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Honda 2002 CBR150R, Manual, Page: 277 / 303

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Honda 2002 CBR150R Manual Download Page 277

Summary of Contents for 2002 CBR150R

Page 1: ...ailed procedure If you don t know the source of the trouble go to sec tion 22 TROUBLESHOOTING ALL INFORMATION ILLUSTRATIONS DIRECTIONS AND SPECIFICATIONSINCLUDEDINTHIS PUBLICA TION ARE BASED ON THE LA...

Page 2: ...cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe Please understand that those warnings could not cove...

Page 3: ...olybdenum disulfide grease containingmore than 3 molybdenum disulfide NLGl 2 or equivalent Example Molykote BR 2plus manufactured by Dow Corning U S A Multi purpose M 2 manufactured by Mitsubishi Oil...

Page 4: ...tem have cooled before handling theseparts USED ENGINE OIL Usedengine oil may causeskin cancer if repeatedly left in contact withtheskinfor prolongedperiods Although this is unlikely unless you handle...

Page 5: ...otter pins and lock plates when reassembling 5 When tightening bolts or nuts begin with the larger diameter or inner boltfirst Thentighten to the specified torque diagonally in incremental steps unles...

Page 6: ...R I The frame serial number is stamped on the right side of The engine serial number is stamped on the lower left side the steering head of the crankcase CARBURETOR IDENTIFlCAT1ON NUMBER The carbureto...

Page 7: ...system Air filtration Crankshaft type Engine dry weight Cvlinder arranaement SPECIFICATIONS 1 910 mm 75 2 in 552 mm 25 7 in 1 065 mm 41 9 in 1 286 mm 50 6 in 776 mm 30 6 in 312 mm 12 3 in 172 mm 6 8 i...

Page 8: ...m Charging system Regulator rectifier Lighting system SPECIFICATIONS CV Constantvelocity type 25 rnm 0 98 in or equivalent Multi plate wet Mechanical type Constant mesh 6 speed 3 260 75 23 2 933 44 15...

Page 9: ...6 rnm 1 12 1 4 in Coolant capacity IRadiator cap relief pressure Thermostat Begin to open Fully open Valve lift Radiator and engine Reserve tank 1 0 76 liter 0 20 US qt 0 17 Imp qt I 0 24 liter 0 06 U...

Page 10: ...th IN EX 1 2 1 610 05 0 06 1 9 0 07 Valve spring free length Valve lifter O D I IN EX Bore I D Camshaft Cam lobe height IN EX Runout Camshaft holder I D IN EX Camshaft O D INEX Camshaft to camshaft lN...

Page 11: ...69 17 980 0 7074 0 7079 17 9 0 70 c2 22 984 23 005 0 9049 0 9057 22 9 0 90 I I Gear to shaftclearance I M5 0 032 0 068 0 0012 0 0027 1 0 10 0 004 1 Gear to bushingclearance C1 10 020 0 052 0 0008 0 00...

Page 12: ...e length Spring direction 60g 2 1 02 max 412 4 16 24 404 1 15 91 With the tightly wound end facing 1 9 Pipe runout I0 20 0 008 Fluid level Fluid capacity 131 5 2 206 f2 5 crn3 7 0 0 08 US oz 7 3 f 0 0...

Page 13: ...disc runout I I 0 1 10 004 DOT 3 or DOT 4 To groove 3 8 4 2 0 15 0 17 3 0 0 12 Master cylinder I D Master piston O D Calioer cvlinder I D 1 Caliper piston O D I 31 948 31 998 1 2578 1 2598 1 31 94 1...

Page 14: ...0 14 I Ignition pulse generator peak voltage 0 7 V minimum Bulbs Headlight Hi low beam Brake taiI light License IiQht 12 V 18 18W x 2 12v 10 5w x 2 1 2 V 5 W Front turn signal light Rear turn signal l...

Page 15: ...head cover bolt Cylinder head nut Cylinder head bolt Cam sprocket bolt Cam chain tensioner plug Camshaft holder bolt CLUTCHlGEARSHlFT LINKAGE Clutch center lock nut Primary drive gear lock nut Gearshi...

Page 16: ...d pin Bleed valve Rear brake reservoir cover screw Rear master cylinder mounting bolts Rear master cylinder push rod nut Main step holder mounting bolt OTHER FASTENERS Chain slider screw ENGINE REMOV...

Page 17: ...sembly collar Assembly shaft Clutch center holder Ball race remover Valve guide driver Peakvoltage adaptor Valve spring compressor attachment Tapet hole protector Valve guide reamer Rotor puller TOOL...

Page 18: ...piece ran kshaft thrust surfaces rimary drive gear nut threads and seating surface lywheel nut threads and seating surface Shift drum grooves Starter clutch rolling surface Starter reduction gear 3il...

Page 19: ...surface Brake pad pin sliding surface Brakecaliper pin bolt Brake lever pivot bolt sliding surface Brake lever to master piston contacting area Rearbrakemasterpiston to push rodcontacting area Throttl...

Page 20: ...GENERAL INFORMA TlON CABLE HARNESS ROUTING CLUTCH CABLE FRONT BRAKE HOSE I THROTTLE CAB RIGHT HANDLE6 SWITCH WIRE IGNITIONSWITCH WIRE MAIN WIRE HARNESS HORNWIRE TACHOMETER 2P CONNECTOR 1 17...

Page 21: ...GENERAL INFORMA TlON CLUTCH CABLE 1 18...

Page 22: ...GENERAL INFORMA TlON IGNITION CONTROL MODULE IICM IGNITION COIL FUELTUBE I FUEL UNIT3P CONNECTOR RADIATOROVERFLOWTUBE NEUTRALSWITCH CONNECTOR CARBURETORDRAINTUBE 1 19...

Page 23: ......

Page 24: ...3P CONNECTOR RIGHT HANDLEBAR SWITCH LEFT HANDLEBAR SWITCH9P CONNECTOR I CHOKE CABLE PAIR CONTROL VALVE FUELAUTO VALVE VACUUMTUBE THROlTLE CABLE FUELTUBE 1 THERMO SENSOR WIRE CARBURETORAIR VENT TUBE SU...

Page 25: ...GENERAL INFORMA TlON REAR BRAKELIGHTSWITCH 2P CONNECTOR I REGULATOR RECTIFIER I DIODE 1 22...

Page 26: ...GENERAL INFORMA TlON SPARE FUSE 10A SPARE FUSE 20A RADIATOR RESERVE TANK CAP STARTER RELAY SWITCH MAIN FUSE 20A 1 23...

Page 27: ...ted to sunlight Carbon monoxide does not react in the same way but it is toxic Honda Moter Co Ltd utilizes lean carburetor settings as well as other systems to reduce carbon monoxide and hydrocarbons...

Page 28: ...and changes a consid erable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor This model has the pulse secondary air injection PAIR control valve and P...

Page 29: ...FRAMElBODY PANELSlEXHAUST SYSTEM BODY PANEL LOCATIONS 2 0...

Page 30: ...llowed to cool before components are removed or serviced This section covers removal and installation of the body panels and exhaust system Always replace the exhaust pipe gaskets after removing the e...

Page 31: ...e seat and remove the seat backward Installation is in the reverse order of removal GRAB RAIL REMOVAL INSTALLATION Remove the four bolts and grab rail Installation is in the reverse order of removal D...

Page 32: ...ses Disconnect the rear combination light 6P connector Remove the screw and collar Release the rear combination light bosses from frame grommets then remove the rear combination light Remove the two b...

Page 33: ...of the frame and radiator Releasethe speedometer cable from the guide left middle cowl only and remove the middle cowl NOTE Do not damage the tabs of the upper cowl and speedom eter cable guide of the...

Page 34: ...SSEMBLYIASSEMBLYl INSTALLATION Removethe rear view mirrors Remove the screws and upper cowl lids Removethe two bolts and combination meter Removethe stay Removethe three screws and head light assembly...

Page 35: ...ve the exhaust pipe mounting bolt nut washer collar and mounting rubbers Removethe muffler and exhaust pipe as assembly Removethe exhaust pipe gasket DlSASSEMBLY ASSEMBL Y MOUNTING RUB MUFFLER EXHAUST...

