaged if overcharged or undercharged, or if left to discharge for long periods. These same conditions contribute to shortening the "life span" of the battery. Even under normal use. the performance of the battery
deteriorates after 2 - 3 years.
Battery voltage may recover after battery charging, but under heavy load, the battery voltage will drop quickly and
eventually die out. For this reason, the charging system is often suspected as the problem. Battery overcharge often
results from problems in the battery itself, which may appear to be an overcharging symptom. If one of the battery
cells is shorted and battery voltage does not increase, the regulator/rectifier supplies excess voltage to the battery.
Under these conditions, the electrolyte level goes down quickly.
Before troubleshooting the charging system. check for proper use and maintenance of the battery. Check ifthe battery is frequently under heavy load, such as having the headlight and taillight ON for long periods of time without riding the vehicle.
The battery will self-discharge when the vehicle is not in use. For this reason, charge the battery every two weeks to
prevent sulfation from occurring.
Filling a new battery with electrolyte will produce some voltage, but in order to achieve its maximum performance,
always charge the battery. Also. the battery life is lengthened when it is initially charged.
When checking the charging system, always follow the steps in the troubleshooting flow chart (page 15-3).
For alternator service, refer to section 10.

15-1

BAlTERYICHARGING SYSTEM
Battery charging
This model comes with a maintenance free (MF) battery. Remember the following about MF batteries.
- Use only the electrolyte that comes with the battery.
- Use all of the electrolyte.
- Seal the battery properly.
-Never open the seals again.
@

CAUTION:
For battery charging, do not exceed the charging current and time specified on the battery. Using excessive current or
extending the charging time may damage the battery.
BAlTERY TESTING
Refer to the instructions in the Operation Manual for the recommended battery tester for details about battery testing
The recommended battery tester puts a "load" on the battery so that the actual battery condition can be measured.
Recommended battery tester

BM-210-AH, BM-210, or BATTERY MATE or equivalent

SPECIFICATIONS
SPECIFICATIONS

ITEM
Battery

Alternator

12V-8Ah

Capacity
Current leakage

0.1 mA max.

Voltage
(20"c/68"F)

Fully charged
Needs charging

Below 12.3 V

Charging
current

Normal
Quick

Capacity
Charging coil resistance (2O"C/68"F)

15-2

13.0 - 13.2 V
0.9Ax5-10h

4.0 A x 10 h
147 W/5,000 rpm
0.1 - 1.0

BAlTERYICHARGING SYSTEM

TROUBLESHOOTING

Battery is damaged or weak
~-

1. Remove the battery (page 15-4).
Check the batterv condition usin(l the recommended battery tester.

Incorrect +*

Faulty battery

RECOMMENDED BATTERY TESTER:
BM-210-AH, BM-210. or EATERY MATE or

"7"'

2. Install the battery (page 15-41.
Check t h e battery current leakage (Leak
test: page 15-5).

SPECIFIED CURRENT LEAKAGE:
0.1 rnA rnax.

- Incorrect

3. Check the alternator charging coil (page
15-71.
STANDARD: 0.1 - 1.0 D I2OoC/68"F)

4. Measure and record the battery voltage
using a digital multimeter (page 15-4).
Start the engine.
Measure the charging voltage (page 15-51.
Compare the measurement to result of the
following calculation.

-1

Correct

Disconnect the regulatorlrectifier 6P connector
and rechecn the batten, current leakage.

1
Faulty regulator1
rectifier
Shorted wire harness
Faulty ignition sw tch

Incorrect V Faulty charging coil

.
~

Correct

+Faulty battery

MEASURED BATTERY VOLTAGE.

Not overheating

12. Accelerate or run at high speed - Engine knocks

-c

Excessive carbon build-up in
combustion chamber
Use of poor quality fuel
Clutch slipping
Lean fuel mixture

>. Worn piston and cylinder
Use of poor quality fuel
Excessive carbon build-up in
combustion chamber
Ignition timing too advanced
(Faulty ICM)
Lean fuel mixture

Engine does not knock

POOR PERFORMANCE AT LOW AND IDLE SPEED
Possible cause
1. Check carburetor pilot screw
adjustment

Incorrect

b. See section 5

Leaking

Correct

2. Check for leaking carburetor ~insulator

Loose carburetor insulator bands
Damaged carburetor insulator
Faulty carburetor insulator O-ring

No leak
I

3. Perform spark test

Faulty spark plug
Fouled spark plug
Loose or disconnected ignition system wires
Broken or shorted spark plug wire
Faulty ignition coil
Faulty ignition pulse generator
Faulty exciter coil
Faulty engine stop switch
Faulty ignition switch
Faulty ignition control module (ICM)

Weak or intermittent spark *-

Good spark

4. Check ignition timing

Incorrect

>. Faulty ICM

Faulty ignition pulse generatoi

20-3

TROUBLESHOOTING

POOR PERFORMANCE AT HIGH SPEED
Possible cause
1. Disconnect fuel tube a t
carburetor

