Honda 2005 FOURTRAX FOREMAN TRX500 FE Service Manual Download

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Summary of Contents for 2005 FOURTRAX FOREMAN TRX500 FE

Page 1: ...2 0 0 5 2 0 0 6 S E R V I C A N U A L rr X 5 0 0 F E F FOURTRAX FOREMAN...

Page 2: ...ou of every conceivable hazard that can Follow the procedures and precautions in this arise in performing service and repair procedures Only you can decide manual carefully whether or not you should p...

Page 3: ...ety Messages preceded by a safety alert symbol A and one of three signal words DANGER WARNING or CAUTION These signal words mean You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions A...

Page 4: ...molybdenum disulfide grease containing more than 3 molybdenum disulfide NLGI 2 or equivalent Example Molykote BR 2 plus manufactured by Dow Corning U S A Multi purpose M 2 manufactured by Mitsubishi O...

Page 5: ...ANCER SPECIFICATIONS 1 10 FRONT WHEEL SUSPENSION STEERING SPECIFICATIONS 1 10 REAR WHEEL SUSPENSION SPECIFICATIONS 1 10 BRAKE SYSTEM SPECIFICATIONS 1 11 FRONT DRIVING MECHANISM SPECIFICATIONS FM FE mo...

Page 6: ...ied torque diagonally in incremental steps unless a particular sequence is specified 6 Clean parts in cleaning solvent upon disassembly Lubricate any sliding surfaces before reassembly 7 After reassem...

Page 7: ...frame The engine serial number is stamped on the left side of the rear crankcase The name plate U S A and U type or safety certification label Can ada type is attached on the right front frame pipe VI...

Page 8: ...IDENTIFICATION NUMBER The vehicle emission information label is attached on the rear fender behind the seat U S A only The color label is attached on the front side of the right front frame pipe When...

Page 9: ...type Cooling system Air filtration Engine dry weight Carburetor type Throttle bore SPECIFICATIONS 2 109 mm 83 0 in 1 188 mm 46 8 in 1 169 mm 46 0 in 1 292 mm 50 9 in 922 mm 36 3 in 925 mm 36 4 in 860...

Page 10: ...0 848 28 33 5 600 28 15x39 13 R N 1 2 3 4 5 Left foot operated return system DC CDI Electric starter motor and emergency recoil starter Triple phase output alternator FET shorted triple phase full wa...

Page 11: ...ouble wish bone 170 mm 6 7 in Double tube Swingarm 170 mm 6 7 in Double tube AT25x8 12 AT25x 10 12 12x6 0 AT 12x7 5 AT KT181 Dunlop KT185 Dunlop Hydraulic disc brake Mechanical drum brake 2 9 mm 11 32...

Page 12: ...in ITEM Cylinder compression at 380 rpm min 1 Valve clearance Valve valve guide Valve spring Rocker arm Camshaft and cam follower Valve stem O D Valve guide I D Stem to guide clearance Valve seat widt...

Page 13: ...96 0 786 0 08 0 003 0 5 0 02 0 6 0 02 0 9 0 04 0 09 0 004 0 09 0 004 0 10 0 004 20 07 0 790 0 10 0 004 CLUTCH GEARSHIFT LINKAGE SPECIFICATIONS ALTERNATOR STARTER CLUTCH SPECIFICATIONS Unit mm in ITEM...

Page 14: ...980 0 8645 0 8654 16 976 16 987 0 6683 0 6688 12 966 12 984 0 5105 0 5112 0 020 0 062 0 0008 0 0024 0 029 0 058 0 0011 0 0023 0 016 0 055 0 0006 0 0022 0 05 0 65 0 002 0 026 0 006 0 018 0 0002 0 0007...

Page 15: ...TANDARD 185 cm3 6 3 US oz 6 5 Imp oz 230 cm3 7 8 US oz 8 1 Imp oz Hypoid gear oil SAE 80 0 05 0 25 0 002 0 010 14 17N m 1 45 1 75kgfm 10 13 Ibf ft 3 3 3 7 0 13 0 15 6 55 6 65 0 258 0 262 2 8 0 11 SERV...

Page 16: ...ARD 12 5 0 49 SERVICE LIMIT 9 0 0 35 LIGHTS METERS SWITCHES SPECIFICATIONS ITEM Bulbs Fuse Headlight high low beam Assist headlight Brake taillight Neutral indicator Reverse indicator Oil temperature...

Page 17: ...il to the threads and seating surface 3 Apply grease to the threads and seating surface 4 ALOC bolt replace with a new one 5 Lock nut replace with a new one 6 Castle nut tighten to the specified torqu...

Page 18: ...utch lock nut Shift drum stopper arm pivot bolt Gearshift cam bolt Gearshift spindle return spring pin Q TY 4 1 1 1 1 1 THREAD DIA mm 6 20 18 6 6 8 TORQUE Nm kgf m Ibfft 12 1 2 9 118 12 0 87 108 11 0...

Page 19: ...case oil check bolt Rear final gear case oil filler cap Rear final gear case oil drain bolt Spark arrester bolt Tie rod lock nut knuckle side Tie rod lock nut steering arm side QTY 1 1 1 1 1 3 2 2 THR...

Page 20: ...DIA mm 10 10 10 30 30 30 TORQUE N m kgf m Ibfft 64 6 5 47 34 3 5 25 44 4 5 32 112 11 4 83 10 1 0 7 112 11 4 83 REMARKS BRAKE SYSTEM ITEM Brake hose oil bolt Front brake caliper bleed valve Front mast...

Page 21: ...Rear brake panel nut Rear wheel hub nut QTY 1 2 6 4 12 3 4 2 THREAD DIA mm 64 10 8 10 10 8 10 20 TORQUE N m kgf m Ibfft 98 10 0 72 49 5 0 36 25 2 5 18 54 5 5 40 44 4 5 32 32 3 3 24 44 4 5 32 137 14 0...

Page 22: ...ate boss outer surface Change clutch disc lining whole surfaces Change clutch lock nut threads and seating surface Centrifugal sprag clutch whole surface Centrifugal clutch drum sprag clutch contactin...

Page 23: ...eads Gear position switch bolt threads Angle sensor bolt threads Coating width 6 5 1 mm 0 26 0 04 in Coating width 6 1 mm 0 24 0 04 in Coating width 6 5 1mm 0 26 0 04 in Coating width 6 5 1mm 0 26 0 0...

Page 24: ...gear case oil seal lips for ring gear Rear final gear case oil seal lips for pinion gear Rear final gear oil filler cap O ring Rear final gear pinion joint O ring Steering shaft spline Front upper arm...

Page 25: ...pin sliding surfaces Front brake caliper pin boot inside Throttle inner cable Choke inner cable Rear brake inner cables Master cylinder piston and cups Caliper cylinder piston and cup Rear final gear...

Page 26: ...P GREEN CONNECTOR A CM type TM model METER 14P GRAY CONNECTOR Except A CM type TM model HANDLEBAR SWITCH 10P GREEN CONNECTOR FRONT BRAKE SWITCH HORN CONNECTORS ASSIST HEADLIGHT 2P BLACK CONNECTOR 4P C...

Page 27: ...BAND FM FE models WIRE BAND CHOKE CABLE FRONT BRAKE HOSE 2WD 4WD SELECT SWITCH WIRE FM FE models REVERSE SELECTOR CABLE REAR BRAKE CABLE REAR BRAKE SWITCH WIRE HANDLEBAR SWITCH WIRE HORN SWITCH WIRE U...

Page 28: ...CASE BREATHER HOSE FRONT BRAKE PIPE White paint RIGHT FRONT BRAKE HOSE CLAMP FM FE models GEAR CASE BREATHER HOSE FRONT SPEED SENSOR WIRE REAR SPEED SENSOR WIRE FINAL CLUTCH WIRE HORN WIRE U type onl...

Page 29: ...DLIGHT WIRE METER WIRE HANDLEBAR SWITCH WIRE 2WD 4WD SELECT SWITCH WIRE FM FE models CARBURETOR HEATER SWITCH WIRE CHOKE CABLE REAR BRAKE PANEL BREATHER HOSE CLAMP REAR BRAKE PANEL BREATHER HOSE COOLI...

Page 30: ...RONT FINAL GEAR CASE BREATHER HOSE FM FE models IGNITION SWITCH WIRE HANDLEBAR SWITCH 10P GREEN CONNECTOR REAR BRAKE PANEL BREATHER HOSE JUNCTION CONNECTOR CLAMP FM FE models FRONT FINAL GEAR CASE BRE...

Page 31: ...FRONT SPEED SENSOR WIRE REAR SPEED SENSOR WIRE FINAL CLUTCH WIRE HORN WIRE U type only FRONT FINAL GEAR CASE BREATHER HOSE FRONT SPEED SENSOR FINAL CLUTCH 2P GREEN CONNECTOR REAR SPEED SENSOR WIRE FR...

Page 32: ...GENERAL INFORMATION FM FE models shown TM model similar FRONT BRAKE HOSE HOSE CLAMPS FRONT BRAKE CALIPER HOSE CLAMPS HOSE GUIDE FRONT BRAKE HOSE 1 28...

Page 33: ...NTSPEED SENSOR 3P BLACK CONNECTOR FM FE models CHOKE CABLE CARBURETOR HEATER SWITCH THROTTLE CABLE CLAMP REAR BRAKE PANEL BREATHER HOSE REAR FINAL GEAR CASE BREATHER HOSE COOLING FAN MOTOR BREATHER HO...

Page 34: ...ABLE CLAMP REAR BRAKE PANEL BREATHER HOSE REAR FINAL GEAR CASE BREATHER HOSE COOLING FAN MOTOR BREATHER HOSE REAR BRAKE CABLE REVERSE SELECTOR CABLE COOLING FAN MOTOR BREATHER HOSE COOLING FAN MOTOR 2...

Page 35: ...t A CM type TM model FUEL LEVEL SENSOR Except A CM type TM model CHOKE CABLE THROTTLE CABLE MAIN WIRE HARNESS CARBURETOR HEATER WIRE FUEL HOSE SPARK PLUG WIRE THROTTLE POSITION SENSOR 3P CONNECTOR THR...

Page 36: ...FORMATION CARBURETOR HEATER WIRE THROTTLE POSITION SENSOR WIRE AIR CUT OFF VALVE VACUUM HOSE CARBURETOR AIR VENT HOSES CHOKE CABLE L THROTTLE CABLE THROTTLE POSITION SENSOR FUEL HOSE CARBURETOR HEATER...

Page 37: ...SELECTOR CABLE STARTER MOTOR CABLE GROUND POINT GEAR POSITION SWITCH 8P GRAY CONNECTOR CLAMP REAR BRAKE PANEL BREATHER HOSE REAR FINAL GEAR CASE BREATHER HOSE GEAR POSITION SWITCH WIRE ENGINE SUB WIR...

Page 38: ...EAR FINAL GEAR CASE BREATHER HOSE GEAR POSITION SWITCH WIRE ENGINE SUB WIRE ALTERNATOR WIRE REVERSE SELECTOR CABLE GEAR POSITION SWITCH WIRE REAR BRAKE PANEL BREATHER HOSE CARBURETOR DRAIN HOSE REAR F...

Page 39: ...TION BATTERY 2P CONNECTOR STARTER RELAY SWITCH 2P CONNECTOR FUSE BOX STARTER MOTOR CABLE BATTERY BATTERY GROUND CABLE STARTER RELAY SWITCH WIRE BANDS TAILLIGHT 3P CONNECTOR REGULATOR RECTIFIER MAIN WI...

Page 40: ...L GEAR CASE BREATHER HOSE REAR BRAKE LEVER CABLE REAR BRAKE PEDAL CABLE CLAMPS secure the wire at the green marks REAR BRAKE PANEL BREATHER HOSE ENGINE SUB WIRE REVERSE SELECTOR CABLE J REVERSE SWITCH...

Page 41: ...GENERAL INFORMATION RIGHT HEADLIGHT HEADLIGHT WIRE LEFT HEADLIGHT LEFTTAILLIGHT ACCESSORY SOCKET WIRE RIGHT TAILLIGHT 1 37...

Page 42: ...ot react in the same way but it is toxic Honda Motor Co Ltd utilizes various systems to reduce carbon monoxide oxides of nitrogen and hydrocarbons EXHAUST EMISSION CONTROL SYSTEM The exhaust emission...

Page 43: ...SE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE FOLLOWINGACTS 1 Removal of or puncturing the muffler baffles header pipes or any other component which conducts exhaust gases 2 Removal of or puncturin...

Page 44: ...2 TECHNICAL FEATURES INTEGRATED ENGINE CONTROL MODULE ECM 2 2 2 1...

Page 45: ...l unit and 2WD 4WD control unit FM FE models are integrated into the ECM to reduce cost and conserve space ICM Ignition Control ESP CONTROL UNIT Electric shift control FAN CONTROL UNIT Cooling Fan Con...

Page 46: ...ING 3 2 FRONT CARRIER CARRY PIPE 3 8 BODY PANEL LOCATIONS 3 3 FRONT FENDER 3 9 SEAT 3 4 REAR CARRIER 3 10 RECOIL STARTER COVER 3 4 REAR FENDER 3 11 SIDE COVER 3 4 ENGINE AIR GUIDE 3 12 FUEL TANK COVER...

