Honda C8R600F4 Service Manual Download

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Summary of Contents for C8R600F4

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Page 2: ...Maintained by CJardine for the Members of CBRForum com ...

Page 3: ...e subsequent pages give detailed procedures If you don t know the source of the trouble go to t lLlion 22 Troubleshooting ALL INFORMATION ILLUSTRATIONS DIREC TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING HONDA MOTOR CO LTD RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCU...

Page 4: ...quivalent Use molybdenum disulfide grease containing more than 3 molybdenum i equivalent Example Molykote BR 2 plus manufactured by Dow Corning U S A Multi pL1rpose M 2 manufactured by Mitsubishi Oil Japan Use molybdenum disulfide paste containing more than 40 molybdenum disulfide NLGI 2 or equivalent Example Molykote G n paste manufactured by Dow Corning U S A Honda Moly 60 U S A only Raco ASP ma...

Page 5: ... engine is run Wear insulated gloves or wait until the engine and exhaust system have cooled before handling these parts LUBRICATION SEAL POINTS 1 16 CABLE HARNESS ROUTING 1 18 EMISSION CONTROL SYSTEMS 1 29 EMISSION CONTROL INFORMATION LABELS 1 32 USED ENGINE OIL Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods Although this is unlikely unless...

Page 6: ... burns Wear protec tive clothing and a face shield If electrolyte gets on your skin flush with water If electrolyte gets in your eyes flush with water for at least 15 minutes and call a physician immediately Electrolyte is poisonous If swallowed drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and call a physician KEEP OUT OF REACH OF CHILDREN 1 Use genuine...

Page 7: ...arburetor body GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER VIN The Vehicle Identification Number VIN is located on the left side of the frame ENGINE SERIAL NUMBER The engine serial number is stamped on the rear side of the upper crankcase The color label is attached on the rear fender under the seat When ordering color coded parts always specify the designated color code 1 3 ...

Page 8: ... size 120 70 ZR17 58W Rear tire size 180 55 ZR 17 73W Front tire brand BRIDGESTONE BT56F RADIAL E DUNLOP D207FJ MICHELIN TX15C Rear tire brand BRIDGESTONE BT56R RADIAL G DUNLOP D207P MICHELIN TX25 Front brake Hydraulic double disc Rear brake Hydraulic single disc Caster angle 24 tr i lengtn 96 mm 3 8 in Fuel tank caoacitv 17 0 4 49 US gal 3 74 Imp aall ENGINE Cylinder arrangement 4 cylinders in li...

Page 9: ...duction 1 822 82 45 Final reduction 2 812 45 16 Gear ratio 1st 2 833 34 12 2nd 2 062 33 16 3rd 1 647 28 17 4th 1 421 27 19 5th I 1 250 25 20 6th 1 130 26 23 Gearshift pattern Left foot ooerated return svstem 1 N 2 3 4 5 6 ELECTRICAL Ignition system Full transistorized ignition Starting system Electric starter motor Charging system Triple phase output alternator Regulator rectifier SCR shorted trip...

Page 10: ...FICATIONS CarburMoridentific n 4 9 s m t C a n a da t e V P 64 C number California e VP64B Main jet _state _Cana _p_e__ No 1 4 carburetor 132 No 2 3 carburetor 135 California t e 128 all carburetors Slow et 4 0 1 1 _ c Pilot screw Floa1level _____ r _ _ _ _ __ _ _ __ c ________ Idle speed 49 state Canad2J Y P e__ _ __i ___ ___________ J California t e COO ING SYSTEM L ITEM SPECIFICATIONS Coolant c...

Page 11: ...e auide l D IN EX 4 000 4 012 0 1575 0 1580 4 04 0 159 Stem to guide clearance IN 0 010 0 037 0 0004 0 0015 0 075 0 0030 EX 0 020 0 047 0 0008 0 0019 0 085 0 0033 Valve guide projection IN 16 1 16 4 0 63 0 65 above cylinder head EX 14 3 14 6 0 56 0 57 Valve seat width I IN EX 0 90 1 10 0 035 0 043 1 5 0 06 Valve spring Free length IN 39 87 l 570 I 38 27 1 507 I EX 36 23 1 426 34 73 1 367 Cvlinder ...

Page 12: ... C2 0 005 0 039 0 0002 0 0015 0 06 0 002 CRANKSHAFT PISTON CYLINDER Unit mm in ITEM STANDARD I SERVICE LIMIT Crankshaft Connecting rod side clearance 0 10 0 25 0 004 0 010 0 30 0 012 Crankpin bearino oil clearance 0 028 0 052 0 0011 0 0020 0 06 0 002 Main journal bearing oil clearance 0 020 0 038 0 0008 0 0015 0 05 0 002 Runout 0 05 0 002 Piston Piston O D at 15 0 6 from bottom 66 965 66 985 2 636...

Page 13: ...ty 290 kPa 2 90 kqf cm2 42 osi Axle runout 0 2 0 01 Wheel rim runout I Radial 2 0 0 08 I Axial 2 0 0 08 Wheel balance weight 60 g 2 1 oz max Drive chain slack 25 3G 1 1 3 8 HYDRAULIC BRAKE Unit mm in ITEM STANDARD SERVICE LIMIT Front Specified brake fluid DOT4 Brake disc thickness 4 4 4 6 0 17 0 18 3 5 0 14 Brake disc runout 0 30 0 012 Master cylinder l D I 15 870 15 913 0 6248 0 6265 15 925 0 627...

Page 14: ...ion timinq F mark 10 BTDC at idle Throttle sensor Resistance 20 C 68 F 4 6kQ Input voltaqe 4 7 5 3 v ELECTRIC STARTER Unit mm in ITEM STANDARD SERVICE LIMIT Starter motor brush lenqth 12 0 13 0 0 47 0 51 6 5 0 26 LIGHTS METERS SWITCHEs ITEM SPECIFICATIONS Bulbs Headliqht Hiqh low beam 12V 60 55W Brake tailli 1ht 12V 21 5W x 2 License liqht 12V 4CP Front turn siqnal runninq liqht 12V 32 3CP 23 8W X...

