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Honda 1988 Z50R, Service Manual

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Honda 1988 Z50R Service Manual Download Page 133

Summary of Contents for 1988 Z50R

Page 1: ...BB 99 Z50R...

Page 2: ...gs and cautions against some specific service methods which could cause PERSONAL INJURY 10 service personnel or could damage a vehicle or render it unsafe Please understand that those warnings could n...

Page 3: ...torques working practices tools and trouble shooting for the section The subsequent pages give detailed procedures for the section If you don t know what the source of the trouble is refer to section...

Page 4: ...handle used oil on a doily basis il is slill advisable 10 Ihoroughly wash your hands wilh soap and waler as soon as possible afler handling used oil 1 Use genuine HONDA Of HONDA recommended parts and...

Page 5: ...he right side of the carburetor body The color label is attached on the left side of the frame above the front of the chain guard 1 2 5S The frame serial number is stamped on the left side of the stee...

Page 6: ...acity a Stit 0 21 US gal 0 18 Imp gal Caster 25 Trail 42 mm 1 7 in ENGINE Type Air cooled 4 cycle OHC Cylinder arrangement Single cylinder 80 inclined from vertical Bore x stroke 39 0x 41 4 mm 1 S4xl...

Page 7: ...uction 4 058 Gear ratio I S8 89 91 92 3 181 After 92 3 272 II 1 823 III 1 190 Final reduction 2 642 Gearshift pattern left foot operated return system ELECTRICAL Ignition CDI Ignition timing 27 BTDC A...

Page 8: ...TEM Q TY THREAD TORQUE REMARKS DIA mm N m Ikg m ft lbJ Engine hanger bolt 2 8 28 2 8 20 Foot peg mounting bolt 4 8 22 2 2 16 Side stand pivot bolt 1 10 13 1 3 9 Side stand nut 1 10 35 3 5 25 Shift ped...

Page 9: ...cific fasteners If a specification is not listed follow the standard torque values below STANDARD TORQUE VALUES ITEM TORQUE Nom kg rn ft Ib ITEM TORQUE Nom kg rn ft Ib 5 mm bolt and nut 5 3 0 53 4 01...

Page 10: ...90200 3 Caburetor fl at level gauge 07401 0010000 4 Valve spring compressor 07757 0010000 6 lock nut wrench 20 x 24 mm 07716 0020100 7 Extention bar 07716 0020500 NOTE 7 Universal holder 07725 0030000...

Page 11: ...he attaching surface thoroughly before applying tape Do not use wires or harnesses with a damaged insulator Repair by wrapping them with protective tape or replace them Route wire harnesses to avoid s...

Page 12: ...THROTTLE SPARK PLUG W IRE GENERAL INFORMATION FR NT BRAKE CABLE _ SF AF PLUG WIRE ALTERNATOR W IRE Prt CARBURETOR DRAIN TUBE 1 9...

Page 13: ...LUBRICATION I PUMP OIL ROTOR 2 0...

Page 14: ...pump can be disassembled with the engine in the frame SPECIFICATIONS Oil capacity Recommended engine oil 0 8 lit 0 85 US qt 0 70 Imp qt 81 disassemblv a Slit 0 63 US qt O 53Impqt at aherdraining Use H...

Page 15: ...ine Install the drain plug TORQUE 25 N m 2 S kg m 18 h Ibl NOTE Check the condition of the sealing washer If it is damaged replace it with a new one Clean the oil filter rotor and screen Fill the cran...

Page 16: ...l pump Remove the three cover screws and remove the oil pump cover Pull out the pump shaft and remove the inner and outer rotors from the pump bodV OIL PUMP INSPECTION Check the inner and outer rotors...

Page 17: ...otor aligning the flat on the shah with thai 01 the rotor Install a new cover gasket and secure the cover with the three screws OIL PUMP INSTALLATION Install the pump shaft pivot in the crankcase Inst...

Page 18: ...clutch cables at their upper ends Thoroughly lubricate the cables and their pivot points with a commercially cable lubricant or a light weight oil I CABLE LUBRICANT THROTTLE BRIIKE LEVER PIVOT STEERIN...

