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Honda 2004 CRF250X, Service Manual

The Honda 2004 CRF250X Service Manual is a must-have for every owner. This comprehensive manual covers everything you need to know about maintaining and servicing your bike. Download it for free from manualshive.com and keep your CRF250X in top condition for years to come.

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Summary of Contents for 2004 CRF250X

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Page 3: ...ow tne lOuree of hiJ troubje go to saction 21 TtoubIe5hoo1lng Ybut u ety and the salery 01 others very important To t eIp you make Informed deciSIOnS we have provided safety messages and Othllr Inkmna...

Page 4: ...enum disulfide grease containing more than 3 molybdenum disulfide NlGI 2 or equivalent Example Molykot BR 2 plus manufactured by Dow Corning U S A Multi purpose M 2 manufactured by Mitsubishl Oil Japa...

Page 5: ...GE SPECIFICATIONS 9 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER SPECIFICATIONS 9 FRONT WHEEL SUSPENSION STEERING SPECiFiCATIONS 0 REAR WHEEL SUSPENSION SPECIFICATIONS 0 HYDRAULIC BRAKE SPECIFICATIONS B...

Page 6: ...nterchangeable with English fastener 4 Inslall new gaskets O rings cotter pins and lock plates when reassembling 5 When tightening bolts or nuts begin with the larger diameter or inner bolt first Then...

Page 7: ...is stamped on the right side of the steering head The engine serial number is stamped on the left side of the lower crankcase The carburetor identification number is stamped on the left side of the ca...

Page 8: ...da is attached on the left side of the down tube NAME PLATE U S A SAFETY CERTIFICATION LABEL CANADA The Vehicle Emission Information Label is attached on the rear fender 04 06 California type After 06...

Page 9: ...ft doses at 1 mm 0 04 in lift California type opens at 1 mm 0 04 in lift doses at 1 mm 0 04 in lift 49 State and Canada type opens at 1 mm 0 04 in lift doses at 1 mm 0 04 in lift California type opens...

Page 10: ...SYSTEM SPECIFICATIONS ITEM Engine oil capacity Transmission oil capacity Recommended engine oil Recommended transmission oil Oil pump rotor 1 6 raining iJter change Atd At Atd Atd isassembly raining...

Page 11: ...NS II A iit c h a c g e _t _ __ ti 13 liter 1 19 US qt 0 99 Imp Qsti i I At disassembly 1 20 liter 1 27 US qt 1 061mp qt Coolant capacity Radiator cap relief pressure Recommended antifreeze Standard c...

Page 12: ...NERAL INFORMATION CYLINDER HEADIVALVES SPECIFICATIONS valve guide stem oem height CYLINDER PISTON SPECIFICATIONS i piston ring clearance 1 8 to ring end gap I Top 0 065 0 100 0 0026 0 0039 0 115 0 004...

Page 13: ...r t c j3eiii1e o u l1aE S I 0 0 iF 020 1 1 07 790 L I 10 0 I J D 0 1 clearance FOlk ew t V V Shift fOlk 1 0 fOlk he U D g 27 020 27 041 i 9859l 27 07 1 066 M4 M5 _E c 9 79l 1 000 i 9555l if 904 C 979...

Page 14: ...Drive chain slack 25 35 1 0 1 4 6012 4 Drive chain size link I DID i 520MXV 1 6 Drive chain slider thickness 5 010 2 Drive chain roller 1 0 04 05 Upper 2911 1 Lower 3911 5 After 05 Upper 29 1 1 Lower...

Page 15: ...70 O 37261 O 89421 ____ 22 573 10 7 BATIERY CHARGING SYSTEM SPECIFICATIONS ITEM SPECifiCATIONS Banery Capacity t2V 4Ah Current leakage 0 1 mA max Voltage FuliV h ge 13 0 13 2 V 20 C 6B F Needs Below 1...

Page 16: ...GENERAL INFORMATION ELECTRIC STARTER SPECIFICATION ITEM STANDARD SERVICE UMIT Starter motor brush length 10 25 0 404 6 75 O 266 LIGHTS METER SWITCHES SPECIFICATIONS 1 12...

Page 17: ...ds 3 Stake 4 U nut 5 Apply grease to the threads 6 left hand threads 7 Apply a high strength locking agent to the threads 8 AlOe bolt replace with a new one ENGINE MAINTENANCE C ITEM Q TY THREAD TORQU...

Page 18: ...06 California 6 9 8 1 0 7 type After 06 COOLING SYSTEM ITEM a TY THREAD TORQUE REMARKS DIA mm N m kgf m IbUtl Water pump impeller 7 12 1 2 9 NOTE 6 CYLINDER HEAD VALVES THREAD TORQUE ITEM a TY DIA lmm...

Page 19: ...aring set plate screw 2 6 9 8 1 0 7 NOTE 2 Gearshift drum bearing set plate bolt 2 6 9 8 1 0 7 NOTE 2 Mainshaft bearing set plate bolt 2 6 9 8 1 0 7 NOTE 2 Balancer shaft bearing set plate bolt 2 6 9...

Page 20: ...Insulator clamp After 06 Cylinder head stud bolt Cylinder stud bolt 1 16 12 0 1 0 mm 0 47 0 04 in 1 t Cylinder head side 9 5 1 0 mm 0 37 0 04 in Carburetor side 1 0 1 0 mm 0 43 0 04 in 0 0 0 22 0 0 5...

Page 21: ...SYSTEM ITEM a TV PAIR control valve mounting nut 2 COOLING SYSTEM ITEM a TV Radiator plug 1 ENGINE REMOVAL INSTALLATION ITEM a TV Engine hanger engine side 1 plate nut frame side 04 2 After 04 2 Engi...

Page 22: ...TE 4 Engine stop button screw 1 4 I 1 5 0 15 1 1 Engine starter switch housing screw 2 4 0 7 0 07 0 5 REAR WHEEl BRAKE SUSPENSION ITEM a TV THREAD TORQUE REMARKS DIA lmm N m kgf m lbf ft Rear axle nut...

Page 23: ...2 2 2 6 6 6 5 4 6 8 8 6 4 8 12 Rear master cylinder p u s h o d o c k n u t ____ L_ 10 10 8 8 8 10 6 LIGHTS METERS SWITCHES I TORQUE N m kgf m IbUt 34 3 5 25 5 9 0 6 4 3 5 9 0 6 4 3 lO 0 1 0 7 5 2 0 5...

Page 24: ...e surface Cylinder bore Clutch lifter piece needle bearing Clutch disc lining surface Clutch center lock nut threads and seating surfaces Primary drive gear bolt threads and seating surface One way cl...

Page 25: ...eads Throttle shaft screw threads Throttle position sensor torx screw threads 04 06 Throttle position sensor bolt threads After 06 i agent Pro Honda Hondalock 3 or equivalent high _____ t_ strength lo...

Page 26: ...ge side collar Rear shock absorber spherical bearing rolling area Rear shock absorber dust seal lips Brake pedal pivot shaft sliding area Shift change pedal sliding area of pin Clutch lever pivot bolt...

Page 27: ...T STAAT CABLE ENGINE STARTER SWITCH ENGINE BUTTON WIRE THROTTLE CABLES TRIPMETEA FRONT BRAKE HOSE MAIN WIRE HARNESS ENGINE STOP BUTTON COI NI CTOR HEADLIGHT CONNECTOR CLUTCH CABLE THROTTLE CABLES HOT...

Page 28: ...R iR 4P NATURAL IGNITION PULSE GENERATOR 2P BLACK CONNECTOR ALTERNATOR 4P BLACK CONNECTOR TH orTO CABLES CLUTCH CABLE TRIPMETER CABLE HOT ST RT CABLE CLUTCH CABLE TRIPMETER CABLE FAONTBRAKEHOSE r j 1...

Page 29: ...STARTER MOTOR CABLE GENERAL INFORMATION GR U D CABLE REAR BRAKE HOSE ALTERNATOR IGNITION GENERATOR WIRE CRANKCASE BREATHER HOSE CARBURETOR OVERFLOW HOSE TRANSMISSION BREATHER HOSE 1 25...

Page 30: ...RADIATOR HOSE DIRECT IGNITION COil HOT START CABLE CRANKCASE HOSE 1 26 R n Tn R SIPHON HOSE CABLES REGULATOR RECTIFIER CLUTCH CABLE THROTTLE POSITION SENSOR CONNECTOR TRANSMISSION BREATHER HOSE REGULA...

Page 31: ...MINAl GENERAL INFORMATION 7AIA VENT HOSES TRANSMISSION BREATHER HOSE 1 hL RADIATOR RESERVE TAN K OVERFLOW HOSE CARBURETOR OVERFLOW HOSE BATTERY POSITIVE TERMINAL BATTERY 0 MAIN WIRE HARNESS STARTER RE...

Page 32: ...R RESERVE TANK OVERFLOW HOSE RADIATOR SIPHON HOSE TAIL LIGHT WIRE MAIN RELAY CONNECTORS reM 6P BROWN CONNECTOR reM 6P NATURAL CONNECTOR TAIL LIGHT 2P WHITE CONNECTOR reM WIRE CONNECTOR TAIL UGHTWIRE C...

Page 33: ...GENERAL INFORMATION SECONDARY AIR SUPPLY SYSTEM 04 06 California type After 06 U y HOSE AIR 1I1 TlrIN VACUUM HOSE PAIR CONTROL VALVE AIR PIPE 1 29...

Page 34: ...rness An optional cooling fan is available for competition use The fan will help avoid engine damage if the engine is kept idling too long hot or when riding in mud or sand or any condition that cause...

Page 35: ...oz Maximum 404 em3 13 7 US oz Minimum 308 em 10 4 US Ol Standard 2 scribe mark 0 42 kgf mm Standard 0 after market parts 23 52 tbf in 340emJ 11 5USoz Maximum 399 em3 13 5 US oz Minimum 303 emJ 10 2 US...

Page 36: ...nON MARK Red and Brack paint Orange paint cH e a vy 5 O O k g Y m m VV h t e p a n t r 280 0Ibf in 5 20 kgf mm 1291 21bll nl Blue paint The standard fork and shock springs mounted on the motorcycle wh...

Page 37: ...d and maintained according to the instruction provided SOURCE OF EMISSIONS The combustion process produces carbon monoxide oxides of nitrogen and hydrocarbons Control of hydrocarbons and oxides of nit...

Page 38: ...ed exhaust gases and changes a considerable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor This model has a pulse secondary air injection PAIR contr...

Page 39: ...rated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of de...

Page 40: ...MEMO...

Page 41: ...RAME BODY PANELS EXHAUST SYSTEM SERVICE INFORMATION 2 2 TROUBLESHOOTING 2 2 SEAT 2 3 SIDE COVER 2 3 RADIATOR SHROUD 2 4 ENGINE GUARD 2 4 FRONT VISOR 2 5 SUB FRAME 2 5 FUEL TANK 2 7 EXHAUST SYSTEM 2 8...

Page 42: ...t Exhaust pipe joint nut Muffler joint band bolt Muffler mounting bolt Heat shield bolt Exhaust pipe protector bolt Rear fender mounting bolt upper lower Diffuser mounting larx screw Radiator shroud u...

Page 43: ...ub frame tab Instal the seat mounting bolts with collars 04 06 only and tighten the bolts to the specified torque TORQUE 26 N m 2 7 kgf m 20 Ibf ft SIDE COVER REMOVAL INSTALLATION Lefr side only Open...

Page 44: ...f ft Left side only Close the left air cleaner housing cover RADIATOR SHROUD REMOVAL INSTALLATION Remove the seat page 2 3 Note that the Remove the bolts collars and radiator shroud thinner collars ar...

Page 45: ...ring stem Install and tighten the bolts securely SUB FRAME REMOVAL Remove the following Radiator reserve tank page 6 9 Battery page 16 6 Air cleaner housing page 5 7 Remove the wire band and main rela...

Page 46: ...ing bolt and sub frame INSTALLATION Install the sub frame upper mounting bolt and wire band Install the rear fender setting washer plain washer 04 06 only and bolts Tighten the bolts to the specified...

