Honda 400ex

~

HOW

TO

USE

THIS

MANUAL

This service manual describes the service procedures

-

for the

TRX400EX.

Follow the Maintenance Schedule (Section

3)

recom

-

mendations

to

ensure that the vehicle is

in

peak oper

-

ating condition and the emission levels are within the

standards

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 to the whole motorcycle.

Section

2

describes procedures for removalfinstalla-

tion of components that may be required to perform

service described in the following sections.

Sections

4

through

18

describe parts

of

the motorcy

-

cle, grouped according to location.

Find the section you want

on

this page, then turn to

the table of contents on the first page of the section.

Most sections start with an assembly or system illus

-

tration, service information and troubleshooting for

the section. The subsequent pages give detailed pro

-

cedures.

If

you don't know the source of the trouble, go to sec

-

tion

20,

Troubleshooting.

.

-

ALL INFORMATION, ILLUSTRATIONS, DIREC

-

TIONS AND SPECIFICATIONS INCLUDED

IN

....

~ ~

THIS PUBLICATION ARE BASED ON THE LAT

-

EST PRODUCT INFORMATION AVAILABLE AT

THE TIME OF APPROVAL FOR PRINTING.

HONDA MOTOR

CO.,

LTD. RESERVES THE

RIGHT TO MAKE CHANGES AT ANY TIME

WITHOUT NOTICE AND WITHOUT INCURRING

ANY OBLIGATION WHATEVER. NO PART OF

THIS PUBLICATION MAY BE REPRODUCED

WITHOUT WRllTEN PERMISSION. THIS MAN

-

UAL

IS

WRITTEN FOR PERSONS WHO HAVE

ACQUIRED BASIC KNOWLEDGE OF MAINTE

-

NANCE ON HONDA MOTORCYCLES, MOTOR

SCOOTERS

OR

ATVS.

HONDA MOTOR CO.. LTD

SERVICE PUBLICATIONS OFFICE

CONTENTS

GENERAL INFORMATION

FRAMEIBODY PANELS/EXHAUST

SYSTEM

MAINTENANCE

LUBRICATION SYSTEM

FUELSYSTEM

a

+

ENGINE REMOVAL/INSTALLATION

2

E

CYLINDER HEAD/VALVE

0

z

CYLINDER/PISTON

a

z

CLUTCH/GEARSHIFT LINKAGE

5

U

Y

W

ALTERNATOR/STARTER CLUTCH

CRANKCASEITRANSMISSIONI

CRANKSHAFT

FRONT WHEEL/SUSPENSION/STEERING

~JI

REAR WHEEL/SUSPENSION

"

s

HYDRAULIC DISC BRAKE

BATTERY/CHARGING SYSTEM

A

a

!!!

U

IGNITION SYSTEM

K

F

ELECTRIC STARTER

YI

WIRING DIAGRAM

TROUBLESHOOTING

INDEX

Date

of

Issue: September,

1998

0

HONDA

MOTOR

CO.,

LTD.

SYMBOLS

The symbols used throughout this manual show specific service procedures. If supplementary information is required per

-

taining to these symbols.

it

would be explained specifically in the

text

without the use of the symbols.

I

-

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

Use recommended engine oil, unless otherwise specified.

Use molybdenum oil solution (mixture of the engine oil and molybdenum grease

in

a ratio of

1

:

1).

Use multi

-

purpose grease (Lithium based multi

-

purpose grease 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.

Use molybdenum disulfide paste (containing more than

40%

molybdenum disulfide, NLGl#2 or

equivalent).

Example: Molykotea G

-

n paste, manufactured by Dow Corning, USA.

Multi

-

purpose M

-

2 manufactured by Mitsubishi Oil, Japan

Honda Moly

60

(U.S.A. only)

Rocol ASP manufactured by Rocol Limited, U.K.

Rocol Paste manufactured by Sumico Lubricant, Japan

Use silicone grease.

Apply a locking agent. Use a middle strength locking agent unless 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 EMISSION CONTROL INFORMATION

TORQUE VALUES 1

-

11

TOOLS 1

-

14

LABEL 1

-

24

I

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.

-

USED ENGINE OIL

The exhaust contains poisonous carbon monoxide gas

that may cause loss of consciousness and may lead to

death.

Run the engine in an open area or with an exhaust evac

-

uation 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.

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.

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 mini

-

mize the hazard caused by

air

borne asbestos fibers.

Inhaled asbestos fibers have been found to cause respi-

ratorv disease and cancer.

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

81

ELECTROLYTE

The

battery gives of explosive gases; keep sparks,

flames and cigarettes away. Provide adequate venti

-

lation when charging or using the battery in an

enclosed space.

The battery contains sulfuric acid (electrolytel.

Contact with skin or eyes may cause severe burns.

Wearprotective 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, imme

-

diately.

Electrolyte is poisonous.

-If swallowed, drink large quantities

of

wafer or

milk and follow with milk

of

magnesia 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

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

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 diago-

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.

design specifications may cause damage to the motorcycle.

fasteners.

nally

in

incremental steps unless

a

particular sequence is specified.

-

1

-

2

GENERAL INFORMATION

MODEL IDENTIFICATION

I

VEHICLE

IDENTIF'ICATION

NUMBER

left side frame down tube.

FRAME

I

The frame serial number

is

stamped on the front side of

the frame.

The Vehicle Identification Number (VIN)

is

located on the

The engine serial number is stamped on the lower left

of

ENGiNE SERIALNUMBER

I

the crankcase.

I

COLOR LABEL

The carburetor identification number is stamped

on

the

left

side of the carburetor body.

The color label is attached on the frame crossmember

under the seat. When ordering color

-

coded parts, always

specify the designated color code.

1

-

3

GENERAL INFORMATION

SPECIFICATIONS

-

GENERAL

DIMENSIONS

FRAME

ENGINE

ITEM

Overall length

Overall width

Overall height

Wheelbase

Seat height

Footpeg height

Ground clearance

Dry weight

Curb weight

Maximum weight capacity

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

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

SPECIFICATIONS

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)

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)

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)

1

-

4

GENERAL INFORMATION

GENERAL

(Cont'd)

r

CARBURETOR

ITEM

Carburetor type

Throttle bore

Clutch system

Clutch operation system

Transmission

Primary reduction

Final reduction

Gear ratio

1st

2nd

3rd

4th

5th

Gearshift pattern

Ignition system

Starting system

Charging system

Regulatortrectifier

Lighting system

SPECIFICATIONS

Piston valve

38

mm

(1.5

in)

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

ICM (Capacitive Discharge Ignition)

Electric starter motor

Single phase output alternator

Single phase

full

wave rectification

Battery

1

-

5

GENERAL INFORMATION

ITEM STANDARD

Engine oil capacity After draining

After draininglfilter change

After disassem bly

Recommended engine

oil

Oil pump Tip clearance

Body clearance

Side clearance

Unit:

mm

(in)

SERVICE LIMIT

1.8 liters (1.9 US qt, 1.6 Imp qt)

1.85 liters (1.95 US qt, 1.63 Imp qt)

2.2 liters (2.3

US

qt, 1.9

Imp

qt)

Honda GN4 or HP4 4

-

stroke oil or

equivalent motor oil

API service classification

SF

or SG

Viscosity:

SAE

1OW-40 or 2OW-50

0.15 (0.006)

0.15

-

0.22 (0.006

-

0.009)

0.02

-

0.09

(0.001

-

0.004)

I

ITEM

-

SPECIFICATIONS

0.12

10.005)

Main jet #148

Jet needle clip position

Pilot screw opening

Float level

3rd groove from top

See page 5

-

13

18.5

mm

10.73 in)

Idle speed 1,400

f

100 rpm

Throttle lever free play 3-8mm(1/8-5/16in)

Valve spring

Stem

-

to

-

guide clearance IN

0.010

-

0.037 (0.0004

-

0.0015) 0.12 10.005)

-

EX

0.030

-

0.057 (0.0012

-

0.0022) 0.14

(0.006)

Valve seat width INEX 1.0

-

1.1 (0.039-0.043) 2.0

(0.08)

Free length Inner 37.19 (1.464) 36.3 11.43)

Outer 44.20 (1.740) 43.1

(1.70)

Cylinder head warpage

-

0.10 (0.004)

GENERAL INFORMATION

ITEM

Cylinder

I.D.

Out of round

STANDARD SERVICE LIMIT

85.000

-

85.010 (3.3465

-

3.3468) 85.10 (3.350)

0.05 (0.002)

-

Piston,

-

Taper

0.05 (0.002)

Warpage

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

-

to

-

piston pin clearance

I

0.002

-

0.014 (0.0001

-

0.0006)

I

0.20

-

0.35

(0.008

-

0.014)

I

0.096 (0.0038)

1

0.50 (0.020)

Piston ring end gap

1

TOP

Piston pin

O.D.

19.994

-

20.000 (0.7872

-

0.7874) 19.964 (0.78601

I

Second

I

0.35

-

0.50 (0.014

-

0.020)

I

0.65 10.026)

Clutch

Piston ring

-

to

-

ring

groove clearance

Oil (side rail)

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)

0.20

-

0.70

(0.008

-

0.028)

Cylinder

-

to

-

piston clearance

Connecting rod small end

I.D.

Connectino rod

-

to

-

Diston

Din

clearance

Outer guide

0.01 5

-

0.050

(0.0006

-

0.0020)

20.020

-

20.041 (0.7882

-

0.7890)

0.020

-

0.047

10.0008

-

0.0019)

0.10 (0.004)

20.067 (0.7900)

0.103

(0.OOAII

I

22.05 (0.868)

I.D.

O.D.

I

27.959-27.980 (1.1007

-

1.1016)

I

27.90 (1.098)

1

22.010

-

22.035 (0.8665

-

0.8675)

ITEM

Mainshafi

O.D.

at

clutch outer wide

I

21.959

-

21.980 (0.8645

-

0.8654)

I

21.91 (0.863)

STANDARD SERVICE LIMIT

Lever free play

Spring free length

Disc thickness

1-7

10

-

20

(3/8

-

3/4)

52.64 (2.072)

50.0

(1.97)

2.92

-

3.08 (0.1 15

-

0.121)

-

2.69 10.106)

Plate

warpage

-

I

0.15

(0.006)

Outer

I.D.

28.000

-

28.021 (1.1024- 1.1032)

1

28.04 (1.104)

ITEM

Starter driven gear

boss

O.D.

STANDARD SERVICE LIMIT

51.705

-

51.718 (2.0356

-

2.0361) 51.67 (2.034)

GENERAL INFORMATION

ITEM STANDARD

SERVICE

LIMIT

rransmission

:rankshaft

~

Runout

0.12

(0.005)

Big

end

side

clearance

Big

end radial clearance

0.05

-

0.45

(0.002

-

0.018)

0.006

-

0.018

(0.0002

-

0.0007)

0.6

(0.02)

0.05

(0.002)

1

-

8

.

ITEM STANDARD SERVICE LIMIT

-

Minimum tire tread depth

Cold tire pressure

I

Standard

27

kPa

10.275

kaWcm2.

4.0

osil

-

4.0 (0.16)

Minimum

Maximum

Tie

-

rod distance between the ball joints

Toe

Shock absorber spring adiuster standard position

-

.,

23

kPa

(0.235

kgf/cmz.

3.4

psi)

31

kPa

(0.315

kgf/cmz,

4.6

psi)

__

370.2 (14.57)

-

Toe

-

in:

17

f

15

(0.7

f

0.6)

4th from softest Dosition

-

~

-

1

-

9

ITEM

Minimum tire tread depth

Cold tire pressure Standard

Minimum

Maximum

STANDARD SERVICE LIMIT

-

4.0

(0.16)

27

kPa

(0.275

kgf/cm2,

4.0

psi)

23

kPa

(0.235

kgWcmz,

3.4

psi)

31

kPa

10.315

kaWcm2.

4.6

osil

-

Axle runout

Drive chain slack

Shock absorber spring installed length

~

-

3.0 10.12)

30

-

40 (1-1/4

-

1-5/8)

-

231.5 (9.11)

-

HYDRAULIC DISC BRAKE

ITEM

Recommended brake fluid

Brake disc thickness Front

Rear

Brake disc runout

Master cylinder I.D.

Master piston O.D.

Caliper cylinder

I.D.

Caliper piston O.D.

STANDARD SERVICE LIMIT

DOT

4

brake fluid

-

2.8

-

3.2 (0.1

1

-

0.13) 2.5 (0.10)

3.8

-

4.2 (0.15

-

0.17) 3.5 (0.14)

-

0.30 10.012)

12.75

(0.502)

12.65 10.498)

34.02

(1.340)

33.87 11.333)

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)

ITEM

r

SPECIFICATIONS

Batten/ 12 V

-

8Ah

-

Capacity

Current leakage

Voltage

(2OoC/68"F) Needs charaina

Fully charged

0.1 mA max.

13.0

-

13.2

V

Below 12.3

V

Alternator

1

__

Charging current Normal

0.9

A x 5

-

10 h

Capacity 147 W/5,000 rpm

Charaina coil resistance (2OoC/68"F)

I

Quick 4.0 Ax 1.0 h

0.1

-

1.0

n

ITEM SPECIFICATIONS

Spark plug Standard DPR8Z (NGK), X24GPR-U (DENSO)

DPR9Z

(NGK), X27GPR-U (DENSO)

For extended hiah weed ridina

Bulbs

Spark plug gap 0.6

-

0.7 mrn (0.024

-

0.028 in)

-

Neutral indicator

I

12

v

-

3.4

w

Ignition coil primary peak voltage

1

-

10

100

V

minimum

~~

Ignition pulse generator peak voltage

Exciter coil peak voltage

I

lanition timina

("F"

mark)

0.7

V

minimum

100

V

minimum

8

"

BTDC

at

idle

ITEM STANDARD

Starter motor brush length 12.5

(0.49)

-

SERVICE LIMIT

8.5

(0.33)

r

ITEM SPECIFICATIONS

Headlight (High/low beam)

12

v

-

30/30

w

x

2

Taillight 12V-5W

GENERAL INFORMATION

TORQUE

VALUES

-

STANDARD

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

TORQUE

N.m

(kgf.m. Ibf4t)

5

(0.5, 3.6)

10 (1.0,7)

22 (2.2, 16)

34 (3.5, 25)

54 (5.5, 40)

FASTENER TYPE

5

mm

screw

6

mm

screw

6

mm

flange bolt

(8

rnm

head, small flange)

6

mm

flange bolt

(8

mm

head, large flange)

(0

6

mm

flange bolt

(10

mm

head) and nut

8

mm

flange bolt and nut

10

mm

flange bolt and nut

TORQUE

N.m

(kgfm, Ibf4t)

4 (0.4, 2.9)

9 (0.9. 6.5)

12 (1.2,9)

26 (2.7.20)

39 (4.0. 29)

-

Torque specifications listed below are for important fasteners.

-

Others should be tightened to standard torque values listed above.

NOTES:

1.

Apply locking agent to the threads.

2.

Apply oil to the threads and seating surface.

3.

Apply grease to the threads and seating surface.

4.

ALOC bolt. replace with a new one.

5.

Castle nut: tighten to the specified torque and further tighten until its grooves align with

the

cotter pin hole,

6.

Stake.

-

ENGINE

ITEM

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

Clutch center lock nut

Primary drive gear nut

Gearshift drum stopper arm pivot bolt

Gearshift spindle return spring pin

Flywheel bolt

Starter clutch bolt

Left crankcase cover stud bolt

Gearshift Dedal Dinch bolt

:LUTCH/GEARSHIFT LINKAGE:

4LTERNATORISTARTER CLUTCH:

an

~

1

4

1

2

1

2

1

4

1

6

1

4

-

THREAD

DIA.

(mml

12

36

7

30

14

12

10

27

16

8

14

12

7

6

10

18

6

8

12

8

6

TORQUE

N.m

1kgf.m. IbfW

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)

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)

44 (4.5.33)

20 (2.0,33)

108 (11.0.80)

88

(9.0. 65)

12 (1.2,9)

24 (2.4, 17)

127 (13.0. 94)

30 (3.1.22)

10 (1.0.7)

20

(2.0,

14)

REMARKS

NOTE

1

VOTE

1

NOTE

1

NOTE

1

VOTE

2

NOTE

2

oage

8-6

VOTE

2,6

VOTE

2

VOTE

2

VOTE

1

-

1

THREAD TORQUE

-

ENGINE

(Cont'd)

QTY

DIA.

(mm)

N.m

(kgf.m, IbfW

ITEM

CRANKCASE/TRANSMlSSlON/CRANKSHAFT:

LIGHTSISWITCHES

Mainshaft bearing setting plate bolt

2 6 12 (1.2,

9)

Neutral switch

1 10 13 (1.3,9)

.

FRAME

ITEM

WAME/BODY PANELS/EXHAUST

SYSTEM:

Footpeg bracket bolt

Skid plate bolt

Muffler mounting bolt

Muffler band bolt

Exhaust pipe protector bolt

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

Upper engine hanger nut

Front engine hanger nut

bolt

Lower engine hanger nut

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

HAINTENANCE

iNGlNE REMOVALIINSTALLATION

:RONT WHEEL/SUSPENSION/STEERING

REMARKS

NOTE

1

0"

4

2

4

2

1

4

1

4

1

2

3

2

8

2

6

4

8

4

1

2

8

2

4

2

1

4

1

THREAD

DIA.