Page 15: ...9 6 5 10 1 0 7 12 1 2 9 12 1 2 9 26 2 7 20 39 4 0 29 ITEM O TY I DIA Imm N m kgf m lbf ft REMARKS MAINTENANCE Spark plug 4 10 12 1 2 9 Timing hole cap 1 45 18 1 8 13 NOTE7 Engine oil filter cartridge 1 20 10 1 0 7 NOTE 4 Engine oil drain bolt 1 12 29 3 0 22 LUBRICATION SYSTEM Oil main gallery sealing bolt 2 20 29 3 0 22 NOTE2 Oil pressure switch 1 PT 1 8 12 1 2 9 NOTE 1 Oil pressure switch termina...

Page 16: ...NKSHAFT PISTON CYLINDER Connecting rod bearing cap nut 8 7 25 2 6 19 NOTE4 ELECTRIC STARTER Starter motor terminal nut 1 6 I 10 1 0 7 LIGHTS METERS SWITCHES Thermosensor 1 PT 1 8 10 1 0 7 NOTE 1 Neutral switch 1 10 I 12 1 2 9 FRAME I ITEM O TV TllREAD TORQUE REMARKS DIA Imm N m kgf m lbf ftl FRAME BODY PANELS EXHAUST SYSTEM Seat cowl screw 2 5 2 0 2 1 4 Front inner fairing screw 4 5 2 0 2 1 4 Uppe...

Page 17: ...14 17 Swingarm pivot lock nut 2 30 64 6 5 47 Swingarm pivot nut 1 18 93 9 5 69 NOTE 5 HYDRAULIC BRAKE Brake caliper bleed valve 3 8 6 0 6 4 3 Front master cylinder reservoir cap screw 2 4 2 0 2 1 4 Rear urakt rn ervuir mounting bolt 1 6 12 1 2 0 Pad pin 5 10 18 1 8 13 Pad pin plug 1 10 3 0 3 2 2 Brake hose oil bolt 5 10 34 3 5 25 Front brake lever pivot bolt 1 6 1 0 1 0 7 Front brake lever pivot n...

Page 18: ... socket Attachment 28 X 30 mm Ball race remover set Driver attachment A Driver attachment B Driver shaft assembly Bearing remover A Bearing remover B Assembly base SltH ni114 Lt lll urivt r 1 14 07631 0010000 07724 0050002 07725 0040000 07733 0020001 07746 0010100 07746 0010200 07746 0010300 07746 0010400 07746 001 0800 077 46 0030100 07746 0030200 07746 0030300 07746 0040400 07746 0040500 07746 0...

Page 19: ...ptor 07HGJ 0020100 Peak voltage tester U S A only Needle bearing remover 07HMC MR70100 Tappet hole protector 07HMG MR70002 Drive chain tool set 07HMH MR10103 Drive chain tool set 07HMH MR10108 U S A only Valve guide driver 07JMD KY20100 Pilot screw wrench 07KMA MN90100 Pilot screw wrench 07KMA MS60101 Bearing remover set 07LMC KV30100 Valve guide reamer 4 008 mm 07MMH MV90100 Compression gauge att...

Page 20: ...liding surfaces Crankshaft thrust surfaces Engine oil filter cartridge threads and seating surface Engine oil Oil cooler bolt filter boss threads and seating surface Cylinder head bolt threads and seating surface Camshaft holder bolt threads and seating surface Clutch disc lining surfaces C h1tr h r 1mtP r lor k n11t thrP irls inrl sP ltino surfar P Starter sprag clutch contacting surfaces Flywhee...

Page 21: ...joints Gearshift pedal pivot Driver footpeg sliding area Passenger footpeg sliding area Side stand oivot Throttle cable outer inside Cable lubricant Clutch cable outer inside Choke cable outer inside Handlebar grip rubber inside Honda bond A or equivalent Steering bearing adjustment nut threads Enoine oil Front brake lever to master piston contacting area Silicon grease Front brake lever pivot Rea...

Page 22: ... CABLE HARNESS ROUTING TURN SIGNAL CONNECTORS BRAKE HOSE HEADLIGHT CONNECTOR OUTER AIR VENT HOSE California type No 8 LEFT TURN SIGNAL WIRE 1 1 LEFT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE RIGHT TURN SIGNAL WIRE ...

Page 23: ...TORS HORN WIRE CHOKE CABLE CLUTCH CABLE WATER HOSE SUB AIR CLEANER DRAIN TUBE SIPHON TUBE RESERVE TANK BREATHER TUBE GENERAL INFORMATION RIGHT HANDLEBAR SWITCH WIRE CABLES Cl lJTl H l ARI F OUTER AIR VENT HOSE California type No 8 1 19 ...

Page 24: ...P Red Headlight and turn signal 9P White BRAKE HOSE FUEL TANK BREATHER TUBE EVAP CAV SOLENOID VALVE 2P Slack CONNECTOR California type only 49 state Canada type SIDE STAND SWITCH FUEL TANK DRAIN TUBE 1 20 AIR VENT CONTROL SOLENOID VALVE I EVAPCAVSOLENO DVALVE California type only IGNITION COIL 6P Black CONNECTOR FUEL TANK BREATHER TUBE 49 state Canada type TANK TUBE ...

Page 25: ...HOSE CRANKCASE BREATHER HOSE IGNITION COILS GROUND POINT FUEL TUBE GENERAL INFORMATION AIR VENT CONTROL SOLENOID VALVE FLOAT CHAMBER OUTER AIR VCNT I IOSC CHOKE CABLE i PAIR CONTROL VALVE VACUUM TUBE Jt o 7 THROTTLE CARBURETOR HEATER WATER TUBES SENSOR 1 21 ...