Page 36: ...t install the muffler and exhaust pipe assembly then temporarily install the all mounting fastners Tighten the exhaust pipe joint nuts Tighten the exhaust pipe mounting bolt Tighten the muffler mounti...

Page 37: ...UTCH SYSTEM SIDE STAND SUSPENSION NUTS BOLTS FASTENERS WHEELSlTlRES STEERING HEAD BEARINGS 3 14 3 15 3 17 3 18 3 18 3 18 3 19 3 19 3 20 3 20 3 21 3 21 3 22 SERVICEINFORMATION GENERAL Gasolineis extrem...

Page 38: ...16 in 80 90 17M C 44P lire air pressure 1 Rear 100 80 17M C52P I Front Rear I200 kPa 2 00 kg cm2 29 psi 1 200 kPa 2 00 kg cm2 29 psi Driver only Driver and passen ger Minimum tire tread depth Front R...

Page 39: ...interest of safety we recommend these items be serviced only by an authorized Honda dealer NOTES 1 For higher odometer readings repeat at the frequency interval established here 2 Service more freque...

Page 40: ...he throttle cable if throttle operation is not smooth Measurethe free play at the throttle grip flange FREE PLAY 2 6 mm 1112 1 4 in Throttle grip free play can be adjusted at either end of the throttl...

Page 41: ...alve opens the enriching circuit via a cable when the choke knob on the fork top bridge is pulled Checkfor smooth choke knob operation and lubricate the choke cable if required Inspect the cable for c...

Page 42: ...ir cleaner cover screws Install the fuel tank page 5 3 CRANKCASE BREATHER Remove the cap from the crankcase breather tube and drain deposites into a suitable container Install the cap to the tube secu...

Page 43: ...ck sooty deposit indicates over rich mix system or lean mixture ture REUSING A SPARK PLUG Cleanthe spark plug electrodes with a wire brush or spe cial plug cleaner Check the gap between the center and...

Page 44: ...e the engine is cold below 35 C 95 F Remove the cylinder head cover page 10 4 Remove the timing hole cap and crankshaft hole cap Rotatethe crankshaft counterclockwise andalign the index line of the T...

Page 45: ...locations The valve lifter can be easily removed with a valve lapping tool or magnet The shims can be easily removed with a tweezers or magnet Measure the shim thickness and record it NOTE Sixty nined...

Page 46: ...tighten the timing hole cap TORQUE 5 9 N rn 0 6 kgfm 4 3 IbfW ENGINE011 OIL LEVEL INSPECTION Start the engine and let it idle for a few minutes Stop the engine supportthe motorcycle uprighton alevel...

Page 47: ...and drain bolt Drain the oil completely Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolongedperiods Although this is unlikely unless you handle used oil on...

Page 48: ...a The exhaust contahs poisonous car bon monoxidegas thatmay museloss o fconsciousness andmaylead to death Run the enginein an open areaor with an exhaust evacuationsystemin enclosedarea NOTE Inspectan...

Page 49: ...evel should be betweenthe UPPER and LOWER level lines with the motorcycle in a vertical position on a flat level surface If necessary remove the driver seat page 2 2 then remove the reserve tank cap a...

Page 50: ...any sign of deterioration Check that all hose clamps are tight Install the right middle cowl page 2 4 StCUNUAKY AIK SUPPLY SYSTEM NOTE This model is equipped built in secondary air supply system The...

Page 51: ...al Check the drive chain slack in the drive chain lower run midway between the sprockets CHAIN SLACK 25 35 mm 1 O 1 4 in ADJUSTMENT Loosenthe rear axle nut Loosen both lock nuts and turn both adjustin...

Page 52: ...80 90 gear oil or drive chain lubricant designed specifically for use with O ring chains Wipe off the excess oil or chain lubricant SPROCKETS INSPECTION Inspect the drive and driven sprocket teeth fo...

Page 53: ...the fluid level is low check entire svstem for leaks baae 3 20 FRONT BRAKE Turn the handlebar to the left side so that the reservoir is level and check the fluid through the sight glass ifthe level is...

Page 54: ...hasentered the system If the lever or pedal feels soft or spongy when operated bleed the air from the system Inspectthe brake hose andfittings for deterioration cracks and signs of leakage Tighten any...

Page 55: ...age and lubri cate the cable Measure the free play at the tip of the clutch lever FREE PLAY 10 20 mm 318 13 16 in I 10 20 mm 0 4 0 8 in Adjust as follows Minor adjustment can be done with the upper ad...

Page 56: ...f the forks by operating the front brake and compressing the front suspension several times Check the entire assembly for signs of leaks damage or loose fasteners Replace damaged components which cann...

Page 57: ...d properly secured WHEELS TIRES NOTE Tire pressure should be checked when the tires are COLD RECOMMENDEDTIRE PRESSURE AND TIRE SIZE Front 200 kpa 2 00 kgflcd 29 psi Rear 200 kpa 2 00 kgflcd 29 psi1 Fr...

Page 58: ...t interferewith handle bar rotation Supportthe motorcyclesecurelyand raisethefrontwheel off the ground Checkthat the handlebar movesfreely from side to side If the handlebar moves unevenly binds or ha...

Page 59: ...LUBRICATION SYSTEM LUBRlCAT10NSYSTEMDIAGRAM U 4 0...

Page 60: ...y left in contactwith the skin for prolongedperiods Although this is unlikelyunless you handle used oil on a dailybasis it is still advisableto thoroughly wash your hands with soap and water as soon a...

Page 61: ...n the engine oil page 3 11 Removethe right crankcasecover page 8 3 Removethe three bolts and oil pump assembly Removethe dowel pins DISASSEMBLY Remove the E clip Removethe oil pump shaft and gear Remo...

Page 62: ...he oil pump body Install the oil pump shaft Measure the tip clearance between the inner and outer rotors SERVICE LIMIT 0 20 mm 0 008 in Measurethe body clearance between the outer rotor and pump body...

Page 63: ...all OUTER ROTOR INNER ROTOR OIL PUMP BODY OIL PUMPDRIVENGEAR LOCK PIN the oil pump shaft lock pin intothe oil pump shaft the oil pump shaft into the oil pump driven gear Installthe outer rotor and inn...

Page 64: ...tallthe dowel pins andtighten the two bolts to the specified torque TORQUE 5 2 N m 0 53kgf m 3 8 Ibf4t Install the oil pump shaft into the oil pump body aligning the flats between the shaft and inner...

Page 65: ...and tighten the three bolts securely Clean the oil strainer screen page 3 12 Installthe right crankcasecover page 8 14 After installation fill the crankcasewith recommendedoil page3 10 and checkthat...

Page 66: ...5 2 5 0 FUEL SYSTEM...

Page 67: ...stored can cause a fire or explosion CAUTION Be sure to remove the diaphragms before cleaning air and fuel passages with compressed air The diaphragms might be damaged Do not remove the sub air cleane...

Page 68: ...ce driveability and poor fuel economy Clogged fuel system Faulty ignition system section 18 Engine cranks but won t start No fuel in tank No fuel to carburetor Clogged fuel strainer Clogged fuel line...

Page 69: ...connector Disconnect the fuel and vacuum tube from the fuel auto valve Installation is in the reverse order of removal FUEL AUTO VALVE INSPECTION Remove the fuel tank See above Connect a commercially...

Page 70: ...val SUB AIR CLEANER REMOVAL INSTALLATION Remove the following fuel tank page 5 3 air cleaner housing See above Disconnect the tubes Remove the sub air cleaner from the frame Check the element and repl...

Page 71: ...the throttle drum VALVE WASHER Disconnect the fuel air vent and drain tubes Loosen the nut and remove the starting enrichment SE valve and washer from the carburetor body Loosen the insurator band scr...

Page 72: ...t of the vacuum chamber if the diaphragm is damaged in any way even if only a pin hole DIAPHRAGM VACUUM PISTON CARBURETOR DISASSEMBLY VACUUM CHAMBER Remove the two screws and vacuum chamber cover NOTE...

Page 73: ...oration or damage spring for deterioration needle of diaphragm for wear air passages for clogging Starting enrichment SE valve cover Remove the two screws wahsers Remove the valve cover and O ring SCR...