(mml

10

8

6

8

4

8

12

10

8

10

4

5

10

14

8

10

12

10

14

8

10

18

8

10

48

14

12

48

TORQUE

N.m

(kgf.m, IbfW

42 (4.3.31)

30 (3.1, 22)

32 (3.3, 24)

23 (2.3, 17)

20 (2.0. 14)

21 (2.1, 15)

2 (0.2, 1.4)

18 (1.8, 13)

54 (5.5,40)

74 (7.5, 54)

54 (5.5, 40)

26 (2.7, 20)

74 (7.5, 54)

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)

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)

REMARKS

NOTE

4

NOTE

5

NOTE

4

NOTE

5

NOTE

3,5

NOTE

4

NOTE

1

NOTE

1

NOTE

1

GENERAL INFORMATION

QTY

ITEM THREAD

DIA.(~~)

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

Rear master cylinder mounting bolt

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

nut

Rear master cylinder reservoir hose joint screw

LIGHTSISWITCHES:

DTHERS:

Headlight mounting bolt

Sub

-

frame lower mounting bolt

Sub

-

frame upper mounting bolt

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

4

(0.4,

2.9)

42 (4.3, 31)

3

8

4 10

4

10

2

8

4

10

2

10

1

6

1

6

2

6

1

4

2

8

2

8

2

8

1

8

1

8

2

8

2

8

2

4

2

8

2

10

NOTE 4

NOTE

1

NOTE 4

NOTE 1

NOTE 4

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

zarburetor float level gauge

Jniversal bearing puller

;ear holder

:lutch center holder

:lywheel holder

iotor puller

iemover weight

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

Remover handle

Bearing remover,

17

mm

Bearing remover set,

15

mm

-

bearing remover,

15

mm

-

remover shaft

-

remover head

-

sliding weight

Needle bearing remover

TOOL NUMBER

07401

-

0010000

07631

-

0010000

07724

-

0010100

07724

-

0050002

07725

-

0040000

07733

-

0020001

07741

-

0010201

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

07936

-

3710100

07936

-

3710300

07936

-

KClOOOO

07936

-

KC10500

07936

-

KClOlOO

07936

-

KC10200

07741

-

0010201

07946

-

KA50000

REMARKS

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

NOTE

2

NOTE

2

NOTE

3:

07936

-

371020A

or

07936

-

3710201

i

i1

3

10

11

1

11.12

11

13

11

13

11

11,12

3,

11, 12, 13

12

11

13

11

12

9

9,

11, 12, 13

7

5

7

14

13

11

13

REF.

SECTION

~

1

-

14

GENERAL INFORMATION

DESCRIPTION

Crankcase assembly

tool

-

assembly collar

-

assemblv shaft

-

threaded adaptor

Assembly collar

Valve guide reamer, 5.5 mm

Spherical bearing driver

Ball

joint remover

TOOL

NUMBER

07965

-

VMOOOOO

07965

-

VMOOlOO

07965

-

VM00200

07965

-

VM00300

07965

-

VMOOlOO

07984

-

2000001

07HMF

-

HCOOlOO

07MAC

-

SLOO200

~~

REMARKS

NOTE

2

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

REF.

SECTION

11

12.13

7

12

1

-

15

GENERAL INFORMATION

LUBRICATION

&

SEAL POINTS

-

ENGINE

LOCATION

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

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

Each oil seal lip

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

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

Alternatorfignition pulse generator wire grommet seating

cover)

surface

MATERIAL

Molybdenum oil solution

(a

mixture of

112

engine oil

and

112

molybdenum

disulfide grease)

Engine

oil

Multi

-

purpose grease

Locking agent

Liquid sealant

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)

1

-

16

GENERAL INFORMATION

Front shock absorber dust seal lips

Air cleaner intake duct

-

to

-

housing mating surface

Throttle cable outer inside

Clutch cable outer inside

-

FRAME

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

LOCATION

Engine oil

Cable lubricant

MATERIAL

Multi

-

purpose grease

..

Front brake lever

-

to

-

master piston contacting area

Front brake lever pivot

Rear brake master piston

-

to

-

push rod contacting area and

Brake caliper pin bolt boots inside

Rear brake caliper parking brake shaft sliding surface

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

Clutch switch retainer screw

Rear axle outer and inner lock nut threads

Rear brake master cylinder hose joint screw threads

boot groove

Front shock absorber lower bushings

1

Molybdenum disulfide Daste

Hand Grip Cement (U.S.A.

only) or equivalent

Silicone grease

DOT

4

brake fluid

Locking agent

Brake lock cable outer inside

Handlebar grip rubber inside

1

Honda Bond A or Honda

REMARKS

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

.

1

-

17

GENERAL INFORMATION

CABLE

&

HARNESS ROUTING

-

THROTTLE CABLE BRAKE LOCK CABLE

BRAKE HOSE ANDLEBAR SWITCH

WIRE

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

I

FUEL TUBE

1

-

21

GENERAL INFORMATION

MASTER

CYLINDER

RESERVOIR HOSE

I

1

-

22

GENERAL INFORMATION

EMISSION CONTROL SYSTEMS

The California Air Resources Board (CARB) requires manufacturers to certify that their ANs 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 hydrocar

-

bons.

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 emis

-

sion 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.

AIR CLEANER CONNECTING TUBE

CARBURETOR

1

AiRCLEANER

CRANKCASE BREATHER STORAGE

e:

FRESH AIR

-+:

BLOW

-

BY GAS

TANK

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 pur

-

poses 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.

J

~

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 on the right side frame down tube.

VEHICLE EMISSION CONTROL

INFORMATION LABEL

1

-

24

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

before

components 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

Nm

(4.3

kgfm,

31

Ibf4t)

30

Nm

(3.1

kgfm,

22

IbfW

32

Nm

(3.3

kgfm,

24

Ibf4t)

23

Nm

(2.3

kgf.m,

17

IbfW

20

N.m

(2.0

kgfm,

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:

D

O

not allow the

assembly to

contact the

muffler when the

exhaust

svstem

is

hot.

FRONT

The rear fender may be deformed

if

it

contacts

the

muffler while the exhaust system is hot.

REMOVAL

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

FENDER

MOUNTING RUBBERS

Gasoline

is

extremely flammable and is explosive

under certain conditions. KEEP

OUT

OF

REACH

OF

CHILDREN.

UPPERCOVER

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.

REATHER TUBE

-

2

-

2

SIDE

COVER

REMOVAL/INSTALLATION

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.

Installation is in the reverse order

of

removal.

When installing

the trim clips,

carefully align

the clip holes to

avoid damaging

the clip.

TABS

\

TRIM

CLIP

\

TRIM

dLlP

SCREW

2

-

3

FRAMElBODY

PANELS/EXHAUST

SYSTEM

FUEL TANK

&

HEAT PROTECTOR

-

BOLTS

REMOVAL/INSTALLATION

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.

Release the two tabs on the rear side of the protector

and remove the protector from the frame.

Installation is in the reverse order of removal.

After installation, turn the fuel valve ON and check

the fuel line for leakage.

GUIDE

AT PROTECTOR

When installing

carefullyalign

the clip holes

to

avoid damaging

the trim clip,

-

the clip.

MOUNTING BOLT

-

AIR

VENTTUBE TRIM CLIP

2

-

4

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.

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

kgfm

31

IbfW

y’

WASHEWBOLT

OUTER MUD GUARD STAY

INNER MUD GUARD ST WASHER BOLT SOCKET BOLTS

~

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

-

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.

Set

the

exhaust

pipe

flange

as

shown.

I

'

GASKET&?

I

EXHAUST PIPE

MOUNTING

BOLTS

INSTALLATION

Install new joint and muffler gaskets.

Install the exhaust pipe and muffler in the reverse

order of removal by loosely tightening

all

fasteners.

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

Nm

(2.3

kgfm,

17

Ibf.ft)

Exhaust pipe

protector bolt:

20

Nm

(2.0

kgfm,

14

IbfW

After installation, inspect the exhaust system for leaks.

EXHAUST PIPE FLANGE:

-

View from front side:

-

2

-

6

3.

MAINTENANCE

ITEM

Throttle lever free play

Spark plug Standard

For extended high speed riding

Spark plug gap

Valve clearance Intake

Exhaust

Recommended engine oil

SERVICE INFORMATION

MAINTENANCE SCHEDULE

FUEL LINE

THROTTLE OPERATION

AIR CLEANER

AIR CLEANER HOUSING DRAIN TUBE

SPARK PLUG

VALVE CLEARANCE

ENGINE OIL

ENGINE OIL FILTER

ENGINE OIL STRAINER SCREEN

IN

OIL TANK

ENGINE IDLE SPEED

DRIVE CHAIN

SPECIFICATIONS

3

-

8 mm (118

-

5/16 in1

DPREZ (NGK), X24GPR-U (DENSO)

DPR9Z (NGK), X27GPR-U (DENSO)

0.6

-

0.7

mm (0.024

-

0.028 in)

0.10 mm (0.004 in)

0.12 mm

(0.005

in)

Honda GN4 or HP4 4

-

stroke oil or eauivalent motor oil

3

-

1

3

-

3

-

4

3

-

4

3

-

5

3

-

6

3

-

6

3

-

7

3

-

9

3

-

1

~~

Engine oil capacity

3

-

12

3

-

12

3

-

13

After draining

After drainingtfilter change

DRIVE CHAIN SLIDER

BRAKE FLUID

BRAKE PADS WEAR

BRAKE SYSTEM

SKID PLATE AND ENGINE GUARD

CLUTCH SYSTEM

SUSPENSION

SPARK ARRESTER

NUTS, BOLTS, FASTENERS

WHEELS/TIRES

STEERING SHAFT HOLDER BEARING

STEERING SYSTEM

3

-

14

3

-

1 4

3

-

1 5

3

-

15

3

-

17

3

-

17

3

-

18

3

-

19

3

-

19

3

-

19

3

-

20

3

-

20

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

I

After disassemblv

Engine idle speed

Viscosity: SAE IOW-40 or 2OW

-

50

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

(2.3

US

qt, 1.9 Imp qt)

1,400

f

100 rpm

3

-

1

Clutch lever free play

Drive chain slack

Recommended brake fluid

10

-

20 mm (318

-

314 in)

-.

30

-

40 mm (1

-

114

-

1-5B in)

DOT

4

brake fluid

Cold tire pressure

(FronffRear) Standard

Minimum

27

kPa

(0.275 kgf/cm2,4.0 psi)

23

kPa

10.235 kof/cm?. 3.4

Dsil

Maximum 31

kPa

(0.315 kgf/cmZ, 4.6 psi)

Tire size Front AT22 x 7

-

10

**

Rear

Front

Rear

TORQUE

VALUES

AT20 x 10-9

**

M/R 101

M/R

501

Spark plug 18 Nm (1.8 kgfm, 13 IbfW

Valve adjusting hole cap 15 Nm

(1.5

kgfm,

11

IbfW

Valve adjusting lock nut 24 Nm (2.4 kgfm, 17 IbfW

Crankshaft hole cap 8 Nm (0.8 kgfm. 5.8 IbfW

Timing hole cap 10 Nm (1.0 kgfm, 7 IbfW

Engine

oil

drain bolt (crankcase) 25 Nm (2.5 kgfm, 18 IbfW

Engine oil drain bolt (oil tank) 20 Nm (2.0 kgfm,

14

IbfW

Engine oil strainer screen (at oil tank) 54 Nm (5.5 kgh, 40 IbfW

Oil pipe joint flare nut 20 Nvn (2.0 kgfm.

14

I

bfW

Axle bearing holder pinch bolt

21

Nm (2.1 kgfm, 15 IbfW

Front master cylinder reservoir cap screw

2

Nm (0.2 kgfm, 1.4 IbfW

Parking brake arm lock nut

18

Nm (1.8 kgfm, 13 IbfW

Rear master cylinder push rod lock nut 18 N.m (1.8 kgh, 13 IbfW

Tie

-

rod lock nut 54 Nm (5.5 kgh, 40 IbfW

Minimum tread depth (FronffRear)

3

-

2

1

4.0 mm (0.16 in)

Toe Toe

-

in:

17

f

15 mm (0.7f 0.6 in)

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

.-

ITEMS

1

FREQUENCY WHICHEVER INITIAL REGULAR

COMES FIRST MAINTENANCE MAINTENANCE INTERVAL

mi 100

600

1,200

Refer

to

km

150

1,000

2,000

ITEMS NOTE HOURS

20

100

200

paw

FREQUENCY WHICHEVER INITIAL REGULAR

COMES FIRST

d

MAINTENANCE MAINTENANCE INTERVAL

U

NOTE

*!

mi 100

600

1,200

Refer

to

km

150

1,000

2,000

paw

HOURS

20

100

200

t

3-19

STEERING SHAFT HOLDER

BEARING

.

-

STEERING SYSTEM

I'

L

I

3

-

20

I

3-20

1

~

Should be 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 AN

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

I

ADJUSTER

/

FUEL LINE

-

Remove the front fender (page

2-2).

Check the fuel line for deterioration, damage or leak

-

age.

Replace the fuel line

if

necessary.

THROlTLE OPERATION

Check for any deterioration or damage to the throttle

cable. Check that the throttle lever for smooth opera

-

tion. 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 lubri

-

cant 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

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.

F

U

E

L

LI~E

BOOT

LOCK NUT

I

MAINTENANCE

AIR CLEANER

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.

Loosen the air cleaner element band screw.

Remove the air cleaner element assembly from the

housing.

Remove the element band and the element core from

the air cleaner 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.

RETAINING

CLIPS

COVER

I

S

CREW

I

ELEMENT

WASH SQUEEZE

OUT

3

-

5

MAINTENANCE

AIR

C

Apply approximately

20

g

(0.7

oz)

of Pro Honda Foam

Filter

Oil

or equivalent oil from the inside of the ele

-

ment.

Place the element into

a

plastic bag and spread the

oil evenly by hand.

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).

EANER

HOUSING DRAIN TUBE

NOTE:

If the vehicle is used in very wet or muddy condi

-

tions, 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.

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.

PRO HONDA

:AM

FILTER

\'

DRAIN TUBE

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).

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

GAP

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.

CENTER ELECTRODE

\

INSULATOR

S

I

D

E

ELECTRO~

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)

EX

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 clear

-

ance.

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 crank

-

shaft hole cap and timing hole cap.

Install the caps and tighten them.

TORQUE:

Crankshaft hole

cap:

8

Nm

(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),

-I

3

-

8

MAINTENANCE

ENGINE

OIL

Engine and exhaust system parts become very hot

and remain hot

for

some time after the engine

is

run.

Wear insulated aloves.

FILLER

HOLE

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.

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.

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

NOTE:

OIL

VISCOSITIES

0 20

40

60

80

100

"F

-

20

-

10 0

10

20

30

40 "C

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

At

Crankcase

Oil

Check

Bolt

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

aspos-

sible after handling used oil.

NOTE:

Change the oil with the engine warm to assure com-

Dlete 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

kgfm,

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).

1

OIL CHECK

BOLT

AND SEALING WASHER

1

I

\e*

DRAIN BOLT AND SEALING WASHER

3

-

1

0

MAINTENANCE

EhGlNE

OIL

FILTER

Pour the recommended oil (page

3-9)

into the oil tank

up to the upper level mark

on

the dipstick.

NOTE:

SPRING

~

The engine takes about

1.85

liters

(1.95

US

qt,

1.63

Imp qt) at oil and filter change. Because only

a

por

-

tion 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

Install the oil filler capldipstick.

Place the vehicle

on

firm level ground.

Start the engine and let it idle for

a

few minutes with

-

out 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.

FILLER

CAPIDIPSTICK

Engine and exhaust system parts become very hot

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 fil

-

ter cover onto the filter and tighten the bolts securely.

ii.

CAUTION

installing

the oil filter backwards wi// resun

in

severe

engine damage.

Fill the engine and oil tank with the engine oil.

,

3

-

1

MAINTENANCE

-

ENGINE

OIL

STRAINER

SCREEN

IN

OIL

TANK

FLAR

Engine and exhaust system parts become very hot

and remain hot 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

all

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.

6

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).

I

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 neu

-

tral 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

*

100 rpm

THRO~LE

STOP

SCREW

3

-

1

2

MAINTENANCE

DRIVE

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.

CHAIN SLACK

30

-

40

mm 11-1/4- 1-5/8

in1

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 hold

-

er 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).

CLEANING

AND

INSPECTION

Clean the chain with a

soft

brush using a non-flam-

mable or high flash point solvent and wipe

it

dry.

Be sure the chain has dried completely before lubri

-

cating.

Inspect the drive chain for possible damage or wear.

Replace any chain that has damaged rollers, loose fit

-

ting links, or otherwise appears unserviceable.

Installing a new chain

on

badly worn sprockets

will

cause the new chain to 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.

DRIVE

CAAIN

U

BEARING HOLDER

PINCH BOLTS

:LEANING S0F;T

BRUSh

3

-

1

3

MAINTENANCE

SPROCKET INSPECTION

Inspect the drive and driven sprocket teeth for dam

-

age 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

when filling the reservoir.

*

Avoid spilling fluid on painted, plastic or rubber

parts. Place a rag over these parts whenever the

system is serviced.

NOTE:

When the fluid level is low, check the brake pads for

wear (page 3

-

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

WORN

SCREWS SERVOIR CAP

a low reservoir level.

If

the brake pads are not worn and the fluid level

is

low, check entire system for leaks (page 3

-

17). LOWER LEVEL LINE

FRONT

BRAKE

Turn the handlebar to the left side

so

that the reser

-

voir 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.

I

CASTING LEDGE

1

TORQUE:

2

N.m

(0.2

kgfm,

1.4

IbfW

3

-

1

4

MAINTENANCE

REAR BRAKE

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.

BRAKE

SYSTEM

RESERVOIR CAP

{[\\

Y?5

REFERENCE PLATE

I

LUG

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.

\

"

-

\

BRAKEHOS€

Tighten any loose fittings.

Replace hoses, pipes and fittings as required.

3

-

1

5

MAINTENANCE

BRAKE LOCK CABLE ADJUSTMENT

LOCK NUT ,ADJUSTING

BOLT

A

lock cable

adjustment may

be required

if

the

parking brake

does not hold

the rear wheels

securely.

Slide the dust cover

off

the lever bracket.

To

adjust the clutch lever free play to more than

30

mm

(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 resis

-

tance

is

felt. Then turn the adjusting bolt

118

turn

counterclockwise and tighten the lock nut while hold

-

ing the adjusting bolt.

TORQUE

18

N.m

(1.8 kgfm, 13 IbfW

LOCK NUT

I

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.

FREE PLAY

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

Nm

(1.8

kgfm,

13 Ibf.ft)

LOCK P!N

,

25

-

30

mm

(1

-

1-118

in)

\

A

LOCK NUT

3

-

1

6

MAINTENANCE

If

adjusting the brake pedal to 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).

If

adjusting to the higher position, make sure that a

portion

of

the lower end

of

the push rod thread

is

vis

-

ible inside the joint.

-

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 for kinks or damage, and

lubricate the cable if necessary.

Measure the clutch lever free play at the end of the

lever

FREE

PLAY

10

-

20

mm

13/8

-

3/4

in1

ISPOSITION: HIGHER POSITION:

THREAD

PEDAL

'

I

10

-

20

mm

(3/8

-

3/4

in)

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.

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.

\

(d

ADJUST

E

R

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.

SUSPENSION

For

detailed

!

I

.

1__

instructions

On

Pre-

load

and

damp-

senin%

see

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 acci-

Owner's

dent and possible injury.