Fuel flow restricted

Fuel flows freely

2. Check carburetor for clogging

___

Clogged

b. Carburetor not serviced frequently
enough

Not clogged

3. Checkvalve timing

Incorrect

b - Faulty ignition control module (ICM)

Cam sprockets not installed properly

Correct

4. Check ignition timing

Correct

5. Check valve spring

Weak

Faulty ignition pulse generator

Faulty valve spring

Not weak

POOR HANDLING
Possible cause
1. If steering is heavy

2. If any wheel is wobbling

3. If vehicle pulls to one side

t. Steering shaft holder bolts too tight
* Damaged steering shaft bushing
Damaged shaft ball bearing

t - Excessive wheel bearing play
Bent rim
* Improper installed wheel hub
* Excessively worn swingarm pivot
bearings
* Bentframe

Tire air pressure incorrect
Faulty shock absorber
Bent tie-rod
Incorrect tie-rod adjustment
* Bent swingarm
Bent frame
* Improper wheel alignment

20-4

Restricted fuel tube
Restricted fuel tank breather tube
Faulty fuel valve
Clogged fuel strainer

21. INDEX
.-

AIR CLEANER .................................
3-5
AIR CLEANER HOUSING .........................................
5-15
AIR CLEANER HOUSING DRAIN TUBE ..................3-6
ALTERNATOR CHARGING COIL .............................
15.7
ALTERNATOR STATOR ...........................................
10-2
BATTERY ...................................................
...... 15.4
BRAKE FLUID ............................................................
3-14
BRAKE FLUID REPLACEMENT/AIR BLEEDING ...... 14-3
BRAKE PAD/DISC
................................................ 14-5
BRAKE PADS WEAR .....
............................. 3-15
BRAKE PEDAL .....................................
BRAKE SYSTEM ..................................
BULB REPLACEMENT ..............................................
18-2
CABLE &HARNESS ROUTING ...............................
1-18
CAMSHAFT/CYLINDER HEAD COVER
INSTALLATION ....................................................
7-18
CARBURETOR ASSEMBLY ......................................
5-7
CARBURETOR DISASSEMBLY/INSPECTION .........5-3
CARBURETOR INSTALLATION
.................... 5-12
CARBURETOR REMOVAL ..............................
CHARGING SYSTEM INSPECTION ...............
CLUTCH ............... ...............................................
9-5
CLUTCH DIODE ..............
............................ 17-10
CLUTCH SWITCH ................................
CLUTCH SYSTEM ................................
CRANKCASE ASSEMBLY ........................................
11-15
CRANKCASE BEARING REPLACEMENT ................ 11-12
CRANKCASE SEPARATION .................
CRANKSHAFT/BALANCER ..................
CYLINDER COMPRESSION .................
CYLINDER HEAD ASSEMBLY/INSTALLATION ...... 7-16
CYLINDER HEAD COVEWCAMSHAFT REMOVAL ... 7-4
CYLINDER HEAD REMOVAVDISASSEMBLY ......... 7-9
CYLINDER/PISTON REMOVAL ................................
8-3
DRIVE CHAIN
................................................... 3-13
DRIVE CHAIN SLIDER ..............................................
3-14
EMISSION CONTROL INFORMATION LABEL ........ 1-24
EMISSION CONTROL SYSTEMS ............................
1-23
ENGINE IDLE SPEED ................................................
3-12
ENGINE INSTALLATION ..........................................
6-4
ENGINE OIL ...............................................
ENGINE OIL FILTER ...................................
ENGINE OIL STRAINER SCREEN IN OIL TANK ..... 3-12
ENGINE REMOVAL ..
.............................. 6-2
EXHAUST SYSTEM ......
........................... 2-6
FLYWHEEL INSTAL
FLYWHEEL REMOV
FOOTPEG/MUD GUARD ..........................................
2-5
FRONT BRAKE CALIPER ..........................................
14-10
FRONT FENDER ..........................
..................2-2
FRONT MASTER CYLINDER ......
FRONT SHOCK ABSORBER .......
FRONT WHEEL AND HUB .......................................
12-6
FUEL LINE .................................................................
3-4
FUEL TANK & HEAT PROTECTOR ..........................
2-4
GEARSHIFT LINKAGE ................
...................3-11
GENERAL SAFETY ...................................................
1-1
HANDLEBAR .............................................................
12-3
HANDLEBAR SWITCH ..............................................
18-4
HIGH ALTITUDE ADJUSTMENT .............................
5-14