Page 74: ...t valve where it contacts the valve seat for stepped wear or contamination operation of the float valve PIN FLOAT FLOAT VALVE Turn the pilot screw in and carefully count the number of turns until it s...

Page 75: ...JET FLOAT PIN JET NEEDLE DRAIN SCREW SPRING SPRING STAY STARTING ENRICHMENT SE VALVE COVER PILOT SCREW WASHER O RING AIR CUT OFF VALVE COVER DIAPHRAGM SPRING FLOAT CHAMBER Install the pilot screw and...

Page 76: ...float level with the float level gauge TOOL Float level gauge 07401 0010000 FLOAT LEVEL 13 mm 0 5 in The float cannot be adjusted Replace the float assembly if the float level is out of specification...

Page 77: ...stall and tighten the two screws washers securely COVER O RING SCREWS Air cut off valve Install the diaphragm to the carburetor body Install a new O ring spring and cover Tighten the screws securery C...

Page 78: ...agm under the chamber cover Install the needle holder by aligning the cut out of the holder and boss of the vacuum piston VACUUM CHAMBER Install the jet needle with washer into the vacuum piston Insta...

Page 79: ...UBE Connect the throttle cable end to the throttle drum and tighten the adjusting nut ADJUSTING NUT DRAIN TUBE ALIGN Check the starting enrichment SE valve for scoring scratches or wear Check the seat...

Page 80: ...indicate a 50 min 1 rpm change 1 Turn the pilot screw 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 D...

Page 81: ...ing air and that the vacuum does not bleed SPECIFIED VACUUM 37 kPa 280 mmHg If the air is drawn in or if the specified vacuum is not main tained install a new PAIR control valve If afterburn occurs on...

Page 82: ...r from the cylinder head Check the reed for damage or fatigue Replace if neces sary Replace the PAIR check valve if the seat rubber is cracked deteriorated or damaged or if there is clearance between...

Page 83: ...COOLING SYSTEM SYSTEM FLOWPATTERN 6 0...

Page 84: ...g Radiator coolant is toxic Keep it away from eyes mouth skin and clothes If any coolant gets in your eyes rinse them with water and consult a doctor immediately If any coolant is swallowed induce vom...

Page 85: ...assages blocked in radiator hoses or water jacket Air in system Faulty water pump Thermostat stuck closed Faulty cooling fan motor Faulty fan motor switch Engine temperature too low Faulty temperature...

Page 86: ...9 I 1 008 I 1 008 1 1 007 I 1 006 I 1 005 I 1 003 1 1 001 I 0 999 I 0 997 I I 10 I1 018 I1 017 I1 017 I1 016 I1 015 I 1 014 I1 013 11 011 I 1 009 I 1 007 I1 005 I 15 I 1 028 I 1 027 I 1 026 I 1 025 I...

Page 87: ...y from eyes mouth skin and clothes if any coolant gets in your eyes rinsethem with wa If any coolant isswallowed induce vomiting gargle If any coolantgets on your skin or clothes rinsethor KEEP OUT OF...

Page 88: ...tube from the radiator and drain the coolant from the reserve tank Connect the siphon tube Install the drain bolt with new sealing washer Fill the system with the recommended coolant through the fill...

Page 89: ...nd adequateeye protection Keepflammablematerialsawayfrom theelectricheat ing element NOTE Do not letthe thermostat or thermometertouch the pan or you will get false readings Replacethe thermostat ifva...

Page 90: ...o the new seal rubber and install it to the thermostat flange Installthe thermostat intothe housingwith its holefacing UP Installthe thermostat housing cover and two bolts Tghtn the bolts securely Fil...

Page 91: ...onnect the lower ra diator hose Loosen the hose band screw and disconnect the upper radiator hose Removethe radiator mounting bolts and collars Slide the radiator to the right side then releasethe upp...

Page 92: ...COOLING SYSTEM Remove the nut and cooling fan Release the motor wire from the clamp Removethe screws and washers Removethe fan motor from the shroud ASSEMBLY RADIATOR COOLING FAN FAN SHROUD 6 9...

Page 93: ...ocking agent to the motor shaft threads Install the cooling fan onto the motor shaft by aligning the flat surfaces Install and tighten the nut securely Install the cooling fan assembly to the radiator...

Page 94: ...mounting bolts Installthe upper radiator hose and tighten the bandscrew securely Install the lower radiator hose and tighten the band screw securely Connect the siphon tube Connect the fan motor 3P c...

Page 95: ...20 Fill the reserve tank with recommended coolant to the upper level line page6 5 WATER PUMP MECHANICAL SEAL INSPECTION Remove the under cowl page 2 3 Check the inspection hose for signs of coolant le...

Page 96: ...ill and bleed the cooling system page 6 5 DISASSEMBLY Remove the right crankcase cover page 8 3 Hold the water pump shaft and remove the impeller and washer Removethe water pumpshaft washer gear and p...

Page 97: ...t into the right crankcase cover using the specialtools TOOLS Driver 07749 0010000 Attachment 36 mm 07945 4150400 INSTALLATION Check the water pump shaft for damage Check the water pump gear for damag...

Page 98: ...oldthe water pump shaftand tighten the impeller to the specified torque TORQUE 10 N m 1 0 kgf m 7 Ibf ft Installthe following right crankcasecover page 8 14 water pump cover page6 12 Fill and bleed th...

Page 99: ...e engine using a jack or other adjustable support to ease of engine hanger bolts removal The following components can be serviced with the engine installed in the frame Oil pump section 4 Clutch gears...

Page 100: ...ge 5 3 air cleaner housing page 5 4 carburetor page 5 4 starter motor terminal and ground cable page 19 4 Disconnect the vacuum tube from the PAIR control valve and air injection hose from the PAIR ch...

Page 101: ...le guide Disconnect the clutch cable end from the clutch lifter arm Loosen the rear axle nut R L drive chain adjusting lock nuts and adjusting nuts Pushthe rear wheel forward and make a drive chain sl...

Page 102: ...e rear engine hanger nuts Removethe rear engine hanger bolts nuts and engine from the frame Note the direction of the hanger bolts ENGINE INSTALLATI0N NOTE Use a floor jack or other adjustable support...

Page 103: ...and nut and tighten the nut to the specified torque TORQUE 59 N m 6 0 kgfm 43 Ibf ft Tighten the rear engine hunger nutsto the specified torque TORQUE 59 N m 6 0 kgfm 43 Ibf ft Install the drive sproc...

Page 104: ...the fixing plate bolts to the specified torque TORQUE 9 8 N m 1 0 kgfm 7 Ibf ft1 Set the drive sprocket cover to the left crankcase l g h t e n the cover bolts securery Adjust the drive chain slack p...

Page 105: ...the clutch lifter arm then install the clutch cable to the clutch cable guide Install the gearshift arm by adjusting the change pedal height as shown Install the radiator hoses and tighten the band sc...

Page 106: ...ion hose to the PAIR check valve cover Install the following starter motor terminal and ground cable page 19 9 carburetor page 5 13 air cleaner housing page 5 4 fuel tank page 5 31 left middle cowl pa...

Page 107: ...CLUTCHlGEARSHlFT LINKAGE 74 12 N m 1 2 kgf m 9 Ibf ft 4 64 N m 6 5 kgfm 47 IbfW 8 0...

Page 108: ...12 2 92 3 08 0 115 0 121 2 60 0 102 0 2 0 008 __ Outer guide O D 22 959 22 980 0 9039 0 9047 22 93 0 903 I D 16 991 17 009 0 6689 0 6696 17 04 0 671 IMainshaft O D at clutch outer guide I 16 996 16 9...

Page 109: ...lutch disc Weak clutch springs Motorcycle creeps with clutch disengaged Incorrect clutch adjustment Faulty clutch lifter Clutch plate warped Hard to shift Damaged gearshift spindle Damaged stopper pla...

Page 110: ...n the engine oil page3 11 Drain the coolant page 6 51 Disconnect the clutch cable end from the clutch lifter arm Loosenthe hose band screws and disconnectthe radiator hoses Remove the ten bolts clamp...