Page 19: ...tion Engine oil See page 2 2 Engine oil filter rotor and Screen See page 2 2 SPECIFICATIONS Throttle grip free play 2 6 mrn 11 8 1 4 in Spark plug S8 NGK CA6HS After 88 NGK CR6HSA S8 and After S8 NIPP...

Page 20: ...R CLEANER NOTE 11 SPARK PLUG VALVE CLEARANCE I ENGINE OIL R ENGINE OIL STRAINER SCREEN ENGINE IDLE SPEED I DRIVE CHAIN INOTE 1 I l BRAKE SHOE WEAR BRAKE SYSTEM I CLUTCH SYSTEM 1 SIDE STANO SUSPENSION...

Page 21: ...3 THROTIl E OPERATION 1 1 3 AIR CLEANER NOTE 1 C C C C 3 5 SPARK PLUG 1 1 1 I 3 6 VALVE CLEARANCE 1 1 1 1 1 3 6 ENGINE OIL R R R R R 2 2 ENGINE OIL STRAINER SCREEN C C 2 2 CAM CHAIN TENSION A A A A A...

Page 22: ...the strainer screen a new D ring and the fuel valve body into the fuel tank After installing turn the fuel valve ON and check that there are no fuel leaks THROTTLE OPERATION Check for smooth throttle...

Page 23: ...t rllS jor cleaning the air cleaner element A fire or explosion could re ull Soak the element in clean gear oil SAE 80 90 Squeeze out the excess oil Install the air cleaner element in the housing Inst...

Page 24: ...ealing washer and replace it if it is damaged With the sealing washer attached thread the spark plug in by hand to prevent crossthreading Tighten it with a spark plug wrench Connect the spark plug cap...

Page 25: ...aps TORQUE 12 N m 1 2 kg m 9 ft Ibl IGNITION TIMING NOTE This Capacitive Discharge Ignition system is factory pre set and cannot be adjusted Ignition timing inspection procedures are given to inspect...

Page 26: ...meter Warm up the engine and shift the transmission into neutral Place the motorcycle on level ground Inspect the idle speed and adjust with the throttle stop screw if necessary IDLE SPEED 1 700 100 r...

Page 27: ...sprocket teeth for excessive wear or damage Replace jf necessary NOTE Never install a new drive chain on worn sprockets or a worn chain on new sprockets Both chain and sprockets must be in good con d...

Page 28: ...ary turn the adjusting nut to obtain the specified free play REAR BRAKE PEDAL FREE PLAY Check the brake pedal free play FREE PLAY 10 20 mm 3 8 3 4 in If necessary turn the adjusting nut to obtain the...

Page 29: ...e on a box or workstand Check the side stand spring for damage or loss of tension and the side stand assembly for freedom of movement Make sure the side stand is not bent Measure the amount of force r...

Page 30: ...l nuts and bolts SPARK ARRESTER CLEANING caiHMM Do not touch th u hout compontnu while the exhaust sysum is hot Pu orm Ihis opualion in Q k eff emiloud Qua rl t from irt ha fud USI odequQu e j pr J t...

Page 31: ...tires Replace the tires if the tread depth reaches the following limits Minimum tread depth 3mm 118 in t STEERING HEAD BEARINGS NOTE Check that the control cables do not interfere with handlebar ro t...

Page 32: ...FUEL SYSTEM 4 0...

Page 33: ...ns of the O ring Replace them during reassembly CAUTION The carburetor top u an integral pan of the Ihroule cable Qssl mbl The lOp cannot lw separated from the llS5embly ithout cQusing damage to the c...

Page 34: ...uns poorly Idle speed incorrect Ignition malfunction Rich mixture Lean mixture Air cleaner clogged Insulator leaks Fuel contaminated lean mixture Carburetor fuel jets clogged Fuel cap vent blocked Fue...

Page 35: ...the tank by pulling it rearward INSTALLATION Install the fuel tank in the reverse order of removal Install the washer and tighten the fuel tank mounting bolt securely Connect the fuel tube and instal...

Page 36: ...osen the air cleaner connecting tube band and remove the housing mounting boh Remove the air cleaner housing Clean the element page 3 51 INSTALLATION InSlelithe air cleaner housing in the reverse orde...

Page 37: ...Disconnect the fuel tube from the carburetor Remove the carburetor top and pull out the throttle valve l oosen the connecting tube band screw Remove the carburetor mounting bolts and the carburetor C...