FRONT

Check the action of the shock absorbers by com

-

pressing 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 compress

-

ing

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.

ADJUSTING NUT

I

Refer to section

13

for shock absorber and linkage

service.

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 (sec-

tion

13).

-

'

,

I

3

-

1

8

MAINTENANCE

SPARK ARRESTER

Wait

until

the exhaust system has cooled before

removing or installing the arrester. Touching the hot

exhaust may result

in

severe

burns.

Remove the three bolts and the spark arrester with

the gasket.

-

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 tight

-

en 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

B

O

L

T

S

I

Tirepressure

should be

checked when

the tires are

Standard:

COLD.

-

Minimum:

Maximum:

Checkthe tire pressure with the tire pressure gauge.

RECOMMENDED TIRE PRESSURE (FrontlRear):

27

kPa

(0.275

kgf/cm2,

4.0

psi)

23

kPa

(0.235

kgf/cm2,

3.4

psi)

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

-

1

9

MAINTENANCE

STEERING SHAFT HOLDER BEARING

Make sure the

cables do not

vehicle securely.

interfere with the

rotation

of

the

side.

handlebar

Raise the front wheels

off

the ground and support the

Check that the handlebar moves freely from side to

If the handlebar moves unevenly, binds, or has hori

-

zontal 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.

When the toe

is

out of specification, adjust

it

by

changing the length of the tie

-

rods equally by loosen

-

ing the lock nuts and turning the tie

-

rods while hold

-

ing 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.

I

TOE

-

'

GAUGE

I

FRONT

-

REAR

7E-ROD

3

-

20

MEMO

4-0

P

4.

LUBRICATION

SYSTEM

ITEM

Engine oil capacity After draining

After draining/filter change

After disassembly

Recommended engine oil

~ ~~

SERVICE INFORMATION

TROUBLESHOOTING

STANDARD

SERVICE

LIMIT

1.8 liters (1.9 US qt, 1.6 Irnp qt)

1.85 liters (1.95

US

qt, 1.63 Imp qt)

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

__

-

__

4

-

1

OIL PUMP &STRAINER

4

-

1

OIL COOLER

81

OIL TANK

Body clearance

1

0.15

-

0.22 (0.006

-

0.009)

4

-

2

4

-

6

0.25 (0.010)

SERVICE INFORMATION

GENERAL

m

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

011

pLmp. oil cooler anoior oil p'pes has been installed, check [hat there are

no

oil leaks.

-~

--

-

.-

-

.~ .~

SPECIFICATIONS

Viscosity:

SAE

1OW-40

Oil

DumD

I

Tip clearance

1

0.15 (0.006)

I

0.20

(0.008)

TORQUE

VALUES

Oil

pipe joint flare nut

Oil pump assembly bolt 20 Nm (2.0 kgfm, 14 IbfW

13 Nm (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.

Remove the following:

-

cotter pin

-

stopper plate

-

spring

-

valve

RELIEF VALVE CHECK

for

YI

Check the spring and vah 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

BOL

Remove the two bolts and separate the pump base

i

from the pump spacer.

Remove the following:

-

drive pin

-

thrust washer

-

inner rotor

-

outer rotor

Separate the pump body from the pump spacer.

Remove the following:

-

pump shaft

-

drive pin

-

dowel pins

-

inner rotor

-

outer rotor

INSPECTION

i

WASH

SHAFT

AND

PUMP

BODY

ROTORS

PINS

PUMP

SPACER

BODY SIDE:

NOTE:

Measure at several places and use the largest read

-

ing 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

..

BASE SIDE:

-

.

-

Measure the pump body clearance.

SERVICE

LIMIT

0.25

mm

10.010

in)

:i

c

F

'i;

I

is

!

-

Measure the pump side clearance.

SERVICE

LIMIT

0.12

mm

(0.005

in)

BASE SIDE:

-

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

PUMP BODY DOWEL PINS

1

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.

PUMP BASE

I

BODY/SPACER

\

1

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 tight

-

en

the

three bolts securely.

Install the clutch assembly (page

9-81,

Install the right crankcase cover (page

9

-

12).

1

OIL

COOLER

&

OIL

TANK

INSPECTION

Remove the front fender (page

2-2).

Check the

oil

cooler air passage for clogging or dam

-

age.

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.

Installation is in the reverse order of removal

Replace the

0

-

rings with new

ones and coat

them with

engine oil.

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

-

Replace the

0-

rings with new

ones and coat

them with

engine oil.

OIL

PIPES

Disconnect the oil pipes from the oil cooler and oil

tank (see above).

Disconnect the oil pipes from the engine by remov

-

ing the bolts.

Remove the dowel pins and O

-

rings.

Check the oil pipes for clogging or damage.

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/ AIR CLEANER HOUSING 5

-

15

INSPECTION 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, result

-

ing 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

Slow jet

#38

________

Jet needle clip position

Pilot screw opening

Float level

Idle speed

Throttle lever free Dlav

TOOL

Carburetor float level gauge

07401

-

0010000

Pilot screw wrench 07908

-

4220201

3rd groove from top

See page 5

-

13

-

18.5

mm

(0.73

in)

1,400

f

100

rpm

3

-

8

mm

(1/8

-

5/16

in)

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

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

section 16)

Engine stalls, hard to start, rough idling

-

Restricted fuel line

*

Contaminated/ deteriorated fuel

*

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)

Afterburn when engine braking is used

*

Lean mixture in slow circuit

-

Faulty air cut

-

off valve

*

Faulty ignition system (section

16)

Fuel mixture too leanlrich

Intake air leak

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)

-

5

-

2

FUEL

SYSTEM

CARBURETOR REMOVAL

Remove the fuel tank (page

2-41.

Place and approved fuel container under the drain

tube. Loosen the drain screw and drain the carbure

-

tor.

Remove the air vent tube from the heat protector and

the fuel tube from the 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

-_

-

Remove the two 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 counterclock

-

wise.

AIR

CUT

-

OFF

VALVE

AIR VENTTUBE CARBURETOR

=-/

BAND SCREW

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 vacu

-

um

is

not applied.

THROTTLE

VALVE

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 carbu

-

retor body, being careful not to damage the jet nee

-

dle.

Remove the

two

screws and valve arm.

Remove the jet needle.

SCREWSAND

-

*(

-

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

I

ACCELERATOR

PUMP

Remove the three screws while holding the accelera

-

I

tor pump cover.

Remove the pump cover, spring and the diaphragm,

SPRING

*

being careful not to damage it.

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.

-

FLOATVALVE

-

FLOAT

\

/

'99-

'00

Remove the float pin, float and float valve.

After

'00

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 num

-

-.

ber 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

I

Remove the pilot screw, spring, washer and O

-

ring.

I

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

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

of

wire will darnacre the carburetor body.

Blow open all air and fuel passages

in

the carburetor

body with compressed air.

THROTTLE VALVE ARM

CARBURETOR ASSEMBLY

AIR CUT

-

OFF VALVE

LINK ARM SHAFT

$2-

FLOAT VALVE

THROTTLE LINK ARM

PLASTIC WASHER

PLANE WASHER THROTTLE VALVE

SPRING WASHER

FLOAT CHAMBER

DRAIN SCREW

FLOAT CHAMBER CAP

THROTTLE STOP SCREW

PILOT SCREW

BAFFLE PLATE

5

-

7

FUEL

SYSTEM

..

FLOAT

AND

JETS

T NEEDLEJET

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.

CAUTION:

Damage to the pilot screw seat

will

occur

if

the 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.

I

'

-

-"

-.

'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

(0.02k

0.01

in)

<VIEW

FROM

AIR

CLEANER

HOUSING

SIDE>

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

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.

BAFFLE PLATE

07401

-

0010000

-.

-

8

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

1

the shaft slowly when inserting.

!

I

5;

Place the spring onto diaphragm. Install and hold the

pump cover, being careful not to 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.

~

-

II

I

-

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.

~

i

EWS

"

'

VALVE

ARM

5

-

9

FUEL

SYSTEM

Set the thrust washer between the valve arm and car

-

buretor 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.

body.

Install

a

new 0-rina into the groove in the carburetor

Install the top cover an

the clamo. tighte

i

-

the three screws with

-.

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.

1

STAY

!

-h

Turn the throttle stop screw to align the butterfly

throttle valve with the edge of the outside by

-

pass

hole in the carburetor.

/

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).

i

Install the air cut

-

off valve and secure

it

with the screw.

i

Connect the vacuum, air vent and fuel tubes

as

shown.

J

TUBES

5

-

1

FUEL

SYSTEM

CARBURETOR INSTALLATION

Install the throttle cable outer to the carburetor body

and connect the cable inner to the throttle drum.

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 connect

-

ing 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).

THROTlLi

JQU

-

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 will 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 accord

-

ing to the tachometer manufacturer’s instructions.

4.

Start the engine and adjust the idle speed with the

throttle stop screw.

IDLE SPEED:

1.40 100

rpm

5.

Turn the pilot screw in or out slowly to obtain the

6.

Lightly open the throttle

2

-

3

times, then adjust

7.

Turn the pilot screw in gradually until the engine

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.

highest engine speed.

the idle speed with the throttle stop screw.

speed drops by

50

rpm.

SCREW THROTTLE STOP SCREW

5

-

1

3

HIGH

ALTITUDE ADJUSTMENT

Between

3,000

-

8,000

ft

Below

Main jet

Pilot screw

oDeninq

1

turns in from

The carburetor must

be

adjusted for high altitude rid

-

ing (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 cham

-

ber cap.

Replace the standard main jet with the high altitude

HIGH ALTITUDE MAIN JET

#142

I

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.

CHAbiatii

wr

_,

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

alti

-

tude to ensure proper high altitude operation.

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.

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

turn

out

5-14

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 from 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 to 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

.

-

I

/

BREATHER TUBE C

RANKCASE

BREATHER

STORAGE TANK

5

-

1

5

ENGINE REMOVAL/INSTALLATION

74 N.m 17.5

kgfm,

54

IbfW

I

26

N.m (i.7

kgfm.

20

Ibf+tl

6

-

0

6.

ENGINE REMOVAL/INSTALLATION

ITEM

SERVICE INFORMATION

6

-

1

ENGINE INSTALLATION

6

-

4

ENGINE REMOVAL

6

-

2

SPECIFICATIONS

SERVICE INFORMATION

. .

Engine oil capacity After draining

After draining/filter change

After disassembly

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

-

1.8 liters (1.9

US

qt, 1.6 Imp qt)

1.85 liters (1.95

US

qt. 1.63 Imp qt)

2.2 liters (2.3

US

at, 1.9

IrnD

at)

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

Nm

(5.5

kgfm,

40

Ibf.ft)

26 Nm (2.7 kgfm, 20 IbfW

74 Nm (7.5 kgfm, 54 IbfW

108 Nm (11.0 kgfm, 80 IbfW

20 Nm (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 pro

-

tector 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.

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.

T

Disconnect the spark plug cap.

Disconnect the cylinder head breather tube.

I

?

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 remov

-

ing 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 with 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.

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.

(1

LNUT

AND

501

6

-

3

ENGINE

REMOVAL/INSTALLATION

Remove the swingarm pivot nut and bolt.

Remove the engine out of the frame to the right.

ENGINE

INSTALLATION

Install the engine into the frame from the right side in

the reverse order of removal.

NOTE:

SWINGARM

PIVOT

BOLT'

-

*

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.

74

Nm

(7.5

kgfm,

54

1bf.h)

/

Tighten the nuts to the specified torque.

108

Nm

(11.0

kgfm

m

(5.5

kgfm

40

IbfW

80

IbfW

74

Nm

(7.5

kgfm,

54

Ibf4t)

6

-

4

ENGINE REMOVAL/INSTALLATION

Install the removed parts from engine removal proce

-

dure (page 6-2 to 6-3) in the reverse order or removal.

TORQUE:

Gearshift pedal

pinch

bolt:

20

Nm

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.

1

Install the following:

-

oil pipes (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

20

44

Nm

17

IbfW

,

2.9

Ibf.ft)

I

7

-

0

7.

CYLINDER

HEAD/VALVE

ITEM

Cylinder compression at rpm

1

IN

~

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/

CYLINDER HEAD COVER/CAMSHAFT INSTALLATION 7

-

16

REMOVAL 7

-

4 CAMSHAFT/CYLINDER HEAD COVER

DISASSEMBLY 7

-

9

CYLINDER HEAD REMOVAL/ INSTALLATION 7

-

18

STANDARD

SERVICE LIMIT

686

-

883

kPa

(7.0

-

9.0

kgf/cm',

100

-

128

psi)

0.10

in

nna

-

SERVICE INFORMATION

Cam

lobe height

~

GENERAL

..

.

-

,

-.

-

.

,

EX

0.12 (0.005)

-

IN

30.673-30.773 (1.2076

-

1.2115) 30.57 (1.204)

30.37 (1.196)

EX

30.468-30.568 (1.1995

-

1.2035)

-

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.

Runout

Shaft

O.D.

1

IN/EX

*

When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original loca

-

tions.

-

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 assem

-

bling 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)

-

0.03 (0.001)

11.53 (0.454)

11,500- 11.518 (0.4528-0.4535)

11.466

-

11.484 (0.4514

-

0.4521) 11.41 (0.449)

____

-

Valve clearance

Camshaft

Rocker arm

Sub

-

rocker arm

Valve,

valve guide

Valve spring

Valve stem

O.D.

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

(8

mm)

Spark plug

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

54 N.m (5.5 kgfm, 40 IbfW

20

Nm (2.0 kgf.m, 14 IbfW Apply locking agent to the threads

4

Nm (0.4 kgfm, 2.9 IbfW

27 N.m

(2.8

kgfm, 20 IbfW Apply locking agent to the threads

27 Nm (2.8 kgfm, 20 IbfW Apply locking agent

to

the threads

26 Nm

(2.7

kgfm, 20 IbfW

18 N.m (1.8 kgfm, 13 IbfW

44

Nm (4.5 kgfm, 33 Ibf.ft) Apply oil to the threads and seating surface

-

07757

-

0010000

07742

-

0010100

07984

-

2000001 or 07984

-

200000D

(U.S.A. only)

077ao-ooi0400

07780

-

0010300

07780

-

0012300

07780

-

0012200

07780

-

001

4000

07908

-

KK60000

07781

-

0010101

or equivalent commercially available

in

U.S.A.

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

-

Leaking or damaged cylinder head gasket

-

Warped or cracked cylinder head

-

Loose spark plug

-

Cylinder head

-

Cylinderlpiston (section

8)

Compression

too

high

-

Excessive carbon build

-

up

on

piston head or combus

-

tion chamber

*

Worn or damaged decornpressor system

Excessive smoke

Worn valve stem or valve guide

*

Damaged stem seal

*

Cylinderlpiston problem (section

8)

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

7

-

2

CYLINDER HE A 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 attach

-

ment into the spark plug hole.

TOOL

Compression gauge attachment

07908

-

KK60000

or

equivalent com

-

mercially available

in

USA.

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 connec

-

tion,

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 pis

-

ton head

CYLINDER HEAD COVER/CAMSHAFT

REMOVAL

Remove the fuel tank under heat protector (page

2-4).

Remove the spark plug cap.

Disconnect the crankcase breather tube from the

head cover.

L

I

CYLINDER

HEAD/VALVE

Remove the upper engine hanger nut, bolt and spacers. NUT

-

I

Remove the timing hole cap, crankshaft hole cap and

valve adjusting hole caps (page

3-71,

The crankshaff

Rotate the crankshaft counterclockwise and align the

should be turned

"

T

"

mark on the flywheel with the index notch in the

clockwise. This

Make sure that the piston is

at

TDC (Top Dead

must be done

to

Center) on the compression stroke.

prevent the one

-

The rocker arms should be loose.

waydecornpres-

If

the rocker arms are tight, rotate the crankshaft

sorsystern func-

counterclockwise one full turn and realign the

"

T

"

tioning

mark with the index notch.

only counter

-

left crankcase cover.

1..

;i

7,-7

F~=.>-:;;"T"

,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.

r

-

Remove the gasket and dowel pins.

-

7

-

4

CYLINDER HEADlVALVE

-_

~

TEN

___

Loosen the cam chain tensioner lifter plug.

Remove the two bolts, cam chain tensioner lifter and

gasket

.

-

Becarefulnotto

Remove the cam sprocket bolt.

let the sprocket

Rotate the crankshaft counterclockwise one turn and

bolts fallinto the

remove the other cam sprocket bolt.

crankcase,

I

i

Remove the cam sprocket from the camshaft flange.

Attach a piece of wire to the cam chain to prevent

it

from falling into the crankcase.

Lift the camshaft and remove

it.

Remove the cam sprocket from the cam chain.

i

I

i

1

,

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

the mating surface of the cylinder head cover.

-

sub

-

rocker arm shafts, being careful not to damage

Remove the shafts, sealing washers, sub

-

rocker arms

and wave washers.

l

i

i,

P

1

-

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.

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

IN

30.57

mm

(1.204

in)

EX

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 corre

-

sponding rocker arm

I.D.

to obtain the rocker arm-to-

shaft 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.

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.

Hold: REVERSE

DECOMPRESSOR

CAM

\

/R

DECOMPRESSOR CAM

7

-

7

CYLINDER

HEAD/VALVE

DECOMPRESSOR CAM

SPRING

Remove the following:

-

thrust washer

-

one

-

way clutch (clutch outer, rollers and springs)

-

reverse decompressor cam

-

stopper pin

-

decompressor cam

-

spring

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.

DECOMPRESSOR

ASSEMBLY

CLUTCH

OUTER

DECOMPRESSOR

CAM

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.

RSE DECOMPRESSOF

ONE WAY CLUTCH

WASHER

CAM SPROCKET FLANGE

Install the springs and rollers into the clutch outer

grooves

as

shown.

Install the thrust washer onto the clutch outer.

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 align

-

tion.

It

will

break

ing the wide groove with the wide tooth.

or crack.

WASHER

SPROCKET FLANGE

7

-

8

CYLINDER HEAD/VALVE

*

-

*

-

.----

I

_

I

CYLINDER HEAD REMOVAL/

DISASSEMBLY

r\,,

,..,-rn

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.

~

-

Remove the gasket and dowel pins.

DOWEL

PINS

-v.

GASKI

Remove the three bolts and the carburetor insulator

from the cylinder head.

Remove the O

-

ring from the carburetor insulator.

i

Remove the valve spring cotters uslng the valve

%CKRs

spring compressor.

.\

TOOL

Valve

spring

compressor

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.