Page 47: ...lowing Radiator reserve tank page 6 9 Battery page 16 6 Air cleaner housing page 5 7 FUEL TANK REMOVAlIlNSTAlLATION Remove the seat page 2 3 Remove the radiator shrouds page 2 4 Turn the fuel valve to...

Page 48: ...T SYSTEM SHROUDS FUEL TANK FUEL VALVE EXHAUST SYSTEM 2 8 MUFFLER REMOVALIINSTALLATION Remove the right side cover page 2 3 loosen the muffler joint band bolt Remove the muffler mounting bolts washer m...

Page 49: ...he muffler to the exhaust pipe Install and tighten the muffler mounting boils to the specified torque TORQUE 26 N m 2 7 kgf m 20 Ibf ft Tighten the muffler joint band bolt to the specified torque TORQ...

Page 50: ...tbf ft 2 10 12 N m 1 2 kgf m 9 Ibf ft Install the protector and mounting bolts Tighten the bolts to the specified torque TORQUE 12 N m 1 2 kgf m 9 Ibf ft Install a new gasket to the cylinder head Alwa...

Page 51: ...E BODY PANELS EXHAUST SYSTEM Install the exhaust pipe flange and joint nuts Tighten the exhaust pipe joint nuts to the specified torque TORQUE 21 N m 2 1 kgf m 15 Ibf ftj Install the muffler page 2 8...

Page 52: ...MEMO...

Page 53: ...AINER SCREEN 3 8 BRAKE SYSTEM 3 27 THROTTLE OPERATION 3 8 HEADLIGHT AIM 3 28 HOT START 3 9 CLUTCH SYSTEM 3 28 AIR CLEANER 3 10 CONTROL CABLES 3 29 CRANKCASE BREATHER 3 11 EXHAUST PIPE MUFFLER 3 29 SPA...

Page 54: ...I iil0il I engine oil Option At I 3 5mm I1l8 3I 6In 2 3 mm 111 6 8 In 0 8 0 9 mm 10 03 0 04 mm 0 In i 1 70 mp qt 0 75 lit 1 79 qt IImp qt VUH24D VUH i Cnt motor oil 9 oil and I f eoomm mJi r m Olf____...

Page 55: ...12 IbUt 5 9 N m 0 6 kgf m 4 3 Ibfft 127 N m 13 0 kgfm 94Ibf ft 12 N m 1 2 kgf m 9Ibf ft 31 N m 3 2 kgf m 23 IbUt 32 N m 3 3 kgf m 24 Ibf ft 1 5 N m 0 15 kgfm l llbfft 1 5 N m 0 15 kgf m l llbf ft 21 N...

Page 56: ...3 13 w COOLING SYSTEM 1 1 1 1 1 3 13 SECONDARY AIR SUPPLY SYSTEM NOTE 2 1 1 3 14 TRANSMISSION OIL R R R R R 3 20 DRIVE CHAIN NOTE 1 I L I L Every 300 mi 500 km 3 21 or 3 month DRIVE CHAIN SLIDER NOTE...

Page 57: ...LANT NOTE 3 1 R 3 13 COOLING SYSTEM 1 1 1 1 _ 1 3 13 SECONDARY AIR SUPPLY SYSTEM NOTE 2 1 1 3 14 TRANSMISSION OIL R R R R R 3 20 DRIVE CHAIN NOTE 1 I L 1 L Every 300 mi 500 km or 3 21 3 month DRIVE CH...

Page 58: ...NorE 3 1 INOrE 21 3 13 NOTE 4 I 3 14 INorE 3J R 3 17 3 17 IRINGS R I R C ORIVE CHAIN R DRIVE CH N 1 2 c IBRAKE FLUID INOrE 21 IWEAR 1 27 H INOTE 51 ei 3 29 IFORK OJL INorE 31 R I R 13 21 r HEAD I This...

Page 59: ...l Chain adjuster bolt Air cleaner Note Cause Compression leak Wear or discoloration leakage Damage Cause Wear Fatigue or damage Wear or damage Damage Damage Damage Free play or damage Free play or dam...

Page 60: ...in high flash point cleaning solvent Check that the O ring is in good condition and install it onto the fuel valve Install the fuel joint in the reverse order of removal Install the fuel tank page 2 7...

Page 61: ...urning the adjuster After adjustment tighten the lock nut securely TORQUE After 06 3 9 N m 0 4 kgf rn 2 9 Ibf ft Recheck the throttle operation Install the fuel tank page 2 7 HOT START Check for smoot...

Page 62: ...er Wash again if necessary Allow the air cleaner to dry thoroughly After drying soak the air cleaner in clean Pro Honda Foam Filter Oil or an equivalent Apply air filter oil to the entire surface of t...

Page 63: ...he piston ring and cylinder CRANKCASE BREATHER Remove the breather hose drain plug then drain any fluids or dirt from the hose into a proper con tainer Reinstall the drain plug SPARK PLUG REMOVAL Remo...

Page 64: ...QUIVALENT Standard NGK IMR8C9H DENSO VUH24D Optional NGK IMR9C9H DENSO VUH270 To prevent Check the gap between the center and side elec damagmg the trodes with a wire type feeler gauge indium ceMer el...

Page 65: ...the UPPER level line with 1 1 mixture of distilled water and antifreeze Reinstall the filler cap Install the left side cover page 2 3 COOLING SYSTEM Remove the fuel tank page 2 7 Remove the radi ator...

Page 66: ...r pinched VALVE CLEARANCE DECOMPRESSOR SYSTEM VALVE CLEARANCE INSPECTION Inspect and adjust Remove the cylinder head cover page 8 6 the valve clearance Remove the crankshaft hole cap and D ring whIle...

Page 67: ...gauge valve for reference In shim selectJon If adjustment IS reqUired VALVE CLEARANCE EX 0 28 0 03 mm 0 011 0 001 in VALVE CLEARANCE ADJUSTMENT Remove the camshaft page 8 7 The shims may stick to the...

Page 68: ...posits result in a calculated dimension of over 2 450 mm Aeface the exhaust valve seat if carbon deposits result in a calculated dimension of over 2 900 mm Install the newly selected shims on the valv...

Page 69: ...l is below or near the lower level line on the dipstick add the recommended engine oil to the upper level line through the oil filler hole Add the recommended engine oil to the upper level line RECOMM...

Page 70: ...oil completely drains Remove the bolts O ring and oil filter cover Remove the oil filter and spring Apply oil to the threads and seating surface Install the engine oil drain bolt with a new sealing wa...

Page 71: ...S qt 0 61 Imp qtl at oil filter change Install the oil filler cap dipstick Recheck the oil level page 3 17 Make sure there are no oil leaks Install the engine guard page 2 4 ENGINE IDLE SPEED NOTE Ins...

Page 72: ...ealing washer and filler cap securely TRANSMISSION OIL CHANGE Transmission oil should be changed at least every six races or 15 hours of operation to ensure consistent performance and maximum service...

Page 73: ...osen the axle nut and adjuster lock nuts and turn the adjusting bolts Check that the chain adjuster index marks are in the same position on each side then tighten the axle nut to the specified torque...

Page 74: ...0 0 Lubricate the drive chain with 80 90 gear oil or drive chain lubricant designed specifically for use LUBRICATE with O ring chains Wipe off the excess oil or chain lubricant REPLACEMENT 80 90 GEAR...

Page 75: ...et count Ihe drive chain links STANDARD LINKS 16 LINKS REPLACEMENT CHAIN DID520MXV MAINTENANCE MASTER LINK DRIVE CHAIN TOOL SET I Q 1 LINK 116 LINKS Never reuse the old drive chain master link O R N G...

Page 76: ...DIAMETER OF THE STAKED AREA 5 50 5 80 mm 0 217 0 228 in A drIVe cham wnh a After staking check the staked area of the master c lfrtype master Imk link for cracks must not be used If there is any crack...

Page 77: ...e O 5 bolt nut to the specified torque UPPER ROLLEA TORQUE Upper hott 12 N m 1 2 kgf m 9Ibf ft Lower nut 12 N m 1 2 kgf m 9lbHt Install the drive chain upper roller Green with the flat faci ng out 04...

Page 78: ...ounts for a low reservoir level If the brake pads are not worn and the fluid level is low check the entire system for leaks page 3 26 FRONT BRAKE Turn the handlebar so that the reservoir is level and...

Page 79: ...orn to the bottom of the wear limit groove For brake pad replacement page 15 10 BRAKE SYSTEM Apply grease to the contact faces of the adjuster bolt and piston LEVER POSITION INSPECTION The brake lever...

Page 80: ...w on the front visor CLUTCH SYSTEM 3 28 Measure the clutch free play at the lever end FREE PLAY 10 20 mm 3 8 13 16 in 10 20 mm 3 8 13 16 in I Ii f1t 2 Minor adjustments can be made at the cable end ad...

Page 81: ...cable upper end from the levers It IS nornecessary Thoroughly lubricate t he cable ends with a commer to lubricate the cially available cable lubricant entire cable Apply grease to the clutch cable en...

Page 82: ...THREEBQND 1901 or equivalent to the bolt threads Install the gasket spark arrester assembly and bolts Tighten the bolts to the specified torque TORQUE 6 9 N m 0 7 kgf m 5 1 Ibf ft INSPECTION CLEANING...

Page 83: ...sev eral times Check the entire assembly for signs of leaks dam age or loose fasteners Make sure the fork protectors and dust seals are clean and not packed with mud and dirt Remove any dirt that has...

Page 84: ...age 14 13 SWINGARM SHOCK LINKAGE 3 32 Raise the rear wheel off the ground by placing 8 workstand or equivalent under the engine Check for worn 5wingarm bearings by grabbing the rear swingarm and attem...

Page 85: ...engine Hold the front fork leg and move the front wheel sideways with force to see if the wheel bearings are worn Raise the rear wheel off the ground by placing a workstand or equivalent under the en...

Page 86: ...in U S A SPOKE 3 7 N m 0 38 kgf m 2 7 Ibl ft RIM LOCK 12 N m 11 2 kgf m 9Ibf ft STEERING HEAD BEARINGS 8e sure the control cables do flor inter fere with handlebar rotation 3 34 Raise the front wheel...

Page 87: ...4 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM 4 2 PRESSURE RELIEF VALVE 4 5 SERVICE INFORMATION 4 3 OIL JET 4 6 TROUBLESHOOTING 4 3 OIL PUMP 4 7 OIL STRAINER _ _ 4 4 4 1...

Page 88: ...LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM CAMSHAFT OILPUMP ___ RELIEF Oil PUMP DRIVE COUNTERSHAFT ONE WAY VALVE OIL STRAINER SCREEN 4 2...

Page 89: ...O 7 U S q t O 5 9 m p qt 1 _ At disassembly 0 75 liter 0 79 US qt 0 66 Imp qt Recommended engine oil Pro Honda GN4 4 stroke oil U SA and I Canada or equivalent motor oil Recommended transmission oil A...

Page 90: ...e left crankcase cover page 1 4 Remove the oil strainer screen Check the oil strainer screen for damage or clogs INSTALLATION Install the oil strainer screen to the crankcase Install the left crankcas...

Page 91: ...he left crankcase cover Check the relief valve for damage or clogs INSTALLATION Apply oil to a new O ring and install it onto the relief valve Install the relief valve into the left crankcase cover In...

Page 92: ...he oil jet for damage or clogging Blow open the oil passage in the oil jet with com pressed air INSTALLATION 04 ApplV locking agent to the oil jet threads and tighten it to the specified torque TOROUE...

Page 93: ...es page 12 7 Remove the gasket and dowel pins Remove the oil pump inner outer rotor and shaft Remove the one way valve INSPECTION Check the oil pump driven gear for wear or damage Check the oil pump s...

Page 94: ...Otate it in its grOOllB to be sure It IS fully seated Measure the clearance with the gasket ins ailed 4 8 Temporarily install the oil pump shaft Install the outer and inner rotors into the crankcase M...

Page 95: ...ne way valve onto the left crankcase as shown Install the new gasket and dowel pins Assemble the left and right crankcase page 12 21 I Install the engine to the frame page 7 7 Install the drive pin in...

Page 96: ...MEMO...