Page 111: ...ch lifter bearing and clutch lifter plate bolts NOTE Loosen the clutch lifter plate bolts in a cirsscross pattern in2 3 steps Remove the lifter plate and clutch springs Install the clutch center holde...

Page 112: ...washer judder spring spring seat clutch discs and plates Remove the pressure plate _____ CLUTCH DISC B e 9 CLUTCHDISC A INSPECTION Clutch lifter bearing Turn the inner rece of the lifter bearing with...

Page 113: ...DISC A DISC B Check the clutch discs for signs of scoring or discolora tion Measure the thickness of the discs SERVICE LIMITS Disc A 3 1 mrn 0 12 in Disc B 2 60 mm 0 102in1 NOTE ReDlace the discs and...

Page 114: ...mal wear made by the clutch discs Check the serrated teeth of the primary driven gear for wear or damage Clutch outer guide Measure the clutch outer guide SERVICE LIMIT I D 17 04 mm 0 671 in O D 22 93...

Page 115: ...nstall the clutch discs and plates alternately inthe clutch outer Install the tabs of outside clutch disc A into the shallow slots of the clutch outer Disc A has larger I D than Disc B Install the jud...

Page 116: ...ighten the four bolts Installthe washer and lock nut Hold the clutch assembly and tighten the lock nut to the specified torque TOOLS Lock nut wrench 20 x 24 mm TORQUE 74 N m 7 5 kgfm 54 IbfW Remove th...

Page 117: ...e shift drum Remove the bolt washer stopper arm and return spring Remove the gearshift spindle Check the gearshift cam plate and stopper arm for wear or damage Check the stopper arm return spring for...

Page 118: ...bf ft Lower the stopper arm and install the pins Install the gearshift cam plate by aligning the pin hole in the cam plate with the pin Apply locking agent to the gearshiftcam plate boltthreads Instal...

Page 119: ...716 0020100 Install the washer Installthe woodruff key onto the crankshaft Installthe primary drive gear by aligning the groove with the woodruff key Install the clutch assembly page8 9 Apply engine o...

Page 120: ...indle Align the cover hole and cut out of the lifter arm spindle by turning the lifter arm spindle Apply engine oil to the lifter piece Insert the lifter piece to the cover hole and lifter arm spindle...

Page 121: ...sesandtighten the hose bandscrews Connect the clutch cable end to the lifter arm Adjust the clutch lever free play page3 21 Installthe under cowl page 2 3 Fill and bleed the cooling system page 6 5 Fi...

Page 122: ...ALTERNATORlSTARTER CLUTCH SYSTEM DIAGRAM 9 0...

Page 123: ...Refer to section 17 for alternator stator inspection Refer to section 19for starter motor servicing TORQUE VALUES Stator bolt Flywheel nut Starter clutch bolt Ignition pulse generator bolt TOOLS Flyw...

Page 124: ...cover page 7 3 Remove the bolts washer and left crankcase cover Remove the gasket and dowel pins ALTERNATOR STATO R STATOR REMOVAL Remove the two ignition pluse generator mounting bolts and ignition p...

Page 125: ...ition pulse generator and stator mounting bolts threads Routethe wire properly andtighten thetwo ignition pulse generator mounting bolts TORQUE 5 2 N m 0 53 kgfm 3 8 Ibf ft Tighten the three stator mo...

Page 126: ...wheel using the special tool TOOL Rotor puller 07KMC HEOOIOO Remove the woodruff key STARTER CLUTCH REMOVAL Remove the flywheel page9 3 Remove the starter reduction gear Remove the starter driven gear...

Page 127: ...er 07725 QQ4QOQQ Remove the starter clutch assembly from the flywheel Remove the sprag clutch from the starter clutch outer INSPECTION Check the starter reduction gear for wear or damage Check the sta...

Page 128: ...tthreads Install the starter clutch assembly onto the flywheel and install the bolts Holdthe flywheel with the specialtool and tighten the bolts to the specified torque TOOL Flywheel holder 07725 0040...

Page 129: ...all the woodruff key in the crankshaft key groove Installthe flywheel onthe crankshaft aligning the key way with the woodruff key Apply oil to the flywheel nut threads and seating surface and install...

Page 130: ...COVER INSTALLATION Install the dowel pin and a new gasket Install the left crankcase cover Install the washer and bolts and tighten them securely Install the drive sprocket cover page 7 6 Connect the...

Page 131: ...CYLINDER HEADNALVES 10 N m 1 0kgfm 7 Ibf ft 9 N m 6 5 Ibf 29 N m 12 N m 1 2kgf m 9 1bf W kgfm 10 0...

Page 132: ...0 1486 0 1492 3 765 3 780 0 1482 0 1488 3 800 3 812 0 1496 0 1501 3 89 0 153 0 010 0 037 0 0004 0 0015 0 020 0 047 0 0008 0 0019 15 5 0 61 13 1 0 52 3 7 0 15 3 7 0 15 0 075 0 0029 0 085 0 0033 This se...

Page 133: ...0100 07780 0014000 TROUBLESHOOTING Engine top end problems usually affect engine performance These can be diagnosed by a compression or leak down test or by tracing engine noises to the top end with a...

Page 134: ...l the way and crank the engine with the starter motor until the gauge reading stops rising STANDARD 1 370 kPa 13 9 kgf cmz 197 7 at 680rpm If compression is high it indicates that carbon deposits have...

Page 135: ...emove the two bolts and radiator with water hoses installed Disconnectthe upper radiatorhosefrom the cylinder head Disconnect the vacuum tube Remove the bolt and PAIR control valve Disconnectthe air i...

Page 136: ...inder head surface as shown Make sure the piston is at TDC Top Dead Center on the compression stroke If the piston is at TDC on the exhaust stoke rotate the crankshaft counterclockwise 360 1 fu l turn...

Page 137: ...y remove the dowel pins from the camshaft holders CYLINDER HEAD REMOVAL Drain the coolant page 6 5 Remove the radiator page 6 8 Remove the following camshaft page 10 5 exhaust system page 2 5 carburet...

Page 138: ...pins CAM CHAIN TENSIONER LIFTER REMOVAL Remove the two bolts and cam chain tensioner lifter INSPECTION Remove the tensioner lifter plug Check the lifter operation The tensioner shaft should not go int...

Page 139: ...oner in the fully retracted position Install a new gasket on the cam chain tensioner lifter Installthe tensioner lifter into the cylinder and tighten the mounting bolts Remove the stopper tool from th...

Page 140: ...ent07JME KY20100 Valve spring compressor Tapet hole protector 07JMG KY20100 07757 001oooO Loosen the valve spring compressor and remove the fol 1 lowing spring retainers valve springs spring seats int...

Page 141: ...ft to camshaftholder clearance SERVICE LIMIT 16 960 mm 0 6677 in If the camshaft to camshaft holder clearance exceeds the service limit replacethe camshaft and leftcamshaft holder as a set and recheck...

Page 142: ...n Valve lifter Check the valve lifter bore for scoring scratches or damage Measure the each valve lifter bore 1 0 SERVICELIMIT 22 5 mm 0 89 in Check the valve lifter for scoring scratches or damage Me...

Page 143: ...ecking the valve guide Always rotatethe reamerclockwise nevercounterclock wise when installing removing and reaminq TOOL Valve guide reamer 07JMH KY20100 Measureand recordeachvalveguideI D with aballg...

Page 144: ...3 8mm 07GMD KT70100 While the cylinder head is still heated drive new valve guides in the cylinder head from the camshaft side until the exposed height is following dimensions TOOL Valvc guide driver...

Page 145: ...otwithin specification refacethe valve seat page 10 15 1 2 1 6 mm 0 05 0 06 in CAUTION VALVE SEAT CONTACTWIDTH The valve cannot be ground tf a valve face is burned or badly worn or it contact the seat...

Page 146: ...neces sary Usea 45 degreecutter to remove the roughness or irregu larities from the seat NOTE Refacethe valve seatwith a 45 degree cutter when a valve guide is replaced TOOLS Seat cutter 24 mrn EX Se...

Page 147: ...be lowered using a 32degree flat cutter Ifthe contactarea is too low onthe valve the seat must be raised using a 60 degree inner cutter Refinish the seat to specifications using a 45 degree seat cutte...