CTAM

-

Remove the carbon deposits from the combustion

-5

chamber and clean

off

the gasket surface, being care

-

ful 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

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)

EX

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 correspond

-

ing guide I.D. to obtain the stem

-

to

-

guide clearance.

SERVICE LIMITS

IN:

0.12

mm

(0.005

in)

EX

0.14

mrn

(0.006

in)

If the stem

-

to

-

guide clearance exceeds the service

limit, determine if

a

new guide with standard dimen-

sions 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

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 tem

-

perature.

Wear heavy gloves to avoid burns when handling

the heated cy1;nder head.

CAUTION:

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 cham

-

ber side.

TOOL

Valve guide driver,

5.5

mm

07742

-

0010100

ALV

RIVER

-

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

Let the cylinder head cool to room temperature.

07742

-

0010100

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

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 opera

-

tion.

Clean the cylinder head thoroughly to remove any

metal particles after reaming and reface the valve

seat (page 7

-

14).

Y

&

/'

\#

O

-

RING'

.c

VALVE GUIDE REAMER'

f

*=

\

*a-*

/

7

-

1

2

CYLINDER HEADNALVE

VALVE SEAT INSPECTION/REFACING

INSPECTION

.~

Clean all intake and exhaust valves thoroughly to

remove carbon deposits.

Apply a light coating of Prussian Blue to each valve

seat.

Tap the valve against the valve seat several times

without rotating the valve, to 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:

-

Damaged face:

-

Replace the valve and reface the valve seat.

-

Replace the valve and reface the valve seat.

UNEVEN SEAT

WIDTH

I

DAMAGED FACE

-

Contact area (too high ortoo low)

-

Reface the valve seat.

NOTE:

The valve cannot be ground. If the valve face is

burned or badly worn or

if

it

contacts the seat

unevenly, redace the valve

7-1

3

CYLINDER HEAD/VALVE

REFACING

NOTE:

*

Follow the refacing manufacturer's operating

instructions.

-

Be careful not to grind the seat more than neces

-

sary.

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.

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)

07780

-

0010400

07780

-

0010300

Cutter holder,

5.5

mm

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)

07780

-

0012300

Flat cutter,

30

mm

(EX)

07780

-

0012200

Cutter holder,

5.5

mm

07781

-

0010101

or equivalent commercially available

in

U.S.A.

OLD SEAT

WIDTH

CONTACT TOO HIGH

*

OLD SEAT

WIDTH

CONTACT TOO LOW

*

ROUGHNESS

\

OLD SEAT WIDTH

\

1

7

-

14

CYLINDER HEAD/VALVE

Using a

60

"

interior cutter, remove

114

of the existing

valve seat material.

TOOLS:

Interior cutter,

30

mm

07780

-

0014000

Cutter holder,

5.5

mm

07781

-

0010101

or

equivalent commercially available

in

USA.

Using

a

45

"

seat cutter, cut the seat to the proper

width.

VALVE SEAT

WIDTH:

1.0

-

1.1

mm

(0.039

-

0.043

in)

Make sure that

all

pitting and irregularities are

removed.

OLD SEAT WIDTH

-+

1.0

-

1.1

mm

(0.039

-

0.043

in)

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 dam

-

age the seat.

Change the angle

of

lapping tool frequently to

prevent uneven seat wear.

Do

not allow lapping compound to enter the

guides.

After lapping, wash any residual compound

off

the

cylinder head and valve and recheck the seat contact.

i

7

-

1

5

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

molyb

-

denum oil solution.

lnsett the valve into the guide while turning

it

slowly

to avoid damage to the stem seal.

i

r

>rKll\b

btAl

-

.

.. -.

Install the inner and outer valve springs with the

tightly wound coils facing the combustion chamber.

Install the spring retainer.

-

TIGH"

I,

I

-

I

WOL

COIL

-

Combustion chamber

511

3e

7

-

1

6

CYLINDER HEADlVALVE

Grease the

cot

-

ters

to

ease

compressor.

insfallation.

Install the valve spring cotters using the valve spring

TOOL

Valve spring compressor

07757-0010000

CAUTION:

To

prevent loss

of

tension,

do

not compress the

valve springs more than necessary to install the cot

-

ters.

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 posi

-

tioned in the cylinder grooves.

Install the dowel pins and a new gasket.

7-1

7

CYLINDER HEADWALVE

Install the bearing setting pins, spring and plunger,

being careful not to drop them into the crankcase.

\/

CAP

NuTs-a

Route the cam cnain tnrough the cylhoer head and

instal. the cylinoer head

onto

the cylinder.

CYLlhDER

HEAD

\

SP

-

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.

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.

!ARK:

7

-

1

8

CYLINDER HEADNALVE

The crankshaft

should be turned

only counter

-

clockwise. This

must be done to

prevent the one

-

way decompres-

sor

system func

-

tioning.

Install the cam sprocket onto the cam chain

so

that

the index lines on the sprocket with the upper surface

of the cylinder head.

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.

F

I

Apply locking agent to the cam sprocket bolt threads.

Align the bolt holes in the cam sprocket and

camshaft flange and install the cam sprocket bolt.

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

to

the same

toque. \Align

c

...~

(when aligning

rioicii

aiiu

I

IIWTK,

CAM CHAIN TENSIONER LIFTER

INSTALLATION

Remove the cam chain tensioner lifter plug and

0-

ring.

Check the lifter operation:

-

The tensloner shaft should not go into the body

k

when

it

is pushed.

1

-

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.

7-1

9

CYLINDER HEAD/VALVE

Make

a

tensioner shaft stopper tool

of

a

thin piece of

steel

(0.8

mm 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 posi

-

tion.

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 ten-

sioner 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

R.

IN.

ROCKER ARM

SUB

-

ROCKER ARM "A"/

L,

EX, ROCKER ARM

COPPER WASHT WAVE WASHER

\

R,EX.

/

n/R,RARM

ROCKER ARM

EXHAUST SUB

-

ROCKER ARM SHAFTS

I

COPPER WASHERS

ROCKER ARM

"

IN

"

/

WAVE WASHER

SUB

-

ROCKER

ARM

"

IN

"

/

\AlA\lE

1AIACUER

..-Y.,LI.

IN

T

AKE

SUB

-

ROCKER

COPPER ARM SHAFTS

WASHERS

.

-.

--

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.

5i

7

y-"

-

Apply

locking agent to the

2

-

3

threads

of

the rocker

arm shafts and tighten the shafts.

WASHER

TORQUE: 27

Nm

12.8 kgfm.

20

Ibf4t)

Install the sub

-

rocker arms and wave washers in the

cylinder head cover as shown, noting each identifica

-

tion mark as shown.

Install the sub

-

rocker arm shafts with new sealing

5-7

,.

.

washers.

Apply

locking agent to the

2

-

3

threads

of

the sub-

rocker arm shafts and tighten the shafts.

TORQUE: 27

Nm

(2.8 kgfm, 20

IbfW

-\/

"

I

N

"

7

-

22

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.

down.

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

._

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 in

2

or

3

steps.

TORQUE:

8

mm

bolt:

23

Nm

(2.3

kgfm

17

IbfW

Install the spacers, upper engine hanger bolt and nut,

and tighten the nut.

TORQUE:

54

Nm

(5.5

kgfm

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).

i

~

7

-

24

MEMO

CYLINDER/PISTON

44

Nm

(4.5

kgfm,

33

Ibf.ft)

/

8

-

0

8.

CYLINDER/PISTON

Cylinder

-

to

-

piston clearance

Connecting rod small end

I.D.

Connecting rod

-

to

-

piston pin clearance

SERVICE INFORMATION

8

-

1

CYLINDER/PISTON REMOVAL

8

-

3

TROUBLESHOOTING

8

-

2

PlSTONlCYLlNDER INSTALLATION

a

-

7

0.015

-

0.050

(0.0006

-

0.0020)

20.020

-

20.041 (0.7882

-

0.7890)

0.020

-

0.047

lO.0008

-

0.0019)

0.10 (0.004)

20.067 (0.7900)

0.103 (0.0041)

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 STANDARD SERVICE

LIMIT

I.D.

I

85.000

-

85.010 (3.3465

-

3.3468)

I

85.10 (3.350)

Cylinder

Piston,

piston pin, pis

-

ton ring

TORQUE VALUES

Cylinder bolt

(10

mm)

Cylinder stud bolt

44

Nm

(4.5

kgfm,

33

IbfW

20

Nm

(2.0

kgfm

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.

Remove the cam chain guide (front).

Remove the four

10

mm cylinder bolts and washers.

Remove the cylinder.

Do

not strike the

cylinder

too

hard

and do

not

dam

-

age the mating

surface with a

screwdriver.

Remove the gasket and dowel pins.

PISTON REMOVAL

Place a clean shop towel over the crankcase to pre

-

vent 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

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.

PISTON

),*

”

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.

i

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)

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)

over

-

size 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).

r

I

TOP

’

-

’

-

BOTOM

8

-

4

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)

-

I_

-

PlSTONlPlSTON RING

Inspect the piston rings for movement by rotating the

rings. The rings should be able to move in their

E

grooves without catching.

r

Push the ring until the outer surface

of

the piston ring

is nearly flush with the piston and measure the ring

-

to

-

ring groove clearance.

SERVICE LIMITS: Top: 0.14

mm

(0.006

in)

Second:

0.12

mrn

(0.005

in)

i

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 piston-

to

-

cylinder clearance (page

8

-

4).

8-5

CYLINDER/PISTON

-a

-

I_

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)

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

Carefully install the piston rings into the piston ring

grooves with the markings facing up.

CAUTION:

Be careful not to damage the piston and rings during

-

installafion.

D

TOPRING

SECOND RING

OIL

RING

Stagger the piston ring end gaps

120

"

degrees apart

from each other.

Stagger the side rail end gaps as shown.

MARK

/

20

mm

(0

8

in)

OR

MORE

20

mm

(0.8

in)

OR

MORE

NOTE:

*

Do

not confuse the top and second rings.

-

To install the oil ring, install

the

spacer first, then

install the side rails.

OIL

RING

-

PISTON INSTALLATION

Place

a

clean shop towel over the crankcase to pre

-

vent 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 pis

-

ton 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 crank

-

case thoroughly, being careful not to damage

it,

and

careful not to allow gasket material into the crank

-

case.

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

cylin

-

der wall.

Apply oil to 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

Nm

(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 RIGHT CRANKCASE COVER

INSTALLATION 9

-

12

CLUTCH 9

-

5

-

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 dis-

engaged, 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).

L

SPECIFICATIONS

Unit:

mm

(in)

TORQUE

VALUES

Clutch center lock nut

Primary drive gear nut

Gearshift drum stopper arm bolt

TOOLS

108 Nm (11.0 kgfm,

80

IbfW

88

Nm

(9.0

kgfm,

65

IbfW

12

Nm

(1.2 kgfm,

9

IbfW

Apply oil to the threads and seating surface.

Stake.

Apply oil to the threads and seating surface.

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

USA,

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

*

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)

Improper oil viscosity or oil additive used

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

L

CLUTCHlGEARSHlFT LINKAGE

RIGHT

CRANKCASE COVER REMOVAL

1-

I

IETFR

ARM

-I-----

PAR1

E

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.

-

fi

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

Remove the gasket and dowel pins.

Remove the O

-

ring and oil pump driven sprocket from

the oil pump.

DOWEL

-

PINS

-

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.

I

-

BEARING

9

-

4

CLUTCH

DISASSEMBLY

CLUTCHlGEARSHlFT LINKAGE

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

USA.

9

-

5

CLUTCH/GEARSHIFT LINKAGE

Remove the lock washer, plain washer and clutch

center.

Remove the thrust washer, clutch outer and clutch

outer guide.

INSPECTION

LIFTER

BEARING

Turn the inner race of the lifter bearing with your fin

-

ger.

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

07749

-

0010000

Attachment,

28

x

30

mm

07746

-

1870100

Pilot,

17

rnrn

07746

-

0040400

CLUTCH

SPRING

Measure the clutch spring free length.

SERVICE LIMIT

50.0

mm

11.97

in)

Replace

the

clutch springs

as

a

set.

I

BEARING

-

9

-

6

CLUTCH/GEARSHIFT LINKAGE

-

~

CLUTCH DISC

Check the clutch discs for signs

of

scoring or discol

-

Measure the clutch disc thickness.

SERVICE LIMIT 2.69

mm

10.106

in)

Replace the

-

clutch discs and

oration.

plates as a set.

-

CLUTCH PLATE

Replace the

clutchdiscsand

plares as

a

set

Check the plates for discoloration.

Check the plate warpage on 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 dam

-

age.

Check the slots in the clutch outer for nicks, indenta

-

tion 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.

at

the clutch outer guide.

SERVICE

LIMIT

21.91

mm

(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 fac

-

ing

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

USA.

TORQUE:

108

N.m

(11.0

kgfm

80

IbfW

Becarefulnotto

mainshaft

threads.

Stake the clutch center lock nut into the mainshaft

damage the

groove.

Coat the clutch discs

with

clean engine oil.

Install the seven clutch discs and six plates alternately,

starting with the disc.

Install the

out

-

side clutch

disc tabs into the

shallow slots in

the clutch outer.

I

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

Nm

(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

kgfm,

9

Ibf.ft)

9

-

1

ALTERNATOR/STARTER CLUTCH

-

kgfm.

10-0

10.

ALTERNATOR/STARTER CLUTCH

ITEM

SERVICE INFORMATION

10-1

FLYWHEEL REMOVAL

10

-

5

TROUBLESHOOTING

10

-

1

STARTER CLUTCH

10

-

6

ALTERNATOR STATOR

10

-

2

FLYWHEEL INSTALLATION

10

-

8

-

STANDARD

SERVICE

LIMIT

TORQUE VALUES

Flywheel bolt

Starter clutch bolt

Left crankcase stud bolt

TOOLS

Flywheel holder

Rotor puller

127 Nm (13.0 kgf.m, 94 Ibf.ft)

30

N.m (3.1 kgf.m, 22 IbfW

10 Nm (1.0 kgf.m, 7 IbfW

Apply oil to the threads and seating surface.

Apply locking agent to

the

threads.

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.

-

L

-

'L

.

-

Remove the gasket and dowel pins.

Remove the starter reduction gear shaft and gear.

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.

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 genera

-

tor

and tighten the two bolts securely.

Apply locking agent to the wire clamp bolt threads.

Install the wire clamp and tighten the bolt securely.

,GROMMET

C

s......

.

BOLTS

GENERATOR

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

Nm

(2.0

kgfm,

14

Ibf4t)

...

10

-

4

ALTERNATORlSTARTER CLUTCH

Route the alternator wire properly (page

1-18).

Connect the alternator connectors.

Install the seatlrear fender (page

2

-

21.

L

-

Install the starter idle gear shaft, gear and spacer

in

the left crankcase cover.

Install the dowel pins and

a

new gasket.

i

r--

Install the starter idle gear cover and tighten the four

bolts securely.

CF.

i

3

FLY

W

H

E

L

R

E

MOVAL

Remove the left crankcase cover (page

10-2).

I

Hold the flywheel

with

the special tool and loosen the

flywheel bolt.

r"'

TOOL

t

Flywheel holder 07725-0040000or

I.

equivalent commercially

available

in

USA.

Remove the flywheel bolt and special washer.

I

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.

".

"

-.

b-

Remove the needle bearing, spacer anu woooruff

,_SPAEL

?"

'*c

i

rr-

key.

STARTER CLUTCH

REMOVAL

Remove the flywheel (page

10-5).

Remove the starter driven gear while turning it coun

-

terclockwise.

Remove the washer.

DRIVEN

GEAR

Hold

the flywheel with the special tool and remove

the starter clutch bolts.

TOOL

Flywheel holder

07725

-

0040000

Remove the starter clutch assembly from the flywheel.

Remove the sprag clutch from the starter clutch

outer.

FLYWHEEL

-

10

-

6

ALTERNATOWSTARTER CLUTCH

im

F

GFAR

bmi

iriinN

GFAR

INSPECTION

Check the starter idle gear and reduction gear for

-

wear or damage.

Check the starter clutch outer and sprag clutch for

abnormal wear or damage.

SPRAG

ri

(ITCH

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)

L

.

_.

INSTALLATION

Install the sprag clutch into the starter clutch outer

with the flange side facing the flywheel side.

-

10

-

7

SPR

ALTERNATOR/STARTER CLUTCH

Apply locking agent to the starter clutch bolt threads.

Install the starter clutch assembly onto the flywheel

and install the bolts.

Hold the flywheel

with

the special tool

and

tighten

the bolts.

TOOL

Flywheel holder 07725-0040000or

equivalent commercially

available

in

USA.

TORQUE:

30

N.m

(3.1

kgf.m,

22

Ibf.ft)

Install the starter driven gear with the washer while

turning

it

counterclockwise.

Make sure that the starter driven gear turns counter

-

clockwise smoothly and does not turn clockwise.

Install the flywheel.

7RIVENGEAR

-

/

Fl

Install the starter drive gear.

ic

fWHEEL INSTALLATION

-

Lubricate the needle bearing with oil.

Install the

5.6

mm spacer and needle bearing onto the

crankshaft.

Clean any

oil

from the tapered portions of the crank

-

shaft and flywheel.

Install the woodruff key

in

the crankshaft key groove.

I

i

lnsta

I

the flvwhcel on tne crankshaft, aligning tne

kcy way

mitn

rhe woodruff key.

ii.

i

10

-

8

ALTERNATORlSTARTER CLUTCH

Apply

oil

to the flywheel bolt threads and seating sur

-

face, 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

Nm

113.0 kgfm,

94

Ibf4t)

Install the left crankcase cover (page

10-41,

10

-

9

CRANKCASE/TRANSMISSION/CRANKSHAFT

-

11

-

0

1

1.

CRANKCASE/TRANSMISSION/CRANKSHAFT

~

ITEM

I.D.

SERVICE

-

INFORMATION 11-1 CRANKSHAFTlBALANCER

11

-

9

TROUBLESHOOTING 11

-

2 CRANKCASE BEARING REPLACEMENT 11

-

12

CRANKCASE SEPARATION 11

-

3 CRANKCASE ASSEMBLY

11

-

15

TRANSMISSION 11

-

4

SERVICE

IN

FORMATI0

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.