Page 38: ...ftoal valve if it is damaged If the seat is damaged replace the carburetor body Remove the main jet needle jet holder and throttle stop screw NOTE Before removing the air screw record the number of t...

Page 39: ...E Handle all jets and needles with care They can easily be scored or scratched Set the air screw at the position recorded during disassembly Install the float valve float and float pin then secure the...

Page 40: ...O rings for wear or fatigue Install the float chamber and tighten the two screws THROTTLE VALVE ASSEMBLY Install the needle clip on the jet needle STANDARD GROOVE POSITION 2nd Install the jet needle i...

Page 41: ...etor is overhauled or cleaned 1 Turn the air screw clockwise unit it seats lightly and then back it out to standard setting CAUTION The oj screw seal wifl be damaged if the screw it lightened against...

Page 42: ...ENGINE REMOVAL INSTALLATION 5 0 2 2 7 kg m 2Oft lb 10 N m 1 0 kg m 7 2ft lb 22 N m 2 2 kg m 16 ft Ib 12 N m 1 2k m 10 N m 1 0 kg m 7 2 ft Ibl...

Page 43: ...VALUES Engine hanger bolt Engine oil drain plug Swingarm pivot nut Exhaust pipe joint nut Air cleaner case mounting bolt Exhaust pipe mounting bolt Exhaust pipe mounting nut Foot peg assemblv mounting...

Page 44: ...r Remove the carburetor top and the air cleaner case mounting bolt Remove the intake pipe bolts then remove the intake pipe car buretor and air cleaner housing together Remove the following seat and r...

Page 45: ...28 N m 12 8 kg m 20 ft lbJ Exhaust pipe joint nut 10 N m 11 0 kg m 7 2 ft Ibl Exhaust pipe mounting bolt 27 N m 2 7 kg m 20 h tb Elthaust pipe mounting nut 12 N m 11 2 kg m 9 ft lb Foot peg assembly m...

Page 46: ...After 91 11 N m 1 1 kg m 8 ft Ib 11 N m n T kg rn 8 ft Ib 0 11 N m Copper Washer 1 1 kg m 8 ft Ib 6 0 12 N m 1 2 kg m 9 fHb 12 N m 1 2 kg m 9 ft Ib 12 N m 2 kg m 9 ft Ib 10 N m 1 0 kg m 7 2 ft Ib o r...

Page 47: ...1 Camshafl to end hole clearance R 0 0100 0 025 l 0 01 0 0 025 Rocker arm I D 10 000 10 015 Rocker arm shaft 0 0 9 977 9 987 Cylinder head warpage Valve spring free length I INNER 32 78 I OUTER 35 55...

Page 48: ...d and can usually be diagnosed by a compression test Engine noises can usually be traced to the top end with a sounding rod or stethoscope l ow compression Valves Incorrect valve adjustment Burned or...

Page 49: ...r head left side cover and gasket S8 91 Remove the left side cover Remove the sealing bolt washer cam chain tensioner spring and push rod page 9 31 Remove the left cranKcase cover page 9 21 Tum the cr...

Page 50: ...from falling into the crankcase 88 91 Remove the camshaft After 91 Remove the valve adjusters fuly adjuster covers and loosen the valve Temporarily screw the cam sprocket bolts into the camshaft and...

Page 51: ...micrometer SERVICE LIMITS R 19 75 mm 10 778 in L 28 75 mm 11 132 in After 91 Turn the outer race of the camshaft bearing with fingers The outer race should turn smoothly and guietly Also check that t...

Page 52: ...damage SERVICE LIMITS IN 19 67 mm 0 775 in EX 19 66 mm 0 774 in CAMSHAFT TO END HOLE INSPECTION 88 91 Measure and record the end hole I D SERVICE LIMITS R 20 20 mm 10 795 in L 29 20 mm 1 150 in Calcu...

Page 53: ...inspect the cam lobes for scoring chipping or flat spots Measure the 1 0 01 each rocker arm SERVICE LIMIT 10 10 mm 10 398 in ROCKER ARM SHAFT INSPECTION Inspect the rocker arm shafts for wear or dama...