Page 26: ...RTER MOTOR CABLE 1 22 AIR SUPPLY HOSES California No 16 SPEED SENSOR 60 GROUND CABLE SPEED SENSOR 3P Black CONNECTOR VAl UUIVI TUBE 1r lifnr ni No 10 PULSE SECONDARY AIR INJECTION PAIR CONTROL VALVE OIL PRESSURE SWITCH IGNITION PULSE GENERATOR 2P RAdl CONNECTOR THROTTLE SENSOR WIRE ...

Page 27: ...SOR CONNECTORS FUEL TANK DRAIN TUBE STARTER MOTOR CABLE STARTER RELAY SWITCH t ust l lox FUEL PUMP 2P Black CONNECTOR GENERAL INFORMATION FUEL FILTER THROTILE STOP SCREW REAR BRAKE LIGHT SWITCH 2P White CONNECTOR 1 23 ...

Page 28: ...IR VENT CONTROL SOLENOID VALVE RELAY 49 state Canada type only TURN SIGNAL RELAY FUEL CUT OFF RELAY CLAMP 1 24 REGULATOR RECTIFIER I Clamp WHITE TAPE LICENSE LIGHT WIRE SEAT LOCK CABLE REAR BRAKE LIGHT SWITCH WIRE GROUND CABLE REAR BRAKE LIGHT SWITCH ...

Page 29: ...NT CONTROL SOLENOID VALVE No 4 HOSE EVAPUHA I IV E Ml IUN CRANKCASE BREATHER HOSE To air r IP anP r ho11 ing No 15 HOSE No 6 HOSE No 5 HOSE GENERAL INFORMATION VACUUM CHAMBER AIR VENT HOSE From air cleaner housing No 5 HOSES 1 25 ...

Page 30: ...GENERAL INFORMATION California type only EVAPPURGECONTROLVALVE No 4 HOSE 1 26 ...

Page 31: ...GENERAL INFORMATION No 4 HOSE Nv 2 HOSE No 1TUBE STARTER MOTOR CABLE No 2 HOSE MAIN WIRE HARNESS 1 7 ...

Page 32: ...No 1 No 4 EVAP CANISTER EVAPPURGE CONTROL VALVE FUEL TANK CARBURETORS No 2 r _ t f 1 4 1 I No 5 Open air No 6 __ No 4 No 8 No a Open air AIR VENT CONTROL SOLENOID VALVE No 7 from air cleaner housing EVAP CAV SOLENOID VALVE ...

Page 33: ...imited Warranty for Honda Motorcycle Emission Control Systems is necessary in order to keep the emissions system warranty in effect SOURCE OF EMISSIONS The combustion process produces carbon monoxide and hydrocarbons Controlling hydrocarbon em1ss1ons is very important because under certain conditions they react to form photochemical smog when subjected to sunlight Carbon monoxide does not react in...

Page 34: ...s and carbon monoxide into relatively harmless carbon dioxide and water vapor This model has the pulse secondary air injection PAIR control valve and PAIR check valves PAIR check valve prevents reverse air flow through the system The PAIR control valve reacts to high intake manifold vacuum and will cut off the supply of fresh air during engine deceleration thereby preventing afterburn in the exhau...

Page 35: ...AV SOLENOID VALVE g J Engine stop TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to...

Page 36: ...s shown Instructions for obtaining the update label are given in Service Letter No 132 When readjusting the carburetors back to the low altitude specifications be sure to remove this update label VACUUM HOSE ROUTING DIAGRAM LABEL California type only The Vacuum Hose Routing Diagram Label is located on the air cleaner housing cover as shown The fuel tank must be removed to read it VACUUM HOSE ROUTI...

Page 37: ...tored can cause a fire or explosion This section covers removal and installation of the body panels fuel tank and exhaust system Always replace the exhaust pipe gasket when removing the exhaust pipe from the engine Always inspect the exhaust system for leaks after inslallaliun TORQUE VALUES Exhaust pipe joint nut Muffler band bolt Seat cowl screw Front inner fairing screw Front fairing to side fai...

Page 38: ...d then down to lock it SEAT COWL 2 2 Remove the seat Remove the two ooeket bolto Remove the two screws Remove the two trim clips Disconnect the taillight connectors Pull the seat cowl back out of the frame while opening the front portion of it Installation is in the reverse order of removal NOTE Make sure that the mating surfaces of the cowl bottom are seated onto the rear fender properly before t...

Page 39: ...gtng between the end of the shock absorber and the the mounting recess of the tank bottom properly as shown rubbers and tank Turn the fuel valve OFF and disconnect the follow ing fuel tube drain tube breather tube California No 1 tube fuel level sensor connectors Remove the eyelet wrench and rest the fuel tank on the frame Remove the two 8 mm mounting bolts and seat retainer Remove the fuel tank I...

Page 40: ...ge the rubber nuts in the side fairing when tightening the front side bolts TORQUE Socket bolt Three bolts on front side 2 N m 0 2 kgf m 1 4 lbf ft FRONT INNER FAIRING 2 4 Remove the following four trim clips four screws inner fairing by releasing front fairing tabs from inner fairing slits Installation is in the reverse order of removal NOTE Make sure that the mating areas are aligned proper ly b...

Page 41: ...bolt hole studs and rest it on the front fender Disconnect the headlight and turn signal connec tors Installation is in the reverse order of removal NOTE Install the front fairing air duct grill over the air intake ducts and the bosses into the fairing stay grommets and align the front fairing tabs with the inner fairing slits When tightening the fairing socket bolts be careful not to dislodge the...

Page 42: ...ul not to scratch the shield surface DIRECT AIR INTAKE DUCT 2 6 Remove the duct cover page 2 3 Remove the instrument panel page 2 5 Loosen the connecting tube band screw Right duct Remove the outer air vent hose California No 8 from the duct by releasing the hose clip Left duct Remove the wire harness from the duct Remove the air intake duct from the air duct grill of the front fairing and the fro...

Page 43: ...ION EXHAUST PIPE If the joint stud bolts are loose tighten them Be sure to verify the distance from top of stud to the cylinder head surface as shown Install new joint gaskets into the exhaust ports Set the exhaust pipe onto the engine by aligning the exhaust flanges with the cylinder head studs then install the joint nuts and the mounting bolV washer and nut Tighten the joint nuts TORQUE 12 N m 1...