STANDARD

SERVICE

LIMIT

13.000

-

13.021 (0.5118

-

0.5126) 13.05 10.514)

I

SPECIFICATIONS

Unit:

mm

lin

Claw thickness

Shaft

O.D. 12.966

-

12.984 (0.5105

-

0.5112)

5.93

-

6.00 (0.233

-

0.236)

~______

Shift fork

Transmission

Crankshaft

5.5 (0.22)

12.90 (0.508)

TORQUE VALUES

Mainshaft bearing setting plate bolt

Gearshift spindle return spring

bolt

12 Nm (1.2

kgfm.

9

IbfW

24

Nm

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

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

07936

-

KCIOOOO

not available in U.S.A.

07936

-

KC10500

07936

-

KClOlOO

not available in USA.

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

11

-

2

i

1

i

CRANKCASEITRANSMISSIONICRANKSHAFT

CRANKCASE

SEPARATION

Remove the following:

-

engine (section

6)

-

cylinder head (section

7)

-

cylinder and piston (section

8)

-

clutch, gearshift linkage, primary drive gear

-oil pump (section 41

-

flywheel (section 101

-

starter motor (section 18)

-

bolt, tensioner sliderlcollar and washer

-

cam chain

-

cam chain drive sprocket

(section

9)

-11_

TENSiONER

SLIDER

-

two right 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

at

several locations with

a

soft

hammer.

CAUTION:

Do

not

pry

the crankcase apart

with

a

screwdriver.

-

11

-

3

CRANKCASElTRANSMlSSlONlCRANKSHAFT

Remove the gasket and dowel pins.

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.

I

GASKET

-

-1

rr?:

FORK

SHAF

11

-

4

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: M4 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: M4 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, C3 24.92

mm

(0.981

in1

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.

I

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

mm

(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

Clean

all

parts

in

solvent and dry them thoroughly.

7ING

Apply molybdenum

oil

solution to the gear teeth,

sliding surface, shifter grooves and bushings.

Assemble the mainshaft and countershaft.

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.

CORRECT INCORRECT

SNAP

RING

11

-

6

CRANKCASE/TRANSMISSION/CRANKSHAFT

MAINSHAFT

THRUST WASHER

SPLINE WASHER

/

SPLINE WASHER

M4 GEAR (22T)

M4

GEAR BUSHING

THRUST WASHER

WASHER AND SNAP RING DIRECTION:

I

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

C1 GEAR (35T)

I

THRUST WASHER

:

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.

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.

Be

sure

to

install

the thrust

washers.

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 up (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

FORK

'3

Coat the shift fork shaft with oil.

Install the shift fork shaft through the shift forks and

into the left crankcase.

L

i

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.

I

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 to damage the crankcase mating sur

-

face 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

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.

INSPECTION

CRANKSHAFT

Set the crankshaft as shown and measure the runout

using a dial indicator.

SERVICE

LIMIT

0.12

mm

10.005

in1

-/

i

UhlVERSAL

BEARING

#.

PROTECTOR

I

P

I

6

mm-

Measure the radial clearance at the connecting rod

big end

in

an

X

and

Y

directions.

SERVICE

LIMIT:

0.05

mm

(0.002

in)

m

-8

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)

11

-

10

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 07749

-

0010000

Attachment, 72

x

75 mm 07746

-

0010600

Pilot.

30

mm 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

-/ROD

cob.

Assemble the special

tools

onto the crankshah.

Draw tne crankshatt into the bearing 'nner race.

-

TOOLS:

Crankcase assembly tool 07965

-

VMOOOOO

not available in U.S.A.

-

Assembly collar 07965

-

VMOOlOO

-

Assembly shaft 07965

-

VM00200 or

07931

-

ME40100 and

07931

-

HB3020A

07965

-

VM00300 or

07931

-

KF00200

-

Threaded adaptor

CAUTION:

~

Be careful not to let the connecting rod 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).

\

:OLLAR

-

CRANKCASE BEARING REPLACEMENT

-

RIGHT

CRANKCASE

BEARING

Remove the balancer bearing with the special tools.

TOOLS:

Bearing remover set, 15

mm

-

Bearing remover, 15

mm

i

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.

i

.1

-

Remover, 15

mm

-

Remover shaft

BEARING

REMOVEFi'

-

Sliding weight 07741

-

0010201 or

-

07936

-

371020A or

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 bear

-

ings in with the marking side facing up using the spe

-

cial

tools.

TOOLS:

Mainshaft bearing:

Driver

07749

-

0010000

Attachment,

42

x

47

mm

07746

-

0010300

Pilot,

22

mm

07746

-

0041000

Crankshaft bearing:

Driver

07749

-

0010000

Attachment,

72

x

75

mm

07746

-

0010600

AND

-

PILOT

-

Be

sure

to

align the

notch in the

couniershafl

oil

seal

with

ihe

crankcase

passage.

Pilot,

30

mm

07746

-

0040700

Balancer bearing:

Driver

07749

-

0010000

Attachment,

37

x

40

mm

07746

-

0010200

Pilot,

15

mm

07746

-

0040300

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

07749

-

0010000

Attachment,

42

x

47

mm

07746

-

0010300

Pilot.

17

mm

07746

-

0040400

SE

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

lll~i

:

.

--

/&.

LEFT CRANKCASE

Remove the countershaft and gearshift spindle

oil

seals.

-

i

k

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 07936

-

3710300

Remover handle 07936

-

3710100

Sliding weight 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.

CAUTION:

Do

not 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 07749

-

0010000

Attachment, 52

x

55 mm 07746

-

0010400

Pilot, 25

mm

07746

-

0040600

Balancer bearing:

Driver 07749

-

0010000

Attachment, 32

x

35

mm

07746

-

0010100

Pilot, 12

mm

07746

-

0040200

Drive the mainshaft bearing

in

with the sealed side

facing down using the special tools.

TOOLS:

Driver 07749

-

0010000

Attachment, 37

x

40

mm 07746

-

0010200

Pilot,

17

mm

07746

-

0040400

Install new countershaft and gearshift spindle oil

seals.

IVER

-

A

L..

ATrACH

M

E

-

1

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 all the parts are installed

in

the left

crankcase.

Install the right crankcase over the left crankcase.

.-

..-*..-

,..

..

-

Install the left crankcase bolts and tighten them in 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 crank

-

shaft, by aligning the wide groove with the wide

tooth.

I

Install the cam chain onto the drive sprocket and

;TENSIONER

s

-.

through the crankcase.

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 (sec

-

piston and cylinder (section

8)

-

cylinder head (section

7)

~

oil pump (section

4)

-

starter motor (section

18)

-

engine (section

6)

tion

9)

i

WASHER;COLLA&OLT

.

.~

-

flywheel (section

10)

-

11

-

16

MEMO

FRONT

WHEELlSUSPENSlONlSTEERlNG

39

Nm

(4.0

kgfm,

44

Nm

(4.5 kgfm,

42

Nm

(4.3 kgfm,

31

1bf.e

9

Nm

(3.0

kgf.m,

33 IbfW

64

Nm

(6.5 kgfm,

47

Ibf.ft)

12

-

0

12.

FRONT

WHEEL/SUSPENSION/STEERING

ITEM

Minimum tire tread depth

Cold tire pressure Standard

Minimum

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

-

~

STANDARD

SERVICE

LIMIT

4.0 (0.16)

27 kPa (0.275 kgf/cmZ, 4.0 psi)

23 kPa (0.235 kgf/cm2,

3.4

psi)

-

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

Maximum

Tie

-

rod distance between the ball joints

Toe

~

31 kPa (0.315 kgf/cm2, 4.6 psi)

370.2 (14.57)

-

17

f

15 (0.7

f

0.6)

-

I

Shock absorber sDrina adiuster standard nosition

1

4th

from softest nosition

-

TORQUE VALUES

Handlebar lower holder nut

Throttle housing cover screw

Left

handlebar switch housing screw

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

-

Front wheel nut

-

39

Nm

(4.0 kgfm, 29 IbfW

4

Nm

(0.4 kgfm, 2.9

IbfW

2

Nm

(0.2 kgfm, 1.4

IbfW

64

N.m

(6.5 kgfm, 47 IbfW

59

N.m

(6.0

kgfm, 43 Ibf+t)

42

Nm

(4.3 kgfm, 31 Ibf.ft)

44

Nm

(4.5 kgfm, 33 Ibf.ft)

39

Nm

(4.0 kgfm. 29 IbfW

29

Nm

(3.0 kgfm, 22 Ibf+t)

54

Nm

(5.5

kgfm.

40

IbfW

44

N-m

(4.5 kgfm, 33

IbfW

69

N.m

(7.0 kgfm,

51

Ibf4t)

32

Nm

(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

TROUBLESHOOTING

Hard steering

.

Damaged steering shaft bearinglbushing

*

Insufficient tire pressure

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

Steering shaft holder too tight

Front wheel wobbling

-

Bent rim

-

Worn or damaged wheel hub bearings

*

Faulty tire

-

Wheel hub not tightened properly

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

Soft

suspension

-

Weak shock absorber spring

-

Faulty shock absorber damper

*

Loose front suspension fasteners

Hard suspension

Bent shock absorber damper rod

-

Improperly installed suspension arms

*

Faulty suspension arm spherical bearings

Front suspension noise

Binding suspension link

Loose front susuension fasteners

12

-

2

FRONT

WHEEL/SUSPENSlON/STEERlNG

HANDLEBAR

REMOVAL

c

Remove the fuel tank breather tube from the handle

-

bar 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 han

-

~

dlebar carefully.

Remove the wire bands.

I

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.

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 hous

-

ing.

MASTER THROTLE HOUSING

CYLINDER

I

LEVER BRACKET SWITCH RETAINER

SWITCH

H

O

USING COF~NECTORS'

12

-

3

FRONT

WHEEL/SUSPENSION/STEERlNG

Remove the screw and grip end.

Remove the handlebar grip.

Remove the four bolts and the upper holders:

Remove the handlebar from the lower holders.

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.

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 align

-

ing the flats.

Install the handlebar switch housing by aligning its

locating pin with the hole in the handlebar.

Install the two attaching screws and tighten the

upper screw first, then tighten the lower screw.

TORQUE:

2

Nm

(0.2

kgfm,

1.4

1bf.h)

GRIP

END

I

HANDLEBAR GdlP

PUNCH MARKS

I

HANI~LEBAR

U&ER

HOLDERS

I

G

R

I

P

E

N

D

SWITCH

I

12

-

4

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.

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.

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.

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

DISASSEMBLY

Remove the three attaching screws and the throttle

housing cover.

Remove the gasket.

MARK

BOLTS

CONNECTORS

MASTER CYLINDER

"

UP

"

MARK

THROTTLE HOUSING

COVER

GA

S

KET

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 hous

-

ing.

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 sur

-

faces.

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

-

three bolts and brake disc

-

side collars

-

dust seals.

-

cotter pin

-

hub nut

-

wheel hubldisc

:"-I

IT

c

i

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.

Remove and discard the bearings

if

the races do not

turn smoothly and quietly or if they fit loosely in the

hub.

FRONT

WHEEL/SUSPENSlON/STEERlNG

12

-

7

Replace

the

bearings in

pairs.

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

07746

-

0050100

Bearing remover head,

15

mm

07746

-

0050400

NOTE

Replace the wheel bearings in pairs.

Do

not reuse old

bearings.

FRONT

WHEEL/SUSPENSION/STEERING

DRIVER

/

HUB

ASSEMBLY

Drive in

a

new inner bearing (brake disc side1 squarely

with the marking side facing up until it

I

S

fully seated.

Install the distance collar with the large dia. facing

the inner bearing.

Drive in a new outer bearing squarely with the mark

-

ing side facing up until

it

is

fully seated.

TOOLS

Inner bearing (disc side):

Driver

07749

-

0010000

Attachment.

42

x

47

mm

07746

-

0010300

Pilot,

20

mm

07746

-

0040500

ATTACHMENT AND

PILOT

Outer bearing (wheel sideJ:

Driver

07749

-

0010000

Pilot,

15

mm

07746

-

0040300

-

Attachment,

32

x

35

mm

07746

-

0010100

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:

Wheel side:

Assembly collar

07965

-

VMOOlOO

Attachment,

32

x

35

mm

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 fur

-

ther tighten it until its grooves align with the cotter

pin hole.

TORQUE:

59

Nm

(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

Nm

13.1

kgfm,

22

Ibf4tJ

Install the disc guard and tighten the bolt.

\

Qm

**

DUSl

il~fi~a

DISC

x

P

BOLTS

C/

12

-

8

FRONT

WHEEL/SUSPENSION/STEERlNG

WHEEL INSTALLATION

Install the wheel onto the hub with the tire valve fac

-

ing 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)

TIRES

REMOVAL

NOTE:

.

L

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 to

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.

I

TIRE.‘VALVE

I

-

This service requires the Universal Bead Breaker

(GN-AH-958-661).

-

Remove and install the

tire

from the rim side

omosite the valve stem.

PRESS

BLOCK

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.

I

\

I

\

BLADE

12

-

9

FRONT

WHEEL/SUSPENSION/STEERlNG

WHITE

NYLON BUTTON:

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.

I

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

at

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

to

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 remain

-

der

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.

BREAKER ARM ASSEMBLY

\

I

ADAPTER THREADED SHAFT

'RESS

HEAD BOLT

TOP EDGE

OF

RIM

BEAD BLOCKS

12

-

1

0

FRONT

WHEELlSUSPENSlONlSTEERlNG

TIRE

REPAIR

NOTE:

Use the manufacturer’s instructions for the tire repair

kit you are using. If your kit does not have instruc

-

tions, use the procedures provided here.

Check the tire for puncturing objects.

Chalk mark the punctured area and remove the punc

-

turing 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

(5/8

in). 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.

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.

Becarefulnotto

push

the plug

all

the way into the

tire

to

prevent

it

from

falling

inside.

Allow the repair to dry. Drying time will vary with air

temperature. Refer to the tire repair kit manufactur

-

er’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

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

rol

I

e

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.

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

wn

cause the tire to shift on

the rim and lose air pressure during riding.

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.

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):

Front tire:

Reartire:

Standard:

27

kPa

10.275

kgflcm’,

4.0

psi)

Minimum:

23

kPa

10.235

kciflcmz.

3.4

osil

fl-

-

FRONT TIRE:

LEFT

RIGHT

TIRE

CALVE

I

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

-

1

2

FRONT

WHEEL/SUSPENSION/STEERlNG

rz--

_.______^,,r^

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.

NOTE:

If

necessary, apply penetrating type lubricant to

loosen the ball joint.

Release the ball joints of the upper and lower arms

off

the knuckle, using the special tool according to

the following instructions.

PRESSURE BOLT

Apply

grease

here

c

,

I

.

TOOL

Ball

joint

remover

Once the tool is in place, turn the adjusting bolt as

07MAC

-

SLOOZOO

PRESSURE

,

BOLT

necessary to make the jaws parallel.

Then hand

-

tighten the pressure bolt and recheck the

jaws to make sure they are still parallel.

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

-

1

3

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 bear

-

ings 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

con

-

tacts 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.

INSTALLATION

Pack

3

g

(0.1

02)

of

grease into each arm pivot as

shown.

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

-

pivot nuts

-

shock absorber lower mounting bolt and nut

-

brake hose clamp with bolt

TORQUE:

side

Upperllower arm:

39

Nm

(4.0

kgfm,

29

IbfW

Shock absorber:

44

Nm

(4.5

kgfm,

33

Ibf.ft)

I

BEARING

DRIVER

BEARING

*

STOPPER RING

COLLARS

/

W

\

12

-

1

5

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

Nm

(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,

Adjust the toe (page

3

-

22).

FRONT

SHOCK

ABSORBER

REMOVAL

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

Remove the lower pivot collar and dust seals.

Check the pivot collar and dust seals for wear or

damage.

COTTER

F

\

WAS

/

'INS

HER

i

TOLLAR

/

-

/

DUST

SEALS

12

-

1

6

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

guide.

removingthe

Remove the front fender (page

2-21,

Release the cables and wire harness from the cable

Remove the bolt and brake hose clamp from the

front fender.

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

-

1

7

FRONT

WHEELlSUSPENSlONlSTEERlNG

Remove the cotter pins from 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

I

frame.

i

INSPECTION

Inspect the tie

-

rod for distortion or damage.

Inspect the

ball

joint rubbers for tears of other dam

-

age by moving the ball joint studs.

They should move freely and smoothly.

Check the steering shaft bushing for wear or damage.

-

..

12

-

1

8

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

07749

-

0010000

Attachment,

32

x

35

mm

07746

-

0010100

Drive in

a

new bearing squarely with the marking

side facing up until

it

is fully seated.

TOOLS:

Driver

07749-0010000

Attachment,

37

x

40

mm

07746

-

0010200

Pilot,

17

mm

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

i

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.

Temporarily tighten the lock nuts while the ball joints

position are

180

"

from each other.

Tighten these

nuts after

installing the tie

-

rod into the

knuckle and

steering shaft.

INSTALLATION

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.

Install the shaft holders with the two bolts as shown.

Tighten the holder bolts.

TORQUE:

32

Nm

13.3

kgfm,

24

Ibf4t)

Install the shaft collar into the dust seal.

Install the end nut and tighten

it.

TORQUE:

69

Nm

17.0

kgfm,

51

Ibf4t)

Install a new cotter pin.

6.5

rnm

6.5

rnm

(0.26

in)

.

-

STEERING

I

-5Ai

BUSHING

I

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

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.

following procedure:

c7

1

NUT

TORQUE: 54 Nm 15.5 kgfm, 40 Ibf4t)

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

andcableprop

-

erlylpage

1-18),

Tighten the nuts.

Install the handlebar assembly onto the steering

shaft with the lower holder nuts and washers.

TORQUE:

39

Nm

14.0 kgf.m,

29

IbfW

Install the cables and wire harness into the guide

on

HANDLE-

C

the shaft holder.

I

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

108

Nm

(11.0

kgf.m,

80

Ibf4t)

\

I

137

Nm

(14.0 kgfm, 101 IbfW

64

N.m

(6.5

kgf.m. 47 Ibf.ft)

13

-

0

13.

REAR

WHEEL/SUSPENSION

Drive chain slack 30-40(1-1/4-1-5/8)

~

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

Shock absorber spring installed length

1

231.5 (9.11)

A

contaminated brake disc or Dad reduces stODpino Dower. Discard contaminated Dads and clean a contaminated

-

.. _.