Page 97: ...4 TROUBLESHOOTING 5 5 THROTTLE POSITION SENSOR REPLACEMENT 5 26 CARBURETOR ADJUSTMENT 5 6 PILOT SCREW ADJUSTMENT 5 27 AIR CLEANER HOUSING 5 7 HIGH ALTITUDE ADJUSTMENT CARBURETOR REMOVAL 5 11 Californi...

Page 98: ...FUEL SYSTEM COMPONENT LOCATION 3 9 N m 0 4 kgf m 2 9 IbOt Y 13 N m 1 3 kgf m 9 Ibf ft 49 N m 5 0 kgf m 36 IbOt 5 2...

Page 99: ...carbure tor If the vehicle is 10 be stored for more than one month drain the float chamber Fuel left in the float chamber may cause clogged jets resulting in hard starting or poor driveability SPECIF...

Page 100: ...9 N m 0 4 kgf m 2 9 Ibf ft 2 0 N m 0 2 kgf m 1 4 Ibf ft 1 5 N m 0 15 kgf m 1 1 Ibf ft 1 0 N m 0 1 kgf m 0 7 Ibf ft 1 5 N m 0 15 kgf m 1 1 Ibfft 1 5 N m 0 15 kgf m 1 1 Ibf ft 2 0 N m 0 2 kgf m 1 4 Ibf...

Page 101: ...re Afterburn during acceleration Ignition system faulty Lean mixture Accelerator pump faulty Rich mixture Choke valve in the ON position Float valve faulty Float level too high Air jets dogged Air dea...

Page 102: ...6 49 State and Canada type 130 California type 132 JET NEEDLE 04 06 49 State and Canada type NCVT California type NCYU After 06 49 State and Canada type NLAT California type NLBU JET NEEDLE CLIP POSIT...

Page 103: ...MA MN9 Al00 U S A only If the engine runs rich exiting a corner turn the pilot screw clockwise to lean the mixture If the engine runs lean exiting a corner turn the pilot screw counterclockwise to ric...

Page 104: ...ft up the sub frame over 90 to avoid dam aging the wire harness Tighten the sub frame upper mounting bolt to the specified torque TOROUE 30 N m 3 1 kgf m 22 Ibf ft 04 06 49 states Disconnect the breat...

Page 105: ...er housing and seal thoroughly if any sign of inadequate sealing is detected Apply sealmg agent Install the removed parts in the reverse order of all the way around removal the connecting surface of t...

Page 106: ...n and overflow hoses securely Connect the breather hose 04 06 California Install the coliar clamp and bolt type After 06 Clamp the radiator siphon and overflow hoses securely Route the wires and hoses...

Page 107: ...n the air cleaner housing Install the following Battery page 16 6 Muffler page 2 10 Side covers page 2 3 Fuel tank page 2 7 Seat page 2 3 CARBURETOR REMOVAL Lift up the sub frame page 5 7 Remove the s...

Page 108: ...ve from the carburetor Disconnect the hot start cable end from the hot start valve and remove the valve spring Check the hot starter valve for nicks grooves or other damage Check the hoI start valve s...

Page 109: ...l air vent and overflow hoses Remove the bolts clamp top cover and D ring 04 06 Remove the needle holder and jet needle After 06 Remove the jet needle holder assembly 04 06 Check the jet needle for we...

Page 110: ...tor screw lift up the throttle shaft arm and remove the throttle valve assembly Remove the throttle valve plate from the throttle valve Check the throttle valve throttle valve seal and throttle valve...

Page 111: ...tle position sensor is factory pre set and no adjustment is necessary unless the throttle position sensor is replaced For sensor inspection page 17 9 For sensor replacement page 5 26 ACCELERATOR PUMP...

Page 112: ...ver adjusting link lever screw IS factory pre S8t Ad ustment and disassembly are not necessary 5 16 Check the diaphragm for deterioration or pin hole Check the spring for damage or fatigue Check the p...

Page 113: ...the valve seat for wear or damage Replace or clean the parts if necessary Remove the following Main jet Needle jet Baffle plate Starter jet Slow jet Before removing the pilot screw turn it in counting...

Page 114: ...t igue or damage Replace these parts if necessary Blow open all carburetor body openings with com pressed air o CARBURETOR ASSEMBLY 04 06 THAOTILE VALVE SEAL THROTTLE THROTTLE POSITION SENSOR D RING V...

Page 115: ...locking agent to the orx screw threads Tighten the tooe screw to the specified torque TORQUE 3 9 N m 0 4 kgf m 2 9 IbUt Ahar 06 Apply locking agent to a new boll threads Tighten the bolt to the specif...

Page 116: ...0 15 kgf m 1 1 Ibf ft Needle jet 2 0 N m to 2kgf m 1 4 Ibf ft M ain jet 1 5 N m 0 15 kgf m 1 1 Ibf ft Install the float valve float and float pin Check the float level after checking the float valve a...

Page 117: ...a new O ring to the float chamber Install the float chamber to the carburetor Install the hose guides and four float chamber screws Tighten the screws to the specified torque TORQUE 2 0 N m 0 2 kgf m...

Page 118: ...rottle direction of the valve throttle vaNe plate 5 22 Install the throttle valve assembly into the carbure tor with the valve plate facing towards the engine side Make sure the throttle valve moves s...

Page 119: ...pe California type no position 2nd position 04 06 Install the jet needle and jet needle holder into the thronle valve Tighten the needle holder to the specified torque TORQUE 2 0 N m 0 2 kgf m 1 4 Ibf...

Page 120: ...onnect the overflow air vent and fuel hoses proper ylpage 23 CARBURETOR INSTALLATION 5 24 Connect the throttle cables to the throttle drum Set the cables into the carburetor body grooves as shown Tigh...

Page 121: ...sor 3P connector Install the wire band Perform the fo llowing inspections and adjustments Throttle operation page 3 8 Hot start lever page 3 9 Install the shock absorber upper mounting bolt and nut Ti...

Page 122: ...rx screw threads and loosely install the screw Apply locking agent to a new bolt threads and loosely install the bolt Measure the resistance between the Blue and Black wire terminals of the sensor sid...

Page 123: ...rately indicate a 50 rpm change Damage to the pilot 1 Turn the pilot screw clockwise until it seats screw seat will lightly then back it out the specified number of occur if the pilot turns screw is t...

Page 124: ...uum pump to the PAIR control valve vacuum hose joint 5 Apply the specified vacuum to the PAIR control valve vacuum hose more than 56 kPa 420 mmHg VACUU HOSE 6 Start the engine and adjust the idle spee...

Page 125: ...power will decrease about 3 5 for each 1 OOO foot 300 meter increase in altitude The effect of alti tude on horsepower will be greater than this if no carburetor modification is made This engine when...

Page 126: ...tor may cause the engine overheat resulting in seri ous engine damage and increased exhaust emissions For use at low altitudes you should return the car E buretor to original factory specifications R...

Page 127: ...e If the air is not drawn in check the air suction hose for clogs With the engine running gradually apply vacuum to the PAIR control valve vacuum hose Check that the air suction hose stops drawing air...

Page 128: ...at is cracked deteriorated or damage or if there is clear ance between the reed and seat Installation is in the reverse order of removal AIR SUPPLY PIPE REMOVALI INSTALLATION Remove the right radiator...

Page 129: ...D ring with engine oil and install it onto the air supply pipe Connect the air supply hose to the pipe Install the air supply pipe and tighten the bolt to the specified torque TORQUE 9 8 N m 1 0 kgf m...

Page 130: ...MEMO...

Page 131: ...SYSTEM flOW PATIERN 6 2 SERVICE INFORMATION 6 3 TROUBLESHOOTING 6 4 SYSTEM TESTING 6 5 6 COOLING SYSTEM COOLANT REPLACEMENT 6 6 RADIATOR 6 8 RADIATOR RESERVE TANK 6 9 WATER PUMP 6 10 6 1...

Page 132: ...COOLING SYSTEM SYSTEM FLOW PATTERN RADIATORS RAIDIA TO HOSE OVIERFI OW HOSE RADIATOR CAP 1 SIPHON HOSE RESERVE TANK CONNloCTING HOSES RAD ATC R HOSE WATER PUMP 6 2...

Page 133: ...m services can be done with the engine in the frame Avoid spilling coolant on painted surfaces After servicing the system check for leaks with a cooling system tester SPECIFICATIONS II TE M 07 S PECIF...

Page 134: ...t_ _ V _ _ _ble in U S _ _ A_ _____ ___ Driver 07749 0010000 TROUBLESHOOTING Engine temperature too high Faulty radiator cap Insufficient coolant Anachment 28 x 30 mm 07946 1870100 Passage blocked in...

Page 135: ...sure the engine is cool remove the radiator r 1 1 cap Test the coolant specific gravity using a hydrome ter STANDARD COOLANT CONCENTRATION 1 1 Look for contamination and replace the coolant if necessa...

Page 136: ...6 seconds COOLANT REPLACEMENT PREPARATION 6 6 If any coolant gets in your eyes rinse them with water and consult a doctor immediately If any coolant in swallowed induce vomiting gargle and consult a p...

Page 137: ...ose from the radiator Drain the reserve tank coolant Empty the coolant and rinse the inside of the reserve tank with water Reinstall the radiator siphon hose Fill the system with the recommended coola...

Page 138: ...level if necessary Reinstall the radiator cap 4 Check the level of coolant in the reserve tank and fill to the upper level line if it is low RADIATOR REMOVAL Drain the coolant page 6 7 Remove the radi...

Page 139: ...bleed the air page 6 7 After installation check the radiator and radiator hoses for leaks RADIATOR RESERVE TANK REMOVAL INSTALLATION Drain the coolant page 6 7 Remove the left side cover page 2 3 Dis...

Page 140: ...p must be replaced as an assembly REMOVAL Drain the coolant page 6 7 Loosen the hose band screw and disconnect the water hose Remove the drain bolt and sealing washer Remove the three bolts and water...

Page 141: ...ter pump shaft bearing with your finger The bearing should turn smoothly and quietly Also check that the bearing outer race fits tightly in the right crankcase caver Replace the water pump shaft beari...

Page 142: ...A 07741 0010201 07936 1660110 not available in U S A 07936 1660120 not available in U S A Bearing remover 12 mm 07936 166010A Remover handle 07936 3710100 Remover weight 07936 3710200 or 07936 371020...

Page 143: ...l as shown TOOL Water seal driver 0794S KA30000 o r 07965 41S000A U S A only Drive in a new bearing into the right crankcase cover using the special tools as shown TOOLS Driver Attachment 28 x 30 mm P...

Page 144: ...ORQUE 12 N m 1 2 kgf m 9 Ibf ft Install the right crankcase cover page 10 6 Install a new O ring onto water pump cover Install the dowel pin Install the water pump cover and tighten the bolts Tighten...

Page 145: ...7 ENGINE REMOVAL INSTALLATION COMPONENT LOCATION 7 2 ENGINE REMOVAL 7 5 SERVICE INFORMATION 7 3 ENGINE INSTALLATION 7 7 DRIVE SPROCKET 7 4 7 1...

Page 146: ...N 04 3 9 N m 0 4 kgf m 2 9Ibf ft 26 N m 2 7 kgf m 20 Ibf ft After 04 34 N m 3 5 kgf m 25 Ibf ftl 54 N m 5 5 kgf m 40Ibf ft 38 N m 3 9 kgf m 28 Ibf ft 7 2 88 N m 9 0 65Ibf ft 54 N m 5 5 kgf m 40 Ibf ft...

Page 147: ...onda GN4 4 stroke oil U S A and Canada or equivalent motor oil API service classification SG or Higher Engine oil capacity At draining At filter change At disassembly Transmission oil capacity At drai...

Page 148: ...ster lock nuts and turn the adjusting bolts clockwise fully Remove the bolts clamp sprocket cover and spacer Shift the transmission into except neutral position Remove the sprocket bolt thrust washer...

Page 149: ...age 5 11 Drive sprocket page 7 4 Kickstarter pedal page 10 5 Gearshift pedal page 10 25 Brake pedal page 15 24 04 06 Califorma Remove the PAIR control valve page 5 31 type Ahar 06_ Remove the direct i...