Page 47: ...Ibf ft Front carry pipe bolt 37 N m 3 8 kgfm 27 Ibf ft Rear carrier bolt 37 N m 3 8 kgf m 27 Ibf ft Muffler band bolt 23 N m 2 3 kgf m 17 Ibf ft Muffler cover band bolt 3 2 N m 0 33 kgf m 2 4 Ibf ft E...

Page 48: ...e 3 8 2 FRONT FENDER page 3 9 3 FUEL TANK COVER page 3 5 4 RECOIL STARTER COVER page 3 4 5 REAR FENDER page 3 11 6 SEAT page 3 4 7 REAR CARRIER page 3 10 8 CENTER MUD GUARD page 3 6 9 SIDE COVER page...

Page 49: ...ing rubbers then press down to lock it SEAT CENTER PRONGS FRONT PRONGS BOSSES LOCK LEVER RUBBERS RETAINERS RECOIL STARTER COVER Remove the recoil starter cover by releasing the three bosses from the g...

Page 50: ...SLIT TAB FUEL TANK COVER REMOVAL INSTALLATION Remove the following seat page 3 4 recoil starter cover page 3 4 left side cover page 3 5 nine trim clips two 6 mm setting bolts fuel fill cap fuel tank c...

Page 51: ...m the slits Assemble the fuel tank covers in the reverse order of disassembly RIGHT FUEL TANK SIDE COVER LEFT FUEL TANK SUB SIDE COVER LEFT FUEL TANK SIDE COVER SLITS FUEL TANK TOP COVER TRIM CLIPS CE...

Page 52: ...3 6 five trim clips front mud guard Install the front mud guard in the reverse order of removal TRIM CLIPS FRONT MUD GUARD INNER FENDER Theright fender stay has the Ft mark at the upper end RIGHT INNE...

Page 53: ...M CLIPS BOLTS FRONT CARRIER CARRY PIPE FRONT CARRIER Remove the following Be careful notto two 6 mm bolts and collars scratch thefront four 8 mm bolts fender front carrier Install the front carrier in...

Page 54: ...lt 37 N m 3 8 kgf m 27 Ibfft 6 mm BOLTS CARRY PIPE 8 mm BOLTS FRONT FENDER Remove the following front carrier and carry pipe page 3 8 headlight and accessory socket connectors fourteen trim clips four...

Page 55: ...ing two tapping screws six trim clips and wire clamp taillight grille Install the rear taillight grille in the reverse order of removal WIRE CLAMP TAPPING SCREWS TRIM CLIPS TAILLIGHT GRILLE REAR CARRI...

Page 56: ...2P connector battery 2P connector starter relay switch 2P CONNECTORS FUSE BOX STARTER RELAY SWITCH BATTERY Remove the taillight 3P connector from the storage box and disconnect it Remove the following...

Page 57: ...IGHT ENGINE AIR GUIDE TABS TRIM CLIPS LEFT ENGINE AIR GUIDE Remove the left side cover page 3 5 Remove the screw Release the grommet from the tab of the fuel tank sub side cover and remove the left en...

Page 58: ...bolts flange bolts and left engine cover LEFT ENGINE COVER SOCKET BOLTS FLANGE BOLTS Loosen the muffler band bolts Remove the exhaust pipe joint nuts exhaust pipe and gasket Remove the muffler gasket...

Page 59: ...N m 0 33 kgf m 2 4 Ibfft 5 4 N m 0 55 kgf m 4 0 Ibfft MUFFLER COVER BANDS HEAT PROTECTOR BAND 57 Fit the muffler cover to the mounting stay of the muffler HEAT PROTECTOR BAND HEAT PROTECTOR BAND 5 4 N...

Page 60: ...s and loosely tighten the joint nuts and muffler band bolts Tighten the exhaust pipe joint nuts Tighten the muffler band bolts TORQUE 23 N m 2 3 kgfrn 17 Ibf ft Tighten the muffler mounting bolt GASKE...

Page 61: ...7 REVERSE LOCK SYSTEM 4 19 AIR CLEANER HOUSING DRAIN HOSE 4 9 SPARK PLUG 4 9 SKID PLATE ENGINE GUARD 4 19 CLUTCH SYSTEM 4 19 VALVE CLEARANCE 4 10 SUSPENSION 4 20 ENGINE OIL 4 11 SPARK ARRESTER 4 20 E...

Page 62: ...cosity SAE 10W 40 1 400 100 rpmfmin 1 75 cm3 2 5 US oz 2 6 Imp oz 100 cm3 3 4 US oz 3 5 Imp oz Hypoid gear oil SAE 80 185 cm3 6 3 US oz 6 5 Imp oz 230 cm3 7 8 US oz 8 1 Imp oz Hypoid gear oil SAE 80 H...

Page 63: ...EERING SHAFT HOLDER BEARING STEERING SYSTEM WHICHEVER COMES FIRST NOTE1 NOTE 2 NOTE 3 NOTE1 NOTE 1 2 mi km HOURS INITIAL MAINTE NANCE 100 150 20 I R R I I I I I I I REGULAR MAINTENANCE INTERVAL 600 1...

Page 64: ...TIRES STEERING SHAFT HOLDER BEARING STEERING SYSTEM WHICHEVER COMES FIRST NOTE1 NOTE 2 NOTE 3 NOTE 1 NOTE 1 2 mi km HOURS INITIAL MAINTE NANCE 100 150 20 I R R I I I I I I I REGULAR MAINTENANCE INTERV...

Page 65: ...loses in all steering positions If the throttle lever does not return properly lubri cate the throttle cable and overhaul and lubricate the throttle housing If the throttle lever still does not return...

Page 66: ...lips and turn over the rubber seal Slide the rubber boot off the adjuster Loosen the lock nut turn the adjusting nut as required and tighten the lock nut Install the rubber boot securely Recheck the t...

Page 67: ...screw Pull the element holder up and remove the air cleaner element assembly from the housing AIR CLEANER COVER T RETAINING CLIPS Remove the element band and the element core from the air cleaner ele...

Page 68: ...nt properly Install the element band onto the air cleaner ele ment BAND ELEMENT CORE Install the element holder onto the element by aligning the hole with the boss and the element assembly over the co...

Page 69: ...stion chamber Remove the spark plug Check the insulator for cracks or damage and the electrodes for wear fouling or discoloration Replace the plug if necessary RECOMMENDED SPARK PLUG BKR5E 11 NGK K16P...

Page 70: ...he T mark on the flywheel with the index mark on the rear crankcase cover Make sure the piston is at TDC Top Dead Center on the compression stroke This position can be obtained by confirming that ther...

Page 71: ...it onto the timing hole cap Install the timing hole cap and tighten it TORQUE 10 Nm 1 0 kgf m 7 Ibf ft Install the recoil starter cover page 3 4 Install the heat guard plate page 6 22 VALVE ADJUSTING...

Page 72: ...nstall the left side cover page 3 5 OIL CHANGE NOTE Pour the engine oil after replacing the oil filter see below Change the oil with the engine warm to assure complete and rapid draining Remove the le...

Page 73: ...ver onto the filter and tighten the bolts TORQUE 10N m 1 0 kgf m 7 Ibfft Fill the crankcase with the recommended engine oil page 4 12 ENGINE IDLE SPEED NOTE Inspect and adjust the idle speed after all...

Page 74: ...L GEAR CASE OIL LEVEL CHECK Place the vehicle on a level surface Remove the oil check bolt and check that the oil flows out of the check bolt hole Check for leaks if there is no oil flow Remove the oi...

Page 75: ...Ibf ft Fill the final gear case with the recommended oil page 4 14 OIL CAPACITY 75 cm3 2 5 US oz 2 6 Imp oz after draining 100 cm3 3 4 US oz 3 5 Imp oz after disassembly DIFFERENTIAL OIL FM FE only LE...

Page 76: ...n material to enter the system when filling the reservoir When the fluid level is low check the brake pads for wear page 4 17 A low fluid level may be due to wear of the brake pads If the brake pads a...

Page 77: ...when the front brake is applied Refer to page 15 6 for brake pad replacement REFERENCE MARK LUG BRAKE LIGHT SWITCH NOTE The front brake light switch cannot be adjusted If the front brake light switch...

Page 78: ...if necessary For cable lubrication Disconnect the brake cable at the brake lever or pedal Thoroughly lubricate the cables and their pivot points with a commercially available cable lubricant or a ligh...

Page 79: ...ID PLATE ENGINE GUARD Check the skid plate and engine guard for cracks damage or looseness Tighten any loose fasteners Replace the skid plate or engine guard as required SKID PLATE ENGINE GUARD SKID P...

Page 80: ...igns of leaks damage or loose fasteners Replace damaged components which cannot be repaired Tighten all nuts and bolts Front Raise the rear wheel off the ground by supporting the frame securely Check...

Page 81: ...Front Rear Standard 25 kPa 0 25 kgf cm2 3 6 psi Minimum 22 kPa 0 22 kgf cm2 3 2 psi Maximum 28 kPa 0 28 kgf cm2 4 0 psi With cargo 25 kPa 0 25 kgf cm2 3 6 psi Check the tires for cuts embedded nails o...

Page 82: ...out 1 15 mm 1 32 19 32 in FM FE Toe out 30 15 mm 1 3 16 19 32 in NOTE Toe out means the front measurement is greater than the rear measurement When the toe is out of specification adjust it by changi...

Page 83: ...5 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM 5 2 COOLING FAN 5 5 SERVICE INFORMATION 5 3 LOWER OIL COOLER 5 7 TROUBLESHOOTING 5 3 OIL PUMP 5 8 UPPER OIL COOLER 5 4 RELIEF VALVE 5 10 5 1...

Page 84: ...LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM ROCKER ARMS SHAFT LOWER OIL COOLER FLYWHEEL STARTER CLUTCH CENTRIFUGAL CLUTCH UPPER OIL COOLER CHANGE CLUTCH COUNTERSHAFT 5 2...

Page 85: ...for oil cooling system inspection SPECIFICATIONS Unit mm in ITEM Engine oil capacity After draining After draining filter change After disassembly Recommended engine oil Oil pump Tip clearance Body cl...

Page 86: ...screw driver and remove insects mud or other obstruc tions with compressed air Check for any oil leakage from the oil cooler and hose joints REMOVAL INSTALLATION Drain the engine oil page 4 12 Remove...

Page 87: ...kcase with the recommended engine oil page 4 12 COOLING FAN REMOVAL Remove both inner fenders page 3 7 Remove both engine air guides page 3 12 Disconnect the breather hose from the cooling fan Disconn...

Page 88: ...5 N m 0 15 kgf m 1 1 Ibf ft FAN MOTOR SHROUD Install the cooling fan on the fan motor shaft by aligning the flat surfaces Apply locking agent to the fan nut threads Install and tighten the fan nut TOR...

Page 89: ...reather hose to the cooling fan Install both engine air guides page 3 12 Install both inner fenders page 3 7 COOLING FAN ASSEMBLY CONNECTOR LOWER OIL COOLER REMOVAL INSTALLATION Drain the engine oil p...

Page 90: ...ll the cooling fan page 5 7 Fill the crankcase with the recommended engine oil page 4 12 OIL PUMP REMOVAL Remove the front crankcase cover page 10 6 Remove the four bolts oil guide plate and oil pump...

Page 91: ...mm 0 004 in ASSEMBLY Dip all parts in clean engine oil Install the outer and inner rotors into the pump body Install the drive pin into the pump shaft and install the shaft into the inner rotor and pu...

Page 92: ...ing and valve from the front crankcase cover INSPECTION Check the relief valve and spring for wear or dam age and replace them if necessary ASSEMBLY Install the relief valve with the long projection s...

Page 93: ...RMATION 6 3 TROUBLESHOOTING 6 4 AIR CLEANER HOUSING 6 5 CARBURETOR REMOVAL 6 6 CARBURETOR DISASSEMBLY INSPECTION 6 7 CARBURETOR ASSEMBLY 6 12 CARBURETOR INSTALLATION 6 17 PILOT SCREW ADJUSTMENT 6 19 H...

Page 94: ...FUEL SYSTEM SYSTEM COMPONENTS 2 3 N m 0 23 kgf m 1 7 Ibf ft 6 2...

Page 95: ...s note the locations of the O rings Replace them with new ones on reassembly If the vehicle is to be stored for more than one month drain the float chamber Fuel left in the float chamber may cause clo...

Page 96: ...uum piston Faulty throttle valve Rich mixture SE valve open Clogged air jets Faulty float valve Float level too high Dirty air cleaner Worn jet needle or needle jet Faulty vacuum piston Engine stalls...

Page 97: ...ver page 3 5 air intake duct by loosening the band screw Disconnect the air vent hose from the carburetor Loosen the connecting hose band screw BAND SCREW Remove the two air cleaner housing mounting b...

Page 98: ...e 6 5 Disconnect the carburetor heater 2P connector Disconnect the throttle position sensor connector Remove the carburetor heater and throttle position sensor wires from the clamp Loosen the starting...

Page 99: ...rom the throttle drum Remove the carburetor THROTTLE DRUM COVER THROTTLE DRUM THROTTLE CABLE CARBURETOR DISASSEMBLY INSPECTION Remove the following from the carburetor body air cleaner connecting hose...

Page 100: ...the attaching screw and air cut off valve SCREW VACUUM HOSE Remove the O rings and joint pipe JOINT PIPE VACUUM CHAMBER Remove the screw set plate air joint and O ring SCREW AIR JOINT Remove the four...