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 of the shock absorber, release the nitrogen by 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)

ITEM

STANDARD

I

SERVICE

LIMIT

I

4.0 (0.16)

-

Mini m u

m

-

Maximum

I

31 kPa (0.315 kgf/cm', 4.6 psi)

-

I

23

kPa

(0.235 kgf/cm2, 3.4 psi)

Axle runout

-

I

3.0 10.12)

I

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 Nm (6.5 kgfm. 47 IbfW

137 Nm (14.0 kgfm. 101 IbfW

59

Nm

(6.0 kgfm, 43 Ibf.ft)

44

Nm

(4.5 kgfm, 33 IbfW

59

Nm

(6.0 kgfm, 43

IbfW

59 Nm (6.0 kgfm, 43 IbfW

59 Nm (6.0 kgfm, 43 Ibf.ft)

88

Nm

(9.0

kgfm, 65 IbfW

128 Nm (13.0 kgfm, 94 IbfW

108 Nm (11.0 kgfm

80

IbfW

59

Nm

(6.0 kgfm. 43 IbfW

Apply grease to the threads and seating surface/Castle nut

Apply locking agent to the threads

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

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

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

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 sec-

tion

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.

TORQUE: 64

Nm

16.5

kgfm

47

IbfW

REAR AXLE

REMOVAL

TAPERED SIDE

INNER

LOC

i

CAUTION:

k

i

Suooort the caliDer

so

that

it

does not hang from the

~

brake hose.

Do

not twist or bend the brakehose.

-

I(

%.

~

-

-.

Remove the rear brake caliper (page

14

-

6).

-

,

.

-

1_

\

.

-

Thelocknuts

has

left

hand

Loosen the axle inner lock nut while holding the

outer lock nut, using the special tools.

threads

OUTER

LOCK

NUT

TOOLS

Lock nut wrench,

56

mm

07916

-

HA20000

or

07916

-

HA2010A

(U.S.A.

only)

07916

-

1870101 or

equivalent commercially

available

in

USA.

Lock nut wrench,

45

mm

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,

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.

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

prevent the threads from beingdamage.

NUT

‘STOPPER

RING

!

axle to

Remove the axle by driving the axle out of the bear

-

ing holder in the swingarm, using a rubber mallet.

13

-

4

REAR

WHEELlSUSPENSlON

Remove the O

-

ring.

Remove the nuts, bolts and driven sprocket.

Remove the snap ring from the bearing holder.

s1

Remove the caliper stay and stopper bushing.

Remove the O

-

rings from the bearing holder and stay

groove.

\

SPROCKET

\

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

(0.12

in1

13

-

5

REAR WHEEL/SUSPENSION

Replace the axle

bearings

in

osirs.

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.

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

0-~NGS

BOLTS

DRIVEN

SPROCKET

I

'

RING

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

07749

-

0010000

Attachment,

62

x

68

mm

07746

-

0010500

Pilot,

40

mm

07746-0040900

ATTACHMENTA

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.

ND

PILOT

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 bush

-

ing.

Install the snap ring into the bearing holder gropve

with the

"

OUT

SIDE

"

facing out to secure the caliper

stay.

-

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

S

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

it

between the

-

driven sprocket flange and axle.

Apply grease

to

the hub nut threads and seating sur

-

face.

Install the wheel hub and hub nut onto the axle.

Tighten the hub nut to the specified torque and fur

-

ther 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).

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.

'ROCKET

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 seat

-

ing 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

-

07916

-

1870101 or

equivalent commercially

available

in

U.S.A.

-

Refer to torque

wrench reading

mformation

on

page

13-1

"

SERVICE

lock bolt threads.

INFORMATION

"

.

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

Tighten the inner lock nut while holding the outer

lock nut.

TOOLS

Lock nut wrench, 56 mm 07916

-

HA20000

or

07916

-

HA2010A

(U.S.A. only)

07916

-

1870101 or

equivalent commercially

available in U.S.A.

TORQUE: Actual: 128

N.m

(13.0 kgf.m, 94 Ibf4tl

Lock nut wrench, 45

mm

-

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

UTER

LOCK NUT

WRENCH

\\

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

bearing.

Remove the upper pivot collar and check the needle

bearing, pivot collar and dust seals for wear or dam-

Checkthe damper unit for leakage or other damage.

Replace the shock absorber assembly if necessary.

rollers

of the

age.

13-9

REAR WHEEL/SUSPENSION

BEARING REPLACEMENT

Press

the

mark

-

ing side

of

the

bearing.

Remove the dust seals.

Press the needle bearing out

of

the shock absorber.

TOOL

Needle bearing remover 07946

-

KA50000

DRYER

I

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

(0

22

in).

TOOLS:

Driver 07749

-

0010000

Attachment, 24

x

26 mm 07746

-

0010700

Pilot, 17 mm 07746

-

0040400

-

"I

1

ry

/

Make sure that the need

e

rollers

are

in positJon.

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

COLLAR

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).

i

13

-

1

0

REAR WHEELlSUSPENSlON

SHOCK

LINKAGE

I

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:

1

-

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

1

?

-

INSPECTION

Becarefulnotto

lose

the

needle

rollers

of

the

bearing.

Remove the pivot collars and check the needle bear

-

ings, pivot collars and dust seals for wear or damage.

BEARING REPLACEMENT

Remove the dust seals.

Press the needle bearing out of the shock arm and

shock link.

TOOLS:

Needle bearing remover

07946

-

KA50000

Assembly collar

07965

-

VMOOIOO

-

NEEDLE BEARING

i

REMOVER

\

COLLAR

/

I

13

-

1

I

REAR

WHEEL/SUSPENSION

Press the mark

-

ing side

of

the

bearing

Note the installa

-

tion

of

the pivot

bolts. All bolts

are installed

from

the right

side.

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

07749

-

0010000

Attachment,

24

x

26

mm

07746

-

0010700

Pilot,

17

mm

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 nee

-

dle bearings.

Install the pivot collars.

-

INSTALLATION

Install the shock arm into the frame with the

"

UP

"

mark facing up and the bolt and nut.

StiOCJ.

A?M

-.

-

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:

F"

\-

Shock arm

-

to

-

frame:

59

Nm

(6.0

kgfm,

43

Ibf4t)

Shock arm

-

to

-

shock link

Shock link

-

to

-

swingarm:

Shock absorber mounting:

1

b,

7

59

Nm

(6.0

kgfm,

43

Ibf4tl

44

Nm

14.5

kgfm,

33

IbfW

59

Nm

(6.0

kgfm,

43

Ibf4t)

-

I

n

0

sc,

)CK

ARM

-

13

-

1

2

.

REAR WHEEL/SUSPENSION

SWINGARM

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

CLAr

I

-

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 bear

-

ings, pivot collars and dust seals for wear or damage.

\

n

t

iviuvtn

/

I.+---

AnACH

M

EF

INNER

DUST

/

I

SLIDER COLLARS

BEARING REPLACEMENT

EDLE BEAR1

Remove the inner dust seals.

Press the needle bearing and thrust bushing

out

of

the swingarm.

TOOLS:

Needle bearing remover 07946

-

KA50000

Attachment, 35

mm

I.D.

07746

-

0030400

13

-

1

3

REAR

WHEEL/SUSPENSION

Press the

marking side

of

the bearing.

Instail the slider

with the wear

limit groove fac

-

ing

up,

aligning

its slit with the

lug.

Apply grease to new needle bearing rollers.

Carefully press the needle bearing and thrust bush

-

ing into the swingarm pivot until the bushing is fully

seated.

TOOL

Needle bearing remover

07946

-

KA50000

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

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.

TORQUE:

108

N.m

(11.0

kgfm,

80

Ibf.ft)

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:

Shock absorber mounting:

44

Nm

(4.5

kgfm,

33

Ibf.ftl

59

N.m

(6.0

kgfm,

43

Ibf4tl

NEEDLE BEARING

RFhfln\/FR

?

SHlNG

-

\RING

/

-

;i

-

JPIVOT'BOLT

AND

N

JT

BOLTS AND NUTS

SHOCI:

LINK'

-_I_

-

ABSORBER

-

13

-

14

REAR WHEELlSUSPENSlON

Install the brake hoselcable clamp with the bolt to

secure the brake lock cable.

Install the brake hose clamp with the screw.

Install the rear axle (page

13-6).

SCREW/

CLAMP

1

s

i

h

7

I

\

’

BRAKE HOSE LOCK CABLE

.

13-1

5

HYDRAULIC DISC BRAKE

34

Nm

(3.5 kgfm, 25 IbfW

34

Nm

(3.5 kgfm, 25 Ibf.ft)

14

-

0

14.

HYDRAULIC DISC

BRAKE

-

ITEM

STANDARD

SERVICE

LIMIT

~

Recommended brake fluid

Brake disc thickness Front

2.8-3.2(0.11 -0.13) 2.5 (0.10)

Rear

3.8-4.2 (0.15

-

0.17) 3.5 (0.14)

Brake disc runout

__

0.30 (0.012)

Master cylinder

ID.

I

12.700

-

12.743(0.5000-0.5017) 12.75

(C

Master piston

O.D.

12.65

(C

Caliper cylinder

I.D.

33.960

-

34.010 (1.3370- 1.3390) 34.02

(1

Caliper piston

O.D.

33.895

-

33.928 (1.3344

-

1.3357) 33.87

(1:ssSl

DOT

4

brake fluid

-

12.657

-

12.684 (0.4983

-

0.4994)

-

SERVICE INFORMATION 14

-

1 FRONT BRAKE CALIPER 14

-

10

TROUBLESHOOTING 14

-

2 REAR MASTER CYLINDER 14

-

13

BRAKE FLUID REPLACEMENT/ REAR BRAKE CALIPER 14

-

16

AIR BLEEDING

14-3

BRAKE PEDAL 14

-

20

BRAKE PAD/DISC 14

-

5

FRONT MASTER CYLINDER

14-7

:m

SERVICE

INFORMATION

GENERAL

L

A

confarninafed brake disc or pad reduces stopping

power.

Diswrd

contaminatedpads and clean

a

contaminated disc

with

a

high

quality brake degreasing agent.

1.502)

1.498)

1.3401

-

Caliper bleed valve

6

Nm

(0.6

kgfm,

4.3

IbfW

3

Nm

(0.3

kgfm,

2.2

IbfW

18

Nm

(1.8

kgfm

13

IbfW

34

Nm

(3.5

kgfm,

25

Ibf.ft)

17

Nm

(1.7

kgf.m,

12

IbfW

6

N.m

(0.6

kgfm,

4.3

IbfW

6

Nm

(0.6

kgfm,

4.3

Ibf4t)

13

Nm

(1.3

kgfm,

9

Ibf4t)

2

Nm

(0.2

kgfm,

1.4

Ibf.ft)

23

Nm

(2.3

kgfm,

17

Ibf.ft)

18

Nm

(1.8

kgfm,

13

IbfW

30

Nm

(3.1

kgfm,

22

IbfW

23

Nm

(2.3

kgfm,

17

IbfW

18

Nm

(1.8

kgfm,

13

Ibf-ft)

30

Nm

13.1

kgfm,

22

IbfW

23

N.m

(2.3

kgfm

17

IbfW

Front brake caliper pad pin plug

Front 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

Rear brake caliper pad pin

18

Nm

(1.8

kgfm,

13

IbfW

~

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

*

Misaligned disc

Sticking caliper piston

07914

-

SA50001

-

14-2

HYDRAULIC DISC BRAKE

BRAKE FLUID REPLACEMENT/

AIR BLEEDING

-

A

contaminated brake disc or pad reduces stopping

power. Discard contaminated pads and clean a cont

-

aminated 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).

1

.,

-

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.

~

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.

*

I

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.

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

Nm

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).

1

R

14

-

4

HYDRAULIC DISC BRAKE

BRAKE

PAD/DISC

FRONT BRAKE PAD REPLACEMENT

Always

replace

the brake pads in

pairs

to

ensure

even discpres-

sure.

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 instal

-

lation

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 push

-

ing 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

Straighten the lock plate tabs and loosen the pad

the brake pads in

pins.

pairs

to

ensure

even discpres

-

sure.

Remove

the

mounting bolts and rear brake caliper.

Push the caliper piston

all

the way in to allow instal

-

lation 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.

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.

I

1

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

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.

Remove the master cylinder holder bolts, holder and

the master cylinder.

Remove the following:

-

pivot nut, bolt and brake lever

-

piston boot

MASTER CYLINDER

BRAKE

H

O

S

E

H

OLDER

I

LEVER

14

-

7

HYDRAULIC DISC BRAKE

-

snap ring

TOOL

Snap

ring

pliers

-

master piston

-

spring

07914

-

SA50001

Clean the master cylinder, reservoir and master pis

-

ton in clean brake fluid.

INSPECTION

Check the piston cups for wear, deterioration or dam

-

age.

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

SNAP

RING

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 and master Diston into the master

.I

cylinder.

CAUTION:

Do

not allow the oiston

C

U

D

lim

to turn inside out.

I

/

I

/

PISTON

/

I

..

Install the snap ring into the groove in the master

cylinder, using the special tool.

TOOL

Snap

ring

pliers

CAUTION:

07914

-

SA50001

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.

TORQUE:

6

Nm

(0.6

kgfm,

4.3

IbfW

Install the pivot nut and tighten

it.

TORQUE:

6

Nm

(0.6

kgfm,

4.3

Ibf4tl

I

BOLT

AND NUT

BOOT

1

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).

"

UP

"

MARK

P

U

N

C

H

M

ARK

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

sys

-

tem is serviced.

DISASSEMBLY

Remove the front wheel (page

12-61.

Drain the brake fluid from the front brake hydraulic

system (page

14-3).

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.

Removethe brake pads (page

14-5).

Loosen the slide pin and remove the following:

-

caliper bracket and washer

-

pad spring

-slide pin and boots

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.

A

-

I

/L

OIL

RO!

i

'

a

'LUG AND

SLIDE

\

BOOTS

-

\

WASHER

Do

not use high pressure air or bring the nozzle too

close to the inlet.

Push the dust seal and piston seal

in

and lift them

out.

CAUTION:

Be careful not to damage the piston sliding surface.

Clean the seal grooves, caliper cylinder and piston

with clean brake fluid.

14

-

1

0

HYDRAULIC DISC BRAKE

INSPECTION

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

in1

ASSEMBLY

BLEED VALVE PAD PIN PLUGS

\

CALIPER BODY

PISTON SEAL

\

CALIPER BRACKET

WEAR REFERENCE PLATE

WASHER 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 with 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 care

-

ful 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

Nm

(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,

14-1

2

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.

Clean the master cylinder and master piston

in

clean

brake fluid.

Remove the boot from the master cylinder.

Remove the snap ring and push rod using the special

tool.

TOOL

Snap

ring

pliers

Remove the master piston and spring.

07914

-

SA50001

14

-

1

3

HYDRAULIC

DISC

BRAKE

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

INSPECTION

Check the piston cups for wear, deterioration or dam

-

age.

Check the spring for damage.

Check the master cylinder and piston for scoring,

-

-.

MASTER CYLINDER

I

L

PUSH

ROD

SPRING

TER PISTON

OD

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.

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

1

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.

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).

\SNAP

RING

PLIERS

Tighten the lock nut.

Adjust the brake pedal height if necessary (page

3-

16).

1

-1

80

mm

(3.1

in)

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 cylin

-

der 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 kgfm 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

-

1

5

HYDRAULIC DISC BRAKE

Connect the push rod to 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

sys

-

tem

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.

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).

ADJUSTING

BOLT

RM

Loosen the slide pin and remove the following:

-

caliper bracket and washer

-

pad spring

-slide pin and boots

-

caliper piston

B

14

-

1

6

c

HYDRAULIC DISC BRAKE

CAUTION:

Be

careful

not

to

damage the piston sliding

surface.

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 dam

-

age.

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

WASHER

ASSEMBLY

CALIPER BRACKET WASHER

1

SLIDE PIN

OTS

BRAKE PADS

IM

PISTON SEAL PAD SPRING

DUSTSEAL

\

BOOT

SZN

BLEED VALVE

WEAR REFERENCE PLATE

-RING

PARKING BRAKE BASE

BRAKE SHAFT

-BOOT

\

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 brake pads (page

14-61,

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).

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 care

-

ful not to damage the pin boot.

Make sure that the boots are seated securely into the

pin grooves.

-

SLIDE

Apply silicone grease to the brake shaft outer sur

-

face.

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.

The brake shaft

has left-hand

threads.

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).

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.

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.

ADJUS

BOLT

-

\

i

3TTER

JO

14

-

20

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

and secure the joint pin with

a

new cotter pin.

Din

l

a$*

+p

COTTERPIN

14

-

21

BAlTERY/CHARGING SYSTEM

FUSE

(15A)

"r$

r

BI

:

Black

R

:

Red

-

P

:

Pink

G

:

Green

-

~

-

15

-

0

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.

-

If

swallowed, drink large quantifjes of water

or

milk and follow

with

milk

of

magnesia or vegetable

oil

and call a

-

Electrolyte is poisonous.

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 igni

-

tion 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 to 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 con

-

ditions 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

if

the bat

-

tery

is

frequently under heavy load, such as having the headlight and taillight

ON

for long periods of time without rid

-

ing 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:

ITEM

Battery Capacity

Current leakage

Voltage Fully charged

(20"c/68"F) Needs charging

Charging Normal

current

-

Quick

Alternator Capacity

Charging coil resistance (2O"C/68"F)

For battery charging, do not exceed the charging current and time specified on the battery. Using excessive current or

extending the charging time may damage the battery.

-

SPECIFICATIONS

12V-8Ah

0.1 mA max.

13.0

-

13.2

V

Below 12.3

V

0.9Ax5-10h

4.0

Ax

10

h

147

W/5,000 rpm

0.1

-

1.0

n

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

15

-

2

BAlTERYICHARGING

SYSTEM

TROUBLESHOOTING

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.

MEASURED BATTERY VOLTAGE<MEA-

SURED CHARGING VOLTAGEcl5.5

V

Battery

is

damaged or weak

-

~

-

1.

Remove the battery (page

15-4).

Incorrect

+*

Faulty battery

Check the batterv condition

usin(l

the rec

-

.

ommended battery tester.

RECOMMENDED BATTERY TESTER:

BM

-

210

-

AH, BM-210.

or

EATERY MATE

or

-

"7"'

I

2.

Install the battery (page

15

-

41.

Check the battery current leakage (Leak

test: page

15-5).

SPECIFIED CURRENT LEAKAGE:

0.1 rnA rnax.

-

Correct

I

5.

Perform the regulator/rectifier wire harness Incorrect

V-

Open circuit in related wire

-

Loose or poor contacts

of

related terminal

inspection (page

15

-

61.

a

Disconnect the regulatorlrectifier 6P connector

and rechecn the batten, current leakage.