Page 148: ...new valve stem seal Lubricate each valve stem with molybdenum oil Insertthe intake and exhaust valve into the valve guides To avoid damage to the seal turn the valve slowly when inserting Installthe...

Page 149: ...e stems gently with two plastic hammer to firmly seat the cotters CAUTION Supportthe cylinder head above the work bench surface to prevent valve damage Apply coolantto the newO ringand install itto th...

Page 150: ...Apply oil to the threads and seating surface of the four nuts and install them and washers Tighten the nuts to the specified torque in the specified sequence as shown TORQUE 30 Nm 3 1 kgf m 22 IbfW I...

Page 151: ...tions Apply oil to the threads and saeting surfaceof the camshaft holder bolts Installthe bolts and tighten them ina crisscross pattern in 2 or 3 steps TORQUE 12 Nm 1 2 kgfm 9 1bf h Turn the camshaft...

Page 152: ...s shown Temporarily align the index line on the sprockets with the surfaceof the cylinder headwithout movingthe cam chain Install the cam sprockets onto the camshafts NOTE Be sure that the index lines...

Page 153: ...ON Install the gasket new O ringand dowel pinto the cylinder head cover Install the cylinder head cover onto the cylinder head Installthe rubber washers with the UP marks facing up Install and tighten...

Page 154: ...iator hose to the cylinder head Install the radiator and two bolts Tighten the bolts Installthe following right and left middle cowl page 2 4 air cleaner housing page5 4 fuel tank page 5 3 Fill the co...

Page 155: ...CYLINDER PISTON 11 0...

Page 156: ...ons SPECIFICATIONS IN mark facing toward the intake side 63 47 63 49 2 4988 2 4996 6 5 10 36 from bottom of skirt Unit mm in 63 40 2 496 ITEM 15 002 15 008 0 5960 0 5909 14 994 15 000 0 5903 0 5906 0...

Page 157: ...d piston Compressiontoo high overheating or knocking Excessive carbon built up on piston or combustion chamber Excessivesmoke Worn cylinder piston or piston rings Improper installation of piston rings...

Page 158: ...cylinder head page 10 4 Loosen the band screw and disconnectthe water hose Remove the cam chain guide Remove the cylinder Clean the top of the cylinder thoroughly CAUTION Avoid damaging the gasket sur...

Page 159: ...or taper at three levels in an X and Y axis Take the maximum readingto determine the taper SERVICE LIMIT 0 10 mm 0 004 in I Checkthe cylinder for warpage by placing a straight edge and a feeler gauge...

Page 160: ...ire brush it will scratch the grooves INSPECTION Inspect the piston for cracks or other damage Inspect the ring grooves for excessive wear and carbon build up Measure each piston O D NOTE Take measure...

Page 161: ...ays replace the piston rings as a set Inspect the piston ring and replace them ifthey are worn Temporarily install the piston rings page 11 7 into the piston grooves Push in the ring untilthe outer su...

Page 162: ...t confuse the top and second rings After installing the rings they should rotate freely with out sticking Space the ring end gaps 120 degrees apart MARK PISTON 9 TOP RING SECOND RING SIDE RAIL TOPRING...

Page 163: ...e NOTE Place a shop towel over the crankcase opening to pre vent piston pin clips from falling into the crankcase Set the piston pin clip inthe groove properly Do not align the clip s end gap with the...

Page 164: ...INDER PISTON Insert the cam chain guide into cylinder and crankcase Install it by aligning the its bosses with the grooves in the cylinder and crankcase securely Install the cylinder head page 10 19 1...

Page 165: ...TRANSMISSION 12 0...

Page 166: ...drive gear gearshift linkage section8 Oil pump section 4 Flywheel section9 Be careful not to damage the crankcase mating surfaces when servicing Countershaft O D SPECIFICATIONS C1 gear bushing C2 gear...

Page 167: ...d or chipped transmission gear Worn or damaged transmission bearing Hard to shift Bent shift fork Bent shift fork shaft Damaged shift drum guide groove Damaged shift fork guide pin Transmissionjumps o...

Page 168: ......

Page 169: ...own Carefully separate the left crankcase from the right crankcasewhile tapping them at several locations with a soft hammer Do not ply the crankcase halves Remove the dowel pins Pull the fork shaft a...

Page 170: ...re the O D of each bushing SERVICE LIMITS C1 17 9 m m 0 70 in C 2 22 9 m m 0 90 in Measure the I D of each bushing SERVICE LIMITS C1 18 10 m m 0 713 in C2 20 10 m m 0 791 in Mainshaftlcountsrshaft Che...

Page 171: ...nce of sufficient lubrication Check the shift drum grooves for abnormal wear or dam age Measure the shift drum O D at right end SERVICE LIMIT 25 08 mm 0 987 in Check the shift drum journal inthe right...

Page 172: ...htness Measure the shift fork shaft O D SERVICE LIMIT 9 93 mm 0 391 in Transmission Bearing Turn the inner race of each bearing with your finger The bearingsshould turn smoothly and quietly Also check...

Page 173: ...om the left crankcase Remove the countershaft bearing from the inside of the left crankcase Remove the bearingswith following tools TOOLS Right crankcase countershaft beraing Bearing remover head 15 m...

Page 174: ...ttachment 42 x 47 mm Pilot 20 rnm 07749 0010000 07746 0010200 07746 0040400 07749 001oooO 07746 0010100 07746 0040300 07749 001oooO 07746 0010100 07746 0040200 07749 0010000 07746 0010300 07746 004050...

Page 175: ...vement or rotation pnthe shaft Install the washers and snap rings with the chamfered edges facing the thrust load side Do not reuse worn snap ring which could easily spin in the groove Checkthat the s...

Page 176: ...MISSION COUNTERSHAFT C3 GEAR 30T I SPLINE WASHER THRUST WASHER C5 GEAR 25T LOCKWASHER 1 SPLINE WASHER I c1 C1 GEAR BUSHING THRUST GEAR 37T WASUFR WASHER II C4 GEAR 27T WASHER AND SNAP RING DIRECTION 1...

Page 177: ...nly countershaft both ends MAINSU AFT M Y C I Each shift fork has an identification marks PR right PC center PL left Installthe shift forks into the shifter gear grooveswith the marks facing down righ...

Page 178: ...rank case mating surface except the oil passage area Make sure all the parts are installed in the left and right crankcases CAUTION Do not force the crankcasehalves together H there is ex cessiveforce...

Page 179: ...drive sprocket through the crankcase Install the cam chain tensioner plate and bolt Tighten the bolt securely Install the remaining parts Install the engine in the frame section 7 I Install the spring...

Page 180: ...CRANKSHAFTIBALANCER 13 0...

Page 181: ...tachment 37 x 40 mm Attachment 72 x 75 m m Pilot 12 mm Pilot 35 mm Crankcase assembly tool assembly collar assembly shaft Universal bearing puller 07749 0010000 07746 0010100 07746 0010600 07746 00402...

Page 182: ...ancer drive gear If the barancer drive gear is scratched file off the scratchedpart TOOL Universal bearing puller 07631 0010000 NOTE Always replace the left bearing with a new one if it comes out with...

Page 183: ...big end SERVICE LIMIT 0 05 mm 0 002 in Balancer Gear Check the balancer gear for wear or damage CrankshaftIBalancer Bearing Turn the inner race of each bearing with your finger The bearings should tu...

Page 184: ...stamp mark before Installthe crankshaft bearing Right side TM SCO7A87CS26 Left side TM SCO7A87CS42 Drive the crankshaft bearing to the right crankcase using the special tools TOOLS Driver 07749 001ooo...

Page 185: ......

Page 186: ......

Page 187: ...L A contaminatedbrake disc orpad reducesstoppingpower Discardcontaminatedpads and cleana Contaminateddisc with a high qualitybrake degreasing agent This section covers maintenance of the front wheel f...

Page 188: ...axle Wheel installed incorrectly Faulty steering head bearing Bentframe Faulty wheel bearing Worn swingarm pivot components Front wheel wobbling Bent rim Worn wheel bearings Bent or loose spoke Fault...