Page 101: ...the needle holder spring jet needle and washer Check the jet needle for stepped wear Check the vacuum piston for wear or damage Check the diaphragm for pin hole deterioration or damage Check the vacu...

Page 102: ...NOTE Remove the carburetor heater and collar after removing the float chamber if necessary SCREWS DIAPHRAGM FLOAT CHAMBER CARBURETOR HEATER COLLAR Remove the following baffle plate float pin float fl...

Page 103: ...and carefully count the num ber of turns until it seats lightly Make a note of this to use as a reference when reinstalling the pilot screw Remove the pilot screw spring washer and O ring Check each...

Page 104: ...FLOAT CHAMBER SPRING DRAIN HOSE PILOT SCREW BAFFLE PLATE FLOAT AND JETS Damage to the pilot Install the pilot screw with the spring washer and screwseatwill new O rings and return it to its original...

Page 105: ...at valve seated and the float arm just touching the valve measure the float level with the float level gauge TOOL Carburetor float level gauge 07401 0010000 FLOAT LEVEL 18 5 mm 0 73 in The float canno...

Page 106: ...he needle holder and set the needle holder into the vacuum piston WASHER JET NEEDLE NEEDLE HOLDER DIAPHRAGM VACUUM PISTON SPRING Turn the needle holder clockwise while pressing it until it locks Holde...

Page 107: ...easing the vacuum piston VACUUM CHAMBER COVER SPRING Align Install the screws with the clamps and tighten them CLAMPS Install a new O ring into the air joint groove Set the set plate into the air join...

Page 108: ...the throttle stop screw to align the butterfly throttle valve with the edge of the outside by pass hole in the carburetor body if the throttle stop screw was removed Clean the strainer screen thorough...

Page 109: ...o the throttle drum Install the throttle cable adjuster into the carburetor body and temporarily tighten the lock nut Install the throttle drum cover onto the carburetor and tighten the screw Install...

Page 110: ...m 0 23 kgfm 1 7 Ibfft Connect the fuel hose to the carburetor Clamp the carburetor heater and throttle position sensor wires as shown Connect the throttle position sensor connector Connect the carbur...

Page 111: ...r 07KMA MN9A100 U S A only INITIAL OPENING 1 1 4 turns out 2 Warm up the engine to operating temperature Stop and go riding for 10 minutes is sufficient 3 Stop the engine and connect a tachometer acco...

Page 112: ...titude The effect of alti tude on horsepower will be greater than this if no carburetor modification is made This engine when operated at high altitude with the carburetor modifications for high altit...

Page 113: ...at resulting in seri ous engine damage and increased exhaust emissions For use at low altitudes you should return thecar buretor to original factory specifications Replace the main jet with the standa...

Page 114: ...rward and dis connect the fuel level sensor 2P red connector Remove the fuel tank from the frame Unhook the seal rubber from the heat guard plate Remove the fuel hose throttle cable and choke cable fr...

Page 115: ...7 ENGINE REMOVAL INSTALLATION SYSTEM COMPONENTS 7 2 ENGINE REMOVAL 7 4 SERVICE INFORMATION 7 3 ENGINE INSTALLATION 7 8 7 1...

Page 116: ...ENGINE REMOVAL INSTALLATION SYSTEM COMPONENTS 54 N m 5 5 kgf m 40 Ibf ft N m 5 5 kgf m 40 Ibf ft kgf m 24 Ibf ft 32 N m 3 3 kgf m 24 Ibf ft 7 2...

Page 117: ...CATIONS 55 2 kg 121 7 lbs 55 5 kg 122 4 lbs 57 7 kg 127 2 lbs 2 4 liters 2 5 US qt 2 1 Imp qt 2 5 liters 2 6 US qt 2 2 Imp qt 3 0 liters 3 2 US qt 2 6 Imp qt TORQUE VALUES Lower engine hanger nut left...

Page 118: ...retor assembly page 6 6 heat guard plate page 6 22 TM FM model only pinch bolt and gearshift pedal Remove the bolt and battery ground cable Remove the rubber cap terminal nut and starter motor cable P...

Page 119: ...reverse selector cable from the stay and disconnect it from the selector arm Disconnect the following TM FM model oil temperature sensor connector FM model oil temperature sensor reverse switch 2P gre...

Page 120: ...oint out of the output shaft only FM ME models Remove the boot band and pull the dust boot off the only outer ring of the front final clutch Pull the propeller shaft out of the outer ring Remove the u...

Page 121: ...rubbers bolts and lower engine hanger bracket right lower engine hanger nut and bolt spacer and mounting rubbers Move the engine forward and disconnect the out put shaft from the universal joint Remo...

Page 122: ...ting rubbers into the engine lower mounts Install the dust seals with the lip side facing out Apply molybdenum disulfide grease to the output shaft splines Install the engine in the frame from the lef...

Page 123: ...ts TORQUE 32 Nm 3 3 kgf m 24 Ibfft 3 engine side upper engine hanger bolts TORQUE 32 Nm 3 3 kgf m 24 Ibfft 4 frame side upper engine hanger nut TORQUE 54 Nm 5 5 kgf m 40 Ibfft Install the spark plug c...

Page 124: ...into the lower mount Install the spacer between the left side of the differ ential and frame 10 mm bolt and a new nut Install the bracket 8 mm bolts and nut Tighten the 10 mm bolt and nut TORQUE 44 N...

Page 125: ...hten the two bolts ARM GUARD V PLATE STAY JS CABLE Coat new O rings with engine oil and install them onto the oil cooler hose joints Install the oil cooler hose joints onto the engine and tighten the...

Page 126: ...at the lower edge is horizontal and tighten the pinch bolt Install the following fuel tank page 6 22 carburetor assembly page 6 17 exhaust system page 3 13 left and right inner fenders page 3 7 left a...

Page 127: ...REFACING 8 13 TROUBLESHOOTING 8 6 CYLINDER COMPRESSION 8 7 CYLINDER HEAD ASSEMBLY 8 16 CYLINDER HEAD INSTALLATION 8 18 CYLINDER HEAD COVER REMOVAL CYLINDER HEAD COVER ASSEMBLY DISASSEMBLY 8 7 INSTALLA...

Page 128: ...CYLINDER HEAD VALVE SYSTEM COMPONENTS 39 N m 4 0 kgf m 29 Ibf ft 32 N m 3 3 kgf m 24 Ibf ft 8 2...

Page 129: ...CYLINDER HEAD VALVE 20 Nm 2 0 kgfm 15 tbf ft 12 N m 1 2 kgfm 9 Ibf ft 8 3...

Page 130: ...er O D Follower bore I D Follower to bore clearance IN EX IN EX IN EX IN EX IN EX Inner Outer IN EX IN EX IN EX IN EX IN EX IN EX IN EX Cylinder head warpage STANDARD 440 kPa 4 5 kgf cm3 64 psi 0 15 0...

Page 131: ...lent commercially avail able in U S A or equivalent commercially avail able in U S A or equivalent commercially avail able in U S A Flat cutter 33 mm EX 32 07780 0012900 Interior cutter 37 5 mm IN 60...

Page 132: ...uck open Cylinder head Leaking or damaged cylinder head gasket Warped or cracked cylinder head Loose spark plug Cylinder piston problem page 9 3 Compression too high Excessive carbon build up on pisto...

Page 133: ...lly reached within 4 7 seconds COMPRESSION PRESSURE 440 kPa 4 5 kgf cm2 64 psi at 380 rpm min1 Check that there is no leakage at the gauge connection Low compression can be caused by blown cylinder he...

Page 134: ...Remove the following rocker arm shafts rocker arms setting plates O rings ROCKER ARM PLATE INSPECTION ROCKER ARM SHAFT Check the rocker arms and shafts for wear or dam age If the rocker arm follower i...

Page 135: ...e 8 7 sparkplug Be careful not to let the nuts and wash ers fall into the cyl inder Remove the engine hanger nut and bolts then remove the hanger bracket and mounting rubbers Remove the two bolts Loos...

Page 136: ...y Valve spring compressor 07757 0010000 Mark all the parts Remove the following so they can be placed back in their originallocations spring retainer outer and inner valve springs valve stem seal spri...

Page 137: ...ding burning or abnormal wear Measure each valve stem O D and record it SERVICE LIMITS IN 5 95 mm 0 234 in EX 5 93 mm 0 233 in Ream the valve guides to remove any carbon build up before measuring the...

Page 138: ...temperature indica tor sticks available from welding supply stores to be sure the cylinder head is heated to the proper temperature NOTICE Using a torch to heat the cylinder head may cause warpage Sup...

Page 139: ...the seat unevenly replace the valve Remove the valve and inspect the valve seat face The valve seat contact should be within the speci fied width and even all around the circumference STANDARD 1 2 mm...

Page 140: ...ng a 45 seat cutter remove any roughness or witha45 cutter irregularities from the seat whenever a valve guide isreplaced TOOLS Seat cutter 40 mm 45 IN Seat cutter 33 mm 45 EX Cutter holder 6 0 mm 077...

Page 141: ...per width VALVE SEAT WIDTH 1 2 mm 0 05 in Make sure that all pitting and irregularities are removed After cutting the seat apply lapping compound to the valve face and lap the valve using light pres s...

Page 142: ...ALVE GUIDE INTAKE VALVE Blow through the oil passage in the cylinder head with compressed air Install the spring seats and new stem seals EXHAUST VALVE Lubricate the valve stem sliding surface with mo...

Page 143: ...stall the valve spring spring compressor TOOL Valve spring compressor cotters using the valve SPRING COMPRESSOR 07757 0010000 Support the cylin der head so the valveheads will not contact anything tha...

Page 144: ...22 N m 2 2 kgf m 16 Ibf ft Connect the spark plug cap Insert theframe Install the mounting rubbers onto the hanger sidehanger bolt bracket bushing with the large I D side facing in fromthefrontside In...

Page 145: ...STALLATION Clean the mating surfaces of the head cover andcyl inder head being careful not to damage them Temporarily install the push rods Make sure the piston is TDC Top Dead Center on the compressi...

Page 146: ...ng sur faces of the cylinder head and head cover Install the nine bolts and tighten them in a criss cross pattern in several steps Tighten the rocker arm shaft retaining bolts Adjust the valve clearan...

Page 147: ...er block and insert a pin to secure it Remove the two bolts and cam chain tensioner lifter 91 TENSIONER LIFTER Remove the following tensioner pivot bolt cam chain tensioner washer cam chain guide spro...

Page 148: ...es not turn smoothly and quietly BEARING CAM LOBES Measure each cam lobe height SERVICE LIMITS IN 35 60 mm 1 402 in EX 35 38 mm 1 393 in Check the decompressor cam operation Press on the decompressor...

Page 149: ...the cam follower and follower bore for scor ing scratches or damage Measure each follower O D SERVICE LIMIT 22 46 mm 0 884 in Measure each follower bore I D SERVICE LIMIT 22 54 mm 0 887 in Subtract e...

Page 150: ...valent topro tect it from dam age Lubricate the cam chain with engine oil and install it over the cam sprocket Turn the camshaft so the punch mark faces up Donot turnthe Install the cam chain over the...

Page 151: ...ensioner lifter and tighten the bolts Remove the pin from the tensioner lifter Make sure the timing mark punch on the cam sprocket is aligned with the index mark V on the crankcase when the T mark on...

Page 152: ...9 CYLINDER PISTON SYSTEM COMPONENTS 9 2 CYLINDER PISTON REMOVAL 9 4 SERVICE INFORMATION 9 3 CYLINDER PISTON INSTALLATION 9 8 TROUBLESHOOTING 9 3 9 1...

Page 153: ...CYLINDER PISTON SYSTEM COMPONENTS 9 2...

Page 154: ...07 3 6214 20 002 20 008 0 7875 0 7877 19 994 20 000 0 7872 0 7874 0 002 0 014 0 0001 0 0006 0 15 0 30 0 006 0 012 0 30 0 45 0 012 0 018 0 20 0 70 0 008 0 028 0 030 0 060 0 0012 0 0024 0 030 0 060 0 00...

Page 155: ...ift the cylinder and remove it being careful not to damage the piston and piston rings with the stud bolts CYLINDER Remove the gasket and the two dowel pins PISTON REMOVAL Place a clean shop towel ove...

Page 156: ...0 mm 3 626 in Calculate the cylinder to piston clearance Refer to page 9 6 for measurement of the piston O D SERVICE LIMIT 0 10 mm 0 004 in Calculate the cylinder taper and out of round at three level...

Page 157: ...ng is nearly flush with the piston and measure the ring to ring groove clearance SERVICE LIMIT Top Second 0 09 mm 0 004 in Insert each piston ring into the bottom of the cylin der squarely using the p...

Page 158: ...necting rod small end I D SERVICE LIMIT 20 07 mm 0 790 in Calculate the connecting rod to piston pin clearance SERVICE LIMIT 0 10 mm 0 004 in CYLINDER STUD BOLT REPLACEMENT Thread two nuts onto the st...

Page 159: ...D RING OIL RING SIDE RAILS SPACER PISTON INSTALLATION Place a clean shop towel over the crankcase to pre vent the clip from falling into the crankcase Apply engine oil to the piston pin hole and conne...

Page 160: ...he cylinder with compressed air Apply liquid sealant to the crankcase mating areas as shown Install the two dowel pins and a new gasket Apply engine oil to the cylinder wall piston outer surface and p...