Page 150: ...ove the bolls nuts engine hanger plates and washer Loosen the swingarm pivot nut Loosen the engine front and lower mounting nuts Remove the swingarm pivot nut washer and bolt Remove the engine front a...

Page 151: ...properly page 1 23 Do not tighten the 5wingarm pivot nut and engine mounting nuts yet Each engine hanger plates have an identification mark l is for the left side and W is for right side Install the h...

Page 152: ...tor insulator band r Install the crankcase breather hose to the clamp Connect the upper radiator hose and tighten the band screw securely Connect the clutch cable into the clutch lifter lever Install...

Page 153: ...nia Install the PAIR control valve page 5 31 type After 06 Fill the system with the recommended coolant and bleed the air page 6 7 fill the engine with the recommended engine oil page 3 17 Fill the tr...

Page 154: ...MEMO t...

Page 155: ...IDE REPLACEMENT 8 19 CYLINDER COMPRESSION TEST 8 6 VALVE SEAT INSPECTION REFACING 8 19 CYLINDER HEAD COVER REMOVAL 8 6 CYLINDER HEAD ASSEMBLy 8 23 CAMSHAFT ROCKER ARM REMOVAL 8 7 CYLINDER HEAD INSTALL...

Page 156: ...CYLINDER HEADIVALVES COMPONENT LOCATION 04 06 California type After 06 _ 8 2 9 8 N m 1 0 kgf m 7 bf ft o 04 06 California type After 06 16 N m 1 6 kgf m 12Ibf ft t...

Page 157: ...nder head cover and cylinder head SPECIFICATIONS F inder compression ITEM valve guide stem height I TORQUE VALUES i Ii 0 0 49 Canada California Cylinder head cover boh Camshaft holder mounting bolt Cy...

Page 158: ...45Q IN 07780 0010800 or equivalent commercially avail able in U S A Flat cutter 28 mm 3r EX 07780 0012100 or equivalent commercially avail able in U S A Cutter holder 5 0 mm 07781 0010400 or equivalen...

Page 159: ...ve adjustment Burned or bent valves Incorrect valve timing Broken valve spring Uneven valve seating Cylinder head Leaking or damaged cylinder head gasket Warped or cracked cylinder head loose spark pl...

Page 160: ...eading is usually reached not leak within 4 7 seconds COMPRESSION 392 kPa 4 0 kg cm2 57 psi at 800 rpm Low compression can be caused by Improper valve adjustment Valve leakage Blown cylinder head gask...

Page 161: ...bolt but do not remove it yet Remove the crankshaft hole cap and O ring Turn the crankshaft clockwise to align the punch mark with the index mark on the right crankcase cover Make sure the piston is...

Page 162: ...001A100 U S A onlv A tool can easily be made from a thin 1 mm thick piece of steel as shown 9 07 1 mm m 0 12mm 0 5 in 3 5 m O r i m in 8 5mm 0 33 in Loosen the camshaft holder bolts in a crisscross i...

Page 163: ...locations Remove the shims Be careful not to let the shims fall into the left crankcase Make all shims to ensure correct reassembly in their original locations ROCKER ARM CYLINDER HEADIVALVES Remove t...

Page 164: ...ct the rocker arm oil passage for clog Measure the rocker arm 1 0 SERVICE LIMIT 12 07 mm 0 475 in Inspect the rocker arm shaft fo r wear or damage Measure the rocker arm shaft 0 0 SERVICE LIMIT 11 93...

Page 165: ...tion replace if necessary Turn the outer race of each bearing with your finger The bea ring should turn smoothly and quietly Also check that the bearing inner races fit tightly in the camshaft Replac...

Page 166: ...topper plate by aligning the tab of the stopper plate with the hole of the camshaft as shown l oosely install the stopper plate bolt CYLINDER HEAD REMOVAL Remove the following Spark plug page3 1j Exha...

Page 167: ...washers fall into the left crankcase Remove the engine hanger plate bolts nuts plates and washer Remove the cylinder head mounting bolts Loosen the cylinder mounting bolt Loosen the cylinder head nuts...

Page 168: ...er head page 8 12 Remove the left crankcase cover page 11 4 Remove the flywheel page 11 5 Remove the cam chain guide Remove the bolt cam chain lensioner collar and washer INSPECTION Inspect the cam ch...

Page 169: ...h the groov8 in the crankcase and the tab with the groove in the cylinder Install the following Flywheel page 11 6 l eft crankcase cover page 1 7 Cylinder head page 8 25 CYLINDER HEAD DISASSEMBLY Remo...

Page 170: ...the valve spring cotters using the special tension do not tools compress the valve springs more than TOOLS necessary to Valve spring compressor remove the cotters Compressor attachment Mark all parts...

Page 171: ...t edge and feeler gauge SERVICE LIMIT 0 05 mm O 002 in Check the valve lifter bore for scoring scratches or damage Measure each valve lifter bore 1 0 SERVICE LIMIT 22 54 mm 0 887 in VALVE SPRING Check...

Page 172: ...07984 MA6000D U S A only Measure and record each valve guide 1 0 using a ball gauge or inside micrometer SERVICE LIMITS IN EX 5 052 mm 0 1989 in Subtract each valve stem 0 0 from the correspond ing gu...

Page 173: ...ve the guides from the freeler Drive in the guides until the marks are parallel with the cylinder head Check that the valve guides are at the proper depth adjust the height if necessary SPECIFIED DEPT...

Page 174: ...alve seat page 8 20 Inspect the valve seat face for Uneven seat width Replace the valve and refaee the valve seat Damaged face Replace the valve and refaee the valve seat The valves cannOI Contact are...

Page 175: ...eat cutter 27 5 mm 07780 0010200 Seat cutter 33 mm 07780 0010800 Cutter holder 5 0 mm 07781 0010400 or equivalent commercially available in U S A Use a 32 flat cutter remove 1 4 of the existing valve...

Page 176: ...ping will dam age this coating Use the intake valve as a new one EXHAUST SIDE After cutting the exhaust seats apply lapping com pound to the exhaust valve face and lap the exhaust valve using light pr...

Page 177: ...bricate the valve stem and stem end sliding sur face with molybdenum oil solution Insert the valves into the guide while turning it slowly to avoid damage to the stem seal Install the valve springs wi...

Page 178: ...nor Valve spring compressor compress rhe valve attachment SpflngS more than necesS8ry 07757 0010000 07JME KY20100 Support tile Tap the valve stems gently with two plastic ham cylinder head so mers as...

Page 179: ...head nul seating surface Install the cylinder head onto the cylinder Be careful nOl T Olet Install the washers and cylinder head nuts the nuts and Tighten the nuts In a crisscross pattern in two or wa...

Page 180: ...m 20 Ibfo ft 34 N m 3 5 kgf m 25 Ibl ttl 04 06 California Connect the vacuum hose to the boost joint type Aftet 08 Connect the radiator hose and tighten the band screw securely 04 06 Califorma Instal...

Page 181: ...l to the O ring and install it onto rocker arm shaft cap Apply grease to the rocker arm shaft cap threads Install the rocker arm shaft cap and tighten to the specified torque TORQUE 5 9 N m 0 6 kgf m...

Page 182: ...older cam lobes facing up matmg surfaces Align the index line of the cam sprocket with the cyl and In the holder inder head surface bolt holes INDEX MARK PUNCH MARK Check the set ring for damage Apply...

Page 183: ...hreads Install the camshaft holder bolts Tighten the bolts to the specified torque in a criss cross pattern in two or three steps TORQUE 16 N m 1 1 6 kgf m 12 1bf ftJ Remove the special tool from the...

Page 184: ...it to the specified torque TORQUE 15 N m 11 5 kgf m l Ibf ft Install the cylinder head cover page 8 30 CYLINDER HEAD COVER INSTALLATION 8 30 Check the plug hole seal is in good condition replace if n...

Page 185: ...and t ighten the bolts to the specified torque TORQUE 9 8 N m 1 0 kgf m 7 IbUt Connect the cylinder head breather hose Install the direct ignition coil Install the fuel tank page 2 7 CYLINDER HEADIVA...

Page 186: ...MEMO...

Page 187: ...INDER PISTON COMPONENT LOCATION 9 2 PISTON REMOVAL 9 4 SERVICE INFORMATION 9 3 CYLINDER PISTON INSPECTION 9 5 TROUBLESHOOTING 9 3 PISTON INSTALLATION 9 8 CYLINDER REMOVAL 9 4 CYLINDER INSTALLATION 9 8...

Page 188: ...CYLINDER PISTON COMPONENT LOCATION 9 2...

Page 189: ...BLESHOOTING 0 065 O lOa 0 0026 0 0039 0 115 O 0045 Engine top end problems usually affect engine performance These problems can be diagnosed by a compression test or by tracing engine noise to the top...

Page 190: ...an shop Remove the piston pin clips with pliers towel over the crankcase to prevent the clips from fallmg the cran ccase PiS ton rings are easily broken take care not to damage them during removal 9 4...

Page 191: ...O D page 9 6 SERVICE LIMIT 0 085 mm 0 0033 in CYLINDER PISTON Calculate the taper and out ot round at three levels in the X and Y axes Take the maximum reading to determine the cylinder condition SER...

Page 192: ...e service limit or nearly 15 0 hours of running time have elapsed replace the pis ton with a new one Calculate the piston la cylinder clearance SERVICE LIMIT 0 085 mm 0 0033 in Measure the piston pin...

Page 193: ...oves with the marked Do not damage the piston ring by spreading the ends too far side facmg up Be careful not to damage the piston during pis ton ring installation Do not align the oil ring side rails...

Page 194: ...ston pin outer surface and piston pin hole of the piston Install the piston with the IN mark facing intake side Be careful no to Install the piston pin and new piston pin dips drop the piston pin clip...

Page 195: ...gasket cam chain tensioner lifter and bolts Tighten the cam chain tensioner lifter mounting bolts securely Install the cylinder head page 8 25 After tightening the cylinder head mounting nut tighten t...

Page 196: ...MEMO...

Page 197: ...ER CLUTCH KICKSTARTER GEARSHIFT LINKAGE COMPONENT LOCAnON 10 2 CLUTCH 10 7 SERVICE INFORMATION 10 3 KICKSTARTER 10 15 TROUBLESHOOTING 10 4 STARTER CLUTCH 10 19 RIGHT CRANKCASE COVER 10 5 GEARSHIFT LIN...

Page 198: ...CLUTCH STARTER CLUTCH KICKSTARTER GEARSHIFT LINKAGE COMPONENT LOCATION 22 N m 2 2 kgf m 16Ibf ft 12 N m 1 2kgf m 9lbHt I 38 N m 3 9 kgf m 281bf ft 10 2 kgf m 9 Ibf ft J 12 N m 11 2 kg m 9Ib h...

Page 199: ...0810 115 0 1211 _ 1 _ 1 3 0810 115 0 1211 gear TORQUE VALUES Clutch center lock nut Clutch spring bolt Gearshift drum center pin Gearshift drum stopper arm bolt Starter gear holder mounting boll Kicks...

Page 200: ...n shift arm return spring loose stopper plate bolt Bent shift fork shaft Damaged shift drum cam groove Damaged or bent shift fork Worn gear engagement dogs or slot Gearshift pedal will not return Weak...

Page 201: ...arter pedal bolt and kickstarter pedal Loosen the band screw and disconnect the radiator hose from the water pump cover Loosen the right crankcase cover bolts in a criss t iii cross pattern in two or...

Page 202: ...e cover bolts in a criss cross pattern in two or three steps Connect the radiator hose to the water pump cover and tighten the band screw securely Install the kickstarter pedal and bolt Tighten the ki...

Page 203: ...the five clutch spring bolts in a crisscross pattern in two or three steps Remove the clutch springs Remove the clutch pressure plate Remove the clutch fifter assembly and clutch tifter rod Remove the...

Page 204: ...h center holder 07724 0050001 or 01724 0050002 or equivalent com mercially avail able in U S A Remove the lock washer and thrust washer Remove the clutch center Remove the thrust washer and clutch out...