Page 54: ...press he I oh e springs more than necessary 10 remove he collers TOOLS Valve spring compressor Attachment 07757 0010000 079S9 KM301 0 1 Remove the carbon deposits from the combustion chamber and exhau...

Page 55: ...Inspect each valve for trueness burning scratches or abnormal stem wear Check the valve movement in the guide Measure and record each valve stem 0 0 SERVICE lIMITS INfex 4 92 mm 10 194 in Ream the va...

Page 56: ...eated qlinder head CAUTION Do nOilise a torch to heal he cylinder head il may cause warping Support the cylinder head and drive out the old guides from the combustion chamber side of the cylinder head...

Page 57: ...w or has low spots it must be refinished for good sealing VALVE SEAT REFACING NOTE Follow the instructions are supplied with the valve seal refacing equipment Use the 45 degree cutter to remove any ro...

Page 58: ...Prussian Blue to the valve seat Without reating the valve insert it through the valve guide and onto the seat to make a clear pattern If the contact surface is too high cut the seat using the 32 degr...

Page 59: ...he outer springs and retainers After 91 NOTE Install new valve stem seals after disassembling Lubricate each valve stem with oil and insert the valves into the guides Install the spring seats stem sea...

Page 60: ...evenT possible valve damage CYLINDER HEAD INSTALLATION Clean off and gasket material from the cylinder surface Install the O ring dowel pins collar and a new gasket Check that the orifice is not clogg...

Page 61: ...icture at right Tighten the nuts and washers in a criss cross pattern in 2 or 3 steps to the specified torque Then tighten the cylinder head mounting bolt TORQUE 11 N m 11 1 kg m 8 fl tbl NOTE Be care...

Page 62: ...ealing bolt ipage 9 4 Install the cylinder head left side cover aligning the boss of the left side cover with the cutout in the cylinder head Install the following intake pipe carburetor and air clean...

Page 63: ...on the cam sprocket with cut out on the cylinder head Install the cam chain o er the sprocket Install and tighten the cam sprocket bolts to the specified torque Torque 9 N m 0 9 kg m 6 5 Ib ft Recheck...

Page 64: ...S Install the following intake pipe carburetor and air cleaner housing exhaust pipe with the joint nuts and mounting bolts lpage 5 31 front wheel page 11 6 left crankcase cover Adjust the tappet clear...

Page 65: ...CYLINDER PISTON 7 0 10 N m 1 0 kg m 7 2 ft Ib...

Page 66: ...08 0 5 119 0 5121 13 10 0 516 rings Piston Pi 0 0 12 994 13 000 0 5 116 0 5118 12 98 0 511 Piston Io pin clearance 0 002 0 01 4 0 0001 0 00061 0 08 0 0031 Piston rlng to ring TOP 0 015 0 050 O 0006 0...

Page 67: ...remov ing the cVlinder Remove the dowel pins O ring and gasket PISTON REMOVAL Stuff a shop towel into the crankcase Remove the piston pin clips with needle nose ptiers NOTE Do not let the clips fall i...

Page 68: ...der for out at round at three levels in an X and Y axis Take the maximum reading to determine the out o round SERVICE LIMIT 0 10 mm O 004 in The cylinder must be rebored and an oversize piston selecte...

Page 69: ...linder Measure the piston pin bore I D SERVICE LIMIT 13 10 mm 10 516 In Measure the piston pin 0 0 SERVICE LIMIT 12 98 mm 10 51 1 in Calculate the piston Io piston pin clearance SERVICE LIMIT 0 08 mm...

Page 70: ...rings e i II 1 TOP RING 1 2 SECOND RING 3 OIL RING PISTON INSTALLATION Install the piston with its IN mark on the intake valve side Install the piston pin with new piston pin clips NOTE 00 not align t...

Page 71: ...g installation Do not let the cam chain fall into the crankcase Install the cam chain guide roller washer and guide roller bolt Install the cylinder mounting bolt but do not tighten it yet Install the...

Page 72: ...CLUTCH GEARSHIFT LINKAGE 12 N m 2 kg m 9 ft lb 40 N m 4 0 kg m 29 ft Ib 9 N m 0 9 kg m 6 5 ft lbl 8 0...