Page 189: ...e bolts master cylinder holder and master cylinder NOTE Keep the brake reservoir upright to prevent air from enterina the hvdraulic svstem Remove the throttle housing screws Remove the throttle upper...

Page 190: ...emovethe clutch switch connectors Removethe clutch lever holder bolts Remove the clutch lever holder and clutch lever bracket assembly Removethe screws and left handlebar switch housing Removethe grip...

Page 191: ...pecified torque TORQUE 27 Nm 2 8 kgf m 20 Ibf4t Install the stopper ring into the groove on the fork pipe Install the right handlebar in the same manner as for the left handlebar If the left handlebar...

Page 192: ...ble end Connect the throttle cable to the throttle pipe Installthe throttle housing and align its locating pin of the throttle housing cover with the hole on the handlebar Installthe screws and tighte...

Page 193: ...he handlebar referto page 14 51 Install the grip end Tighten the grip end screw to the specified torque TORQUE 8 8 Nm 0 9 kgfm 6 5 Ibf4t Installthe left handlebar switch housing aligning its locat ing...

Page 194: ...nt wheel NOTE Do not operate the front brake lever after the front wheel is removed The caliper piston will move out and make assembly difficult INSPECTION Axle Place the axle in V blocks and measure...

Page 195: ...rbox dust seal and speed ometer retainer Remove the side collar and dust seal from the right hub Remove the brake disc bolts and brake disc NOTF Check for disc warpage see page 16 8 WHEEL BEARING REPL...

Page 196: ...earingswith its marking side facing out TOOLS Driver 07749 0010000 Attachment 37 x 40mm 07746 0010200 Pilot 12 mm 07746 0040200 Installthe distance collar Drivethe new left bearing in using the same t...

Page 197: ...g its tabs with the slots in the hub 15 3 Apply greaseto a new left dust seal lips then install it into the wheel hub Install a new right dust seal and brake disc with the stomped mark MIN TH 3 5mm fa...

Page 198: ...front axle from the right side CAUTION When installing the front wheel fit the brake disc care fullvbetween thebrakeDadstoavoid darnasinstheDads Install and tighten the axle nut to the specified torq...

Page 199: ...fork pipe DISASSEMBLY Carefully remove the fork bolt The fork bolt is under spring pressure Use care when rernovino it and wear eve and face motection Removethe spring collar spring seat Removethe fo...

Page 200: ...in a vise with piece of woods or shop towel Remove the fork socket bolt and sealing washer NOTE If the socket bolt turn together with the fork piston tem porarily install the fork spring and fork bolt...

Page 201: ...Pipe Slider Piston Check the fork pipe slider and piston for score marks scratches or excessive or abnormal wear Check the rebound spring for damage Check the piston ring for wear or damage Replaceany...

Page 202: ...reassembly wash all partswith a high flash pointor non flammable solvent and wipe them off completely Installthe oil lock pieceand fork tube into the fork slider FORK BOLT O RING SPRING SEAT 4 REBOUND...

Page 203: ...fork bolt Apply fork fluid to the lip of the oil seal Drive the oil seal using the oil seal driver rooLs Fork seal driver 07747 0010100 Fork seal driver attachment 07747 0010300 Install the oil seal s...

Page 204: ...luid to a new O ring Installa new O ring onto the fork bolt and install it loosely NOTE Installthe fork bolt but do not tiahten vet INSTALLATION Install the fork leg and temporarily tighten the fork b...

Page 205: ...QUE 23 Nm 2 3 kgfm 17 Ibf4t Tighten the handlebar pinch bolt TORQUE 27 N rn 2 8kgfm 20 Ibf4t Install the following front fender page 2 3 front wheel page 14 12 brake cariper page 16 19 STEERINGSTEM RE...

Page 206: ...pper bearing steering stem lower bearing CAUTION Be carefulnot to lose any of the bearing BEARING RACE REPLACEMENT NOTE Replacethe bearing and races as a set Remove the ball races using the special to...

Page 207: ...nut Remove the bottom cone race dust seal and dust seal washer Install the new dust seal and bottom cone race Drive a new bottom cone race onto the steering stem us ing the special tool TOOL Steering...

Page 208: ...o the initial torque using the spe cial tool while holding steering stem securely TOOL Steering stem socket 07916 3710101 TORQUE 27 N m 2 8 kgfm 20 Ibf4t Move the steering stem right and left lock to...

Page 209: ...f the ground Position the steering stem to the straight ahead position Hook a spring scale to the fork pipe between the fork top and bottom bridges Make sure that there is no cable or wire harness int...

Page 210: ...REAR WHEEL SUSPENSION 39 N m 4 0 kgfm 29 Ibf ft 44 N 88 N m 9 0 kgfm 65 Ibf ft 15 0...

Page 211: ...balance directly affects the stability handling and overallsafety of the motorcycle Carefully check balance before reinstalling the wheel CAUTION To avoid damaging the rim when using the tire lever al...

Page 212: ...torcycle Bent rim Bentspokes Damaged tire Axle not tightened properly Chain adjusters not adjusted equally Soft suspension Weakspring Oil leakage from damper unit Tire pressure too low Hard suspension...

Page 213: ...l indicator reading SERVICELIMIT 0 20 mm 0 008 in Wheel rim runout Check the rim runout by placing the wheel in a turning stand Spin the wheel slowly and read the runout using a dial indicator Actual...

Page 214: ...ore than 60 grams to the wheel Wheel bearing Turn the inner race of each bearing with your finger Bearingsshould turn smoothly and quietly Also checkthat the bearing outer race fits tightly inthe hub...

Page 215: ...side collar and dust seal Remove the side collar and dust seal Remove the driven flange from the left wheel hub NOTE If you will be disassemble the driven flange remove the driven sprocket nuts before...

Page 216: ...removal Install the bearing remover head into the bearing From the opposite side install the bearing remover shaft and drive the bearing out of the wheel hub TOOLS Bearing remover head 12 mm 07746 005...

Page 217: ...Never installan oldbearing has beenremoved the bear ina must beredaced with a new one Drive a new right bearing squarely with its marking side facing out TOOLS Driver 07749 001QQQQ Attachment 37 x 40...

Page 218: ...lts Tghten the brake disc bolts to the specified torque TORQUE 42 Nm 4 3 kgfm 31 IM ft Install a new dust seal and apply grease to the dust seal lip Install the right side collar Do not get grease on...

Page 219: ...drive chain slack page3 15 SHOCKABSORBER REMOVAL Remove the rear cowl assembly page2 2 Support the motorcycle securely using a hoist or equiva lent Remove the shock absorber lower mounting boltand nut...

Page 220: ...9 Nm 4 0 kgf m 29 Ibf ft Install the shock absorber lower mounting bolt and nut and tighten the nut to the specified torque TORQUE 44 Nm 4 5 kgfm 33 Ibf4t Check the operation of the shock absorber pag...

Page 221: ...bly from the swingarm Removethe bolts and drive chain cover Removethe shockabsorberlower mounting bolt and nut Remove the swingarm pivot nut Remove the swingarm pivot bolt from the left side and remov...

Page 222: ...EEL SUSPENSION Checkthe chain slider for wear or damage Removethe screw collar and chain slider Checkthe rubber bushingsfor wear damage or fatigue ASSEMBLY CHAIN SLIDER I SWING ARM SCREW CHAIN ADJUSTE...

Page 223: ...kgfm 4 3 Ibf ft Placethe drive chain adjusters into the swingarm INSTALLATION Installthe swingarm onto the frame Installthe swingarm pivot bolt to the frame from the left side Temporarily tighten the...

Page 224: ...tt lnstallthe brake hoseguide andtightenthe screw securely Install the rear brake caliper bracket assembly on the swingarm aligning the slat on the bracket with boss on the swingarm Install the rear w...

Page 225: ...BRAKE SYSTEM 34 N m 3 5 kgf m 25 Ibf ft 34 N m 3 5 kgfm 25 Ibf ft 30 N m 3 1 kgf m 22 Ibf ft 16 0...

Page 226: ...ear indicator 25 318 25 368 0 9968 0 9987 25 300 0 9960 To woove Never allow contaminates dirt water etc to get into an open reservoir Once the hydraulic system has been opened or if the brake feels s...