-

Incorrect

-~

Correct

-1

1

-

Faulty regulator1

rectifier

.

-*

Shorted wire harness

-

Faulty ignition

sw

tch

Incorrect

V-

Faulty charging coil

t

3.

Check the alternator charging coil (page

15

-

71.

STANDARD:

0.1

-

1.0

D

I2OoC/68"F)

~

Correct

+-

Faulty battery

15

-

3

BAlTERY/CHARGING SYSTEM

BAlTERY

REMOVAL/INSTALLATION

With the ignition switch

OFF,

disconnect the negative

(-)

cable first, then the positive

(+)

cable.

Remove the two bolts, battery holder and battery

from the battery box.

Install the battery in the reverse order

of

removal.

NOTE:

-

Connect the positive

(+)

cable first, then the nega

-

tive

(-1

cable.

*

After connecting the battery cables, coat the termi

-

nals with grease.

VOLTAGE INSPECTION

Measure the battery voltage using

a

commercially

available digital multimeter.

VOLTAGE (2O0C/68"FI: Fully

charged:

13.0

-

13.2

V

Under charged: Below

12.3

V

BATTERY CHARGING

-

The battery gives off explosive gases; keep

sparks, flames and cigarettes away. Provide ade

-

quate ventilation when charging.

-

Turn the power ON/OFF at the charger, not at the

battery terminals.

Remove the battery.

Connect the charger positive

(+I

cable to the battery

positive (+)terminal.

Connect the charger negative

(-)

cable to the battery

negative

(-)

terminal.

CHARGING CURRENT/TIME:

Standard

0.9

A/5

-

10

h

Quick

4.0

A/1.0

h

CAUTION:

*

Quick charging should only

be

done in an emer

-

gency; slow charging is preferred.

-

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.

(+)

CABLE HOLDER

(-

CABLE

~

15

-

4

BAlTERY/CHARGING SYSTEM

CHARGING SYSTEM INSPECTION

CURRENT LEAKAGE TEST

Turn the ignition switch

OFF,

and disconnect the neg

-

ative

(-)

cable from the battery.

Connect the ammeter

(+)

probe to the negative

(4

cable and the ammeter

(-)

probe to the battery

(-)

ter

-

minal.

With the ignition switch

OFF,

check for current leak

-

age.

NOTE:

-

When measuring current using

a

tester, set

it

to

a

high range, and then bring the range down to an

appropriate level. Current flow higher than the

range selected may blow out the fuse in the tester.

-

While measuring current, do not turn the ignition

switch

ON.

A

sudden surge of current may blow

out the fuse in the tester.

'

-

SPECIFIED CURRENT LEAKAGE:

0.1

mA

max.

If current leakage exceeds the specified value,

a

shorted circuit is likely.

Locate the short by disconnecting connections

one

by one

and

measuring the current.

CHARGING VOLTAGE INSPECTION

If the engine must be running to do some work,

make sure the area is well ventilated. Never run the

engine in an enclosed area. The exhaust contains

poisonous carbon monoxide gas that may cause loss

of consciousness and may lead to death. Run the

engine in an open area or with an exhaust evacua

-

tion system in an enclosed area.

NOTE:

Be sure that the battery is in good condition before

performing this test.

I

Start the engine and warm it up to the operating

tern-

perature; stop the engine.

Connect the multimeter between the positive and

negative terminals of the battery.

CAUTION

-

To

prevent short, make absolutely certain which

are the positive and negative terminals or cable.

-

Do

not disconnect the battery or any cable in the

charging system without first switching

off

the

ignition switch. Failure to follow this precaution

can damaae the tester or electrical comnonenh.

15

-

5

BATTERYKHARGING SYSTEM

Connect the tachometer

NOTE:

Read the instructions for tachometer operation.

Restart the engine, turn the headlight on and shift

it

to High beam.

Measure the voltage on the multitester when the

engine runs at

5,000

rpm.

STANDARD:

Measured battery voltage (page 15-4lc

Measured charging voltage45.5

Vat

5,000

rpm

REGULATOR/RECTIFIER

WIRE HARNESS INSPECTION

Disconnect the regulatorlrectifier

6P

connector.

Check the connector for loose contact or corroded

terminals.

BAlTERY LINE

Measure the voltage between the red wire terminal

and ground.

There should be battery voltage at all times.

GROUND LINE

Check the continuity between the green wire terminal

and ground.

There should be continuity at all times.

CHARGING COIL LINE

Measure the resistance between the yellow and pink

wire terminals.

STANDARD:

0.1

-

1.0

Q

(2OoC/68"F)

Check for continuity between the yellow wire termi

-

nal and ground, and

the

pink wire terminal and

ground.

There should not be continuity.

VOLTAGE FEEDBACK LINE

Measure the voltage between the black wire terminal

and ground.

There should be battery voltage with the ignition

switch ON, and no voltage with the ignition switch

OFF.

I

\\2

15

-

6

BAlTERYICHARGING SYSTEM

REMOVAL/INSTALLATION

REGULATOR/RECTIFIER

Remove the two bolts and regulatorlrectifier from the

,-

removal.

-

ALTERNATOR CHARGING COIL

INSPECTION

Remove the seathear fender (page

2-2).

Disconnect the alternator

4P

connector.

Measure the resistance between the

yt

wire terminals of the alternator side connector.

STANDARD:

0.1

-

1.0

0

(20°C/68"Fl

Check for continuity between the yellow wire termi

-

nal and ground, and the pink wire terminal and

iw

and pi1

.

ground.

There should not be continuity.

Replace the alternator stator if resistance is out of

specification, or if any wire has continuityto ground.

Refer to section

10

for alternator stator reDlacement.

4P

CONNECTOR

15

-

7

IGNITION

SYSTEM

IGNITION SWITCH

I

ENGINE STOP SWITCH

IGNITION CONTROL MODULE

(ICM)

IGNITION COIL

IGNITION PULSE GENERATOR

IGNITION CONTROL

MODULE

(I

C M)

SPARK

EXCITER

IGNITION

PULSE

IGNITION

Y

:

Yellow

G

:

Green

R

:

Red

W

:

White

BI

:

Black

Bu

:

Blue

16

-

0

16.

IGNITION

SYSTEM

-

Spark plug Standard

SERVICE INFORMATION 16

-

1 IGNITION COIL 16

-

6

TROUBLESHOOTING

16

-

2

IGNITION CONTROL MODULE

(ICM)

16

-

6

IGNITION SYSTEM INSPECTION 16

-

3 IGNITION TIMING

16

-

7

-

DPR8Z (NGK), X24GPR-U (DENSO)

SERVICE

INFORMATION

GENERAL

CAUTION:

Some electrical components may be damaged if terminals or connectors are connected or disconnected while the igni

-

tion switch is

ON

and current is uresent.

Spark plug gap

When servicing the ignition system, alwaysfollow the steps in the troubleshooting

on

page 16-2.

The ignition timing cannot be adjusted since the ignition control module (ICM) is factory preset.

The ICM may be damaged if dropped. Also, if the connector is disconnected when current is flowing, the excessive

voltage may damage

the

ICM. Always turn

off

the ignition switch before servicing.

A

faulty ignition system is often related to poor connections. Check those connections before proceeding.

Use

a

spark plug

of

the correct heat range. Using spark plug with an incorrect heat range can damage the engine.

For ignition switch and engine stop switch inspection, see section

18.

For exciter coil and ignition pulse generator (alternator stator) removallinstallation, see section 10.

0.6

-

0.7

mm

(0.024

-

0.028

in)

SPECIFICATIONS

Ignition coil primary peak voltage

I

ITEM

100

V

minimum

I

SPECIFICATIONS

I

lanition Duke aenerator

Deak

VOltaae

0.7

V

minimum

Exciter coil peak voltage 100

V

minimum

Ignition timing ("F" mark)

TOOL

Peakvoltage tester

(U.S.A.

only) or

Peak voltage adaptor

07HGJ

-

0020100 (not available in U.S.A.) with commercially available digital

multimeter (impedance

10

MWDCV minimum)

._

8

"

BTDC

at

idle

.

-

16

-

1

IGNITION

SYSTEM

TROUBLESHOOTING

Inspect the following before diagnosing the system.

-

Faulty spark plug

-

Loose spark plug cap or spark plug wire connections

-

Water got into the spark plug cap (Leaking the ignition coil secondary voltage)

*

If there

is

no spark

at

cylinder, temporarily exchange the ignition coil with a good one and perform the spark test.

If

there is

spark, the exchanged ignition coil

is

faulty.

No spark at spark plug

gnition coil

ximary

ioltage

ixciter coil

UNUSUAL CONDITION

anition pulse

ienerator

Low peak voltage

No

peak voltage

Peak voltage is normal, but no

spark jumps

at

plug

Low peak voltage

No

peak voltage

Low peak voltage

Uo

peak voltage.

PROBABLE CAUSE (Check in numerical order)

1.

Incorrect peak voltage adaptor connections. (System

is

normal if mea

-

sured voltage is over the specifications with reverse connections.)

2.

The multimeter impedance is too low;

10

MOIDCV.

3.

Cranking speed is too low.

*

Battery is undercharged.

4.

The sampling timing

of

the tester and measured pulse were not

synchronized. (System

is

normal if measured voltage is over the

standard voltage

at

least once.)

5.

Poorly connected connectors or an open circuit

in

ignition system.

6.

Faulty exciter coil. (Measure peak voltage.)

7.

Faulty ignition coil.

8.

Faulty ignition control module (ICM) (when above

No.

1

through

7

are normal.)

1.

Incorrect peak voltage adaptor connections. (System

is

normal if mea

-

sured voltage is over the specifications with reverse connections.)

2.

Short circuit in engine stop switch (blacklwhite) wire.

3.

Faulty ignition switch or engine stop switch.

4.

Loose or poorly connected ICM connectors.

5.

Open circuit or poor connection in ground (greenlwhite) wire

of

6.

Faulty peakvoltage adaptor.

7.

faulty exciter coil. (Measure peak voltage.)

8.

Faulty ignition pulse generator. (Measure peak voltage.)

9.

Faulty ICM (when above

No.

1

through

8

are normal.)

1.

Faulty spark plug or leaking ignition coil secondary current ampere.

2.

Faultv ianition coil.

the ICM.

1.

The multimeter impedance is too low;

10

MOIDCV.

2.

Cranking speed is too slow.

*

Battery is undercharged.

3.

The sampling timing of the tester and measured pulse were not

synchronized. (System is normal if measured voltage is over the

standard voltage at least once.)

4.

Faulty exciter coil (when above

No.

1

through

3

are normal).

1.

Faulty peak voltage adaptor.

2.

Faulty exciter coil.

1.

The multimeter impedance is too low;

10

MOIDCV.

2.

Cranking speed is too slow.

*

Battery is undercharged.

3.

The sampling timing of the tester and measured pulse were not

synchronized. (System is normal if measured voltage

is

overthe

standard voltage

at

least once.)

4.

Faulty ignition pulse generator (when above

No.

1

through

3

are

normal).

1.

Faulty peak voltage adaptor.

2.

Faulty ignition pulse generator.

16

-

2

IGNITION

SYSTEM

IGNITION SYSTEM INSPECTION

NOTE:

*

If

no spark jumps at the plugs, check all connec

-

tions for loose or poor contact before measuring

each peakvoltage.

*

Use

a

commercially available digital multimeter

(impedance

10

MOIDCV minimum).

*

The display value differs depending upon the

internal impedance

of

the multimeter.

Connect the peak voltage adaptor to the digital multi

-

meter, or use the peak voltage tester.

TOOLS

Peak voltage tester

(U.S.A.

only1 or

Peak voltage adaptor

with commercially available digital multimeter

[impedance

10

Mill

DCV

minimum)

IGNITION PRIMARY PEAK VOLTAGE

07HGJ

-

0020100

[not

available

in

U.S.A.)

NOTE:

*

Check

all

system connections before this inspection.

Poor connections can cause incorrect readings.

*

Checkthe cylinder compression and check that the

spark plug

is

installed correctly

in

the cylinder.

Disconnect the spark plug cap from the spark plug.

Connect good known spark plug to the spark plug

cap and ground the spark plug to the cylinder head

as done in a spark test.

Remove the left side cover [page

2-3).

With the connector connected, connect the peak volt

-

age tester or adaptor probes to the ignition coil pri

-

mary terminal and body ground.

CONNECTION:

Blacklyellow

I+)

-

Body ground

I

-

)

Turn the ignition switch ON.

Crank the engine with the starter motor and read the

ignition coil primary voltage.

PEAK

VOLTAGE:

100

V

minimum

Avoid

touching the spark

plug

and tester probes

to

Prevent electric shock.

If the peak voltage is lower than the standard value,

follow the checks described in the troubleshooting on

page

16-2.

Install the side cover [page

2-3).

DIGITAL MULTIMETER

16

-

3

IGNITION

SYSTEM

NOTE:

Check that the cylinder compression is normal and

the spark plug is installed correctly in the cylinder

head.

Disconnect the ignition control module (ICM) connec

-

tors.

Connect the peak voltage tester or adaptor probes to

the connector terminals of the wire harness side.

CONNECTION:

EXCITER COIL PEAK VOLTAGE

wh

ICM CONNECTORS

Turn the ignition switch ON.

Crank the engine with the starter motor and read the

peak voltage.

PEAK VOLTAGE:

100

V

minimum

Avoid touching the spark plug and tester probes

to

prevent electric shock.

If the voltage measured at

ICM

connector is abnor

-

mal, measure the peak voltage

at

the exciter coil con

-

nector.

Remove the seathear fender (page

2

-

2).

Disconnect the exciter coil connector and connect the

peak voltage tester or adaptor probes to the alterna

-

tor side connector terminal and ground.

In the same manner as at the ICM connectors, mea

-

sure the peak voltage and compare

it

to

the voltage

measured

at

the ICM connectors.

*

If the peak voltage measured

at

the ICM connec

-

tors is abnormal and the one measured at the

exciter coil connector

is

normal, the blackJred wire

has an open or short circuit, or loose connections.

*

If both peak voltages are abnormal, follow the

checks described in the troubleshooting on page

16-2.

See section

10

for alternator stator replacement.

Install the seathear fender (page

2-21

16

-

4

IGNITION

SYSTEM

IGNITION

PULSE

GENERATOR PEAK

VOLTAGE

NOTE

Check that the cylinder compression is normal and

the spark plug is installed correctly in the cylinder

head.

Disconnect the ignition control module (ICM)

4P

con

-

nector.

Connect the peak voltage tester or adaptor probes to

the connector terminals

of

the wire harness side.

CONNECTION:

Bluelyellow

I+)

-

Greenlwhite

(4

Turn the ignition switch

ON.

Crank the engine with the starter motor and read the

peak voltage.

PEAK VOLTAGE

0.7

V

minimum

If

the voltage measured

at

ICM connector is abnor

-

mal, measure the peak voltage

at

the alternator con

-

nector.

Remove the seatlrear fender (page

2

-

2).

Disconnect the alternator

4P

connector and connect

the peak voltage tester or adaptor probes to the

bluelyellow and green wire terminals

of

the alterna

-

tor side connector.

In the same manner as

at

the ICM connector, mea

-

sure the peak voltage and compare

it

to the voltage

measured at the ICM connector.

-

If

the peak voltage measured at the ICM connector

is abnormal and the one measured

at

the alterna

-

tor connector is normal, the bluelyellow wire has

an open or short circuit, or loose connections.

-

If

both peak voltages are abnormal, follow the

checks described in the troubleshooting on page

16-2.

See section

10

for alternator stator replacement.

Install the seatlrear fender (page

2-2),

16

-

5

IGNITION

SYSTEM

IGNITION COIL

REPLACEMENT

Remove the left side cover (page

2-31.

Disconnect the primary coil connector.

Remove the spark plug cap from the plug.

Remove the two bolts, ground wire terminals

and

the

ignition coil from the frame.

Install

a

new ignition

coil

in the reverse order

of

removal.

IGNITION CONTROL MODULE

(ICM)

REPLACEMENT

Remove the ICM with the rubber suspension from

the stay.

Disconnect the connectors and remove the ICM.

Remove the

ICM

from the rubber suspension.

Install

a

new ICM in the reverse order

of

removal.

TERMINALS

16

-

6

IGNITION

SYSTEM

IGNITION TIMING

If the engine must be running to do some work,

make sure the area is well ventilated. Never run the

engine in a closed area. The exhaust contains poiso

-

nous 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.

Start the engine and warm

it

up operating tempera

-

ture.

Stop the engine and remove the timing hole cap.

Connect the timing light and tachometer.

NOTE:

Read the instructions for timing light and tachometer

operation.

Start the engine, let

it

idle and check the ignition tim

-

ing.

The ignition timing is correct if the

"

F

"

mark on the

flywheel aligns with the index notch in the left

crankcase cover at idle.

Increase the engine speed and make sure the

"

F

"

mark begins to move counterclockwise.

Coat

a

new O

-

ring with grease and install

it

onto the

timing hole cap.

Install

and tighten the timing hole cap.

TORQUE:

10

Nm

(1.0

kgfm

7

Ibf4t)

16

-

7

ELECTRIC

STARTER

IGNITION

SWITCH

I

STARTER’MOTOR

FUSE (15A)

IGNITION SWITCH

rBl4

NEUTRAL INDICATOR

n

I

DIODE

I.

Lg

YjG

pjd

CLUTCH

SWITCH

Y

:

Yellow

G

:

Green

R

BI

: :

Red

Black

Lg

:

Light

green

-

RELAY

-

STARTER SWITCH

MOTOR

17.

ELECTRIC STARTER

ITEM

SERVICE INFORMATION 17

-

1 STARTER RELAY SWITCH 17

-

9

TROUBLESHOOTING 17

-

2 CLUTCH

DIODE

17

-

10

STARTER MOTOR 17-4

-

STANDARD SERVICE LIMIT

SERVICE

INFORMATION

GENERAL

Always

turn the ignition switch

OFF

before servicing the starter motor. The motor could suddenly start, causing

rwi-

ous

injury.

17

-

1

TROUBLESHOOTING

Starter

motor

will

not turn

*

Check for

a

blown fuse

(15

A).

*

Check that the battery

is

fully charged and in good condition

ELECTRIC STARTER

-

Abnormal

d-

Poorlv connected batterv cable

Open'circuit in battery cable

Normal

1

Check for loose or poorly connected starter

relav switch terminals and connectors. Abnormal

--)a

Poorly connected terminals or connectors

Normal

t

Check for loose or poorly connected starter

I

motor cable. and oDen circuit in starter motor

cable.