Page 44: ... and bolts Slide the rear fender rearward then remove the mounting collars between the seat rail and fender and remove the fender from the seat rail Remove the fuel tank page 2 3 Remove the following wire harness bands ignition control module ICM bolts and regulator rectifier bolts collars and fuel pump Secure the reservoir so that it remains upright Remove the nuts bolts washer and the passenger ...

Page 45: ...ll ventilated Never run the engine in an enclosed area The exhaust contains poisonous carbon monoxide gas that may cause loss ofconsciousness and lead to death Run the engine in an open area or with an exhaust evacuation system in an enclosed area SPECIFICATIONS ITEM I SPECIFICATIONS Throttle grip free olav 2 6 mm 1 16 1 4 in Spark plug I 49 state Canada type CR9EH 9 NGK U27FER 9 DENSO I Californi...

Page 46: ... 3 2 Rear Front Rear Front Rear Front Rear Front Rear 120 70 ZR17 58W 180 55 ZR17 73W BRIDGESTONE BT56F RADIAL E DUNLOP D207FJ MICHELIN TX15C BRIDGESTONE BT56R RADIAL G DUNLOP D207P MICHELIN TX25 1 5 mm 0 06 in 2 0 mm 0 08 in 12 N m 1 2 kgf m 9 lbf ft 18 N m 1 8 kgf m 13 lbf ft 10 N m 1 0 kgf m 7 bf ft 29 N m 3 0 kgf m 22 lbf ft 93 N m 9 5 kgf m 69 lbf ft 12 N m 1 2 kgf m 9 lbf ft Apply grease to ...

Page 47: ...ON I I I 3 13 z ENGINE IDLE SPEED I I I 3 14 0 Ui RADIATOR COOLANT NOTE3 I I R 3 14 COOLING SYSTEM I I I I 3 15 w l SECONDARY AIR SUPPLY SYSTEM I I 3 15 I EVAPORATIVE EMISSION NOTE4 3 16 CONTROL SYSTEM DRIVE CHAIN 3 16 BRAKE FLUID l 20 LU t I BRAKE PAD WEAR 3 21 Cl LU BRAKE SYSTEM 3 22 I I BRAKE LIGHT SWITCH 3 22 J LU HEADLIGHT AIM 3 23 cc z CLUTCH SYSTEM 3 23 0 U5 SIDE STAND 3 24 SUSPENSION 3 24 ...

Page 48: ...commercially available cable lubricant or a light weight oil If the throttle grip still does not return properly replace the throttle cahlP Reusing a damaged or abnormally bent or kinked throttle cable can prevent proper throttle slide operation and may lead to a loss of throttle control while riding With the engine idling turn the handlebar all the way to the right and left to ensure that the idl...

Page 49: ...de Check for smooth choke lever operation and lubri cate the choke if required Check the choke cable for frayed kinked or other damage AIR CLEANER NOTE f he viscous paper element type air cleaner can not be cleaned because the element contains a dust adhesive If the motorcycle is used in wet or dusty areas more frequent inspections are required Raise the fuel tank and support it page 2 3 Remove th...

Page 50: ...tor down without disconnecting the water hoses and secure it to the fork legs Dii r nnnAr t thA ignition coil 2P connectors and remove the direct ignition coils Clean around the spark plug bases NOTE This motorcycle adopted the direct type ignition coil that the spark plug cap and ignition coil are integrated Clean around the spark plug bases with compres sed air before removing the plugs and be s...

Page 51: ...o not use wire brush to clean the electrodes The plug cleaner should be used with the air pressure of less than 6 kgf cm2 85 psi and for less than zo seconds Replace the plug if the center electrode is rounded as shown Always use SPECIFIED SPARK PLUG CR9EHVX 9 NGK specified spark plugs on this motorcycle Measure the gap between the center and side elec trodes with a wire type feP IP r g iugP CAUTI...

Page 52: ...ber be tween the frame and radiator VALVE CLEARANCE INSPECTION 3 8 NUfE Inspect and adjust the valve clearance while the en gine is cold below 35 C 95 F Remove the cylinder head cover page 8 3 Remove the timing hole cap Rotate the crankshaft clockwise and align the T mark on the ignition pulse generator rotor with the index notch on the right crankcase cover The timing marks IN for intake and EX f...

Page 53: ... the index 11uld1 Measure the No 2 and No 4 cylinder exhaust valve clearance VALVE CLEARANCE EX 0 28 0 03 mm 0 011 0 001 in Rotate the crankshaft clockwise 1 2 180 turn from previous position and align the T mark with the index notch Measure the No 2 and No 4 cylinder intake valve clearance VALVE CLEARANCE IN 0 20 0 03 mm 0 008 0 001 in Rotate the crankshaft clockwise 1 2 180 turn from previous po...

Page 54: ... equation below A B C D A New shim thickness B Recorded valve clearance C Specified valve clearance D Old shim thickness NOTE Make sure of the correct shim thickness by meas uring the shim with the micrometer Reface the valve seat if carbon deposits result in a calculated dimension of over 2 900 mm Install the newly selected shims on the valve re tainers Install the valve lifters and camshafts pag...

Page 55: ...lower level marks in the inspection window If the oil level is below or near the lower level mark remove the oil flller cap and add the recommended engine oil up to the upper level mark RECOMMENDED ENGINE OIL Honda GN4 4 stroke oil or equivalent motor oil API service classification SF or SG Viscosity SAE 10W 40 NOTE Other viscosities shown in the chart may be used when tt1e i IVt li ll Je Le1111 1...

Page 56: ...olonged periods Although this is unlikely unless you han die used oil on a daily basis it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil Apply oil to the 0 ring and threads of a new oil fil ter cartridge and install the filter cartridge TORQUE 10 N m 1 0 kgf m 7 lbf ft After draining the oil completely check that the seal ing washer...