Page 205: ...lay Clutch springs should be replaced as a sa f one or more IS less rhe servrce l m 1 Disconnect the clutch cable from the dutch lifter lever Remove the clutch lifter lever from the left crank case IN...

Page 206: ...the friction spring to be pressed unevenly A damaged friction spring also causes the weak contact between the discs and plates or uneven disclplate contact CLUTCH CENTER Check the clutch center for ni...

Page 207: ...OUTER GUIDE Check the needle bearing for wear or damage Check the mainshaft for wear or damage at the slid ing surface of the clutch outer guide Check the clutch outer guide for abnormal wear or damag...

Page 208: ...ClUTCH UFTER ASSEMBLY 12 N m 1 2 kgf m 9Ibf ft SPRING PRESSURE PLATE 04 06 Install the clutch lifter lever into the left crankcase r Install the clutch lifter lever stay and tighten the bolt Connect t...

Page 209: ...hten the clutch cable nut securely Apply transmission oil to the needle bearing Apply molybdenum oil solution to the clutch outer guide sliding surface Install the clutch outer guide and needle bearin...

Page 210: ...r equivalent com mercially avail able in U S A TORQUE 80 N m 8 2 kgf m 59 Ibf tt Bend the tab of the lock washer up against clutch center lock nut Coat the dutch plates and discs with clean transmis s...

Page 211: ...ts in a crisscross pattern in two or three steps TORQUE S S N m 0 9 kgf m 6 5 Ibf ft Install the brake pedal page 15 25 Adjust the clutch lever free play page 3 28 Fill the cooling system with the rec...

Page 212: ...for wear or damage Check the kickstarter pinion for wear or damage Check the kickstarter spindle for bend wear or dam age Measure the kickstarter pinion gear 1 0 SERVICE LIMIT 16 55 mm 0 652 in Measur...

Page 213: ...DLE RETURN PRING Apply molybdenum oil solution to the kickstarter spindle spline and gear rolling area Install the thrust washer into the kickstarter spindle Install the pinion gear and thrust washer...

Page 214: ...INSTALLATION Install the ratchet spring Apply transmission oil to the kickstarter spindle journal Be sure the spong Install the kickstarter assembly to the crankcase and seal did not falloff rotate th...

Page 215: ...nstall the right crankcase cover page 10 6 STARTER CLUTCH REMOVAL Remove the following Right crankcase cover page 10 5 Clutch page 10 7 loosen the water pump drive gear nut using the special tool TOOL...

Page 216: ...Remove the dowel pin DISASSEMBLY INSPECTION Check that the starter driven gear turns clockwise smoothly and does not turn counterclockwise Remove the driven gear and needle bearing from starter clutc...

Page 217: ...en gear boss 1 0 SERVICE LIMIT 35 07 mm 11 381 in Measure the driven gear boss 0 0 SERVICE LIMIT 45 64 mm 1 797 in Check the one way clutch sprag for abnormal wear or damage Check the starter clutch o...

Page 218: ...ce for wear or damage Measure the starter gear holder shaft 0 0 SERVICE LIMIT 11 98 mm 0 472 in ASSEMBLY Apply molybdenum oil solution to the starter gear holder rolling surfaces Install the starter r...

Page 219: ...LLATION Install the dowel pin Install the starter gear holder assembly and socket bolt Tighten the bolts to the specified torque TORQUE 22 N m 2 2 kgf m 16Ibf ft Install the starter clutch while align...

Page 220: ...iversal holder 07725 030000 TORQUE 108 N m 11 0 kgf m 80 IbUt Install the collar onto the balancer shaft Install the water pump drive gear while aligning its wide cut out in the splines with the punch...

Page 221: ...dal disassembling the gearshift pedal mark the pedal position to ensure correct reassembly In its original locatJon Remove the gearshift spindle assembly and washer from the crankcase Remove the shift...

Page 222: ...wls Plungers Springs Clean the ratchet pawls plungers springs and drum shifter with clean transmission oil Check each part for wear or damage Assemble the drum shifter springs plungers and ratchet paw...

Page 223: ...the drum center in a position other than neutral While holding the ratchet pawls in place in the guide plate and drum shifter Install the drum shifter assembly by aligning the hole of the drum shifter...

Page 224: ...original position as marked during removal Tighten the bolt to the specified torque TORQUE 12 N m 1 2 kgf m 9 Ibf tt Move the gearshift pedal and check the shift mecha nism for smooth operation Instal...

Page 225: ...11 ALTERNATOR COMPONENT LOCATION 2 STATOR 5 SERVICE INFORMATION 3 FLyWHEEL 5 LEFT CRANKCASE COVER REMOVAL 4 LEFT CRANKCASE COVER INSTALLATION 7 11 1...

Page 226: ...ALTERNATOR COMPONENT LOCATION 5 2 N m 0 53 kgf m 3 8Ibf ft 2 5 N m 0 26 kgf m 1 91bf ft 11 2 0 lL __ 12 N m 1 2 kgf m 91bHt 64 N m 6 5 kgf m 47 Ibf ft...

Page 227: ...cap Ignition pulse generator mounting bolt Stator mounting screw TOOLS Flywheel holder 070MB KAN0100 or 07AMB KRNA100 U S A only 64 N m 6 5 kgf m 47 Ibf ft 5 9 N m 0 6 kgf m 4 3Ibf ft 5 2 N m 0 53 kg...

Page 228: ...Gearshift pedal page 10 25 Drain the engine oil page 3 17 Remove the wire band Disconnect the alternator 4P Black connector and ignition pulse generator 2P Black connector loosen the bolts in a criss...

Page 229: ...tion pulse generator mounting bolt and stator mounting screw threads Install the wire clamp and tighten the ignition pulse generator mounting bolts and stator mounting screws to the specified torque T...

Page 230: ...e crank shaft Install the flywheel to the crankshaft by aligning the groove in the flywheel with the woodruff key Apply oil to the flywheel nut threads and seating surface Install the washer and nut H...

Page 231: ...e left crankcase cover bolts in a crisscross panern in two or three steps Connect the ignition pulse generator 2P Black con nector and alternator 4P Black connector Clamp the wire with the band Instal...

Page 232: ...MEMO...

Page 233: ...SHAFT REMOVAL 12 12 SERVICE INFORMATION 12 3 CRANKCASE BEARING REPLACEMENT 12 13 TROUBLESHOOTING 12 5 CRANKSHAFT INSTALLATION _ 12 18 BALANCER GEAR BALANCER 12 6 TRANSMISSION ASSEMBLy 12 19 CRANKCASE...

Page 234: ...8 N m 1 0 After 06 2 1 N m 0 2 kgf m 1 5Ibf ft 12 2 9 8 N m 1 kgf m 7Ibf ft 9 8 1 0 kgf m 7Ibf ft 04 06 __ 12 N m 1 2 kgf m 9Ibf ft 1 li After 06 20 N m 2 0 kgf m 14Ibf ft 04 06 22 N m 2 2 kgf m 16 I...

Page 235: ...the frame for this service The following parts must be removed before separating the crankcase Balancer page 12 6 Clutch page 10 7 Staterclutch page 10 19 Kickstarter page 10 15 Gearshift linkage pag...

Page 236: ...Ibf ft 12 N m 1 2 kgf m 9 Ibf ft 22 N m 2 2 kgf m 16 Ibf tt 16 N m 1 6 kgf m 121bf ft 2 1 N m 0 2 kgf m 1 5Ibf ft Bearing remover 20 mm 07936 3710600 Driver 07749 010000 Attachment 37 x 40 mm 07746 00...

Page 237: ...lancer installation Worn seized or chipped transmission gear Worn or damaged transmission bearing Transmission jumps out of gear Worn gear dogs Worn gear shifter groove Bent shift fork shaft Broken sh...

Page 238: ...s Turn the balancer shaft so it does not interfere with the crankcase as shown and remove it INSPECTION Check the balancer shaft for wear damage or exces sive scratches Check the balancer shaft gear f...

Page 239: ...splines with the punch mark on the balancer shaft Align the punch mark of the driven gear with the punch mark of the drive gear by turning the bal ancer shaft Install the following Flywheel page 1 6 S...

Page 240: ...transmission oil drain bolt and washer Loosen the crankcase bolts in a crisscross pattern in two or three steps Remove the crankcase bolts and stay After 06 Remove the transmission oil drain bolt and...

Page 241: ...ssary to replace with a new one Blow open passage in the orifice with compressed air TRANSMISSION DISASSEMBLY Separate the crankcase halves page 12 7 Temporarily install the right crankcase Place the...

Page 242: ...07 mm 0 790 in 21 07 mm 11 066 in 25 07 mm 0 987 in C1 C2 C3 BUSHING Check the bushings for damage or excessive wear Measure the 0 0 of each bushing SERVICE LlMITS M4 M5 22 96 mm 0 904 in C1 19 95 mm...

Page 243: ...the shift fork shaft 0 0 SERVICE LIMITS Center 10 97 mm 0 432 in Right and left 11 95 mm 0 410 in SHIFT DRUM Inspect the shift drum for scoring scratches or evi dence of insufficient lubrication Chec...

Page 244: ...Set the dial indicator on the main journal Rotate the crankshaft two revolutions 720Q and read the runout SERVICE LlMITS l 0 05 mm 0 002 inl R 0 03 mm 0 001 in Measure the connecting rod big end radi...

Page 245: ...17 x 35 x 10 OIL SEAL 04 06 39 56 x 7 After 06 39 x 56 7 5 RIGHT MAINSHAFT BEARING 22 47 x 14 RIGHT CRANKCASE LEFT CRANKCASE BEARING 20 32 14 Oil SEAL 20 33 5 Oil SEAL 38 x 52 7 CRANKSHAFT BEARING lE...

Page 246: ...0 12 14 Attachment 52 x 55 mm Right crankshaft bearing Driver Attachment 62 x 68 mm Pilot 30 mm 07749 0010000 07746 0010500 07746 0040700 Clean and apply a locking agent to the set plate torx screws N...

Page 247: ...al to the specified depth below the crankcase surface as shown TRANSMISSION BALANCER SHIFT DRUM BEARINGS LEFT CRANKCASE Remove the countershaft oil sea and balancer shaft oil seal Remove the screws an...

Page 248: ...n the new Drive new bearings into the left crankcase using the bearings squarely special tools with the markmg side facmg toward TOOLS the mSlde of the Countershaft bearing crankcase 04 06 12 16 Drive...

Page 249: ...tighten the screws to the specified torque TORQUE 9 8 N m 1 0 kgf m 7 Ibf ft Apply grease to the countershaft and balancer shaft oil seal lips Install the oil seals to the crankcase until it is flush...

Page 250: ...07746 0041000 07749 0010000 07746 0010100 07746 0040400 Clean and apply a locking agent to the set plate socket bolts Install the bolts with the set plates and tighten the bolts to the specified torq...

Page 251: ...sion oil to the gear teeth of the each gears Assemble the mainshaft and countershaft MAINSHAFT Ml 13T MAINSHAFT M3 21T M4 BUSHING THRUST WASHER SNAP RING SPLINE WASHER M2 16T COUNTERSHAFT SPLINE WASHE...

Page 252: ...assembly into the right crankcase Each shift fork has an identification mark Rn is for the right shift fork l is the left shift fork and C is for the center shift fork Face the shift fork marks to the...

Page 253: ...0 2 kgf m 1 5 Ibf ft Temporarily install the left crankcase Place the left crankcase facing down and separate the left and right crankcase halves Install the oil pump inner outer rotor and shaft in th...

Page 254: ...hree progressive steps Carefully trim the protruding gasket material from the cylinder base gasket surface NOTE Do not let gasket material fall into the crankcase Do not damage the base gasket surface...

Page 255: ...13 FRONT WHEEL SUSPENSION STEERING COMPONENT LOCATION 13 2 SERVICE INFORMATION 13 3 TROUBLESHOOTING 13 6 FRONT WHEEL 13 7 FORK 13 12 HANDLEBAR 13 31 STEERING STEM 13 37 13 1...