I

Normal

With the ignition switch ON, push the starter

switch and check for

a

"

Click

"

sound from the

starter relay switch.

1

I

No clicks

I

17-9).

Normal

To

page

17-3

Abnormal

+-

Poorly connected starter motor cable

-

ODen circuit in starter motor cable

Connect the starter motor terminal directly to

the battery positive terminal. (Because

a

large

~

Clicks

Starter motor turns Starter motor

does not turn

t

-

Faulty starter motor

i

-

Loose or disconnected starter motor cable

-

Faulty starter relay switch

Abnormal

+.

Faulty neutral switch

Faultydiode

-

Faulty clutch switch

-

Loose or poor connector contact

-

Open circuit in wire harness

17

-

2

ELECTRIC

STARTER

From page 17-2

I

Check the starter relay voltage (page 17

-

10). Abnormal

Nor'mal

1

+-

Faulty ignition switch

*

Blownfuse

-

Faulty engine stop switch

-

Faulty starter switch

*

Loose or poor connector contact

*

Open circuit in wire harness

Abnormal

--).

Faulty starter relay switch

Check the starter relay

17

-

10).

.-

Starter motor turns slowly

*

Weak battery

-

Poorly connected battery cable

Poorly connected starter motor cable

Faulty starter motor

Starter motor turns,

but

engine

does

not turn

-

Faulty starter clutch (section 10)

Starter relay switch

"

clicks

"

,

but

engine

does

not

turn

over

*

Crankshaft does not turn due to engine problem

*

Faulty starter reduction gear (section 10)

*

Faulty starter idle gear (section

10)

17

-

3

ELECTRIC

STARTER

MOTOR

REMOVAL

Always

turn

the ignition switch

OFF

before servicing

the starter motor. The motor could suddenly start,

causing serious

injury.

Remove the rubber cap, terminal nut and starter

motor cable.

Remove the two mounting bolts, cable guide and the

starter motor from the crankcase and left crankcase

cover.

Remove the O

-

ring from the starter motor.

DISASSEMBLY/INSPECTION

Remove the starter motor case bolts.

Remove the front cover, thrust washer and seal ring.

SEAL

RING

ril

FRONT~EOVER

.A

-

17

-

4

ELECTRIC STARTER

Record

the

loca-

tion

and

number

ofshims.

Remove the rear cover, shims and seal ring.

Remove the armature from the motor case.

-

SHIMS

REAR COVER

I

/

F

Check the bearing and oil seal in the front cover for

wear or damage.

Check the commutator bars of the armature

for

dis

-

coloration.

NOTE:

Do

not use emery

or

sand paper on the commutator.

Check for continuity between pairs of commutator

bars.

There should be continuitv.

17

-

5

ELECTRIC STARTER

Check for continuity between each commutator bar

and the armature shaft.

There should be

no

continuity.

I

-

Check for continuity between the insulated brush

-

.

and cable terminal.

There should be continuity.

c

Check

for

continuity between the cable terminal and

motor case.

There should be

no

continuity.

Remove the following:

-

nut

-

washer

-

insulator washers

-

O

-

ring

-

brush holder assembly

li

f

I

WASHER

I

/

17

-

6

ELECTRIC STARTER

Remove

the brushes from the brush holder.

Measure the brush length.

SERVICE

LIMIT

8.5

mm

10.33

in)

ASSEMBLY

FRONT

COVER

-

TOR

CASE

NUT

ARMATURE

/

WASHER

I

INSULATOR

w

WASHERS

/

REAR COVER

-

jl_*

-

.,

=z

-_

--_

Install

the

brushes into the brush holder.

17

-

7

ELECTRIC STARTER

Install the brush holder assembly into the rear cover

by aligning the tab

of

the holder with the groove in

the rear cover.

Install the following:

-

new O

-

ring

-

insulator washers

-

washer

-

nut

Install the armature into the motor case while hold

-

ing the armature tightly to keep the magnet of the

case from pulling the armature against

it

CAUTION:

The

coil

may be damaged

if

the magnet

pulls

the

armature asainst the case.

Install the same number of shims in the same loca

-

tions as noted during disassembly.

Install

a

new seal ring.

Install the rear cover by aligning the brush holder tab

with the motor case groove.

Install the thrust washer and

a

new seal ring.

Apply grease to the oil seal lip in the front cover.

Install the front cover.

Align the index lines

on

the front cover and motor

case.

Install the set plates and new O

-

rings onto the motor

case bolts.

Install and tighten the motor case bolts.

G

SEAL

RING

Align

I

-BOLT

-

Align

i

17

-

8

ELECTRIC STARTER

INSTALLATION

Coat

a

new O

-

ring with oil and install it into the

starter motor groove.

L

Install

the

starter motor into the left crankcase cover

and onto the crankcase.

Install the cable guide and mounting bolts, and tighten

the bolts securely.

Install the starter motor cable and terminal nut onto

the motor terminal and tighten the nut securely.

Install the rubber cap over the motor terminal securely.

STARTER RELAY SWITCH

INSPECTION

Shift the transmission into neutral.

Turn the ignition switch

ON.

Push the starter switch.

The coil is normal if the starter relay switch clicks.

If

you don't hear the switch

"

CLICK

"

. inspect the

relay switch using the procedure below.

Remove the seathear fender (page

2-21,

I

START

E

R

RELAY

SWITCH

GROUND

LINE

I

YellowlGreen

Disconnect the yellowlgreen wire connector

of

the

starter relay switch.

Check for continuity between the wire harness side

connector terminal and ground.

If there is continuity when the transmission

is

in neu

-

tral or when the clutch

is

disengaged, the ground cir

-

cuit

is

normal. (In neutral, there

is

a

slight resistance

due to the diode.)

17

-

9

ELECTRIC STARTER

STARTER RELAY VOLTAGE

Disconnect the yellowlred wire connector

of

the

starter relay switch.

Measure the voltage between the wire harness side

connector terminal

(+)

and ground

(-).

If

the battery voltage appears only when the starter

switch is pushed with the ignition switch

ON,

the cir

-

cuit

is

normal.

OPERATION

CHECK

Disconnect the starter relay switch connectors and

cables.

Connect the fully charged

12

V

battery positive termi

-

nal to the relay switch yellow/red wire connector ter

-

minal and negative terminal to the yellowlgreen wire

connector terminal.

There should be continuity between the large termi

-

nals while the battery is connected, and

no

continuity

when the battery is disconnected.

CLUTCH

DIODE

INSPECTION

Remove the seathear fender (page

24

Disconnect the starter relay switch (Yellow/green)

and neutral switch (Light green) connectors.

Check for continuity between the wire harness side

connector terminals.

If there is continuity in one direction, the diode is nor

-

mal.

When there is continuity,

a

small resistance value will

register.

lellow/Aed

!+)

/

-

STARTER

RELAY SWITCH

17-1

0

MEMO

LlGHTSlSWlTCHES

-

HANDLEBAR SWITCH

\

NEUTRAL INDICATOR

18

-

0

18.

LIGHTS/SWITCHES

Bulbs

SERVICE INFORMATION 18

-

1 HANDLEBAR SWITCH

BULB REPLACEMENT 18

-

2 CLUTCH SWITCH

IGNITION SWITCH 18

-

3 NEUTRAL SWITCH

Headlight (High/low beam)

Taillight

12V-5W

Neutral indicator

12

v

-

3.4w

12

v

-

30130

w

x

2

18

-

4

18

-

4

18

-

5

Fuse (main fuse)

SERVICE

INFORMATION

15A

GENERAL

-

A

continuity test can be made with the switches installed on the vehicle.

All

plastic connectors have locking tabs that must

be

released before disconnecting, and must be aligned when

reconnecting.

-

To isolate an electrical failure, check the continuity of the electrical path through the part.

A

continuity check can usu

-

ally be made without removing the part from the vehicle. Simply disconnect the connectors and connect

a

continuity

tester to the terminals or connections.

SPECIFICATIONS

I

ITEM

I

SPECIFICATIONS

I

TORQUE VALUES

Headlight mounting bolt

Neutral switch

4

Nm

(0.4

kgfm,

2.9

IbfW

13

N.m

(1.3

kgfm.

9

IbfW

18

-

1

LIGHTS/SWITCHES

BULB REPLACEMENT

HEADLIGHT

Remove the front fender (page

2-2).

Remove the dust cover from the headlight.

Remove the bulb socket by turning

it

counterclock

-

wise while pushing

it

in.

Replace the headlight bulb with

a

new one.

Installation is in the reverse order

of

removal.

NOTE:

Align the bulb tab with the headlight groove.

HEADLIGHT REPLACEMENT

Release the wires from the clip.

Remove the two mounting bolts and headlight from

the front fender.

Install the headlight by aligning the tab with the slit

in the fender. Install the bolts, align the bolt centers

with the index marks, and tighten them.

TOROUE:

4

N.m

10.4

kgf.m,

2.9

Ibf.ft1

Secure the wires with the clip.

DUST

COVER

I

TAILLIGHT

Remove the bulb socket from the taillight by turning

it counterclockwise while pushing it in.

18

-

2

LlGHTSlSWlTCHES

Blacklwhite

Color

Position

Pull the taillight bulb out of the socket.

Install

a

new bulb and the socket in the reverse order

of removal.

-

Green Red Black

NEUTRAL INDICATOR

Remove the indicator lens from the bulb socket.

Remove the neutral indicator from the front fender.

Pull the indicator bulb out of the socket,

Install a new bulb, the lens and socket in the reverse

order of removal.

OFF

-

IGNITION

SWITCH

INSPECTION

C

lo

Disconnect the ignition switch connectors.

Check for continuity between the connector terminals

in each switch position.

Continuity should exist between the color coded

wires

as

follows:

I

ON

I

I+I

REPLACEMENT

Disconnect the ignition switch connectors.

Remove the ignition switch from the front fender

while pushing in the two stopper tabs.

Install new ignition switch by aligning the lug with

the groove in the front fender.

Connect the ignition switch connectors.

I

LENS,

CONNECTORS

TABS

IGNITIONS\

/

NITCH

18

-

3

LlGHTSlSWlTCHES

Color Blackfwhite

Position

HANDLEBAR SWITCH

Green

INSPECTION

Disconnect the handlebar switch

6P

connector.

Check for continuity between the connector terminals

in each switch position.

Continuity should exist between the color coded

wires as follows:

OFF

ENGINE STOP SWITCH

0

I

0

I

Black Brown

Color

Position

OFF

u

t

OFF

0

I

0

Color

1

Blue

I

White

Position

HI

I

0

I

l

I

RUN

1

ON

0

I

0

(Nl

0

n

0

LIGHTING

/

1

DIMMER

I

ENGINE STOP

STARTER

LO

LIGHTING SWITCH

DIMMER

SWITCH

0

I

0

CLUTCH SWITCH

REMOVAL/INSTALLATION

Remove the screw, retainer and clutch switch from

the lever bracket.

Disconnect the wire connectors from the switch and

remove the switch.

Install the clutch switch in the reverse order of

Replace the

new one.

screw

with a

removal.

-

CLUTCk

1

SWITCH

Y

\,u

‘

S

C

R

E

W

18

-

4

LIGHTS/SWITCHES

INSPECTION

Remove the clutch switch and check for continuity

between the switch terminals.

'

There should be no continuity with the switch

plunger pushed in, and continuity with the switch

plunger released.

.

NEUTRAL

SWITCH

INSPECTION

Disconnect the neutral switch wire connector.

Check for continuity between the switch terminal and

engine ground.

There should be continuity with the transmission in

neutral, and no continuity with the transmission in

any gear except neutral.

REMOVAL/INSTALLATION

Disconnect the neutral switch wire connector.

Remove the neutral switch from the crankcase

Install the neutral switch with a new sealing washer

and tighten it.

TOROUE:

13

Nm

(1.3

kgfm,

9

IbfW

Connect the neutral switch wire connector.

18

-

5

MEMO

TROUBLESHOOTING

ENGINE

LACKS

POWER

Possible cause

I

1.

Raise wheel

off

the ground Wheels does not spin freely

-*

Brake dragging

and spin by hand

*

Worn or damaged wheel bearings

Wheel spins freely

*

Drive chain too tight

1

Pressure low

b.

Faulty tire valve

*

Punctured tire

4

i

I

2.

Checktire pressure

Pressure normal

I

Engine speed doesn't change

U-

Clutch slipping

accordingly when clutch is

*

Worn clutch discs/plates

released

-

Warped clutch discstplates

3.

Accelerate rapidly low to

second

Engine speed reduced when

clutch is released

*

Additive in engine oil

-

Weak clutch spring

I

Engine speed does not increase Choke valve closed

Clogged air cleaner

En ine speed increases

*

Restricted fuel flow

4.

Accelerate lightly

*

Clogged muffler

-

Restricted fuel

tank

breather tube

Incorrect

+-

Faulty ignition control module

(ICM)

1

5.

Check ignition timing

1

Cowect

-

Faulty ignition pulse generator

Low compression

+-

Valve clearance too small

*

Valve stuck open

Worn cylinder and piston rings

*

Damaged cylinder head gasket

*

Seized valve

-

Improper valve timing

J

6.

Test cylinder compression

I

Normal compression

Clogged

k-

Carburetor not serviced frequently

7.

Check carburetor for clogging

~

enough

I

Not clogged

Fouled or discolored

-.

Plugs not serviced frequently

enough

i

+

i

8.

Remove and inspect

spark plugs

Not fouled or discolored

I

-

Incorrect spark plug used

Incorrect

+-

Oil

level too high

*

Oil level too low

9.

Check

oil

level and condition

~

Correct

-

Contaminated oil

I

To page

20-3

I

20-2

TROUBLESHOOTING

From page

20-2

4

Possible cause

-

10.

Remove cylinder head cover

~

Valve train not lubricated

-*

and inspect lubrication properly

Valve train lubricated properly

I

11.

12.

Overheating

Check for engine overheating

-

Not overheating

c

I

>.

J

Accelerate or run at high speed

-

Engine knocks

>.

-c

Engine does not knock

Clogged oil passage

Clogged oil orifice

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

POOR PERFORMANCE AT LOW AND IDLE SPEED

Possible cause

1.

Check carburetor pilot screw

~

Incorrect

b.

adjustment

Correct

I

2.

Check for leaking carburetor

~

-

insulator

No

leak

I

Leaking

*.

Weak or intermittent spark

-*

t

3.

Perform spark test

I

Good spark

Incorrect

.-

4.

Check ignition timing

>.

i

See section

5

Loose carburetor insulator bands

Damaged carburetor insulator

Faulty carburetor insulator O

-

ring

Faulty spark plug

Fouled spark plug

Loose or disconnected ignition sys

-

tem 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)

Faulty

ICM

-

Faulty ignition pulse generatoi

20

-

3

TROUBLESHOOTING

POOR PERFORMANCE AT

HIGH

SPEED

Possible

cause

-

1.

Disconnect fuel tube

at

Fuel flow restricted

+-

Restricted fuel tube

carburetor

*

Restricted fuel tank breather tube

Fuel

flows

freely

-

Faulty fuel valve

-

Clogged fuel strainer

I

-

Clogged

b.

Carburetor not serviced frequently

2.

Check carburetor for clogging

___

enough

i

I

Not clogged

Incorrect

+.

Cam sprockets not installed properly

.c

I

3.

Checkvalve timing

Correct

Incorrect

b-

Faulty ignition control module (ICM)

I

*

Faulty ignition pulse generator

I

i

4.

Check ignition timing

Correct

Weak

+.

Faulty valve spring

5.

Check valve spring

I

$.

Not weak

POOR HANDLING

Possible

cause

1.

If steering is heavy

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

2.

If any wheel is wobbling

3.

If vehicle pulls to one side

+.

Tire air pressure incorrect

*

Faulty shock absorber

-

Bent tie

-

rod

-

Incorrect tie

-

rod adjustment

*

Bent swingarm

-

Bent frame

*

Improper wheel alignment

20

-

4

21

.

INDEX

.................................

AIR CLEANER

3

-

5

AIR

CLEANER

HOUSING

.........................................

5-15

AIR CLEANER HOUSING DRAIN TUBE

..................

3

-

6

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

-

ALTERNATOR CHARGING COIL

.............................

15.7

.-

.

-

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

I

...

.~

..

IGNITION COIL

.........................................................

16-6

IGNITION CONTROL MODULE

(ICM)

.....................

16-6

IGNITION SWITCH

...................................................

18

-

3

IGNITION SYSTEM INSPECTION

............................

16-3

IGNITION TIMING

....................

16-7

LUBRICATION

&

SEAL POINTS

..............................

1

-

16

MAINTENANCE SCHEDULE

....................................

3-3

MODEL IDENTIFICATION

........................................

1-3

NEUTRAL SWITCH

...................................................

18

-

5

NUTS, BOLTS, FASTENERS

....................................

3

-

19

OIL COOLER &OIL TANK

........................................

4

-

6

OIL PUMP

&

STRAINER

...........................................

4

-

2

PILOT SCREW ADJUSTMENT

.....

5

-

13

PISTON/CYLINDER INSTALLATION

.......................

8-7

PRIMARY DRIVE GEAR

............................................

3-10

REAR AXLE

...............................................................

13-3

REAR BRAKE CALIPER

.............................................

14

-

16

REAR MASTER CYLINDER

......................................

14

-

13

REAR SHOCK ABSORBER

.......................................

13

-

9

REAR WHEEL

............................................................

13-3

REGULATOR /RECTIFIER

.........................................

15-6

RIGHT CRANKCASE COVER INSTALLATION

........

9

-

12

SEAT/REAR FENDER

................................................

2-2

SERVICE INFORMATION

ALTERNATOWSTARTER CLUTCH

...............

10-1

BATTERY/ CHARGING SYSTEM

..................

15-1

CLUTCH/GEARSHIFT LINKAGE ....................

9-1

CRANKCASEFRANSMISSION/

CYLINDER HEADNALVE

...............................

7-1

CYLINDER/PISTON

........................................

8-1

CRANKSHAFT

...........................................

11-1

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

.........................................

............................................................

w

......................................................

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/

CYLINDER HEADNALVE

...................

CY LINDE R/PISTON

ELECTRIC STARTER

......................................

17-2

ENGINE DOES NOT START

OR

IS

HARD

TO START

..................................................

20-1

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

CRANKSHAFT

...........................................

11

-

2

.

21

-

2

Honda 400ex

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