Page 161: ...KAGE SYSTEM COMPONENTS 10 2 SERVICE INFORMATION 10 3 TROUBLESHOOTING 10 5 FRONT CRANKCASE COVER REMOVAL 10 6 CENTRIFUGAL CLUTCH 10 8 CHANGE CLUTCH 10 13 GEARSHIFT LINKAGE 10 20 FRONT CRANKCASE COVER I...

Page 162: ...CLUTCH GEARSHIFT LINKAGE SYSTEM COMPONENTS 118 N m 12 0 kgfrn 87 Ibf ft 108 N m 80 Ibf ft 11 12 N m 1 2 kgf m 12 Ibf ft 10 2...

Page 163: ...thickness Plate warpage Outer l D Outer guide l D O D Mainshaft O D at clutch outer guide Drum l D Weight lining thickness Clutch spring height Clutch weight spring free length Gear l D Crankshaft O...

Page 164: ...nly Driver 07749 0010000 Attachment 42 x 47 mm 07746 0010300 Pilot 17 mm 07746 0040400 Clutch holder 07ZMB HN20000 Puller 35 x 1 0 mm 07933 HA80000 Driver 22 mm I D 07746 0020100 or07ZMB HN2A100 U S A...

Page 165: ...d center grooves Warped clutch plates Loose clutch lock nut Faulty clutch lifter Improper oil viscosity or oil level Hard to shift Incorrect clutch adjustment page 4 19 Worn or damaged gearshift linka...

Page 166: ...el shift control motor and reduction gears page 22 20 Remove the following joint bolts oil cooler hoses O rings thirteen bolts front crankcase cover gearshift spindle oil seal BOLTS CRANKCASE COVER ba...

Page 167: ...emove the crankshaft end bearing with the special tools TOOLS Bearing remover 17 mm Remover handle Remover weight 07936 3710300 07936 3710100 07741 0010201 or 07936 3710200 or 07936 371020A U S A only...

Page 168: ...7ZMB HN20200 or 07ZMB HN2A100 U S A only Remove the lock nut and washer Remove the centrifugal clutch assembly using the special tool TOOL Puller 35 x 1 0 mm 07933 HA80000 or 07933 HB3000A U S A only...

Page 169: ...the drive plate boss and clutch drum inner contact surfaces for abnormal wear or damage CLUTCH DRUM AND LINING Check the weight contact surface for scratches or abnormal wear Measure the drum I D SER...

Page 170: ...lowing outer plate clutch spring inner plate E CLIPS OUTER PLATE INNER PLATE CLUTCH SPRING Measure the height of the clutch spring SERVICE LIMIT 3 6 mm 0 14 in WEIGHT SPRING Replace thesprings Check t...

Page 171: ...SPRING E CLIPS Install with the Install the clutch weights and springs onto the drive spring s open ends plate as shown facing in WEIGHTS SPRINGS Install the following inner plate with flange side fa...

Page 172: ...drum Install the sprag clutch into the clutch drum with the OUT SIDE mark facing up Apply engine oil to the sprag clutch contacting sur face of the drive plate boss Install the clutch weight assembly...

Page 173: ...ZMB HN20100 holder pin 07ZMB HIU20200 or 07ZMB HN2A100 U S A only TORQUE 118 N m 12 0 kgf m 87 Ibf ft Becareful not to Stake the lock nut into the crankshaft groove damage thecrank N h f crankcase cov...

Page 174: ...OL Clutch center holder U S A TOOLS Holder plate Holder collar A 07JMB MN50301 07HGB 001010B or 07HGB 001010A with 07HGB 001020B or 07HGB 001020A Remove the lock nut and washer Remove the following as...

Page 175: ...SPECTION LIFTER BEARING Turn the inner race of the lifter bearing with your finger The bearing should turn smoothly and quietly Replace if necessary Check the lifter plate for deformation or damage LI...

Page 176: ...41 23 mm 1 623 in IMAM Replace the clutch discs and plates as a set Replace the clutch discs and plates as a set CLUTCH DISC Check the clutch discs for signs of scoring or discoloration Measure the cl...

Page 177: ...the clutch outer for nicks indenta tion or abnormal wear made by the clutch discs Measure the clutch outer I D SERVICE LIMIT 29 05 mm 1 144 in CLUTCH OUTER GUIDE Check the outer guide for wear or dama...

Page 178: ...he primary drive gear SERVICE LIMIT 28 93 mm 1 139 in ASSEMBLY Apply engine oil to the primary drive gear inner surface Install the thrust washer and the drive gear onto the crankshaft Apply molybdenu...

Page 179: ...ts in the clutchouter PLATES Apply engine oil to the threads of a new lock nut and install the washer and lock nut Hold the pressure plate bosses with the special tool and tighten the lock nut TOOL Cl...

Page 180: ...ne oil to the lifter bearing and install the bearing holder and bearing Install the lifter lever by aligning the wide groove indicated by punch mark with the wide tooth on the spindle spline Install t...

Page 181: ...rm bolt guide plate gearshift plate washer gearshift cam while holding stopper arm with a screwdriver dowel pin bolt stopper arm washer return spring Check the gearshift plate cam plate and stopper ar...

Page 182: ...dowel pin into the shift drum Hold the stopper arm with a screwdriver and install the gearshift cam by aligning the pin hole with the dowel pin Install the washer onto the sub gearshift spindle Instal...

Page 183: ...se cover and crankcase thoroughly being careful not to damage them Blow through the oil passages in the crankcase cover with compressed air Coat a new O ring with engine oil and install it onto the cl...

Page 184: ...her onto the crankshaft Install the two dowel pins and anew gasket G A S K E T S j J i r mi DOWEL PINS W k JJ WASHER Apply engine oil tothe lips ofa new spindle oil seal Install the oilseal until it i...

Page 185: ...s into the crankcase cover and tighten the joint bolts Install the following FE model shift control motor and reduction gears page 22 20 left engine cover page 3 15 right engine cover page 20 11 engin...

Page 186: ...11 ALTERNATOR STARTER CLUTCH SYSTEM COMPONENTS 11 2 RECOIL STARTER 11 4 SERVICE INFORMATION 11 3 ALTERNATOR STATOR 11 7 TROUBLESHOOTING 11 3 FLYWHEEL STARTER CLUTCH 11 10 11 1...

Page 187: ...ALTERNATOR STARTER CLUTCH SYSTEM COMPONENTS 108 N m 11 0 kgf m 80 Ibf ft 11 2...

Page 188: ...ter driven gear boss O D STANDARD 51 705 51 718 2 0356 2 0361 SERVICE LIMIT 51 69 2 035 TORQUE VALUES Starter clutch bolt Recoil starter driven pulley bolt Alternator stator bolt Ignition pulse genera...

Page 189: ...using and secure the pulley with a vise pliers or equivalent tool to prevent the pulley from rewinding Untie the starter rope and remove the rope Insert a new starter rope through the pulley hous ing...

Page 190: ...ve the starter rope from the drive pulley Check the starter rope for wear or damage ROPE Ensure thatthe spring doesnot pop out ofthe housing during installation Check the starter spring and replace it...

Page 191: ...ise and hold it PULLEY Hook CUTOUT Route the rope end through the starter housing and grip holes while the pulley remains held in place Tie the rope end in a square knot Install the ratchet spring by...

Page 192: ...n it Check that the recoil starter for smooth operation by pulling the grip COVER INSTALLATION Install the recoil starter assembly and tighten the RECOIL STARTER ASSEMBLY four mounting bolts Install t...

Page 193: ...g removal eleven bolts and clamp alternator cover two dowel pins gasket oil seal drive from the stator side using a mm collar STATOR AND IGNITION PULSE GENERATOR REMOVAL Remove the following grommet t...

Page 194: ...through the oilpassage inthe alternator cover with compressedair Check that thestarter reduction gears areinstalled in position Apply molybdenum oil solution to the reduction gear shaft journals and...

Page 195: ...il pulley holder 07SMB HM70100 TORQUE 108 N m 11 0 kgf m 80 Ibf ft Install the recoil starter page 11 7 Install the air cleaner housing page 6 5 FLYWHEEL STARTER CLUTCH REMOVAL Remove the alternator c...

Page 196: ...g it clockwise DRIVEN GEAR Hold the flywheel with the special tool and remove the starter clutch bolts TOOL Flywheel holder 07725 0040000 or equivalent commercially available in U S A Remove the start...

Page 197: ...race fits loosely in the alternator cover replace the bearing as follows BEARING REPLACEMENT Remove the stator and ignition pulse generator page 11 8 Heat the alternator cover to approximately 80 C 1...

Page 198: ...holder 07725 0040000 or equivalent commercially available in U S A TORQUE 30 N m 3 1 kgf m 22 Ibfft BOLTS FLYWHEEL HOLDER Install the starter driven gear while turning it clockwise DRIVEN GEAR INSTALL...

Page 199: ...LYWHEEL DRIVEN GEAR Temporarily install the recoil starter driven pulley and bolt and tighten it to seat the flywheel page 11 10 Remove the bolt and driven pulley Apply engine oil to the reduction gea...

Page 200: ...SSION CRANKSHAFT BALANCER SYSTEM COMPONENTS 12 2 TRANSMISSION 12 11 SERVICE INFORMATION 12 4 CRANKSHAFT BALANCER 12 20 TROUBLESHOOTING 12 7 CRANKCASE BEARING 12 24 CRANKCASE SEPARATION 12 8 CRANKCASE...

Page 201: ...CRANKCASE TRANSMISSION CRANKSHAFT BALANCER SYSTEM COMPONENTS 12 2...

Page 202: ...CRANKCASE TRANSMISSION CRANKSHAFT BALANCER 12 N m 1 2 kgf m 9 Ibfft 12 3...

Page 203: ...00 0 194 0 197 12 966 12 984 0 5105 0 5112 25 000 25 021 0 9843 0 9851 20 000 20 021 0 7874 0 7882 28 020 28 041 1 1031 1 1040 13 000 13 021 0 5118 0 5126 24 959 24 980 0 9826 0 9835 19 966 19 984 0 7...

Page 204: ...chment 37 x 40 mm 07746 0010200 Attachment 42 x 47 mm 07746 0010300 Attachment 52 x 55 mm 07746 0010400 Attachment 62 x 68 mm 07746 0010500 Attachment 72 x 75 mm 07746 0010600 Pilot 17 mm 07746 004040...

Page 205: ...er handle 07936 3710100 Remover weight 07741 0010201 or 07936 3710200 or 07936 371020A U S A only Assembly collar 07965 VM00100 Assembly shaft 07965 VM00200 Threaded adapter 07965 VM00300 or 07931 ME4...

Page 206: ...alancer installation Transmission jumps out of gear Worn gear dogs or dog holes Worn shift drum guide groove Worn shift fork guide pin Worn gear shifter groove Worn shift fork Bent shift fork shaft Fa...

Page 207: ...h and gearshift linkage page 10 2 oil pump page 5 2 flywheel and starter clutch page 11 2 oil temperature sensor page 21 18 bolt starter motor O ring O RING FE model connector from the reverse switch...

Page 208: ...ly quietly or if the outer race fits loosely in the cover replace the bearing page 12 27 Remove the following TM and FM models thrust washer from the reverse stopper shaft stopper shaft release the st...

Page 209: ...the front crankcase three bolts engine cover stay Loosen thecrank case bolts in acriss cross pattern in several steps three front crankcase bolts thirteen rear crankcase bolts Place the crankcase ass...

Page 210: ...l strainer and strainer plate Wash the strainer thoroughly in non flammable or high flash point solvent until all accumulated dirt has been removed Blow dry it with compressed air to clean completely...

Page 211: ...olt secondary gearshift spindle spindle arm oil seal Do not expand the snap ring more than necessary for removal MAINSHAFT AND COUNTERSHAFT Disassemble the mainshaft and countershaft Clean all disasse...

Page 212: ...D of each gear SERVICE LIMITS M4 25 05 mm 0 986 in M5 20 05 mm 0 789 in C1 C2 C3 CR 28 07 mm 1 105 in Reverse idle 13 04 mm 0 513 in Check the bushings for abnormal wear or damage Measure the gear bus...

Page 213: ...ate the mainshaft gear bushing to shaft clear ance SERVICE LIMIT 0 10 mm 0 004 in Calculate the reverse idle gear to shaft clearance SERVICE LIMIT 0 10 mm 0 004 in OUTPUT SHAFT GEAR Check the teeth an...

Page 214: ...D of each shift fork SERVICE LIMIT 13 04 mm 0 513 in Measure the claw thickness of each shift fork SERVICE LIMIT 4 5 mm 0 18 in GEARSHIFT SPINDLE Check the spindle for damage or bending Check the spin...

Page 215: ...and into the arm by aligning the wide tooth with the wide groove Apply locking agent to the stopper bolt threads Install the bolt and tighten it TORQUE 12 N m 1 2 kgf m 9 Ibf ft NOTE Always install t...

Page 216: ...ASHER THRUST WASHER SNAP RING SPLINE WASHER MAINSHAFT M5 GEAR 33T M2 GEAR 18T M3 GEAR 23T M4 GEAR 28T M3 GEAR 23T M5 GEAR 33T M4 GEAR 28T M1 MRGEAR 13T Gear and bushing sliding surfaces SNAP RING SPLI...