Page 57: ...49 state Canada type 1 300 100 rpm California type 1 400 100 rpm Check the difference between the each carburetor CARBURETOR VACUUM DIFFERENCE Within 30 mm Hg 1 2 in Hg NOTE The base carburetor is the No 4 carburetor Synchronize to specification by turning the synchro nization adjusting screws Rev the engine up several times Recheck the idle speed and synchronization Disconnect the vacuum gauges R...

Page 58: ... be between the UPPER and LOWER level lines with the motorcycle upright on a level surface If the level is low remove the right side fairing page 2 4 and the reserve tank cap and fill the tank to the UPPER level line with a 50 50 mixture of distilled water and antitreeze coolant preparation page 6 4 RECOMMENDED ANTIFREEZE Pro Honda HP Coolant or an equivalent high quali ty ethylene glycol antifree...

Page 59: ...ted over more than 20 of the radiating surface Install the side fairings paqe 2 4 SECONDARY AIR SUPPLY SYSTEM Check the air supply hoses between the pulse sec ondary air injection PAIR control valve and PAIR check valves for damagP or lnnsA r nnner tinns Check the air supply hoses for cracks or deterio ration NOTE If the hoses show any signs of heat damage in spect the PAIR check valves page 5 38 ...

Page 60: ...re not kinked or pinched Refer to the Vacuum Hose Routing Diagram Label and Cable Harness Routing page 1 18 for tube connections and routing DRIVE CHAIN 3 16 CHAIN SLACK INSPECTION Never inspect and adjust the drive chain while the engine is running Turn tho ignition owitch OFF ploco the motorcycle on its side stand and shift the transmission into neu tral Check the slack in the drive chain lower ...

Page 61: ...e chain with a soft brush using a non flam mable or high flash point solvent and wipe it dry Re sure the chain h is rlriPrl com llPtPly hpfore luhri cating Inspect the drive chain for possible damage or wear Replace any chain that has damaged rollers loose fitting links or otherwise appears unservice able Installing a new chain on badly worn sprockets will cause the new chain to wear quickly Inspe...

Page 62: ... driven sprockets If any are loose torque them REPLACEMENT This motorcycle uses a drive chain with a staked master link Loosen the drive chain Assemble the special tool TOOL Drive chain tool set NOTE 07HMH MR10103 or 07HMH MR1010B U S A only When using the special tool follow the manufac turer s instruction Locate the crimped pin ends of the master link from the outside of the chain and remove the...

Page 63: ...he master link from the inside of the drive chain and install the plate with the identification mark facing the outside Measure the master link pin length projected from the plate SPECIFIED LENGTH DID 1 15 1 55 mm 0 045 0 061 in RK 1 20 1 40 mm 0 047 0 055 in Stake the master link pins with the drive chain tool set Make sure that the maser link pins are staked prop erly by measuring the diameter o...

Page 64: ...lastic or rubber parts Place a rag over these parts whenever the system is serviced NOTE When the fluid level is low check the brake pads for wear page 3 21 A low fluid level may be due to wear of the brake pads If the brake pads are worn the caliper pistons are pushed out and this accounts for a low reservoir level If the brake pads are not worn and the fluid level is low check entire system for ...

Page 65: ...l the reservoir cap Install the reservoir onto the stay with the mount ing bolt TORQUE 12 N m 1 2 kgf m 9 lbf ft BRAKE PAD WEAR FRONT BRAKE PAD ChP r k thF hr ikP p irl for WF M_ Replace the brake pads if the wear limit groove of either pad is worn out REAR BRAKE PAD Check the brake pad for wear by looking from the rear side ot the caliper Replace the brake pads if either pad is worn to the bottom...

Page 66: ... turning the adjuster CAUTION Align the arrow on the brake lever with the index mark on the adjuster BRAKE PEDAL HEIGHT ADJUSTMENT Loosen the lock nut and turn the push rod until the correct pedal height is obtained BRAKE LIGHT SWITCH 3 22 NOTE The brake light switch on the front brake master cylinder cannot be adjusted If the front brake light switch actuation and brake engagement are off either ...

Page 67: ...nut and turn the adjuster Tighten the lock nut securely CAUTION The adjuster may be damaged if it is positioned too far out leaving minimal thread engagement If the adjuster is threaded out neat its limit and the correct free play cannot be obtained turn the adjust er all the way in and back out one turn Tighten the lock nut and make a major adjustment as described below Major adjustments are made...

Page 68: ...e worn or damaged suspension parts impair motorcycle stability and control Repair or replace any damaged components before riding Riding a motorcycle with faulty suspension increases your risk ofan accident andpossible injury FRONT SUSPENSION INSPECTION Check the action of the forks by operating the front brakes and compressing the front suspension several times Check the entire assembly for signs...

Page 69: ...ng force To set the standard position turn the adjuster clock wise until it stops then turn it counterclockwise ap prox 1 1 2 turn Align the punch marks REAR SUSPENSION INSPECTION Check the action of the shock absorber by com pressing it several times Chi ck the entire shock absorber assembly for signs of leaks damage or loose fasteners Replace damaged components which cannot be repaired Tighten a...

Page 70: ...tion turn the adjuster clock wise until it stops then turn it counterclockwise ap prox 1 turn Align the punch marks COMPRESSION DAMPING Turn the compression damping adjuster counter clockwise to reduce the compression damping force and turn it clockwise to increase the compres 3ion damping force To set the standard position turn the adjuster clock wise until it stops then turn it counterclockwise ...

Page 71: ...k the front and rear wheels for trueness refer to section 13 and 14 Measure the tread depth at the center of the tires Replace the tires when the tread depth reaches the following limits MINIMUM TREAD DEPTH Front 1 5 mm 0 06 in Rear 2 0 mm 0 08 in STEERING HEAD BEARINGS NOTE Check that the control cables do not interfere with handlebar rotation Raise the front wheel off the ground and support the ...