Page 256: ...LOCATION 108 N m 11 0 kgf m 80 Ibf ft k 23 N m 12 3 kgf m 17 Ib hl i i G D 6 9 N m 0 7 kgf m 5 1Ibf ft 13 2 1F I 21 N m 2 1 kgf m 151bf h 20 N m 2 0 kgf m 14Ibf ft 88 N m 9 0 kgf m 65 Ibf tt 30 N m 3...

Page 257: ...The lock nut wrench increases the torque wrench s leverage so the torque wrench reading will be less than the torque actually applied to the fork damper The specification given on this page is actual...

Page 258: ...0 kgf m 14 Ibf ft 88 N m 9 0 kgf m 65 IbUt 16 N m 1 6 kgf m 12 IbHt 3 7 N m 0 38 kgf m 2 7 Ibf ft 12 N m 1 2 kgf m 9Ibf ft 22 N m 2 2 kgf m 16 Ibf ft 44 N m 4 5 kgf m 33 Ibf ft 9 8 N m 1 0 kgf m 7 Ibf...

Page 259: ...nstaller shaft 07VMF KZ3020Q FRONT WHEEL SUSPENSION STEERING Driver 07749 0010000 Pilot 20 mm 07746 0040500 Piston base 07958 2500001 l ock nut wrench 50 mm 07WMA KZ30100 Attachment 30 mm 1 0 07746 00...

Page 260: ...sted right and left fork legs Front wheel wobbling Bent rim Worn front wheel bearings Bent spokes Faulty tire Axle not tightened properly Unbalanced tire and wheel Wheel hard to turn FaUlty wheel bear...

Page 261: ...emove the axle nut and loosen the leh axle holder boils Loosen the lock nut and disconnect the tripmeter cable loosen the right axle holder bolts Remove the axle and front wheel INSPECTION AXLE Set th...

Page 262: ...quietly or if they fit loosely in the hub WHEEL RIM WHEEL BEARING Check the rim runout by placing the wheelan a 13 8 turning stand Spin the wheel by hand and read the runout using a dial indicator Ac...

Page 263: ...stall old bearings once the bearings have been removed they must be replaced with new ones Replace the bearings in pairs ASSEMBLY 16 N m lo6 kgf m 12Ibf ft TAIPMETER GEAR BOX RIGHT WHEEL BEARING DISTA...

Page 264: ...fied torque TORQUE 12 N m 11 2 kgf m 9Ibf ft Pack all bearing cavities with grease Drive the left wheel bearing in the wheel hub until it is fully seated using special tools Install the wheel bearings...

Page 265: ...aligning its tabs of the gear box with the grooves on the wheel INSTALLATION Clean the clamping surface of the axle and axle holders Install the front wheel between the fork legs while inserting the...

Page 266: ...Ibf ft Connect the tripmeter cable and tighten the lock nut securely Install the brake disc cover and bolts Tighten the bolts to the specified torque TORQUE 13 N m 1 3 kgf m 9Ibf ft REMOVAL Remove the...

Page 267: ...kwise to the softest position to prevent damaging the adjust ment needle be sure to record the number of turns from the starting position Do nor use a loosen the fork damper using the special tool bul...

Page 268: ...tween the axle holder and outer tube and record it before disassembling the fork Hold the outer tube and remove the fork damper from the outer tube using the special tool TOOL l ock nut wrench 50 mm 0...

Page 269: ...opper tool between the axle holder and lock nut TOOL Piston base Fork rod stopper 07958 2500001 or 07AMB KZ3A100 U S A only CFI TFRBOLT Make the mechanic s stopper tool from a thin piece of steel 1 0...

Page 270: ...ssembly from the fork assembly Remove the fork assembly from the vise Remove the fork spring from the fork assembly OUTER TUBE AND SLIDER DISASSEMBLV Be careful nor to Remove the dust seal and stopper...

Page 271: ...ck nUllS removed the piston rod will fall into the fork Dust seal FORK DAMPER DISASSEMBLY Set the fork damper in a vise with a piece of wood or soft jaws to avoid damage Hold the fork damper assembly...

Page 272: ...cessary Apply fork oil to the new O rings and install it FORK CENTER BOLT Check the fork center bolt for damage Check the adjuster rod for stepped wear or damage Check the rebound adjuster for clicks...

Page 273: ...LIMIT 04 05 488 mm 19 2 in After 05 493 mm 19 4 in BUSHING BACK UP RING Check the bushing for excessive wear or scratches If copper appears on the surface replace the bush ing Replace the back up ring...

Page 274: ...the oil seal and dust seal lips with fork oil Install the dust seal and stopper ring onto the slider DUST SEAL Install the oil seal onto the slider with its marked side facing the dust seal Remove th...

Page 275: ...e using the special tool Drive the oil seal into the outer tube using the spe cial tool TOOLS Fork seal driver 47 mm 07VMD KZ30100 or 07VMD KZ3010A U S A onIV FORK SEAL DRIVER Oil SEAL J K UPRI NG GUI...

Page 276: ...ts maximum length Adjust the oil level of the fork damper as shown OIL lEVEL 42 47 mm 1 65 1 85 in 88 careful not fO Apply fork oil to the bushing and new O rings on the damage the fork fork cap assem...

Page 277: ...od 100 mm 3 9 in slowly several times Turn the lock nut clockwise until it is lightly seated NOTE Make sure the rebound adjuster and compres sion adjuster are softest position Check the fork damper pi...

Page 278: ...to the specified torque TORQUE 1 3 N m 0 13 kgf m O 9IbHt FORK DAMPER OPERATION INSPECTION SPRING CHAMBER SPRING CHAMBER OIL HOLE PLUG BOLT SPFIING CHAMBER Turn the compression adjuster counterclockwi...

Page 279: ...chamber or piston rod replace the fork damper assembly Hold the fork damper on level ground and release the fork damper piston rod then check that the pis ton rod extends to its maximum length FORK DA...

Page 280: ...ft in the fork with damper and spring Turn the lock nut SO the length from the rod end is specified STANDARD 11 13 mm 0 4 0 5 in Wipe the oil completely off from the fork damper FORK DAMPER INSTAllATI...

Page 281: ...ngth of the lock nut and piston rod end again STANDARD 11 13mm O 4 0 5 in Instal the push rod into the piston rod until it stops Install the fork center bolt to the fork damper piston rod by aligning...

Page 282: ...be same length STANDARD 317 2 mm 112 5 0 1 inl If the length at assembly is longer than at disassem bly check the center bolt and lock nut installation OIL CAPACITY ADJUSTMENT o c o Remove the fork da...

Page 283: ...pecial tool TOOL Lock nut wrench 50 mm 07WMA KZ30100 TORQUE Actual 34 N m 3 5 kgf m 25 fbf ftl Indicat ed 31 N m 3 2 kgf m 23 Ibf ft STANDARD POSITION loosen the bottom bridge pinch bolts For ease whe...

Page 284: ...outer tube Install the wear rings with their end gaps facing rearward Clean and apply a locking agent to the fork protector mounting boll threads Install the fork protector and tighten the mounting bo...

Page 285: ...visor page 2 5 Remove the handlebar pad from the handlebar Disconnect the fuel cap breather hose from the stem nut Remove the wire bands Remove the screw and engine stop button Remove the bolts and cl...

Page 286: ...n assembly as fol lows Loosen the throttle housing bolts turn the handle bar to the right fully then remove the throWe hous ing If you will disassemble the throttle housing remove the dust cover and b...

Page 287: ...older standard position as shown FORWARD LOWER HOLDER By turning the lower holder 180 degrees you can install it 6 mm 0 24 in rearward of the standard 180DEGREES r STANDARD position By installing the...

Page 288: ...the sliding surface of the throttle pipe Install the throttle housing aligning the end of the housing with the paint mark on the handlebar Tighten the throttle housing upper bolt first then the lower...

Page 289: ...on the left grip with the paint mark on the handlebar PAINT MARK Align the mark on the right grip with the edge of the throttle grip end Align the starter switch housing as shown Install and tighten...

Page 290: ...Ibf ft Install the engine slop bunon on the handlebar Align the end of the holder with the paint mark on the handlebar Tighten the engine stop button screw to the speci fied torque TORQUE 1 5 N m 0 15...

Page 291: ...e front wheel page 13 7 Remove the bolts collars and front fender Remove the bolts and brake hose guides Remove the bolt and tripmeter cable guide Remove the nuts washers tripmeter stay and con nector...

Page 292: ...pper tapered roller bearing and steering stem Check the bearings and outer races for wear or damage BEARING REPLACEMENT Always rep ace the Remove the upper and lower bearing outer races bearmgs and ra...

Page 293: ...ng race installer 2 required Installer shaft 07VMF KZ30100 07VMF KZ30200 LUVV OUTER RACE BEARING RACE INSTALLERS Install a new upper outer race bearing race install ers and installer shaft as shown IN...

Page 294: ...er bearing in the steer ing head Slide the steering stem into the steering head from the boHom Install the upper dust seal Install the steering slem adjusting nut Tighten the steering stem adjusting n...

Page 295: ...ork leg page 13 29 Tighten the stem nut to the specified torque TORQUE 10B N m 11 0 kgf m 80 Ibf ft Recheck the steering stem adjustment by turning bridge lock ta Iock and checking for smoothness Ther...

Page 296: ...MEMO...

Page 297: ...14 REAR WHEEL SUSPENSION COMPONENT LOCATION 14 2 SERVICE INFORMATION 14 3 TROUBLESHOOTING 14 6 REAR WHEEL 14 7 SHOCK ABSORBER 14 13 SHOCK LINKAGE 14 29 SWINGARM 14 35 14 1...

Page 298: ...lbf ft 52 N m 5 3 kgf m __ ____ ilj 38Ibf ft 27 N m 2 8 kgf m 20 Ibf h 12 N m 1 2 kgf m 9lbf ftl After 06 12 N m 1 2 kgf m 9lbf ftl 14 2 12 N m 11 2 kgf m 9lbf ftj 44N m kgf m 33 Ibf ft 88 N m 9 0 kgf...

Page 299: ...n shock springs and spring preload pin spanners are available Refer to gen eral information page 1 30 For brake system information page 15 3 Use genuine Honda replacement bolts and nuts for all suspen...

Page 300: ...3 kgf m 38 Ibf ft 88 N m 9 0 kgf m 65 Ibf ft 12 N m 1 2 kgf m 9 Ibf ft Swingarm pivot nut Drive chain guide mounting bolt nut Drive chain slider screw Rear brake hose guide screw Drive chain adjustin...

Page 301: ...KS6 S10 2 required Pilot 19 mm 07746 0041400 Pilot 25 mm 07746 0040600 Retainer wrench 48 x 15 mm 07YMA KZ40100 or 07HMA KS70100 U S A only Piston ring guide 070MG KZ30100 not available in U S A REAR...

Page 302: ...ck absorber mounting bearing Bent damper rod Damaged swingarm pivot bearings Damaged suspension linkage bearings Bent swingarm pivot Incorrect suspension adjustment Tire pressure too high Steers to on...

Page 303: ...orward to derail the drive chain from the driven sprocket Remove the axle adjusting blocks and rear wheel Do not operate the brake pedal after removing the rear wheel To do so will cause difficulty in...

Page 304: ...fit loosely in the hUb WHEEL RIM RUNOUT WHEEL BEARING Check the rim runout by placing the wheel in a turn r 14 8 ing stand Spin the wheel by hand and read the runcut using a dial indicator Actual runo...

Page 305: ...r ings TOOLS Bearing remover head 25 mm 07746 0050800 Bearing remover shaft 07GGO 0010l00 Never install the old bearings once the bearing have been removed they must be replaced with new ones Replace...

Page 306: ...070MA KZ30100 or equivalent commercially available in U S A TORQUE 3 7 N m 0 38 kgf m 2 7Ibf ft Install the rim band rim lock tube and tire Tighten the rim lock to the specified torque TOROUE 12 N m 1...

Page 307: ...REAR WHEEL SUSPENSION Install the driven sprocket ii ii i Install the bolts washers and nuts and tighten the nuts to the specified torque TORQUE 32 N m 3 3 kgf m 24 Ibf ft Apply grease to a new left...

Page 308: ...en sprocket Apply a thin coat of grease to the axle Install the adjusting block and axle from the left side Install the adjusting block washer and axle nut Adjust the drive chain slack page 3 21 Tight...