Page 217: ...R 28T REVERSE AND C1 GEAR SHIFTER C1 GEAR 55T C5 GEAR 28T COUNTERSHAFT SPACER THRUST WASHER C3 GEAR 37T C4 GEAR 33T C1 GEAR 55T CR GEAR 28T C2 GEAR 43T C3 GEAR 37T C5 GEAR 28T REVERSE AND C1 GEAR SHIF...

Page 218: ...ghts so that they do not inter fere with the mainshaft Be suretoinstall Install the mainshaft and countershaft assemblies thethrust washer as a set into the rear crankcase on the mainshaft MAINSHAFT M...

Page 219: ...POR fork into M3 gear Cfork into C4gear FRfork into gear shifter on countershaft Apply engine oil to the fork shaft Install the fork shaft through the shift forks and into the crankcase Install the s...

Page 220: ...ar crankshaft bearing using the bear ing puller with a suitable protector Discard the bearing TOOL Universal bearing puller 07631 0010000 or equivalent commercially available in U S A NOTE Always repl...

Page 221: ...a new rear crankshaft bearing Drive the crankshaft bearing into the rear crankcase with the marking side facing up TOOLS Driver Attachment 72 x 75 mm Pilot 32 mm 07749 0010000 07746 0010600 07MAD PR9...

Page 222: ...tall the special tools onto the crankshaft and crankshaft bearing TOOLS Assembly collar Assembly shaft U S A TOOLS Assembly collar Assembly shaft Special nut 07965 VM00100 07965 VM00200 07965 VM00100...

Page 223: ...ING REPLACEMENT Remove the balancer and countershaft bearing with the special tools TOOLS Countershaft bearing Remover shaft 20 mm Remover handle Remover weight Balancer bearing Bearing remover 17 mm...

Page 224: ...400 Mainshaft bearing Driver 07749 0010000 Attachment 52 x 55 mm 07746 0010400 Pilot 22 mm 07746 0041000 Countershaft bearing Driver 07749 0010000 Attachment 42 x 47 mm 07746 0010300 Pilot 20 mm 07746...

Page 225: ...mover weight Drive the countershaft and balancer bearings out of the rear crankcase Apply engine oil to new bearings Drive the mainshaft bearing in with the sealed side facing down TOOLS Mainshaft bea...

Page 226: ...over Apply engine oil to a new bearing Drive a new bearing squarely with the marked side facing up until it is fully seated TOOLS Driver 07749 0010000 Attachment 52 x 55 mm 07746 0010400 Pilot 25 mm 0...

Page 227: ...ten the all the bolts in a crisscross pattern in several steps Install the side cover stay and tighten the three bolts Apply engine oil to the lips of a new output shaft oil seal Install the oil seal...

Page 228: ...t shaft DRIVEN GEAR Install the spacer output shaft drive gear and washer onto the countershaft DRIVE GEAR Set the return spring on the reverse stopper shaft as shown OUTPUT SHAFT 1 SPACER Install the...

Page 229: ...ng surfaces of the crankcase cover and crankcase thoroughly being careful not to dam age them Blow through the oil passage in the crankcase cover with compressed air Shift the transmission into neutra...

Page 230: ...ct the reverse switch connector Coat a new O ring with engine oil and install it into the starter motor groove Install the starter motor into the crankcase cover and onto the crankcase Install the ins...

Page 231: ...MPONENTS 13 2 TIRES 13 11 SERVICE INFORMATION 13 3 WHEEL HUB AND KNUCKLE 13 14 TROUBLESHOOTING 13 5 SUSPENSION ARM 13 20 HANDLEBAR 13 6 FRONT SHOCK ABSORBER 13 24 THROTTLE HOUSING 13 9 STEERING SHAFT...

Page 232: ...el shown 12 N m 1 2 kgf m 9 Ibf ft 32 N m 3 3 kgf m 24 Ibf ft 39 N m 4 0 kgf m 29 Ibf ft 108 N m 11 0 kgf m 80 Ibf ft 29N m 3 0 kgf m 21 Ibf ft 34 N m 3 5 kgf m 25 Ibf ft 54 N m 5 5 kgf m 40 Ibf ft 78...

Page 233: ...housing cover screw Throttle arm nut 2WD 4WD select switch screw FM FE only Front wheel nut Front wheel hub nut Front brake disc bolt Splash guard bolt Shock absorber mounting nut Upper arm pivot nut...

Page 234: ...10300 Attachment 52 x 55 mm 07746 0010400 Attachment 22 x 24 mm 07746 0010800 Attachment 20 mm I D 07746 0020400 Pilot 30 mm 07746 0040700 Pilot 22 mm 07746 0041000 Pilot 16 mm 07746 0041300 Driver 07...

Page 235: ...Steers one side or does not track straight Incorrect wheel alignment Unequal tire pressure Bent tie rod suspension arm or frame Worn or damaged knuckle bearing or wheel hub bearing Weak shock absorber...

Page 236: ...the following headlight meter bracket page 21 4 four wire band two screws bracket holder rear parking brake lever bracket three screws handlebar switch lock nut choke knob holder WIRE BANDS BRAKE LEVE...

Page 237: ...ndlebar upper holders handlebar INSTALLATION Place the handlebar onto the lower holders and align the punch mark on the handlebar with the top of the lower holder Route thewires Install the upper hold...

Page 238: ...d tighten the upper bolt first then tighten the lower bolt HOLDER MASTER CYLINDER Install the throttle housing and holder Align the lug of the throttle housing with the mating surface of the master cy...

Page 239: ...ew PUNCH MARK Install the four wire bands Install the headlight meter bracket page 21 4 BRAKE LEVER BRACKET THROTTLE HOUSING DISASSEMBLY Remove the following three screws throttle housing cover gasket...

Page 240: ...aces Install a new lock washer and the throttle arm nut and tighten the nut TORQUE 7 0 N m 0 71 kgf m 5 2 Ibfft Bend up the lock washer tab against the nut Install the housing cover with a new gasket...

Page 241: ...e tire from the rim using a tire changing machine or tire irons and rim protectors TIRE REPAIR NOTE Use the manufacturer s instructions for the tire repair kit you are using If your kit does not have...

Page 242: ...ttom rim supports to the proper rim size Align the flat side of the support with the corre sponding rim size indicator Lube the bead area of the tire with water pressing down on the tire sidewall bead...

Page 243: ...ure over the injury Make a mark around the patch slightly larger than the patch itself Rough the area marked inside the tire with a tire buffer or a wire brush Clean the rubber dust from the buffed ar...

Page 244: ...e following MOUNTING BOLTS so that it does not hang from the brake hose Do not twist or bend the brakehose mounting bolts front brake caliper cotter pin hub nut wheel hub socket bolts splash guard Rem...

Page 245: ...hown This will ease installation of the tool and prevent damage to the pressure bolt threads Insert the jaws carefully making sure that you do not damage the ball joint boot If necessary apply Adjust...

Page 246: ...ring in the wheel hub TM model and knuckle FM FE models with your finger The bearings should turn smoothly and qui etly Also check that the bearing outer race fits tightly in the hub or knuckle Inspec...

Page 247: ...seated TOOLS Driver 07749 0010000 Attachment 52 x 55 mm 07746 0010400 Pilot 30 mm 07746 0040700 Install the snap ring into the knuckle groove with the chamfered side facing in Apply grease to a new ou...

Page 248: ...he knuckle and special tools with B mark side of the remover installer facing to the ball joint in the vise as shown Press the ball joint into the knuckle until it is fully seated A MARK M ATTACHMENT...

Page 249: ...f ft Install new cotter pins Tighten the tie rod ball joint nut by holding the joint stud flat surfaces TORQUE 54 N m 5 5 kgf m 40 Ibf ft Install a new cotter pin Apply molybdenum disulfide grease to...

Page 250: ...two brake hose clamp bolts and the brake hose from the hose guide FM FE only Remove the two bolts and front guard from the lower arm Remove the cotter pins from the ball joint studs Loosen the ball j...

Page 251: ...vot nuts bolts and lower arm UPPER ARM Remove the dust seal caps and pivot collar from the upper arm DUST SEAL CAPS INSPECTION Check the pivot bushings for wear or damage PIVOT BUSHING Inspect the bal...

Page 252: ...T Set the upper arm and special tools with B mark side of the remover installer facing to the ball joint in the hydraulic press as shown Press the ball joint into the upper arm until it is fully seate...

Page 253: ...bolts and new nuts and loosely tighten the nuts Install the wheel hub knuckle assembly onto the upper and lower arms and install the ball joint nuts Tighten each nut to the specified torque and furthe...

Page 254: ...Check the upper pivot bushing for wear or damage Check the damper unit for leakage or other damage Replace the shock absorber assembly if necessary DAMPER UNIT UPPER PIVOT BUSHING Remove the lower piv...

Page 255: ...dust seal lips and install the dust seals into the lower pivot until they are flush with the pivot surfaces Install the pivot collar COLLAR DUST SEALS INSTALLATION Install the front shock absorber in...

Page 256: ...hydraulicsys tem cotter pins ball joint nuts by holding the joint stud flat sur faces tie rods from the steering shaft arm cotter pin steering shaft end nut washer steering shaft arm brake hose from...

Page 257: ...NSPECTION Check the steering shaft bushing for wear or damage Check the steering shaft for distortion or damage Turn the inner race of the steering shaft bearing with your finger The bearing should tu...

Page 258: ...side facing up until it is fully seated using the spe cial tools and a 10 mm washer TOOLS Clutch compressor attachment 07LAE PX40100 Compressor bolt assembly 07GAE PG40200 Attachment 42 x 47 mm 07746...

Page 259: ...Install the brake hose grommet into the hose clip Apply molybdenum disulfide grease to the steering shaft spline Install the shaft arm over the steering shaft by align ing the wide tooth with the wid...

Page 260: ...front fender page 3 9 inner fenders page 3 7 LOWER HOLDER NUTS WASHERS HOSE CLAMP GUIDE CLIP REMOVAL Remove the inner fender page 3 7 Remove the front wheel page 13 10 Remove the cotter pins from the...

Page 261: ...5 mm 0 23 in FM FE model A 8 5 mm 0 33 in B 8 5 mm 0 33 in A difference between distances A and B should be 3 mm 0 12 in max Tighten these nuts Temporarily tighten the lock nuts while the ball joint a...

Page 262: ...14 REAR WHEEL SUSPENSION SYSTEM COMPONENTS 14 2 REAR WHEEL 14 6 SERVICE INFORMATION 14 3 REAR SHOCK ABSORBER 14 6 TROUBLESHOOTING 14 5 SWINGARM 14 8 14 1...

Page 263: ...EAR WHEEL SUSPENSION SYSTEM COMPONENTS 34 N m 3 5 kgf m 25 Ibfft 64 IM m 6 5 kgf m 47 Ibfft 44 N m 4 5 kgf m 32 Ibfft 112 N m 11 4 kgf m 83 Ibfft 10 N m 1 0 kgfm 7 Ibfft 112 N m 11 4 kgfm 83 Ibfft 14...

Page 264: ...pplied to the lock nut The specification given is the actual torque applied to the lock nut not the reading on the torque wrench Do not overtighten the lock nut The specification later in the text giv...

Page 265: ...0 Driver 07949 3710001 Adjustable bearing remover set 07JAC PH80000 Remover attachment 07JAC PH80100 Remover shaft assembly 07JAC PH80200 Not available in U S A or 07736 A01000B or commercially availa...

Page 266: ...rear axle bearings Bent rear axle Rear brake drag Soft suspension Weak shock absorber spring Oil leakage from damper unit Stiff suspension Bent shock absorber damper rod Faulty rear suspension pivot...

Page 267: ...nd right wheels direction Install the wheel nuts with the tapered side facing inward and tighten them TORQUE 64 N m 6 5 kgf m 47 Ibff ft REAR SHOCK ABSORBER REMOVAL Support the vehicle with a support...

Page 268: ...0010800 07746 0041300 Press thebearing Apply grease to the needle rollers of a new bearing with themarked Carefully press the needle bearing into the lower sidefacing up pivot until it is 5 4 5 5 mm 0...

Page 269: ...ghten it TORQUE 44 N m 4 5 kgf m 32 Ibf ft Tighten the upper mounting nut TORQUE 34 N m 3 5 kgf m 25 Ibf ft LOWER MOUNTING SWINGARM REMOVAL Remove the final drive assembly page 17 10 Remove the breath...

Page 270: ...m pivot lock nut using the special tool TOOL Lock nut wrench 07908 4690003 Remove the left and right swingarm pivot bolts and the swingarm from the frame Remove the universal joint from the output sha...

Page 271: ...ment 28 x 30 mm 07749 0010000 07946 1870100 Jit SWINGARM GREASE HOLDER T Remove the outer race from the swingarm using the special tools TOOLS Adjustable bearing remover set Remover attachment Remover...

Page 272: ...and right pivot bolts Tighten the left pivot bolt TORQUE 112 N m 11 4 kgf m 83 Ibfft Tighten the right pivot bolt TORQUE 10 N m 1 0 kgf m 7 Ibfft Move the swingarm up and down several times to seat th...

Page 273: ...dal and install the switch stay onto the frame with a new bolt Install the joint boot over the swingarm securely Position the screw of the boot band facing up as shown and tighten it Route the breathe...

Page 274: ...NENTS 15 2 BRAKE PAD DISC 15 6 SERVICE INFORMATION 15 3 FRONT MASTER CYLINDER 15 8 TROUBLESHOOTING 15 4 FRONT BRAKE CALIPER 15 11 BRAKE FLUID REPLACEMENT REAR BRAKE DRUM SHOES 15 15 AIR BLEEDING 15 5...