Page 72: ...UBRICATION SYSTEM EXHAUST CAMSHAFT INTAKE CAMSHAFT PISTON CRANKSHAFT OIL FILTER OIL COOLER PRESSURE RELIEF VALVE 4 0 i df I I I I I I I i t i 1 1 I I I I OIL STRAINER OIL PUMP OIL PRESSURE SWITCH on1ricc ...

Page 73: ...gine oil level check see page 3 11 For engine oil and filter change see page 3 12 For oil pressure indicator inspection see page 19 12 SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT gine oil capacity Atter draining __ J__ J 2 U i qt_ _ 1 ll_ P_9 ______ After draininq filter chanqe 3 3 2 3 5 US qt 2 9 Imp qt After I 3 7 _3 us qt 3 3 l P_gt equivaTent M RP commended engine oil Honda GN4 4 str...

Page 74: ...t oil being used No oil pressure Oil level too low Oil pressure relief valve stuck open Broken oil pump drive chain Broken oil pump drive or driven sprocket Damaged oil pump Internal oil leak High oil pressure Oil pressure relief valve stuck closed Clogged oil gallery or metering orifice Incorrect oil being used Oil contamination Oil or filter not changed often enough Worn piston rings Oil emulsif...

Page 75: ...7510 MJ10100 or equivalent commercially available in U S A Check the oil level and add the recommended oil if necessary page 3 11 Start the engine and check the oil pressure at 6 000 rpm 80 C 176 F OIL PRESSURE 490 kPa 5 0 kgf cm2 71 psi Stop the engine Clean the sealing bolt threads thoroughly Apply locking agent to the sealing bolt threads and install it TORQUE 29 N m 3 0 kgf m 22 lbf ft Install...

Page 76: ...fter one or two seconds If the oil pressure indicator stays on stop the engine and check the indicator system page 19 12 OIL STRAINER PRESSURE RELIEF VALVE OIL PAN REMOVAL 4 4 Drain tilt tmgine oil page 3 12 Remove the exhaust pipe page 2 7 Remove the reserve tank breather tube from the stay Remove the eleven bolts and the oil pan OIL STRAINER Remove the oil strainer and seal rubber from the oil p...

Page 77: ... wear sticking or other damage Check the spring for fatigue or damage Install the piston spring and spring seat and secure them with the snap ring Coat a new 0 ring with oil and install it into the re lief valve body groove Install the relief valve into the crankcase OIL PAN INSTALLATION Clean the oil pan mating surfaces thorouqhlv be ing careful not damage them Apply sealant to the oil pan mating...

Page 78: ...stall the exhaust pipe and muffler page 2 7 OIL PUMP 4 6 Fill the crankcase with recommended engine oil page 3 12 REMOVAL Remove the clutch and oil pump driven sprocket page 9 3 Remove the three mounting bolts and oil pump DISASSEMBLY Remove the following dowel pins tJull allU IJUlllµ L UVt lf pump shaft thrust washer drive pin inner and outer rotors Clean the disassembled parts thoroughly ...

Page 79: ...ump Measure the rotor tip clearance SERVICE LIMIT 0 20 mm 0 008 in Measure the pump body clearance SERVICE LIMIT 0 3G mm 0 014 in Measure the pump side clearance SERVICE LIMIT 0 10 mm 0 004 in ASSEMBLY Install the outer and inner rotors into the p11mp body with the driver pin grooves in the inner rotor facing the pump cover LUBRICATION SYSTEM 4 7 ...

Page 80: ...nd tighten the bolt TORQUE 8 N m 0 8 kgf m 5 8 Ibf ft INSTALLATION Install the oil pump onto the crankcase while align ing the pump shaft lug with the water pump shaft groove by turning the pump shaft Install the pump mounting bolts and tighten them Install the clutch assembly page 9 9 OIL COOLER REMOVAL Remove the oil filter page 3 12 Drain the coolant from the system page 6 5 Disconnect the wate...

Page 81: ...he oil cooler bolt threads and seating surface Install the oil cooler by aligning the guide groove with the lug on the crankcase Install the cooler bolt and washer with the concave of the washer 0 mark facing the oil cooler Tighten the cooler bolt TORQUE 64 N m 6 5 kgf m 47 bf ft WASHER MARK 0 1ooolecs de Connect the water hoses to the oil cooler Install the oil filter page 3 12 Fill and bleed the...

Page 82: ...FUEL SYSTEM eshown California typ California only 5 0 ...

Page 83: ...ATTERN 49 state Canada type 5 FUEL SYSTEM CARBURETOR INSTALLATION 5 30 PILOT SCREW ADJUSTMENT 5 33 HIGH ALTITUDE ADJUSTMENT 5 34 DIRECT AIR INDUCTION D A I SYSTEM 5 36 FUEL PUMP 5 37 SECONDARY AIR SUPPLY SYSTEM EVAPORATIVE EMISSION CONTROL 5 37 n SYSTEM California type only 5 39 Under 20 km h 18 mph Over 20 km h 18 mph FLOAT CHAMBER INNER AIR VENT HOSE AIR CLEANER HOUSING AIR INTAKE DUCT FLOAT CHA...

Page 84: ...la type Over 20 km h 18 mph 5 2 Under 20 km h 18 mph VACUUM CHAMBER AIR VENT HOSE CARBURETOR No 6 HOSE AIR CLEANER HOUSING No 8 HOSE FLOAT CHAMBER OUTER AIR VENT HOSE EVAP CAV SOLENOID VALVE AIR VENT CONTROL SOLENOID VALVE ...

Page 85: ... remove the diaphragms before cleaning air and fuel passages with compressed air The diaphragms might be damaged For fuel tank and air intake duct removal and installation see page 2 3 For throttle sensor inspection and replacement see page 17 7 For carburetor synchronization see page 3 13 Before disassembling the carburetors place an approved fuel container under the carburetors loosen the drain ...