Page 309: ...the sub frame upper mounting bolt lift the sub frame as shown NOTICE Do not lift up the sub frame over 9 to avoid dam aging the wire harness Tighten the sub frame upper mounting bolt to the specified...

Page 310: ...the chamber cap or oil spills out when releasing the nitrogen from the reservoir Perform this procedure before draining the oil from the damper FbmUhevalveaway Depress the valve core to release the n...

Page 311: ...r to act as a ramp Now use the other screwdriver to pull the stopper ring completely out Check the stopper ring groove for burrs Remove any burrs with a fine emery cloth before pulling the damper rod...

Page 312: ...hrough the damping adjuster hole while slowly pulling the damper rod out 4 Reinstall the damping adjuster after filling the damper The damper must be kept upright to prevent oil from leaking Qut 5 Pla...

Page 313: ...SUSPENSION 1 0 2 0 mm 0 04 0 08 in 1ut Make sure the chamber cap face is level with the reservoir face EQUAL HEIGHT CHAMBER CAP If the chamber cap does not seat fully the chamber cap may fly out when...

Page 314: ...wards the inside to give the stop per ring a square shoulder on which to seat securely To remove the stopper ring first push one end of the stopper ring out of its groove then slip the sec ond screwdr...

Page 315: ...g onto the damper rod parts do not wear gloves while working on the damper rod Set the lower shock mount in a vise with a piece of wood or soft jaws to avoid damage Be careful to file the rod end by h...

Page 316: ...nd blow them dry with compressed air Be careful not to get solvent on the O ring and DIE piston ring l_ _ __________________ The valve arrangement and number of valves shown is typical and may not rep...

Page 317: ...od guide case metal If the metal is worn so that the copper suriace appears replace the rod guide case with a new one Remove the O ring from the rod guide case and replace it with a new one DAMPER ROD...

Page 318: ...hem dry with compressed air before assembly Use care to avoid getting solvem on the piston ring and O ring COMPRESSION VALVES PISTON The valve arrangemenr and number of valves VALVE STOPPER may differ...

Page 319: ...s mat vary rom Ihose shown Install the piston onto the damper rod Note rheinsta a 1Q 1 Install the rebound valves with their polished sur dlreetion of the faces facing down pisron valves NOTICE Be car...

Page 320: ...quiva lent and insert the damper rod assembly carefully Install the stopper ring into the groove in the damper case After assembling check that the stopper ring is seated in the groove of the damper c...

Page 321: ...bleeding air from the reservoir be careful to hold the damper at the angles shown so the filler hole points up Temporarily charge the reservoir with 49 kPa 0 5 kgf cm 7 1 psi of air slowly to inflate...

Page 322: ...e shock absorber lower mount so the rebound adjuster screw is on the same side of the shock reservoir STOPPER RING TAPERED END SAME SIDE One tum of the Turn the spring adjusting nut until the spring l...

Page 323: ...to remove the stopper ring using the special STOPPER RING COLLAR tool TOOL Collar 23 x 17 mm 07GMD KT8Al10 Remove the stopper ring Press the spherical bearing out of the upper mount using the special...

Page 324: ...TALLATION Set the shock absorber onto the shock arm with the rebound adjuster facing right side Install the lower mounting bolt by aligning the flat side of the bolt with the stopper on the shock abso...

Page 325: ...t Tighten the air cleaner connecting boot band screw securely Install the fuel tank page 2 7 Install the seat page 2 3 SHOCK LINKAGE REMOVAL REAR WHEEL SUSPENSION Remove the mounting bolts and side st...

Page 326: ...ve the side coliars pivot collar and dust seals from the shock link Remove the side collars and pivot collars from the shock arm swingarm side shock link side SIDE COLLAR t2 PIVOT COLLAR SIDE COLLARS...

Page 327: ...LACEMENT SHOCK ARM NEEDLE BEARING Press the needle bearings shock link side swingarm side out of the shock link using the spe cial tools and a hydraulic press TOOLS Driver Attachment 24 C 26 mm Pilot...

Page 328: ...4 7 mm D 17 marked Side facing 0 19 in below the end of the shock arm surface Press the needle bearmg Imo the shocJr arm with the marked side facing 0 14 32 TOOLS Oriver Attachment 28 x 30 mm Pilot 20...

Page 329: ...er of needle rollers Shock link side 32 Swingarm side 32 Shock absorber side 27 Install the dust seals and washers shock link side Install the dust seals to the shock arm swingarm side Install the piv...

Page 330: ...ck absorber lower mounting nut 44 N m 4 5 kgf m 33 Ib tt Afler 06 Apply oil to the shock arm and shock link nut threads and flange surface Loosely install the following Shock link Shock link boltlnutl...

Page 331: ...ing bolt to the specified torque TORQUE 54 N m 5 5 kgf m 40 IbUtl Tighten the lower mounting bolt to the specified torque TORQUE 39 N m 4 0 kgf m 29 IbUtl SWINGARM REMOVAL Remove the following Rear wh...

Page 332: ...guide Chain guide slider Drive chain 04 06 Raise the rear wheel off the ground by placing a workstand or equivalent under the engine Remove the shock arm bolt nut and washer swingarm side After 06 Ra...

Page 333: ...der Remove the following Side collars Dust seals Washers Thrust needle bearings Pivot collars Check the dust seals and collars fo r wear damage or fatigue Check the needle bearings for damage or loose...

Page 334: ...se grease Press the needle Press e new needle bearing into the swingarm using beBflng mID the the special tools and a hvdraulic press as shown shock Imk Wllh the marted Side fiIC flg TOOLS out Driver...

Page 335: ...de of the seals mto the swingarm pivots so that the dust seal surface is 1 5 sWIIlgarm WIth the 2 0 mm 0 06 0 08 in below the end of the marked side facmg swingarm surface our Install the side collars...

Page 336: ...9 0 kgf m 65 Ibf ft 04 06 Apply oil to the shock arm nut swingarm side threads and seating surface Install the shock arm bolt nut and washer swingarm side Tighten the nut to the specified torque TORQU...

Page 337: ...ghten the bolts and nuts to the specified torque TORQUE 12 N m 1 2 kgf m 9Ibf ft Do not twist the Install the rear brake caliper to the slide rail on the brake hose swingarm REAR WHEEL SUSPENSION CHAI...

Page 338: ...MEMO...

Page 339: ...2 FRONT MASTER CyLINDER 15 12 SERVICE INFORMATION 15 3 REAR MASTER CYLINDER 15 15 TROUBLESHOOTING 15 5 FRONT BRAKE CALIPER 15 18 BRAKE FLUID REPLACEMENTI REAR BRAKE CALIPER 15 20 AIR BLEEDING 15 6 BRA...

Page 340: ...5 9 N m 0 6 kgf m 4 3 Ibf ftl A 1 __ 34 N m 3 5 kgf m 25 IbUt 15 2 lJ 30 N m 3 1 kgf m 22 Ibf ft 18 N m 1 8 kgf m 13 Ibf ft 1 5 N m 0 15 kgf m 1 1 Ibf ft 2 0 N m 0 2 kgf m 1 4 Ibf ft 34 N m 3 5 kgf m...

Page 341: ...he hydrau lic system has been opened or if the brake feels spongy the system must be bled Always use fresh DOT 4 brake fluid from a sealed container when servicing the system Do not mix different type...

Page 342: ...aster cylinder push rod lock nut TOOL Snap ring pliers 07914 SASO001 15 4 34 N m 3 5 kgf m 25 Ibf h 5 9 N m 0 6 kgf m 4 3 Ibf ft 1 0 N m 0 1 kgf m 0 7Ibf ft 5 9 N m 0 6 kgf m 4 3 Ibf ftl 5 2 N m 0 53...

Page 343: ...ticking worn master cylinder piston Contaminated master cylinder Bent brake lever pedal Brake lever pedal hard Clogged restricted brake system 5ticking worn caliper piston Caliper not sliding properly...

Page 344: ...Do not allow foreign material to enter the system when filling the reservoir Avoid spilling fluid on plastic or rubber parts Place a rag over these parts whenever the sys tem is serviced BRAKE flUID D...

Page 345: ...ILLING AIR BLEEDING Do nor mix different Fill the master cylinder with DOT4 brake fluid to the types o r JId since upper level they are nor compatible W hen using a Connect a commercially available br...

Page 346: ...erform the fol lowing procedure Pressurize the system with the lever until there are no air bubbles in the fluid flowing out of the small hole in the reservoir and lever resistance is felt 1 Pump the...

Page 347: ...r Tighten the reservoir cover screws to the specified torque TORQUE 1 5 N m 0 15 kgf m 1 1Ibf ft Straighten the diaphragm and install it to the rear master cylinder Check the diaphragm installation as...

Page 348: ...s operation causes the level to rise For the front brake remove the pad pin plug and pad pin For the rear brake remove the pad pin Remove the brake pads Install the new brake pads to the pad retainer...

Page 349: ...For the rear brake install a new O ring into the pad pin groove _U Install and tighten the pad pin to the specified torque TORQUE 18 N m l B kgf m 13 IbUt Operate the brake lever or pedal to seat the...

Page 350: ...L Drain the front brake hydraulic system page 15 6 When removing the Remove the brake hose oil bolt sealing washers brake hose bolt and brake hose eyelet cover the end of the hose to prevent contammat...

Page 351: ...e inside of the cylinder and reservoir with brake fluid INSPECTION Check the piston boot primary cup and secondary cup for fatigue or damage Check the master cylinder and piston for abnormal scratches...

Page 352: ...the lever contacting area of the piston Install the boot to the master cylinder Apply silicone grease to the pivot bolt sliding sur face DUST COVER 15 14 Install the brake lever Install and tighten th...

Page 353: ...VAL Drain the rear brake hydraulic system page 15 6 Remove the brake pedal page 15 24 When removing the Remove the brake hose oil bolt seating washers brake hose bolt and brake hose eyelet cover the e...

Page 354: ...r abnormal scratches Measure the master cylinder J D SERVICE LIMIT 9 575 mm 0 3770 in Measure the master piston 0 0 SERVICE LIMIT 9 465 mm 0 3726 in ASSEMBLY Coat all of the parts with clean brake flu...

Page 355: ...ROD STANDARD LENGTH 79 6 mm 3 13 in Tighten the lock nut to the specified torque TORQUE 5 9 N m 0 6 kgf m 4 3 Ibf tt INSTALLATION Install the master cylinder and tighten the mounting bolts to the spe...

Page 356: ...liper body Remove the brake pad spring from the caliper body Remove the brake pad retainer from the caliper bracket Remove the caliper pin boot and bracket pin boot If necessary lightly apply compress...

Page 357: ...IT 27 060 mm 1 0654 in Measure the caliper piston O D SERVICE LIMIT 26 853 mm 11 0572 in ASSEMBLY Coat the new piston seals with clean brake fluid Coat the new dust seals with silicon grease Install e...

Page 358: ...and apply locking agent to the caliper mount ing bolt threads Install and tighten the mounting bolts to the speci fied torque TORQUE 30 N m 3 1 kgf m 221bHt Install the brake hose eyelet to the calipe...

Page 359: ...rs and brake hose eyelet DISASSEMBLY Remove the bolts and brake disc cover Remove the caliper bracket from the caliper body Remove the brake pad spring from the caliper body Remove the brake pad retai...

Page 360: ...our with excessive force that could cause injury Be careful no to damage the piston sliding surface 15 22 Push the dust seal and piston seal in and lift them out Clean the seal grooves caliper piston...

Page 361: ...Install the brake pad retainer onto the caliper bracket Install the pad spring into the caliper body Replace the caliper and bracket pin boots if there is wear deterioration or damage Apply silicone g...

Page 362: ...15 0 Fill the reservoir to the upper level and bleed the hydraulic system page 15 7 Install the caliper guard and tighten the bolts securely BRAKE PEDAL REMOVAL 15 24 Remove the clip brake pedal pivot...

Page 363: ...al and pivot bolt 04 06 only Clean and apply a locking agent to the threads of the brake pedal Install the washer and pivot bolt Tighten the brake pedal pivot bolt to the specified torque TORQUE 04 06...