Page 73: ...6 984 0 6680 0 6689 40 N m 4 0 kg m 29 It Ib 12 N m 1 2 kg m 9 ft Ib 9 N m I0 9 kg m 6 5 ft Ib 07923 0340000 07960 0110000 07716 0020100 8 3 8 9 8 12 mm in SERVICE LIMIT 19 4 10 761 3 15 0 124 2 3 10...

Page 74: ...aise the front wheel off the ground with the quick stand or safety stand Remove the foot peg page 5 3 Remove the kickstarter Remove the right crankcase cover Remove the ball retainer and spring Remove...

Page 75: ...emoval Install the clutch lifter inserting its pin into the hole of the crankcase CLUTCH REMOVAL Remove the oil pass pipe spring clutch lever and clutch cam Remove the clutch outer cover and bearing R...

Page 76: ...rench 20 X 24 mm Extention bar Clutch outer holder 07716 0020100 07716 0020500 or equivalent commercially available in U S A 07923 0340000 Remove lock washer A lock washer B and the clutch assembly Re...

Page 77: ...plates and discs clutch center and drive gear outer Remove the drive plate and clutch springs INSPECTION Measure the spring free length SERVICE LIMIT 19 4 mm 0 76 in Measure the clutch discs if they...

Page 78: ...e warpage on a surface plate using a feeler gauge SERVice LIMIT 0 2 mm 10 01 in Inspect the primary drive gear and collar for wear or damage Measure the primary drive gear 1 0 and the center guide 0 0...

Page 79: ...r for excessive wear 88 91 DAMPER SPRING After 91 CLUTCH no rTFR DAMPER SPRING un PLATE CLUTCH PLATE C CLUTCH CENTER CLUTCH PLATE A DRIVE GEAR OUTER CLUTCH PLATE 8 CLUTCH DISCS CLUTCH FREE SPRING A CL...

Page 80: ...are installed correctly as shown After 91 Install clutch plates A and B the clutch free springs and clutch discs A and S install the set ring with chamfered side the clutel plate B At inslallation in...

Page 81: ...stall the clutch assembly on the crankshaft Install lock washers A and B NOTE Install lock washer B with the OUT SIDE mark facing out Hold the clutch and tighten the lock nut TOOLS lock nut wrench 20...

Page 82: ...all the bearing Install the clutch cam retainer spring and oil pass pipe Install the clutch lever on the gearshift spindle Install the ball retainer as shown Install the R crankcase cover page 8 12 GE...

Page 83: ...o prevent dirt from entering the crankcase Pull the gearshift spindle out of the crankcase disengaging the claw as shown Remove the shift drum stopper plate drum pins and dowel pins by removing the sh...

Page 84: ...he drum pins Install the stopper plate bolt Install the gearshift spindle aligning the return spring with the pin bolt as shown Install the gearshift pedal Install the stopper arm bolt and spring with...

Page 85: ...over NOTE Be careful not to dislodge the clutch ball retainer or damage the kickstarter shaft oil seal Tighten the cover bolts to the specified torque TORQUE 9 N m 0 9 kg m 6 5 ft Ibl Install the kick...

Page 86: ...ALTERNATOR CAM CHAIN TENSIONER 9 0 0 0 0 o 34 N m 3 4 kg m 25 h Ib...

Page 87: ...Sections 13 for alternator inspection SPECIFICATION ITEM Cam chain tensioner push rod 0 0 Cam chain tensioner spring free length TORQUE VALUES flywheel nut TOOLS Common Universal holder Flywheel pulle...

Page 88: ...the flywheel with the universal holder and remove the nut TOOL Universal holder 07725 0030000 0 07933 0010000 Remove the flvwheel with the flywheel puller TOOL Flvwheel puller 07733 0010000 DisconneCl...

Page 89: ...se be careful not to damage the stator cOli O nng Remove the O rings CAM CHAIN TENSIONER REMOVAL Remove the sealing bolt tensioner spring and push rod Remove the PiVOt bolt and tensioner arm INSPECTIO...

Page 90: ...CHAIN TENSIONER INSTALLATION Install the tensioner arm with the pivot bolt Install the push rod and tensioner spring Remove the bolt and washer Pour 1 cc of engine oil into the push rod then install t...

Page 91: ...or Clean the inside of the flywheel then install it by aligning iTS key way with the woodruff key Tighten the flywheel nut TOOL Universal holder 07725 0030000 TORQUE 34 N m 13 4 kg m 25 ft Ibl Install...