Page 275: ...BRAKE SYSTEM SYSTEM COMPONENTS 44 NTTI 4 5 kgf m 32 Ibf ft i 137 N m 14 0 kgf m 101 Ibf ft 34 N m 3 5 kgf m 25 Ibf ft 15 2...

Page 276: ...as they may not be compatible Always check brake operation before riding the vehicle SPECIFICATIONS Unit mm in ITEM Front brake Rear brake Recommended brake fluid Disc thickness Disc runout Master cy...

Page 277: ...isc Sticking worn caliper piston Sticking worn master cylinder piston Bent brake lever Brake lever hard Clogged restricted brake system Sticking worn caliper piston Sticking worn master cylinder pisto...

Page 278: ...bleed valve and pump the front brake lever until no more fluid flows out of the bleed valve Perform above procedure for the other side bleed valve BLEED VALVE M BLEEDHOSE BRAKE FLUID FILLING BLEEDING...

Page 279: ...es in the bleed hose Tighten the bleed valve TORQUE 5 4 N m 0 54 kgf m 4 0 Ibf ft Perform air bleeding for the other side bleed valve After bleeding air operate the front brake lever If it still feels...

Page 280: ...iper pis ton against the pad BRAKE PADS CALIPER BODY SLIDE PIN BOLT BRAKE DISC INSPECTION Remove the front wheel page 13 10 Visually inspect the brake disc for damage or crack Measure the brake disc t...

Page 281: ...and sealing washers Disconnect the front brake switch connectors Remove the master cylinder holder bolts holder and master cylinder MASTER CYLINDER HOLDER Remove the pivot nut bolt and brake lever Rem...

Page 282: ...amage ASSEMBLY Coat the master piston piston cups and oil seal with clean DOT 4 brake fluid Install the oil seal into the master cylinder Install the spring onto the piston end Donotallowthe Install t...

Page 283: ...0 12 kgf m 0 9 Ibf ft Align themating Install the front brake master cylinder and holder surface of the mas with the UP mark facing up Tighten the upper bolt ter cylinder and first then tighten the l...

Page 284: ...nect the brake hose from the brake caliper by removing the oil bolt and sealing washer Loosen the two caliper pin bolts Remove the two mounting bolts and brake caliper assembly Remove the two caliper...

Page 285: ...ng apply small squirts of air pressure to the fluid inlet to remove the piston the nozzle too close to the inlet Remove the caliper piston boot Becareful not to Push the piston seal in and lift it out...

Page 286: ...caliper cylinder groove properly Coat the caliper piston with clean brake fluid and install them into the caliper cylinder with the open side toward the pads and install the piston boot into the pist...

Page 287: ...5 kgf m 32 Ibfft Tighten the caliper pin bolts TORQUE 23 N m 2 3 kgf m 17 Ibfft BOLTS CALIPER BRACKET CALIPER PIN BOLTS Connect the brake hose with the oil bolt and new sealing washers while insertin...

Page 288: ...RAKE DRUM REMOVAL Remove the right rear wheel page 14 6 Remove the following cotter pin hub nut wheel hub cover bolts brake drum cover O ring brake drum COTTER PIN BRAKE DRUM dust seals from the wheel...

Page 289: ...s DISASSEMBLY Remove the following cotter pins setting plate brake shoes springs adjusting nuts joint pins springs brake cables nut and bolt brake arm wear indicator return spring brake cam felt seal...

Page 290: ...oil to the felt seal and install it over the brake cam Install the return spring by aligning its end with the hole Install the wear indicator by aligning its wide teeth with the wide groove Install t...

Page 291: ...s are facing outside as shown and install linings the assembly onto the brake panel Install thecotter Install the setting plate with the chamfered side fac pinsfromthefront ing toward the brake shoe a...

Page 292: ...the axle Install the hub nut and tighten it to the specified torque and further tighten until its grooves align with the cotter pin hole TORQUE 137 Nm 14 kgf m 101Ibf ft Install a new cotter pin Insta...

Page 293: ...e groove in the pivot shaft Connect the brake cable to the pedal and install the pedal onto the pivot shaft Install the washer and a new cotter pin Install the return spring as shown Hook the rear bra...

Page 294: ...AR DISASSEMBLY INSPECTION 16 15 SERVICE INFORMATION 16 3 FRONT FINAL GEAR CASE BEARING TROUBLESHOOTING 16 6 REPLACEMENT 16 22 FRONT DRIVE SHAFT 16 7 F R 0 N T F I N A L G E A R ASSEMBLY 16 25 FRONT FI...

Page 295: ...FRONT DRIVING MECHANISM FM FE models SYSTEM COMPONENTS 44 N m 4 5 kgf m 32 Ibf ft 44 N m 4 5 kgf 32 Ibf ft 7N 5 2 m 10 N m 1 0 kgf 7 Ibf ft 10 N m 7 Ibf ft 22 N m 2 2 kgf m 16 Ibf 16 2...

Page 296: ...Front differential Oil capacity After draining After disassembly Recommended oil Gear backlash Backlash difference Slip torque Face cam to housing distance Differential ring gear depth Cone spring fre...

Page 297: ...mm I D 07746 0030100 Attachment 30 mm I D 07746 0030300 Pilot 15 mm 07746 0040300 Pilot 28 mm 07746 0041100 Driver 07749 0010000 Universal bearing puller 07631 0010000 or equivalent commercially avai...

Page 298: ...remover 15 mm 07936 KC10500 Remover shaft 15 mm 07936 KC10100 Remover head 15 mm 07936 KC10200 Bearing clip compressor 25 mm 070ME HN8A100 Differential inspection tool 07KMK HC50101 Press attachment 0...

Page 299: ...er tooth contact between ring gear and pinion gear Gear noises while coasting Damaged or chipped gears Abnormal noises when turning Worn or damaged ring gear bearing Worn or damaged face cam and cam f...

Page 300: ...other damage Check the drive shaft joints for excessive play or noise by moving thejoints in a circular direction If the outboard joint seems to be worn or damaged the drive shaft must be replaced NOT...

Page 301: ...STOPPER RING INBOARD BOOT SNAP RING BEARING Replace these com ponents as an assembly Check the following for wear or damage bearing cage race steel balls inboard joint INBOARD JOINT STEEL BALLS Remove...

Page 302: ...D JOINT SNAP RING BEARING STOPPER RING BANDB INBOARD BOOT The outboard boot is large and the inboard boot is small Donotinterchange them BAND C OUTBOARD BOOT BAND OUTBOARD BOOT INBOARD BOOT Note the i...

Page 303: ...ing to the drive shaft Install the snap ring with the chamfered side facing to the bearing OUTBOARD BOOT INBOARD BOOT SNAP RING Pack the inboard joint with 55 75 g of specified grease SPECIFIED GREASE...

Page 304: ...ot Bend down the band end and secure it with the lock tabs Tap the lock tabs with a plastic hammer OUTBOARD BOOT BAND BANDC BANDB LOCK TABS INSTALLATION Install a new stopper ring into the groove in t...

Page 305: ...d page 3 8 left drive shaft page 16 7 two bolts guard plate front speed sensor andC D ring two bolts and final clutch cover rear speed sensor and front final clutch wires from the clamp three bolts cl...

Page 306: ...ts and mounting bracket 10 mm mounting nut bolt and spacer 10 mm mounting bolt Move the front final gear assembly forward 8 mm BOLTS SPACER Pull the propeller shaft joint out of the output shaft of th...

Page 307: ...ER SHAFT BOOT Pull the propeller shaft to force the stopper ring past the groove in the outer ring and remove it Remove the stopper ring from the propeller shaft Separate the right drive shaft from th...

Page 308: ...f they are damaged check the splines of the output shaft and outer ring Check the rubber seals for fatigue or damage Check the boots for cuts deterioration or damage BOOTS RUBBER SEAL RUBBER SEAL SPRI...

Page 309: ...ference in measurements exceeds the ser vice limit it indicates that the bearing is not installed squarely or the case is deformed Inspect the bearings and case If the backlash is excessive replace th...

Page 310: ...and shims PRYING POINTS DIFFERENTIAL ASSEMBLY BOLTS SHIMS BEARING INSPECTION Turn the inner race of each bearing in the gear case and case cover with your finger The bearings should turn smoothly and...

Page 311: ...bfft Rotate the ring gear several times in both directions of rotation Check the gear tooth contact pattern through theoil filler hole The pattern is indicated by the Prussian Blue applied to the pini...

Page 312: ...TOO LOW PINION GEAR SHIM FLANK Drive side FLANK Coast side DIFFERENTIAL INSPECTION Install the inspection tools into both sides of the differential TOOL Differential inspection tool 07KMK HC50101 or...

Page 313: ...e cam six cam followers A and six cam followers B face cam CAM FACE CAM FOLLOWERS A AND B CAM FACE DIFFERENTIAL COMPONENTS INSPECTION RING GEAR Check the sliding surface of the ring gear for dam age o...

Page 314: ...ollowers as a set damage 12 pieces CAM FACE CAM FOLLOWERS Temporarily assemble the differential housing face cams and cam followers page 16 27 Measure the height of the face cam from the hous ing mati...

Page 315: ...ASE SHAFT PINION GEAR Heat the final clutch case to about 100 C 212 F Remove the pinion gear bearing from the final clutch case using the special tools TOOLS Bearing remover 30 mm 07936 8890300 Remove...

Page 316: ...ears in the access hole Bend up the end of the ring with a screwdriver Grasp the end of the ring with needle nose pliers and pull the stopper ring out through the access hole Remove the oil filler cap...

Page 317: ...Pilot 15 mm 07749 0010000 07746 0010800 07746 0040300 Place the bearing and tool assembly into a freezer for at least 30 minutes Heat the gear case to 80 C 176 F Remove the bearing and tool assembly...

Page 318: ...BEARING PINION SHIM 10 mm BOLT OIL SEAL FRONT FINAL CLUTCH 8 mm BOLT GEAR CASE COVER DIFFERENTIAL SHIM RIGHT FACE CAM LEFT FACE CAM DIFFERENTIAL BEARING OIL SEAL O RING DIFFERENTIAL HOUSING CAM FOLLOW...

Page 319: ...mm I D Attachment 30 mm I D 07746 0030100 07746 0030300 Be careful not to damage the oil seal lips in the final clutch Press the pinion gear bearing assembly into the front final clutch using the spec...

Page 320: ...e face cam onto the cam followers Measure the depth of the ring gear page 16 20 and the height of the housing to cam page 16 21 and record them Calculate the shim thickness using the equation below Th...

Page 321: ...OLTS FRONT FINAL GEAR CASE ASSEMBLY NOTE When the gear set bearing differential housing and or front final gear case has been replaced check the tooth contact pattern page 16 17 and gear backlash page...

Page 322: ...10mm bolt 49 N m 5 0kgf m 36 Ibfft 8 mm bolt 25 IM m 2 5 kgf m 18 Ibfft Make sure that the gear assembly rotates smoothly without binding PROPELLER SHAFT ASSEMBLY INSTALLATION 10 mm BOLTS 8 mm BOLTS O...

Page 323: ...the outer ring groove Make sure that the stopper ring is seated properly by pulling on the propeller shaft lightly Install the propeller shaft boot over the outer ring securely and the boot band into...

Page 324: ...ll the spacer 10 mm mounting bolt and a new 10 mm mounting nut Install the mounting bracket 8 mm bolts 8 mm mounting bolt and nut Tighten the all mounting fasteners TORQUE 10 mm 44 N m 4 5 kgf m 32 Ib...

Page 325: ...r cover stay and three bolts and tighten the bolts TORQUE 10 N m 1 0 kgf m 7 Ibf ft Clamp the rear speed sensor wire and front final clutch wire Install the final clutch cover while hooking it to the...

Page 326: ...te and two bolts and tighten the bolts TORQUE 10 N m 1 0 kgfm 7 Ibf ft Install the following left drive shaft page 16 11 carry pipe guard page 3 8 both inner fenders page 3 7 left side cover page 3 5...

Page 327: ...3 TROUBLESHOOTING 17 6 REAR AXLE REMOVAL 17 7 REAR FINAL DRIVE REMOVAL 17 10 REAR FINAL GEAR DISASSEMBLY INSPECTION 17 12 REAR FINAL GEAR CASE BEARING REPLACEMENT 17 17 REAR FINAL GEAR ASSEMBLY 17 20...

Page 328: ...REAR DRIVING MECHANISM SYSTEM COMPONENTS 54 N m 5 5 kgf m 40 Ibf ft 137 N m 14 0 kgf m 101 Ibf ft 44 32 5 kgf m 17 2...

Page 329: ...S Unit mm in ITEM Axle runout Rear final drive Oil capacity After draining After disassembly Recommended oil Gear backlash Backlash difference Ring gear to stop pin clearance STANDARD 75 cm3 2 5 US oz...

Page 330: ...746 0010800 Pilot 35 mm 07746 0040800 Pilot 28 mm 07746 0041100 Pilot 14 mm 07746 0041200 Driver 40 mm I D 07746 0030100 Attachment 30 mm I D 07746 0030300 Driver 07749 0010000 Lock nut wrench 30 x 64...

Page 331: ...07947 KA50100 Differential bearing clip compressor 07YME HN4010A Bearing remover 14 mm 07WMC KFG0100 Remover shaft 15 mm 07936 KC10100 Remover weight 07741 0010201 or 07936 371020A or 07936 3710200 U...