IGNITION COIL .........................................................
IGNITION CONTROL MODULE (ICM) .....................
IGNITION SWITCH ...................................................
IGNITION SYSTEM INSPECTION ............................
IGNITION TIMING ....................
LUBRICATION & SEAL POINTS ..............................
MAINTENANCE SCHEDULE ....................................
MODEL IDENTIFICATION ........................................
NEUTRAL SWITCH ...................................................
NUTS, BOLTS, FASTENERS ....................................
OIL COOLER &OIL TANK ........................................
OIL PUMP & STRAINER ...........................................
PILOT SCREW ADJUSTMENT
.....
PISTON/CYLINDER INSTALLATION .......................
PRIMARY DRIVE GEAR ............................................
REAR AXLE ...............................................................
REAR BRAKE CALIPER .............................................
REAR MASTER CYLINDER ......................................
REAR SHOCK ABSORBER .......................................
REAR WHEEL ............................................................
REGULATOR /RECTIFIER .........................................
RIGHT CRANKCASE COVER INSTALLATION ........

16-6
16-6
18-3
16-3
16-7
1-16
3-3
1-3
18-5
3-19
4-6
4-2
5-13
8-7
3-10
13-3
14-16
14-13
13-9
13-3
15-6
9-12

SEAT/REAR FENDER ................................................
2-2
SERVICE INFORMATION
ALTERNATOWSTARTER CLUTCH ...............10-1
BATTERY/ CHARGING SYSTEM .................. 15-1
CLUTCH/GEARSHIFT LINKAGE ....................
9-1
CRANKCASEFRANSMISSION/
CRANKSHAFT ...........................................
11-1
CYLINDER HEADNALVE ...............................
7-1
CYLINDER/PISTON ........................................
8-1
ELECTRIC STARTER ......................................
17-1
ENGINE REMOVAUINSTALLATION ............ 6-1
FRAME/BODY PANELSEXHAUST SYSTEM .. 2-1
FRONT WHEEL/SUSPENSION/STEERlNG ... 12-1
FUEL SYSTEM ...............................................
5-1
HYDRAULIC DISC BRAKE .............................
14-1
IGNITION SYSTEM ........................................
16-1
LIGHTS/SWITCHES .......................................
18-1
LUBRICATION SYSTEM ................................
4-1
MAINTENANCE .............................................
3-1
REAR WHEEUSUSPENSION ........................
13-1
SERVICE RULES .......................................................
1-2
SHOCK LINKAGE ......................................................
13-11
SIDE COVER ..............................................................
2-3
SKID PLATE ..............................................................
2-5
SKID PLATE AND ENGINE GUARD ........................
3-17
SPARK ARRESTER .........................................
SPARK PLUG ............................................................
3-6
SPECIFICATIONS ......................................................
1-4
STARTER CLUTCH ...................................................
10-6
STARTER MOTOR ....................................................
17-4
STARTER RELAY SWITCH .......................................
17-9
STEERING SHAFT AND TIE-ROD
12-17
STEERING SHAFT HOLDER BEARING ................... 3-20
STEERING SYSTEM .................................................
3-20
SUSPENSION ...........................................................
3-18
SUSPENSION ARM ..................................................
12-12
SWINGARM ..............................................................
13-13
~

~~~~~~

~~~~~~~

~~~

............................

21 -1

INDEX
THROTTLE HOUSING ..............................................
12-5
THROTTLE OPERATION ..........................................
3-4
TIRES
.................................................................... 12-9
TOOLS ....................................................................
1-14
TORQUE VALUES
.................................. 1-11
TRANSMISSION .......................................................
11-4
TROUBLESHOOTING
ALTERNATORETARTER CLUTCH ...............10-1
BATrERYKHARGING SYSTEM
........... 15-3
CLUTCH/GEARSHIFT LINKAGE ....................
9-2
CRANKCASEflRANSMlSSlON/
CRANKSHAFT ...........................................
11-2
CYLINDER HEADNALVE ...................
CY LINDER/PISTON
ELECTRIC STARTER ......................................
17-2
ENGINE DOES NOT START OR IS HARD
20-1
TO START ..................................................
ENGINE LACKS POWER ...............................
20-2
FRAME/BODY PANELSEXHAUST
SYSTEM ....................................................
2-1
FRONT WHEEUSUSPENSION/STEERlNG ... 12-2
FUEL SYSTEM ..............
......................... 5-2
HYDRAULIC DISC BRAK
......................... 14-2
IGNITION SYSTEM ........................................
16-2
LUBRICATION SYSTEM ................................
4-1
POOR HANDLING ..........................................
20-4
POOR PERFORMANCE AT HIGH SPEED ..... 20-4
POOR PERFORMANCE AT LOW AND IDLE
SPEED ........................................................
20-3
REAR WHEEUSUSPENSION ........................
13-2
VALVE CLEARANCE ................................
....... 3-7
VALVE GUIDE REPLACEMENT ...............................
7-12
VALVE SEAT INSPECTION/REFACING ...................7-13
WHEELSflIRES .........................................................
3-19
WIRING DIAGRAM
19-1

...................................................

21 -2

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