Page 92: ...TRANSMISSION CRANKSHAFT KICKSTARTER 80 89 91 92 After 92 10 0 0 N m 1 0 kg m 7 2 ft Ib...

Page 93: ...drum 0 0 Transmission Mainshaft 0 0 Countershaft 0 0 Gear 1 0 C1 bushing Crankshaft Connecting rod big end radial clearance Section 7 Section 8 Section 9 Section 2 M2 Cl C3 M2 C1 C3 1 0 0 0 STANDARD 3...

Page 94: ...ROUBLESHOOTING Hard to s hift Clutch adjustment incorrect Shift fork bent Guide pin damaged Gear dogs worn Transmission jumps out of gear Gear dogs worn Shift fork bent Engine noise Main journal beari...

Page 95: ...crankcase Pry out the snapring on the Idckstarter spindle Remove the spring retainer and the spring Remove the rubber cap Remove the bolt and washer holding the gear shift drum Loosen the crankcase bo...

Page 96: ...NKSHAFT INSPECTION Remove the crankshaft Measure the connecting rod big end side clearance with a feeler gauge SERVICE LIMIT 0 6 mm 0 02 in Measure the connecting rod big end radial clearance at symme...

Page 97: ...crankshaft bearings with your fingers The bearings should turn smoothly and quietly Also check that Ihe inner races of the bearings fit tightly on the crankshaft Check the liming sprocket for wear or...

Page 98: ...d disassemble the kickstarter Check the pinion gear kickstarter spindle starter drive ratchet friction spring and return spring for wear or damage Assemble the kickstarter spindle in the reverse order...

Page 99: ...the 1 0 and 0 0 of the bushing SERVICE LIMITS M2 C l C3 Cl bushing I D Cl bushing 0 0 17 10 mm 10 673 in 20 10 mm 10 791 in 1 10 mm 10 673 in 1 08 mm 10 672 in 19 93 mm 10 785 in Check the malnshaft...

Page 100: ...T KICKSTARTER Assemble the transmission in the reverse order of disassembly NOTE Align the snapring end with the center of the spline as shown oo o GEAR 2 1T C1 GEAR 35T Aher 92 36T I poQ 8 o COUNTERS...

Page 101: ...e shift drum 0 0 SERVICE LIMIT 33 93 mm 11 336 in Measure the shih fork 1 0 SERVICE LIMIT 34 15 mm 11 345 in Measure the shift fork pawl thickness SERVICE LIMIT 4 60 mm 10 181 in SHIFT DRUM ASSEMBLY I...

Page 102: ...rshaft oil seal Drive the countershalt and mainshaft bearings out of the left crankcase Drive the mainshaft and countershaft bearings out of the right crankcase Drive new bearings into the crankcase T...

Page 103: ...ate the crankshaft bearings and other con tacting surfaces with clean engine oil Install the dowel pins and a new gasket onto the left crankcase Install the right crankcase over the left crankcase NOT...

Page 104: ...tart er spindle Install the snap ring Refer to the appropriate section for installation of the removed parts alternator cam chain tensioner section 9 oil pump section 2 clutch gearshift linkage sectio...

Page 105: ...FRONT WHEEL BRAKE SUSPENSION STEERING 10 Nom 1 0 7 2 I 11 0 80 N m 33 N m 13 3 kg m 50 N m 5 0 kg m 36 ft Ib 24 ft Ib...

Page 106: ...servicing of the front wheel brake fork assemblV and steering stem Support the engine with a jack or a jack or a block to raise the front wheel off the ground before servicing them SPECIFICATIONS ITEM...

Page 107: ...A 07746 0050300 or equivalent commercially available in U S A 07749 00 10000 07746 0010200 07746 0010100 07746 0040200 07702 002000 1 Soft suspension Weak fork spring Damaged steering head ball race...

Page 108: ...eparate the throttle bousing Disconnect the throttle cable end from the throttle grip Remove the throttle housing and if necessary the throttle grip Remove the two handlebar mounting nuts and handleba...

Page 109: ...ng s boss so it aligns with the hole in the handlebar Tighten the forward screw first then tighten the rear screw TORQUE 3 N m O 3 kg m 2 2 ft Ib Install the front number plate with the screw Check th...