Page 332: ...axle Worn or scored pinion and splines Worn pinion and ring gears Excessive backlash between pinion and ring gears Oil level too low Wobble or vibration in vehicle Axle not tightened properly Bent ax...

Page 333: ...joint pins springs brake cables BRAKE CABLES JOINT PINS Do not get grease onto the brakeshoe linings breather hose four nuts brake panel assembly O ring I SPRINGSJ ADJUSTING NUTS 7 RING BRAKE PANEL co...

Page 334: ...NG BOLT NUTS O RING LEFT AXLE HOUSING left side collar LEFT SIDE COLLAR Remove the rear axle by driving the axle from the left side using a rubber mallet REAR AXLE INSPECTION REAR AXLE Set the axle in...

Page 335: ...seal and drive the axle bearing out of the axle housing DUST SEAL AXLE BEARING Drive the bearing into the axle housing with the sealed side facing down until it is 11 0 11 5 mm 0 43 0 45 in below the...

Page 336: ...07746 0041100 Install the snap ring with the chamfered side facing to the bearing securely Apply grease to a new dust seal lips Install the dust seal with the flat side facing up until it is flush wit...

Page 337: ...rioration or damage Check the splines of the drive shaft for wear or damage If the splines are damaged check the pinion and universal joint splines also Refer to page 14 8 Swingarm for universal joint...

Page 338: ...SERVICE LIMIT 0 2 mm 0 01 in If the difference in measurements exceeds the ser vice limit it indicates that the bearing is not installed squarely or the case is deformed Inspect the bearings and case...

Page 339: ...nts using a screwdriver and remove it PRYING POINTS Remove the ring gear and shims RING GEAR BEARING INSPECTION Turn the inner race of each bearing in the gear case and case cover with your finger The...

Page 340: ...ts in several steps until the cover evenly touches the gear case Then while rotating the pinion gear tighten the bolts to the specified torque in a crisscross pattern in several steps TORQUE 10 mm bol...

Page 341: ...Pinion gear shims A 1 64 mm 0 065 in B 1 70 mm 0 067 in C 1 76 mm 0 069 in D 1 82 mm 0 072 in E 1 88 mm 0 074 in F 1 94 mm 0 076 in G 2 00 mm 0 079 in H 2 06 mm 0 081 in I 2 12 mm 0 083 in J 2 18 mm...

Page 342: ...MB00002 Install the special tools onto the pinion gear shaft and gear case TOOLS Puller shaft Pinion puller base or U S A only Puller shaft Special nut Pinion puller base 07931 ME40000 07HMC MM80110...

Page 343: ...TOOLS Driver 40 mm I D Attachment 30 mm I D 07746 0030100 07746 0030300 REAR FINAL GEAR CASE BEARING REPLACEMENT RING GEAR BEARING Remove the oil seals from the gear case and cover Drive the bearings...

Page 344: ...ver 15 mm 07936 KC10200 Remover weight 07741 0010201 or 07936 371020A or 07936 3710200 U S A only Remove the bearing cage and bearings from the inside of the pinion bearing to allow the special tool t...

Page 345: ...or at least 30 minutes Heat the gear case to 80 C 176 F Remove the bearing and tool assembly from the freezer and drive the bearing into the gear case using the special tools Only strike the driver on...

Page 346: ...AL STOPPER RING RING GEAR BEARING RING GEAR PINION NEEDLE BEARING RING GEAR BEARING PINION GEAR S H M SHIM O RING PIN ON BEARING LOCK NUT STOPPER RING PINION JOINT RING GEAR BEARING 6007 PINION BEARIN...

Page 347: ...E Actual 98 N m 10 0 kgfm 72 Ibf ft wrench reading Indicated 89 N m 9 1 kgfm 66 Ibf ft information on page 17 3 Service Information Becareful not to Stake the lock nut into the case groove damage the...

Page 348: ...s the standard value heat the case cover to approximately 80 C 176 F and remove the stop pin by tapping the cover Install a stop pin shim to obtain the correct tk clearance 7 Keep dust and dirt out of...

Page 349: ...em several steps until the cover evenly touches the case Then while rotating the pinion gear tighten the bolts to the specified torque in a crisscross pattern in several steps TORQUE 10 mm bolt 49 N m...

Page 350: ...groove Insertthebolts Install the right axle housing onto the gear case and fromtherightside swingarm with the four bolts and eight new nuts Tighten the four rear final gear case mounting nuts TORQUE...

Page 351: ...inward CENTER SPLINES REAR AXLE LEFT SIDE COLLAR Coat a new O ring with grease and install it into the gear case groove Install the left axle housing with the skid plate bolt JER MOUNTING BOLT M l I T...

Page 352: ...onto the rear axle being careful not to damage the dust seal lip DUST SEAL Install the hub nut and tighten it to the specified torque and further tighten until its grooves align with the cotter pin ho...

Page 353: ...ders on the brake panel upper holder for lever brake cable and lower holder for pedal brake cable Install the cable springs onto the cables Connect the brake cables to the brake arm with the joint pin...

Page 354: ...CHARGING SYSTEM COMPONENT LOCATION 18 2 BATTERY 18 5 SYSTEM DIAGRAM 18 2 CHARGING SYSTEM INSPECTION 18 7 SERVICE INFORMATION 18 3 ALTERNATOR CHARGING COIL 18 8 TROUBLESHOOTING 18 4 REGULATOR RECTIFIER...

Page 355: ...ING SYSTEM COMPONENT LOCATION FE model shown FUSE BOX MAIN FUSE 30 A ALTERNATOR REGULATOR RECTIFIER SYSTEM DIAGRAM Y Y Y ALTERNATOR MAIN FUSE 30 A Y Y Y G R BATTERY REGULATOR RECTIFIER G Green R Red Y...

Page 356: ...overcharging symptom If one of the battery cells is shorted and battery voltage does not increase the regulator rectifier supplies excess voltage to the battery Under these conditions the electrolyte...

Page 357: ...current leakage below standardvalue NO Shorted wire harness Faulty ignition switch YES Faulty regulator rectifier 4 Alternator Charging Coil Inspection Check the alternator charging coil page 18 8 STA...

Page 358: ...e battery in the reverse order of removal After connecting the battery cables coat the termi nals with grease VOLTAGE INSPECTION Remove the seat page 3 4 Measure the battery voltage using a commercial...

Page 359: ...should only be charged if they register in the YELLOW or REDzone BATTERY CHARGING U S A only Remove the battery page 18 5 NOTE Make sure the area around the charger is well ventilated clear of flammab...

Page 360: ...Retest the battery using the Honda Battery Tester and recharge if necessary using the above steps NEW BATT YELLOW RED 1 TIMER Trickle CHARGING SYSTEM INSPECTION CURRENT LEAKAGE TEST Remove the seat pa...

Page 361: ...ANDARD 0 1 1 0 1 20 C 68 F Check for continuity between each Yellow wire ter minal of the alternator side connector and ground There should be no continuity Replace the alternator stator if resistance...

Page 362: ...19 IGNITION SYSTEM COMPONENT LOCATION 19 2 IGNITION SYSTEM INSPECTION 19 5 SYSTEM DIAGRAM 19 2 IGNITION COIL 19 7 SERVICE INFORMATION 19 3 IGNITION TIMING 19 7 TROUBLESHOOTING 19 4 19 1...

Page 363: ...INE CONTROL MODULE ECM IGNITION PULSE GENERATOR SYSTEM DIAGRAM ENGINE CONTROL MODULE ECM Bu Y W G SPARK P L U G i IGNITION PULSE GENERATOR IGNITION COIL Bl R Y BI G Bu Bl Y Bl W Bl G P or O R BI i IGN...

Page 364: ...nnections Check those connections before proceeding Use a spark plug of the correct heat range Using spark plug with an incorrect heat range can damage the engine For ignition switch inspection see pa...

Page 365: ...r cuit 8 Faulty ignition coil 9 Faulty ECM When above No 1 through 8 are normal 1 Incorrect peak voltage adapter connections System is normal if measured voltage is over the specifications with revers...

Page 366: ...pec tion Poor connected connectors can cause incor rect readings Check the cylinder compression and check that the spark plug is installed correctly in the cylinder head Remove the fuel tank cover pag...

Page 367: ...al measure the peak voltage at the alterna tor connector Disconnect the alternator 5P connector and connect the peak voltage tester or adapter probes to the Blue yellow and White wire terminals of the...

Page 368: ...d warm it up operating temperature Stop the engine and remove the timing hole cap Read the instruc Connect the timing light and tachometer tions fortiming light g t a r t t h j t j d e g n d c h e c k...

Page 369: ...20 ELECTRIC STARTER COMPONENT LOCATION 20 2 STARTER MOTOR 20 6 SYSTEM DIAGRAM 20 2 STARTER RELAY SWITCH 20 12 SERVICE INFORMATION 20 3 DIODE 20 13 TROUBLESHOOTING 20 4 20 1...

Page 370: ...RELAY SWITCH STARTER MOTOR GEAR POSITION SWITCH SYSTEM DIAGRAM STARTER MOTOR STARTER RELAY SWITCH MAIN FUSE 30 A Y R Bl Black G Green Gr Gray Lg Light green P Pink R Red W White Y Yellow Lg R Gr W Gr...

Page 371: ...r quickly enough or supply adequate ignition current If the current is kept flowing through the starter motor to turn it while the engine is not cranking over the starter motor may be damaged See page...

Page 372: ...itchclick YES GO TO STEP 4 NO GO TO STEP 5 4 Starter Motor Inspection Turn the ignition switch to OFF Apply battery voltage to the starter motor directly Does the starter motor turn YES Poorly connect...

Page 373: ...minal NO Faulty starter relay switch Starter motor turns engine slowly Low battery voltage Poorly connected battery cable Poorly connected starter motor cable Faulty starter motor Poorly connected gro...

Page 374: ...move the terminal nut and starter motor cable Remove the two mounting bolts battery cable and the starter motor from the crankcase Remove the O ring from the starter motor TERMINAL NUT MOTOR CABLE BOL...

Page 375: ...E SHIMS Check the bushing in the rear cover for wear or damage BUSHING Check the dust seal and needle bearing in the front cover for deterioration wear or damage DUST SEAL NEEDLE BEARING Check the com...

Page 376: ...ch commutator bar and the armature shaft There should be no continuity Check for continuity between the insulated brush and cable terminal There should be continuity CONTINUITY NO CONTINUITY CONTINUIT...

Page 377: ...ring Remove the brushes from the brush holder Measure the brush length SERVICE LIMIT 9 0 mm 0 35 in INSULATOR WASHER WASHER O RING NUT ASSEMBLY REAR COVER NUT INSULATOR WASHERS O RING BRUSH HOLDER SEA...

Page 378: ...of the case from pulling the armature against it Install a new seal ring onto the motor case Install the same number of shims in the same loca tions as noted during disassembly Install the rear cover...

Page 379: ...r groove Install the starter motor into the rear crankcase cover and onto the crankcase Install the mounting bolts with the battery cable terminal and tighten them securely Install the starter motor c...

Page 380: ...ke sure the engine stop switch is turned to O and turn the ignition switch to ON Measure the voltage between the Yellow red wire terminal of the wire harness side connector and ground If the battery v...

Page 381: ...ove the seat page 3 4 Remove fuse box cover and the diode Check for continuity between the diode terminals When there is continuity a small resistance value will register If there is continuity in one...

Page 382: ...ON SWITCH 21 7 HANDLEBAR SWITCH 21 8 BRAKE LIGHT SWITCH 21 9 FRONT BRAKE SWITCH 21 10 GEAR POSITION SWITCH 21 10 CARBURETOR HEATER CARBURETOR HEATER SWITCH 21 11 COMBINATION METER Except A CM type TM...

Page 383: ...VER SWITCH COMBINATION METER FM FE models ACCESSORY SOCKET FUEL LEVEL SENSOR FM FE models THROTTLE POSITION TP SENSOR FRONT BRAKE LIGHT SWITCH FRONT BRAKE INHIBITOR SWITCH CARBURETOR HEATER SWITCH GEA...

Page 384: ...ht Green Orange Pink R Red W White Y Yellow SPECIFICATIONS ITEM Bulbs Fuse Headlight high low beam Assist headlight Brake taillight Neutral indicator Reverse indicator Oil temperature indicator 4WD in...

Page 385: ...removed parts in the reverse order of removal REMOVAL INSTALLATION Remove the assist headlight bulb page 21 4 Remove the two tapping screws trim clips and the headlight lower cover from the bracket Re...

Page 386: ...rom mets from the tab and two bosses Install the headlight in the reverse order of removal NOTE The headlight beam can be adjusted vertically by removing the access plug and turning the head light bea...

Page 387: ...r from the frame and disconnect it Measure the voltage between the White black and Green wire terminals of the wire harness side connector There should be battery voltage with the ignition switch turn...

Page 388: ...ontinuity between the switch side con nector terminals in each switch position Continuity should exist between the color coded wires as follows Route theignition switch wire prop erly page 1 22 Color...

Page 389: ...ntinuity between the switch sidecon nector terminals in each switch position mmmi n J I Continuity should exist between the color coded LIGHTING SWITCH wires asfollows ENGINE STOP SWITCH STARTER SWITC...