Page 227: ...liper piston Stickinghorn master cylinder piston Contaminated master cylinder Bent brake lever pedal 34 N m 3 5kgf m 25 Ibf ft 1 5 N m 0 15 kgfm 1 1 Ibf ft 1 2 N m 0 12 kgfm 0 9 Ibf ft 5 9 N m 0 6 kgf...

Page 228: ...the hydraulic system has been opened or if the brake feels spongy the system must be bled When using a commercially available brake bleeder follow the manufacturer s operating instructions BRAKE FLUID...

Page 229: ...till feels spongy bleed the system again If a brake bleeder is not available use the following pro cedure Pump up the system pressure with the brake lever pedal until lever pedal resistance is felt 1...

Page 230: ...ingpower Discardcontaminatedpadsandcleana contaminated disc with a high quality brake degreasingagent NOTE Always replace the brake pads in pairs to assure even disc pressure Check the brake fluid lev...

Page 231: ...UE 17 N m 1 7 kgf m 12 Ibf4t REAR BRAKE PAD REPLACEMENT A contaminatedbrakediscorpadreducesstoppingpower Discard contaminatedpadsandcleana contaminateddisc with 8 high quality brake degreasing agent N...

Page 232: ...n install the pad pin Tighten the pad pin to the specified torque TORQUE 17 Nm 1 7 kgfm 12 Ibf4t Install the rubber plug BRAKE DISC INSPECTION Visually inspect the brake disc for damage or cracks Meas...

Page 233: ...ed plastic or rubber parts Place a rag over these parts whenever the system is ser viced Drain the brake fluid from the front brake hydraulic sys tem page 16 31 Remove the front brake light switch con...

Page 234: ...th clean brake fluid and make sure air can ventilate the master cylinder port by compressed air INSPECTION Checkthe boot primary and secondary cups for wear de terioration or damage Check the master c...

Page 235: ...ston cups in clean brake fluid before assembly Install the spring onto the master piston Installthe springlmaster piston and washer into the mas ter cylinder Install the snap ring using the special to...

Page 236: ...pivot bolt and nut to the specified torque TORQUE Pivot nut 5 9 Nm 0 6 kgf m 4 3 Ibf4t Installthe mastercylinder and holder with the UP mark facing up Align the end of the master cylinder with the pun...

Page 237: ...prevent fluid from leaking out Drainthe brake fluid from the rear brake hydraulic system page 16 3 Remove the brake hose bolt sealing washers and brake hose Remove the rear master cylinder mounting bo...

Page 238: ...ce if necessary INSPECTION Checkthe boot primary cup andsecondary cupfor fatigue or damage Checkthe master cylinder and pistonfor scoring scratches or other damage Replace if necessary NOTE Replacethe...

Page 239: ...the recommended brake fluid Apply silicone grease to the push rod contacting area of the master cylindcr Install the spring onto the master piston Install the spring master piston and push rod into th...

Page 240: ...r of the joint pin hole is 84 86 mm 3 3 3 4 in After adjustment tighten the lock nut TORQUE 17 N m 1 7 kgfm 12 Ibf4t Apply brake fluid to the new O ring Install the new O ring and joint pipe Tighten t...

Page 241: ...AKE CALIPER REMOVAL CAUTION Avoid spilling fluid on painted plastic or rubber parts Place a shop towel over these parts whenever the sys tem is senriced Drain the brake fluid from the front brake hydr...

Page 242: ...ause iniurv Pushthe dust and piston seals in and lift them out Clean the seal groove with clean brake fluid CAUTION Be carefulnot to damage the piston sliding surface INSPECTION Check the caliper pist...

Page 243: ...rake fluid and install the pistons into the caliper cylinders with the opening towards the pads If the caliper and bracket pin boots are hard or deterio rated replace them with new ones Apply silicone...

Page 244: ...torque TORQUE 34 N m 3 5 kgfm 25 Ibf4t Fill and bleed the front brake hydrauric system pagel6 3 REAR BRAKECALIPER REMOVAL Drainthe brake fluid fromthe rear brake hydraulic system page 16 31 Remove the...

Page 245: ...rcedout withexcessiveforcethat could cause iniurv Push the dust seal and piston seal in and lift them out CAUTION Be careful not to damage thepiston sliding surface Clean the seal grooves caliper pist...

Page 246: ...fluid to the caliper piston and install it into the caliper cylinder with the opening towards the pads If the caliper and bracket pin boots are hard or deterio rated replace them with new ones Apply s...

Page 247: ...16 5 Temporarily installthe brake hoseeyelet joint to the caliper body with new sealingwashers and bolts Push the brake hose eyelet joint to the stopper onthe caliper then tighten the bolt to the spec...

Page 248: ...ght main step holder Securethe brake pedalwith the washer and a new cotter pin Installthe joint pin and newcotter pin Installthe brakelight switch springto the return springas shown Installthe right m...

Page 249: ...CHARGING SYSTEM SYSTEM DIAGRAM Y Yellow G Green R Red W White 17 0...

Page 250: ...onnect the negative battery cable from the battery terminal The battery can be damaged if overcharged or undercharged or if left to discharge for long periods These same conditions contribute to short...

Page 251: ...M Battery Capacity Current leakage Specific gravity Fully charged Needs charging Quick Charging current Normal Alternator Capacity Chargingcoil resistance 2O0C 68 F Lighting coil resistance 2OoC 68 F...

Page 252: ...atorhectifier Shorted wire harness Faulty ignition switch Checkthe alternator charging coil page 17 7 Faulty barging coil STANDARD 0 2 1 0 R 2OoC 68OF t Correct 1 Measure and record the battery voltag...

Page 253: ...d disconnect the battery positive I cable Remove the battery out of the battery case INSTALLATION Install the battery into the case Coat the battery terminal with clean grease Place the battery into t...

Page 254: ...ck CAUTION Quick chargingshould only be done in an emergency slow charging is preferred For battery charging do not exceed the charging current and time specified on the battery Using excessive curren...

Page 255: ...er when the engine runs at 5 000 min rpm Standard Measured battery voltage page 17 4 Measured charging voltage Seeabove 15 5 V a t 5 000 rprn The battery is normal if voltage reads the regulated volt...

Page 256: ...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 Locatethe short...

Page 257: ...or rectifier 4P connector and check it for loose contact or corroded terminals If the regulated voltage reading see page 17 4 is out of the specification measure the voltage between connec tor termina...

Page 258: ...IGNITION SYSTEM SYSTEM DIAGRAM IGNITION SWITCH IGNITION l 7 1 SWITCH ToTachometer MODULE ICM IGNITION WLSE SPARK GENERATOR PLUG R G N S E 2M 8 1 Black Bu Blue Y Yellow R Red G Green 18 0...

Page 259: ...7 V minimum 12 BTDCat 1 400 k 100 min rpm H the engine must be running to do some work make sure the area is well ventilated Never run the engine in an enclosedarea The exhaust containspoisonous carb...

Page 260: ...time of the tester and measured pulsewere notsynchronized Systemis normalif measuredvoltage is over the standardvoltage at leastones system 4 Poorly connectedconnector or an open circuit in ignition 5...

Page 261: ...se the lmrie diagnostic tester TOOLS lmrie diagnostic tester model 625 or Commerciallyavailabledigital multimeter impedance 10MWlDCV minimum Peakvoltageadaptor 07HGJ 0020100with IGNITION COIL PRIMARY...

Page 262: ...harness refer to the trou bleshooting chart on page 18 2 Installthe removed parts inthe reverse order of removal IGNITIONPULSEGENERATOR PEAKVOLTAGE NOTE Checkcylindercompressionandcheckthat the spark...

Page 263: ...n circuit or loose connection If both peakvoltages measureare abnormal check each item in the troubleshooting chart If all items are nor mal the ignition pulse generator is faulty See section 9 for ig...

Page 264: ...t Installthe removed parts inthe reverse order of removal IGNITIONTIMING 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 Th...

Page 265: ...ition timing is correct if the F mark aligns with the index notch on the left crankcase cover Apply oil to the O ring and install and tighten the timing hole cap to the specified torque TORQUE 6 N m 0...