Page 110: ...h 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 smooth Iy quietly or...

Page 111: ...ll the distance collar into place NOTE Be certain the distance collar is in position before installing the right bearing Drive a new right bearing in squarelv with the sealed side facing out TOOLS Dri...

Page 112: ...s on the fork leg Insert the axle shaft from right side Tighten the axle nut TORQUE 50N m 5 0 kg m 36 ft lb Connect the brake cable to the brake arm Install the brake adjusting nul and adjust the fron...

Page 113: ...brake drum 1 0 SERVICE LIMIT BO 5 mm 13 17 inl DISASSEMBLY Remove the brake shoe spring from the brake panel using a screw driver Remove the brake arm bolt and brake arm Remove the wear indicator pla...

Page 114: ...e to the anchor pin and brake cam Install the brake cam BRAKE SHOES Install the felt seal on the brake panel and apply oil to it Install the wear indicator plate on the cam aligning its wide tooth wit...

Page 115: ...g m 4 3 ft lbl Install the brake shoe and spring Install the brake panel onto the wheel hub Install the front wheel page 1 6 and check the brake operation FRONT SUSPENTION REMOVAL Remo e the front whe...

Page 116: ...leg TOOL Pin driver 4 mm 07944 9350200 equivalent commerciallV available in U S A Check each part for wear or damage Check the fork tubes and covers for bends NOTE Repair or replace the fork tube if...

Page 117: ...oz 8g 2 8 azl SPRING PIN Install the spring assembly on the fork tube and secure it with the spring pin Squirt grease inside the spring Apply grease to the outer surface of the fork tube and fork tub...

Page 118: ...number plate handlebar page 11 3 front wheel page 11 4 fender mounting bolts and fender steering stem nut washer and fork top bolts top bridge NOTE It is not necessary to remove the fork legs Loosen...

Page 119: ...top and bottom ball races into the steering head TOOLS Driver Attachment 37 x 40 mm 07749 0010000 07746 0010200 BOTTOM CONE RACE REPLACEMENT Remove the bottom cone race and dust seal Apply grease to t...

Page 120: ...ER Apply grease to the top ball race and bottom cone race Install the steel balls Install the steering stem top cone race and top thread Tighten the lOp thread and then back it out 11 8 turn Make sure...

Page 121: ...and steering stem nut ST ING STEM NUT TORQUE 80N m 8 0 kg m 58 ft lb Install the front fender and tighten the two bolts TORQUE 10 N m l 1 0 kg m 7 2 ft Ib Install the following handlebar page 11 3 fr...

Page 122: ...REAR WHEEL BRAKE SUSPENSION 33N m 3 3 kg m 24ft lb 50 N m 5 0 kg m 36 33 N m 3 3 kg m 24 ft Ib 12 0 45 N m A 4 5 kg m 33 ft Ib...

Page 123: ...01 Rear wheel rim runout I Radial 2 0 D OB I Axial 2 0 0 08 Rear brake drum 1 0 80 3 151 80 5 13 17 Rear brake lining thickness 3 5 0 14J 2 0 0 08 Rear shock absorber spring free length 190 717 51 18...

Page 124: ...damper weakened Loose swingarm pivot Hard suspension Loose fasteners Faulty shock absorber stopper rubber Bent damper shaft 12 2 Suspension noise Loose fasteners Faulty shock absorber stopper rubber...

Page 125: ...sen the axle nut withdraw the axle and remove the rear wheel Remove the side collar Remove the nuts and the sprocket INSPECTION Place the rear axle in V blocks and measure the runout SERVICE LIMITE 0...

Page 126: ...T Insert the bearing remover head into the bearing From the opposite side install the beating remover shaft and drive the bearing out of the wheel Remove the distance collar and drive out the other be...

Page 127: ...UE 3JN m 13 3 kg m 24 ft Ibl Install the brake panel in the wheel hub Position the wheel inside the swingarm NOTE Align the groove on the brake panel with the boss on the swingarm REAR WHEEL BRAKE SUS...

Page 128: ...Adjust the chain adjusters page 3 8 Tighten the axle nut TORQUE 50N m 5 0 kg m 37 ft Ib Connect the brake rod to the brake arm With the nut then check the pedal free play REAR BRAKE INSPECTION Remove...