Page 390: ...rom the brake lever bracket Disconnect the rear brake lever switch connectors and check for continuity between the switch termi nals There should be continuity with the rear brake lever squeezed and n...

Page 391: ...ach terminal of the switch side connector and ground There should be continuity in each gear position as follows Gear position Reverse Neutral 1st 2nd 3rd 4th 5th Wire color Gray Light green red White...

Page 392: ...en circuit in the wire harness CARBURETOR HEATER INSPECTION Remove the carburetor heater 2P connector from the frame under the rear fender and disconnect it Measure the resistance between the heater s...

Page 393: ...continuity at all times If there is no voltage check for an open circuit in the wire harness 14P GRAY CONNECTOR Route the meter wire properly page 1 22 SPEEDOMETER INSPECTION Check that the hour mete...

Page 394: ...tch to OFF Connect the wire harness side connector terminals with a jumper wire Turn the ignition switch to ON and check the fuel gauge All segments should blink If the fuel gauge does not function pr...

Page 395: ...ents blink during inspection replace the combination meter Turn the ignition switch to OFF Install a new O ring onto the fuel tank Install the fuel level sensor into the fuel tank while aligning the g...

Page 396: ...nction properly If they do not function perform the power ground line inspection page 21 12 If they function check the following Disconnect the connector from the oil temperature sensor and ground it...

Page 397: ...een the oil temperature sensor connector terminal and ground There should be no continuity If there is continuity repair short circuit in the Yellow green wire between the 33P connector and oil temper...

Page 398: ...for short circuit in the Green black wire between the fan motor 2P connector and ECM 5P connector Oil temperature indicator does not come on Disconnect the 33P black connector from the ECM page 21 16...

Page 399: ...re indicator bulb socket METER 14P GRAY CONNECTOR OIL TEMPERATURE SENSOR INSPECTION Drain the engine oil page 4 12 Disconnect the connector and remove the oil tem perature sensor and sealing washer Su...

Page 400: ...move the two trim clips and turn over the rubber seal Disconnect the 3P connector from the TP sensor THROTTLE POSITION SENSOR SENSOR RESISTANCE Measure the resistance between the Black red and Green b...

Page 401: ...EMENT Remove the fuel tank cover page 3 5 Disconnect the TP sensor connector page 21 19 Remove the two sensor screws TP sensor and 0 ring Remove the two screws spacer and O ring Install a new O ring o...

Page 402: ...ff Connect the TP sensor connector Install the removed parts in the reverse order of removal HORN U type only INSPECTION Disconnect the wire connectors from the horn Connect a 12 V battery to the horn...

Page 403: ...MPONENT LOCATION 22 2 ANGLE SENSOR 22 18 SYSTEM DIAGRAM 22 2 CONTROL MOTOR AND REDUCTION GEARS 22 19 SERVICE INFORMATION 22 3 GEARSHIFT SWITCH 22 21 BEFORE TROUBLESHOOTING 22 4 REVERSE SHIFT SWITCH 22...

Page 404: ...WITCH SHIFT CONTROL MOTOR SYSTEM DIAGRAM ENGINE CONTROL MODULE ECM BATTERY R O O R MAIN FUSE 30 A MOTOR FUSE 30 A R BI O O P IGNITION SWITCH PIGP MO PC GEAR POSITION INDICATOR FIAL INDICATOR GEAR POSI...

Page 405: ...e damaged if dropped Also if the connector is disconnected when current is flowing the excessive voltage may damage the ECM Always turn off the ignition switch before disconnecting or connecting the c...

Page 406: ...If the gear position indicator blinks record the number of blinks since this indicates the type of failure Then troubleshoot the indicated failure Refer to the table on page 22 5 for appropriate probl...

Page 407: ...oblem code i e the N is blinking with the transmission in neutral push both the Upshift and Downshift switches to erase the problem codes from the ECM Turn the ignition switch to OFF PROBLEM CODE PROB...

Page 408: ...n when the gear change tool is moved NO Troubleshoot the gear position switch system page 22 11 YES Troubleshoot page 22 8 the ES switch system Gear Position Indicator Problem No problem code indicati...

Page 409: ...4 4 Signal Line Short Circuit Inspection Check for continuity between Gray black wire terminal of the wire harness side meter connec tor and body ground te there continuity NO Repair short circuit in...

Page 410: ...lowing ter minals of the wire harness side connector while pushing the gearshift switch using the special tool TOOL Pin probe Male 07ZAJ RDJA110 With the upshift switch pushed Black red White blue Wit...

Page 411: ...the throttle position sensor 3P con nector page 21 19 Disconnect the ECM 33P black connector Measure the resistance between the Black red and Green blue wire terminals of the wire har ness side connec...

Page 412: ...Is there continuity NO Check the angle sensor connector for loose or corroded terminal YES Repair short circuit in the Green blue wire 7 Angle Sensor Inspection 2 Check that the resistance between the...

Page 413: ...M and or gear position switch connector securely YES GO TO STEP 2 2 Gear Position Switch Inspection at ECM Disconnect the ECM 33P black connector Check for continuity between each terminal of the wire...

Page 414: ...H CONNECTOR Viewed from the terminal side White green Gray Light green red Li blue white Pink Blue white Yellow Problem Code 5 ECM Motor Driver Circuit 1 ECM and Motor Connection Inspection Remove the...

Page 415: ...M 5P connector and motor connector Is there continuity NO Repair open circuit in the Orange and or Green blue wire YES GO TO STEP 5 ECM 5P CONNECTOR CONTROL MOTOR CONNECTOR Viewed from the terminal si...

Page 416: ...the connection of the ECM and alternator connectors Are all connections good NO Connect the ECM and or alternator con nector securely YES GO TO STEP 2 2 Ignition Pulse Generator Inspection at ECM Chec...

Page 417: ...and Green blue wires for continuity between the ECM and rear VSS connectors Is there continuity NO Repair open circuit in the Black orange Pink green and or Green blue wire YES GO TO STEP 4 4 ES Syste...

Page 418: ...ly open position Resistance increases From fully open position to fully closed position Resistance decreases Does the resistance varyproperly NO GO TO STEP 7 YES GO TO STEP 9 4 TP Sensor Resistance In...

Page 419: ...ition to fully closed position Resistance decreases Does the resistancevaryproperly NO Replace the angle sensor YES GO TO STEP 8 8 TP Sensor Signal Line Short Circuit Inspection Check for continuity b...

Page 420: ...istance increase From 5th gear to neutral Resistance decreases INPUT VOLTAGE Turn the ignition switch to ON and measure the input voltage between the Black red and Green blue terminal of the wire harn...

Page 421: ...r shaft hole and gearshift spin dle end Apply locking agent to the socket bolt threads Install the sensor cover and socket bolts and tighten the bolts TORQUE 6 Nm 0 6 kgf m 4 4 Ibf ft Connect the angl...

Page 422: ...l pin reduction gears Check the gear teeth for wear or damage CONTROL MOTOR ASSEMBLY REDUCTION GEARS INSTALLATION Thoroughly clean the gears and journals Apply 3 5 g of specified grease to the gear jo...

Page 423: ...ase cover Install the control motor assembly and tighten the four flange bolts Connect the control motor 2P connector and install it onto the frame Install the wire band Install the angle sensor page...

Page 424: ...open or short circuit in the wire harness or loose or poor connections in the wire harness REVERSE SHIFT SWITCH INSPECTION Remove the engine sub wire harness 2P green con nector from the frame and di...

Page 425: ...23 SELECTABLE 4WD SYSTEM FM FE models COMPONENT LOCATION 23 2 TROUBLESHOOTING CHART 23 3 SYSTEM DIAGRAM 23 2 TROUBLESHOOTING 23 4 SERVICE INFORMATION 23 3 23 1...

Page 426: ...NE CONTROL MODULE ECM G Bu G Bu Bl O I P W Bl O I P G W R W Y H t I i M I i I I I i n P W Bl O P G W R W Y G Br BI Bl G Br W G Bu MAIN FUSE 30A R BI CT O P IGNITION SWITCH IGNFUSE 10A rBI Br O O P LIG...

Page 427: ...clutch information A faulty selectable 4WD system is often related to poorly connected or corroded connections Check those connections before proceeding Refer to page 16 12 and page 16 32 for vehicle...

Page 428: ...indicator denotes the problem codes by blinking from two to five times when the ignition switch is turned from OFFto ON If no 4WD system failure occurs the indicator does not blink perform same proce...

Page 429: ...ont VSS Input Line Inspection Turn the ignition switch to ON Measure the voltage between the wire harness side front VSS 3P black connector terminal and ground Connection Black orange Ground Is the vo...

Page 430: ...ift the transmission in neutral Raise the wheels off the ground and support the vehicle securely with a hoist or equivalent Turn the ignition switch to ON Measure the voltage between the Red clip and...

Page 431: ...CONNECTOR 2 Rear VSS Input Line Inspection Turn the ignition switch to ON Measure the voltage between the wire harness side rear VSS 3P yellow connector terminal and ground Connection Black orange Gr...

Page 432: ...ft the transmission in neutral Raise the wheels off the ground and support the vehicle securely with a hoist or equivalent Turn the ignition switch to ON Measure the voltage between the Red clip and W...

Page 433: ...e voltage between the wire harness side connector terminal and ground using the special tool TOOL Pin probe Male 07ZAJ RDJA110 Connection Black green Ground Standard 11 16 V 20 C 68 F Is the voltage w...

Page 434: ...ow wire YES GO TO STEP 3 3 Front Final Clutch Line Short Circuit Inspection Check the White red and White yellow wires for continuity between the wire harness side clutch 2P connector terminals and gr...

Page 435: ...24 WIRING DIAGRAMS A CM TYPE TM MODEL 24 3 FM MODEL 24 5 U TYPE TM MODEL 24 4 FE MODEL 24 6 24 1...

Page 436: ......

Page 437: ...15A LIGHT 15A FAN 10A ACC 10A IGNITION TAILLIGHTS 12V21 5W X2 LIGHTING STARTER ENGINE STOP SWITCH IGNITION PULSE GENERATOR ALTERNATOR SWITCH CONTINUITY IGNITION SWITCH ON OFF COLOR BAT2 o R BI DC o p...

Page 438: ...CM r FAN MOTOR R6GULATOFVRECTIFIER STARTER RELAY SWITCH VEHICLE SPEED SENSOR ENGINE GROUND GEAR POSITION SWITCH OIL TEMPERATURE SENSOR FUSE BOX ENGINE FRAME GROUND GROUND 30A MAIN 15A LIGHT 15A FAN 10...

Page 439: ...OR REAR VEHICLE SPEED SENSOR ENGINE GROUND G E A R POSITION SWITCH TEMPERATURE SENSOR 30A MAIN 15A LIGHT 15A FAN 10A ACC 10A IGNITION TAILLIGHTS 12V21 5WJX2 ENGINE FRAME GROUND GROUND FRONT FINAL CLUT...

Page 440: ...Gr GRAY 0030Z HP0 A100 0030Z HP0 U100 1 4WD INDICATOR 2 NEUTRAL INDICATOR 3 OILTEMPERATURE INDICATOR 4 REVERSE INDICATOR P l l l l S j i l GEARSHIFT SWITCH LIGHTING STARTER ENGINE STOP SWITCH FUSEBOX...

Page 441: ...25 TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO POOR PERFORMANCE AT LOW AND IDLE START 25 2 SPEED 25 5 ENGINE LACKS POWER 25 3 POOR PERFORMANCE AT HIGH SPEED 25 6 POOR HANDLING 25 6 25 1...

Page 442: ...led spark plug Loose or disconnected ignition system wires Broken or shorted spark plug wire Faulty ignition coil Faulty ignition pulse generator Faulty engine stop switch Faulty ignition switch Fault...

Page 443: ...spring Additive in engine oil YES GO TO STEP 4 4 Engine Performance Inspection Accelerate lightly Does the engine speed increase NO Fuel air mixture too rich or lean Clogged air cleaner Restricted fue...

Page 444: ...nd condition Is the engine oil at the correct level and in goodcondition NO Oil level too high Oil level too low Contaminated oil YES G O TO STEP 10 10 Valve Train Lubrication Inspection Remove the cy...

Page 445: ...bands Damaged carburetor insulator Faulty carburetor insulator O ring NO GO TO STEP 3 3 Spark Test Perform the spark test Is the spark quality good NO Faulty spark plug Fouled spark plug Loose or dis...

Page 446: ...on Timing Inspection Check the ignition timing Is the ignition timing as specified NO Faulty engine control module ECM Faulty ignition pulse generator YES GO TO STEP 5 5 Valve Spring Inspection Check...

Page 447: ...ION 8 18 CYLINDER HEAD REMOVAL 8 9 CYLINDER HEAD VALVE SPECIFICATIONS 1 8 CYLINDER PISTON INSTALLATION 9 8 CYLINDER PISTON REMOVAL 9 4 CYLINDER PISTON SPECIFICATIONS 1 9 DIAGNOSTIC TROUBLESHOOTING 22...

Page 448: ...STEERING SHAFT 13 25 STEERING SHAFT HOLDER BEARING 4 21 STEERING SYSTEM 4 22 SUSPENSION 4 20 SUSPENSION ARM 13 20 SWINGARM 14 8 SYSTEM COMPONENTS ALTERNATOR STARTER CLUTCH 11 2 BRAKE SYSTEM 15 2 CLUT...

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Honda 2005 FOURTRAX FOREMAN TRX500 FE, Service Manual

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