Page 266: ...ELECTRIC STARTER SYSTEM DIAGRAM STARTER SWITCH 8 1 Blade Y Yellow G Green R Red W Whb Lg LightGreen 19 0...

Page 267: ...sing seriousinjury The starter motor can be serviced with the engine in the frame When checking the starter system alwaysfollow the steps inthe troubleshooting flow chart page 19 2 A weak battery may...

Page 268: ...it in starter motor cable Check for loose or poorly connected starter motor cable and open circuit in starter motor cable I Normal Clicks switch and check for a Click sound from the starter relay swit...

Page 269: ...al Faulty starter relay switch page 19 10 Starter motor turns slowly Weak battery Poorly connected battery cable Poorly connected starter motor cable Faulty starter motor Starter motor turns but engin...

Page 270: ...niurv Removethe under cowl page2 3 Remove the rubber cap Ramovethe terminal nut and starter motor cable Removethe two mounting bolts and ground cable Remove the starter motor from the left crankcase D...

Page 271: ...the location and number of shims Check the needle bearing and dust seal in the front cover for wear or damage Checkthe commutator bars of the armature for discolora tion NOTE Do not use emery or sand...

Page 272: ...y between the insulated brush and cable terminal There should be continuity Check for continuity between the cable terminal and rear cover There should be no continuity Remove the following nut washer...

Page 273: ...OCK k y A WASHER NEEDLE BEARING FRONT COVER O RING BOLT Installthe brushes into the brush holder Install the brush holder assembly into the rear cover by aligning the tab of the holderwith the groove...

Page 274: ...maged if the magnet pulls the arma ture aaainst the case Installthe same number of washers and shims inthe same locations as noted during disassembly NOTE The number of shims are different individuall...

Page 275: ...a new O ring with oil and install it into the starter motor groove Install the starter motor into the crankcase Install the ground cable and mounting bolt then tighten the bolts securely Install the s...

Page 276: ...ed the ground circuit is normal Inneutral there is a slight resistance due to the diode STARTER RELAYVOLTAGE Connect the starter relay switch 4P connector Shift the transmission into neutral Measure t...

Page 277: ...INSPECTION Removethe rear cowl page 2 3 Removethe diode Checkfor continuitybetween the diode terminals When there iscontinuity a small resistancevaluewill reg ister If there is continuityin one direct...

Page 278: ...LIGHTS METERS SWITCHES SYSTEM LOCATION 20 0...

Page 279: ...eutral indicator GENERAL 1 2 V 5 W 12 v 10w x 2 12 v 10w x 2 12 v 1 7 w x 4 12V 1 7W 12V 1 7W 12V 1 7W Use an electric heating element to heat the water coolant mixture for the thermosensor inspection...

Page 280: ...is started Faulty lighting and or dimmer switch Faulty bulb Faulty alternator lighting coil section 17 Faulty regulatorhectifier section 17 Loose or poorly connected connector Headlight beamdoes not...

Page 281: ...instthe headlight housing with the TOP mark facinn up FRONT TURN SIGNAL LIGHT Remove the screws and upper cowl lid page 2 5 Turn the bulb socket counterclockwise and remove it Removethe bulb and repla...

Page 282: ...BRAKE LIGHT Turn the bulb socket countercllockwise and remove it While pushing in turn the bulb counterclockwise to remove it Remove the taillbrake light bulb and replace it with a new one LICENSE LIG...

Page 283: ...of the combination meter Remove the bulb from the socket and replace it with a new one DISASSEMBLY Remove the six screws and speedometer front panel Remove the indicator and instrument light bulbs Re...

Page 284: ...ANTTEMPERATUREGAUGE Assemble the speedometer in the reverse order of disassembly NOTE Routethe sub harnessas shown INSTALLATION Assemble the upper cowl page 2 4 NOTE Route the combination meter wire a...

Page 285: ...uity betweenthe wire terminals of the ig nition switch connector in each switch position Continuity should exist between the color coded wires as follows IGNITIONSWITCH 1 REMOVALANSTALLATION Disconnec...

Page 286: ...color coded wire ter minals as follows LIGHTING SWITCH DIMMER SWITCH TURN SIGNAL SWITCH HORNSWITCH COLOR Lb I Gr I 0 I STARTER SWITCH E l COLOR BI BRAKELIGHTSWITCH FRONT Disconnect the front brake li...

Page 287: ...ith the brake pedal is released INSPECTION Make sure that the neutral indicator come on with the ignition switch ON and neutral position If the indicator does not come on inspect as follows Release th...

Page 288: ...iece for wear or damage Replace it if necessary CAUTION Donot bent or tap thedrivepiece wheninstallthe drive piece Bent the drivepiece by forceor crush the contactpoint will causepoor electricity conn...

Page 289: ...swings to FULL Connect the jumper wire between the BlueMlhite and Green wire terminals of the wire harness side Fuel meter is in good condition if the needle returns to EMPTY CAUTION Do not leave the...

Page 290: ...te YellowMlhite I 600 R I 600 R Reconnectthe fuel unit3Pconnector and turn the ignition switch ON Move the fuel unit float up and down and make sure that the fuel gauge needle moves smoothly FLOAT UP...

Page 291: ...y condition burned out bulb or non specified wattage burned fuse ignition switch and turn signal switch function loose connectors If above items all normal check the following Remove the rear cowl pag...

Page 292: ...he body ground Turn the ignition switch ON and check the fan motor Ifthe motor starts check the connection at the fan motor switch terminal If it is OK the fan motor switch is faulty If the motor does...

Page 293: ...rn the ignition switch ON and check the coolant temperarute gauge needle The needle should move to H CAUTION ImmediatelyturntheignitionswitchOFFwhentheneedle move to H hot to prevent the gauge from da...

Page 294: ...or Keep temperature constant for 3 minutes before test ing A sudden change of temperature will result in in correct readings Do not let the thermometer or thermosensor touch the pan Temperature I 50 C...

Page 295: ...betweenthe WhitdGreen and Green 1 wire terminals There should be battery voltage Ifthere is no voltage check for opencircuit inWhite Green wire Start the engine and measure the voltage between the Ye...

Page 296: ...21 WIRING DIAGRAM 21 1...

Page 297: ...carburetor Clogged fuel tank breather Weak or no spark Faulty spark plug Fouled spark plug Faulty ignition control module ICM Broken or shorted spark plug wire Faulty ignition switch Faulty ignition p...

Page 298: ...logged air cleaner Restricted fuel flow Clogged muffler Pinched fuel tank breather Incorrect Faulty ignition control module ICM Faulty ignition pulse generator 1 5 Check ignition timing I Correct Inco...

Page 299: ...wire Faulty ignition pulse generator Faulty ignition switch Loose or disconnected ignition system wires 1 Engine does not knock Ignition timing too advance Faulty ICM Lean fuel mixture POOR PERFORMANC...

Page 300: ...iming Correct I erly 4 Check ignition timing Incorrect Faulty ignition control module ICM I Faulty ignition pulse generator Correct Weak Faulty valve spring 1 1 5 Check valve spring Not weak POOR HAND...

Page 301: ...REPLACEMENT 6 4 COOLANT TEMPERATURE GAUGE THERMOSENSOR CRANKCASEASSEMBLY CRANKCASEBREATHER CRANKSHAFT REMOVAL CYLINDER INSTALLATION CYLINDER HEAD ASSEMBLY 10 17 D REMOVAL 5 3 HANDLEBAR 14 3 20 8 20 1...

Page 302: ...16 2 CLUTCH GEARSHIFTLINKAGE CRANKSHAFT BALANCER CYLINDER HEADNALVESJ CHARGING SYSTEM 17 3 CYLINDER PISTON 11 2 ELECTRICSTARTER 19 2 FRAME BODY PANELS 2 1 FRONTWHEEUSUSPENSION STEERI 14 2 FUEL SYSTEM...

Page 303: ...8 Clutch Gearshift linkage 107 121 9 Alternator Starter Clutch 122 130 10 Cylinder head Valves 131 154 11 Cylinder Piston 155 164 12 Transmission 165 179 13 Crankshaft Balancer 180 185 14 Front wheel...

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