Page 129: ...olt and brake arm Remove the wear indicator plate lell seal and brake cam ASSEMBLY INSTALLATION WEAR INDICATOR PLATE BRAKE PANEL Apply grease to the anchor pin and brake cam Install the brake cam FELT...

Page 130: ...tighten the brake arm boh TORQUE 6N m 0 6 kg m 4 J ft Ib Install the brake shoes and spring Install the fear wheel Ipage 12 5 and check the brake operation SHOCK ABSORBERS REMOVAL DISASSEMBLY Remove t...

Page 131: ...11 80 100 Loosen the lock nut and remove the upper joint INSPECTION Measure the spring free length SERVICE LIMIT 186 9 mm 17 36 in Inspect the parts follows upper and lower bushings for wear or damag...

Page 132: ...joint and tighten the lock nut TOOLS Rear shock absorber compressor Reer shock absorber compressor attachment TORQUE 20N m 2 0 kg m 14 ft Ibl NOTE 07GME 0010OQO 07967 1180100 Instal the spring with i...

Page 133: ...d chain guard Remove the swingarm pivot bolt and swingarm INSPECTION Check the swingarm for cracks or damage Check the pivot bushings and pivot bolt for excessive wear INSTALLATION Apply grease to the...

Page 134: ...l page 12 5 Install the chain cover and chain guard BRAKE PEDAL REMOVAL INSTALLATION Remove the rear brake adjusting nul return spring and cotter pin Remove the rear brake pedal Installation is the re...

Page 135: ...IGNITION SYSTEM SPARK WIRE 13 0 ENGINE STOP SWITCH SPARK ALTERr AHlR IGNITION CONTORL MUUUIL leM IGNITICIN PULSE GENERATOR...

Page 136: ...ry coil without spark plug cap Stator coil resistance at 200 e 68 F Ignition pulse generator resistance at 20 C 68 F Ignition tIming TROUBLESHOOTING Engine cranks but will not start Engine stop switch...

Page 137: ...pulse generator BluefYellow Green If there is no problem check the ignition control module ICM connector for loose terminals If aU wire connectors are OK replace the ignition control module lCM If th...

Page 138: ...th the alternator installed in the engine Disconnect the stator coil wire connector Black IRed and measure the resistance between the wire terminal and ground RESISTANCE 500 900 n at 200 e 6BeF Refer...

Page 139: ...Disconnect the engine stop switch wire connectors green and black white and check the continuity between the connectors There should be continuity as shown by the interconnected cir des 0 01 below R...

Page 140: ...0 9 OFF IGNITION CONTROL MODULE leM I I I I I G BlIY Bu Y BI W BlIA L BIIW1 C BIIW I f _ L ___ G C J G G BIIY G Bu Y 8 1 A o 0 E IG OFF RUN GNITIONCOIL OFF SPARK PLUG COLOR G BI W ALTERNATOR BI BLACK...

Page 141: ...141 Clogged fuel tank cap breather hole WEAK OR NO SPARK III Faulty spark plug 121 Fouled spark plug 131 Faulty ignition control module UeM 141 Broken or shorted spark plug wire 151 Faulty alternator...

Page 142: ...UTCH IS RELEASED 4 Lightly acc relate engine ENGINE SPEED NOT IN 1 Carburetor choke closed ENGINE SPEED INCREASED 1 CREASED SUFFICIENTLY 121 Restricted fuel flow 3 Air cleaner clogged 4 Clogged fuel t...

Page 143: ...TS 1 Excessive carbon build up ENGINE IS NOT OVERHEATED 1 combustion chamber i21 Use of improper Quality fuel 131 Mixture too rich 4 Clutch slipping 13 Accelerate or run at high speed __ ENGINE KNOCKS...

Page 144: ...tor 4 Improper flywheel installation FUEL FLOW RESTAICTEDI ___ 11 lack of fuel in tank 2 Clogged fuel line 31 Clogged fuel tank cap breather hole 4 Clogged fuel valve CLOGGED Clean INCQRRECT __ Cam sp...

Page 145: ...NORMAl ___ Loose or poor contact of ignition control module teM connector Che k the resistances or continuity at the ignition control module leM connector of the wife harness side See page 13 2J ABNOR...

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