Page 364: ...MEMO...

Page 365: ...CHARGING SYSTEM COMPONENT LOCATION 16 2 BATTERy 16 6 SYSTEM DIAGRAM 16 2 CHARGING SYSTEM INSPECTION 16 6 SERVICE INFORMATION 16 3 REGULATOR RECTIFIER 16 7 TROUBLESHOOTING 16 5 ALTERNATOR CHARGING COIL...

Page 366: ...TIERY CHARGING SYSTEM COMPONENT LOCATION REGULATOAIRECTIFIEA SYSTEM DIAGRAM ALTERNATOR 16 2 G Bu Y C REGULATOR RECTIFIER FUSE 15A I I j e BATTERY BATIERY FUSE 15A G Green R Red W White Y Yellow Bu Blu...

Page 367: ...hich may appear to be an overcharging symptom If one of the battery cells is shorted and battery voltage does not increase the regulator rectifier supplies excess voltage to the battery Under these co...

Page 368: ...rent Alternator Capacity TOOLS Battery tester BM 210 AH U S A only 16 4 Fully charged Needs charging Normal Quick Christie battery charger MC101212 U S A only SPECIACATIONS 12V 4Ah 0 1 rnA max 13 0 13...

Page 369: ...Faulty main relay 04 05 only 4 ALTERNATOR CHARGING COIL INSPECTION Check the alternator charging coil page 16 8 Check for continuity between Yellow terminal and Ground Blue terminal and Ground Is ther...

Page 370: ...Digital multimeter Commercially available in U S A CHARGING SYSTEM INSPECTION CURRENT LEAKAGE INSPECTION Remove the seat page 2 3 16 6 Disconnect the negative H cable from the battery Connect the amme...

Page 371: ...ct the regulator rectifier 4P Natural con nector and alternator 4P Black connector and check it for loose contacts or corroded terminals If the charging voltage reading page 16 7 is out of the specifi...

Page 372: ...RGING COIL INSPECTION 16 8 Remove the right radiator shroud page 2 4 Disconnect the alternator 4P Black connector Check for continuity between the terminal of the alternator side connector and ground...

Page 373: ...OMPONENT LOCATION 17 2 IGNITION SYSTEM INSPECTION 17 5 SYSTEM DIAGRAM 17 2 IGNITION CONTROL MODULE lCM 17 8 SERVICE INFORMATION 17 3 IGNITION TIMING 17 8 TROUBLESHOOTING 17 4 THROTILE POSITION SENSOR...

Page 374: ...r r fWV G DIRECT 9 IGNITION Bu Y BI 1 COIL 17 2 R O WG THROTTlE POSITION SENSOR I IGNITION CONTROL MOOULE OCM THROTILE POSITION SENSOR I CONTROL MODULE ICM IG TION PULSE GENERATOR ALTERNATOR GIW W B...

Page 375: ...ge can damage the engine SPECIFICATION ITEM Spark plug Standard NGK IoEN50 Optional NGK DENSO Spark plug gap Ignition coil resistance Primary at 20 CJ68 F Secondary Direct ignition coil input voltage...

Page 376: ...measured voltage is over the specifications with reverse connection 2 Short circuit in engine stop bunon wire 3 Faulty engine stop bunon 4 l oose or poorly connected ICM connectors 5 An open circuit...

Page 377: ...nce 10 MnJDCV minimum IGNITION COIL PRIMARY PEAK VOLTAGE Check all system connections before inspection Check cylinder compression and check that the spark plug is installed correctly Shift the transm...

Page 378: ...A onlyl or Peak voltage adaptor 07HGJ 0020100 not available in U S A with commercially available digital multimeter impedance 10 Mn DCV minimum CONNECTION Blue White 1 White Shift the transmission in...

Page 379: ...ne with the stater motor or kickstaner L _ ______ and read the peak voltage PEAK VOLTAGE 0 7 V minimum If the peak voltage measured is abnormal recheck the following Remove the right radiator shroud p...

Page 380: ...s property page 23 IGNITION TIMING 17 8 The ignition timing is factory preset and only needs to be checked when an electrical system component is replaced Warm up the engine to normal operating temper...

Page 381: ...OSITION SENSOR INSPECTION INSPECTION Remove the fuel tank page 2 7 I l Disconnect the throttle pOSit ion sensor 3P connec tor Measure the resistance between the Blue and Black wire terminals of the se...

Page 382: ...MEMO...

Page 383: ...18 ELECTRIC STARTER COMPONENT LOCATION 18 2 TROUBLESHOOTING 18 4 SYSTEM DIAGRAM 18 2 STARTER MOTOR 18 6 SERVICE INFORMATION 18 3 STARTER RELAY SWITCH 18 11 18 1...

Page 384: ...n R SWITCH CLUTCH SWITCH snlRTI R MOTOR SYSTEM DIAGRAM STARTEA RELAY STARTER MOTOR M SWITCH I VIR G A r l o BVBr STARTER CLUTCH SWITCH SWITCH BVA t C J 18 2 MAIN FUSE 15A j e BATTERY BATIERY STARTER S...

Page 385: ...e steps in the troubleshooting page 18 4 Always disconnect the negative cable at the battery before servicing the starter motor The motor could suddenly start causing serious injury A weak battery may...

Page 386: ...and check the operation Does the starter motor turn7 YES Poorly connected starter motor cable Faulty starter relay switch NO Faulty starter motor 5 Starter Relay Switch Operation Inspection Disconnect...

Page 387: ...lay switch connector Starter motor turns engine slowly Low battery voltage Poorly connected battery cable Poorly connected starter motor cable Faulty starter motor Poorly connected ground cable termin...

Page 388: ...r terminal and remove the terminal nut and starter motor cable Remove the two mounting bolts ground cable stay and starter motor from the crankcase DISASSEMBLYIINSPECTION Remove the following a ring S...

Page 389: ...nsulated brush There should be continuity Check for continuity between the cable terminal and rear cover There should be no continuity Remove the following Nut Washer Insulators D ring Brush holder In...

Page 390: ...Do not Jse emery Inspect the commutator bars of the armature lor or sand paper on discoloration rile commutator 18 8 Check for continuity between pairs of commutator bars There should be continuity Ch...

Page 391: ...the insulator plate onto the cable terminal Install the brush holder assembly to the rear cover aligning the lab with the groove in the rear cover Install the following New D ring Insulators Washer N...

Page 392: ...e rear cover assembly while pushing the brushes into the brush holder Ins all Ihe stllms Install the shims and insulated washer onto the proper yas noted armature shaft dunng removal Install a new sea...

Page 393: ...er page 9 8 STARTER RELAY SWITCH Remove the seat page 2 3 Remove the right side cover page 2 3 OPERATION INSPECTION Shift the transmission into neutral Pull the clutch lever fully and push the starter...

Page 394: ...arter relay switch from the rubber case Remove the terminal bolts and disconnect the starter relay switch cables Remove the 4P connector from the starter relay switch Connect an ohmmeter to the starte...

Page 395: ...GHTS METER SWITCHES COMPONENT LOCATION 19 2 SERVICE INFORMATION 19 3 HEADLIGHT 19 4 TAIL LIGHT 19 5 ENGINE STOP BUTION 19 6 CLUTCH SWITCH 19 7 STARTER SWITCH 19 8 TRIPMETER 19 8 MAIN RELAY 04 05 19 9...

Page 396: ...LIGHTS METER SWITCHES COMPONENT LOCATION STARTER SWITCH HEADLIGHT UNIT 19 2 ENGINE STOP BUnON MAIN RELAY r04 05...

Page 397: ...fail If you touch the bulb with your bare hands clean it with 8 cloth moistened with denatured alcohol to prevent its Barly failure 8e sure to install the dust cover after replacing the bulb Check the...

Page 398: ...I Avoid touching the halogen headlight bulb Finger prints can create hot spots that cause a bulb to break Install a new bulb into headlight unit while aligning the tabs with groove of the headlight u...

Page 399: ...screw spring mounting screws clamp and headlight unit Install the headlight unit in the reverse order of removal TORQUE Headlight mounting screw 0 7 N m 0 07 kgf m 0 5 Ibf ft Adjust the headlight aim...

Page 400: ...the reverse order of removal TORQUE Rear fender mounting bolt 13 N m 1 3 kgf m 9Ibf ft Tail light mounting screw 3 9 N m 0 4 kgf m 2 9Ibf ftl ENGINE STOP BUnON 19 6 Remove the front visor page 2 51 D...

Page 401: ...19 7 Remove the clutch lever bracket page 13 31 Remove the boot Remove the screw stay and clutch switch Disconnect the connectors Check for continuity between the clutch switch ter minals There shoul...

Page 402: ...con nector terminals There should be continuity with the starter switch depressed and no continuity with the switch released TRIPMETER 19 8 REMOVALIINSTALLATION Remove the front visor page 2 5 loosen...

Page 403: ...ter to the main relay connector 8 A n E R YCl terminals CONNECTION Red tenninal Gray terminal Connect the 12 V battery to the main relay connec tor terminals CONNECTION Red terminal Black terminal The...

Page 404: ...MEMO...

Page 405: ...20 WIRING DIAGRAM 04 05 20 2 After 05 20 3 20 1...

Page 406: ...I l AJOIV lEClIF lER M STARTER IoIOTOR II E E ci lI Z STARTER RELAY WITP I Z G l G c C G l Il O l l G lI 0 l OJ Bl ACK Bt IIAOWI I Y YEllOW 0 O NGE IkI E1 UE L b UGtfT BLUE G GREEN I g UGffT GAEEN R I...

Page 407: ...N o tAl AllEANATOfI Sf II AK Pl l JG l IGNITION I UL iE OENtRATOA t 0 uoorr 0 UGtfTGREEN 0 W woom J l m o UO...

Page 408: ...MEMO...

Page 409: ...21 TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD POOR PERFORMANCE TO START 21 2 AT HIGH SPEED 21 6 ENGINE LACKS POWER 21 3 POOR HANDLING 21 7 POOR PERFORMANCE AT LOW AND IDLE SPEED 21 5 21...

Page 410: ...n system wires Broken or shorted direct ignition coil wire Faulty direct ignition coil Faulty igniting pulse generator Faulty exciter coil Faulty engine stop bunon Faulty ignition control module ICM N...

Page 411: ...ive in transmission oil YES GO TO STEP 4 4 Engine Condition Inspection Accelerate lightly Did the engine speed increase NO _ Fueliair mixture too rich or lean Clogged air cleaner Restricted fuel flow...

Page 412: ...olored NO Plug not serviced frequently enough Incorrect spark plug heat range Incorrect spark plug gap YES GO TO STEP 10 10 Engine Oil Inspection Check oil level and condition Is there correct level a...

Page 413: ...carburetor insulator bands Damaged insulator NO GO TO STEP 4 4 Spark Test Perform spark test Is there weak or intermittent spark YES _ Faulty spark plug Fouled spark plug Loose or disconnected ignitio...

Page 414: ...s Is the carburetor clogged YES Carburetor not serviced frequently enough NO GO TO STEP 3 3 Ignition Timing Inspection Check ignition timing Is the ignition timing correct NO _ Faulty ignition control...

Page 415: ...man ual for spring preload adjustment The following recommendations are given in the preferred sequence of adjustment Front End Oversteers It Cuts Too Sharply such as in sand Increase the fork oil cap...

Page 416: ...MEMO I...

Page 417: ...AD COVER REMOVAL 8 6 CYLINDER HEAD DISASSEMBLY 8 15 CYLINDER HEAD INSPECTION 8 17 CYLINDER HEAD INSTALLATION 8 25 CYLINDER HEAD REMOVAL 8 2 CYLINDER HEADNALVES SPECIFICATIONS 8 CYLINDER INSTALLATION 9...

Page 418: ...11 5 STEERING HEAD BEARINGS 3 34 STEERING STEM 13 37 SUB FRAME 2 5 22 2 SUSPENSION 3 31 SWINGARM 14 35 SWINGARM SHOCK LINKAGE 3 32 SYSTEM DIAGRAM BATTERY CHARGING SYSTEM 16 2 ELECTRIC STARTER 18 2 IG...

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