Page 86: ...pe Carburetor vacuum difference base carburetor No 4 Fuel pump flow capacity minimum Throttle qrip free play TORQUE VALUES Starting enrichment SE valve nut Carburetor connecting nut 6 mm 5mm Reed valve cover bolt 2 N m 0 2 kgf m 1 4 lbf ft 9 N m 0 9 kgf m 6 5 Ibf ft 5 N m 0 5 kgf m 3 6 Ibf ft 13 N m 1 3 kgf m 9 lbf ft TOOL 07401 0010000 40 See paqe 5 33 See page 5 34 13 7 0 5 mm 0 54 0 02 in 1 300...

Page 87: ...or EVAP purge control system California type Faulty ignition system section 17 Afterburn when engine braking is used Lean mixture in slow circuit Faulty air cut off valve Faulty pulse secondary air injection PAIR system Faulty ignition system section 17 Backfiring or misfiring during acceleration Lean mixture Faulty ignition system section 17 Poor performance driveability Clogged fuel system t uel...

Page 88: ...lay connec tor Measure the voltage between the Black white 1 terminal of the solenoid valve relay and ground with the ignition switch ON I Voltage Measure the voltage between the Pink yellow terminal of the solenoid valve relay and ground with the ignition switch ON Voltage No sound Go to following page __Normal Check the induction ducts and hoses and the solenoid valve operation page 5 36 Pink wh...

Page 89: ...ION METER Disconnect the solenoid valve 2P Black connec Voltage Check the solenoid valve operation page 5 36 tor and measure the battery voltage between the Pink white and Green terminals at the harness side connector with the ignition switch ON I No voltage Remove the seat cowl page 2 2 Measure the voltage between the Black white 2 terminal of the solenoid valve relay and ground with the ignition...

Page 90: ...d Pink yellow terminals of the solenoid valve relay with the ignition switch ON I Voltage Disconnect the combination meter connector page 19 6 Check for continuity between the Pink yellow ter minal of the meter connector and ground Faulty combination meter 5 8 Continuity Short circuit in Pink yellow wire COMBINATION METER CONNECTOR ...

Page 91: ...r connector and measure the voltage between the Pink yellow and Green terminals of the meter connector with the ignition switch ON I No voltage i Remove the seat cowl page 2 2 Disconnect the air vent control solenoid valve 2P black connector and measure the voltage be tween the Black white terminal at the har ness side connector and body ground with the ignition 5witch ON I Voltage i Normal Go to ...

Page 92: ...uit in Black or Green wire black connector Mea u re ltie vultage between lhe Blac k and Green terminals at the harness side connec tor with the ignition switch ON I Volr Check the induction ducts hoses and the air vent control solenoid valve and EVAP CAV solenoid valve operation page 5 36 and 5 41 5 10 ...

Page 93: ...tch ON Voltage Measure the battery voltage between the Pink yellow terminal of the transfer relay and ground with the ignition switch ON No voltage i Remove the combination meter without discon necting the connector page 19 6 Start the engine shift the transmission into gear and measure the voltage between the Pink yel low and Green terminals of the meter There should be battery voltage when the s...

Page 94: ... is connected to the Black white 1 and Pink yellow terminals of the relay and no continuity when the battery is disconnected Normal Measure the battery voltage between the Black white 2 terminal of the transfer relay con nector and ground with thA ignition switch ON Voltage i Check for continuity between the Black blue Abnormal Faulty fuel pump transfer relay No voltage Open circuit in Black white...

Page 95: ...ite terminal of the fuel cut off relay and ground with the ignition switch ON I Voltage Measure the battery voltage between the Blue black terminal of the fuel cut off relay and ground with the ignition switch ON Faulty fuel cut off relay No voltage Open circuit in Blue black wire FUEL SYSTEM ...

Page 96: ...ndary break the plastic air supply hose California No 15 plugs 5 14 Disconnect the crankcase breather hose from the air cleaner housing loosen the two connecting tube band screws of the air intake ducts Loosen the fom connecting tuhe band scrnws Remove the air cleaner housing off the carburetor intake ports and air intake ducts Disconnect the float chamber inner air vent hose California No 7 and t...

Page 97: ...Disconnect the No 11 tube only California type Disconnect the No 5 tubes only Disconnect the float chamber air vent hoses and the tuel tubes from the carburetor Remove the choke cable from the cable holder and disconnect it from the starting enrichment SE valve arm FUEL SYSTEM No 11 TUBE No 5 TUBES 5 15 ...

Page 98: ... the head intake ports intake ports to prevent any Disconnect the throttle sensor connector foreir n material from dropping into NOTE the engine 5 16 Do not remove the throttle sensor unless it is necessary to replace it or disassemQle the caruure tor For sensor inspection and replacement see page 17 7 Loosen the throttle cable lock nuts then remove the cables from the cable holder and disconnect ...

Page 99: ...cting nut screw and throttle sensor CAUTION Do not remove the throttle sensor from the brack et unless it requires replacement It may cause the sensor to move out of position resulting in improp er ignition timing connecting nut bolt and joint retainer air vent hose joint with 0 ring screw and throttle cable holder joint retainer dowel pin air vent hose joint with 0 ring Loosen the synchronization...

Page 100: ...on page 5 26 for move the thrust spring identification of Remove the following each component joint collar 5 18 fuel tube joint air vent hose joint water tube joint dowel pins Separate the No 3 and No 4 carburetors then re move the thrust spring Remove the following choke cable holder joint collar fuel tube joint air vent hose joint water tube joint dowel pins NO 1 NO 2 No 3 No 4 ...

Page 101: ...ALVE Remove the following valve nut valve spring SE valve Check the SE valve for scoring scratches or wear Check the seat at the tip of the SE valve for stepped wear AIR CUT OFF VALVE Disconnect the vacuum tube from the vacuum pipe Remove the attaching screw and the air cut off valve Remove the 0 rings and joint pipe FUEL SYSTEM 5 19 ...

Page 102: ...m chamber compression cover spring is very long it will jump out of the carburetor when the cover is removed RAmove the compression spring and diaphragm vacuum piston from the carburetor body Be careful not to Screw one of the vacuum chamber cover 4 mm damage the screws into the jet needle holder diaphragm Pull the screw and remove the jet needle holder from the vacuum piston 5 20 CAUTION Do not r...

Page 103: ...r if the dia phragm is damaged in any way even a pin hole FLOAT CHAMBER Remove the three screws and the float chamber Remove the float pin float and float valve Check the float for damage or fuel in the float Check the float valve and valve seat for scoring scratches clogging or damage Check the tip of the float valve where it contacts the valve seat for stepped wear or contamination Check the ope...

Page 104: ...ew seat will occur if the pilot screw is tightened against the seat Remove the pilot screw spring washer and 0 ring Check each jet for wear of damage Check the pilot screw for wear or damage Clean the jets with cleaning solvent and blow open with compressed air CARBURETOR CLEANING Remove the following air funnel SE valve air cut off valve diaphragm vacuum piston main jet needle jet holder and slow...

Page 105: ...nal position as noted during removal FLOAT CHAMBER TOOL Pilot screw wrench 07KMA MN90100 or 07KMA MS60101 Perform the pilot screw adjustment if new pilot screw is installed CAUTION Damage to the pilot screw seat will occur if the pi lot screw is tightened against the seat Install the needle jet holder main jet and slow jet FUEL SYSTEM 5 23 ...

Page 106: ...t level gauge 07401 0010000 FIOAT 1 FVFL n 7 0 i mm 0 54 t 0 02 in The float cannot be adjusted Replace the float assembly if the float level is out of specification Install a new 0 ring into the float chamber groove Install the float chamber and tighten the three screws VACUUM CHAMBER Coat a new 0 ring with oil and install it into the holder groove and the spring into the holder end hole Install ...

Page 107: ...r to set the diaphragm rib into the groove in the carburetor body and install the spring and vacuum chamber cover Be careful not to Install and tighten the three screws pinch the diaphragm under the chamber cover AIR CUT OFF VALVE Install new 0 rings onto the air cut off valve and joint pipe Install the joint pipe into the cut off v ilvP with the stepped side facing the air cut off valve Install t...

Page 108: ...N m 0 2 kgf m 1 4 lbf ft AIR FUNNEL Install a new 0 ring into the groove in the carbure tor body Set the air fonnel through the funnel holder as shown and install them by aligning the cut outs in the funnel with the lugs of the carburetor body Be careful not to Install the four screws and tighten them ptnch the O rtng CARBURETOR COMBINATION THROTTLE STOP SCREW ...

Page 109: ... over the synchronization nut Assemble the No 3 and No 4 carburetors Install the synchronization spring No 1 and No 2 carburetors Install the following onto the carburetor dowel pins water tube joint with new 0 rings air vent hose joint with new 0 rings fuel tube joint with new 0 rings joint collar thrust spring place over the synchronization nut Assemble the No 1 and No 2 carburetors Install the ...

Page 110: ...dowel pin Install the throttle cable holder joint retainer aligning its groove with the joint lug and secure it with the screw Install the connecting bolt nut and tube joint retain er aligning the retainer groove with the joint lug Install the throttle sensor by aligning the tabs of the throttle sensor with the flat of the shaft as shown Install the nut and screw CAUTION Install the throttle senso...

Page 111: ...stall the SE valve arm over the SE valves and onto the carburetors and attach the return spring Install the plastic washers and screws and tighten them Install the throttle stop screw with the washer and spring Turn the throttle stop screw to align the throttle valve with the edge of the outside by pass hole in the No 4 carburetor Align each carburetor No 1 No 2 and No 3 throttle valve with the ou...

Page 112: ...he insulators securely Align the band hole with the insulator boss Tighten each band screw until the clearance be tween the band ends is 11 13 mm 0 4 0 5 in CARBURETOR INSTALLATION c ln NOTE Route the tubes and cables properly page 1 18 Connect the water tubes to the carburetor Connect the throttle cables to the throttle drum and install them into the cable holder Connect the throttle sensor conne...

Page 113: ...nsert the screwdriver through the hole in both sides of the frame and tighten the insulator band screws as shown Install the throttle stop screw into the cable holder Connect the choke cable to the SE valve arm and install it into the cable holder Connect the fuel tubes and the float chamber air vent hoses FUEL SYSTEM 5 31 ...

Page 114: ...y 5 32 Perform the following inspections and adjustment Throttle operation page 3 4 Carburetor choke page 3 5 Install the air cleaner housing page 5 14 Fill and bleed the cooling system page 6 4 Adjust the carburetor iynchronizotion if the corburc tors were disassembled page 3 13 No 5 TUBES No 11 TUBE ...

Page 115: ...rns out 2 Warm up the engine to operating temperature Stop and go driving for 10 minutes is sufficient 3 Stop the engine and connect a tachometer ac cording to the tachometer manufacturer s instruc tions 4 Start the engine and adjust the idle speed with the throttle stop screw IDLE SPEED 49 state Canada type 1 300 100 rpm California type 1 400 100 rpm 5 Turn the No 4 carburetor pilot screw in or o...

Page 116: ...e eye let wrench page 2 3 Warm up the engine to operating temperature Stop and go driving for 10 minutes is sufficient Turn each pilot screw in to the specification given TOOL Pilot screw wrench 07KMA MN90100 or 07KMA MS60101 HIGH ALTITUDE SETTING 1 2 turn in Adjust the idle speed with the throttle stop screw IDLE SPEED 49 state Canada type 1 300 100 rpm California type 1 400 100 rpm Attach the Ve...

Page 117: ...g temperature Stop and go driving for 10 minutes is sufficient T11rn eflch nilot screw out 1 2 turn to its original position TOOL Pilot crew wrench 07KMA MN90100 or 07KMA MS60101 Adjust the idle speed with the throttle stop screw IDLE SPEED 49 state Canada type 1 300 100 rpm California type 1 400 100 rpm NOTE These adjustment must be made at low altitude to ensure proper low altitude operation Rem...

Page 118: ...air cleaner for clogging niscnnnA t thA air vent hose California No 6 from the 3 way joint that goes to the carburetor Disconnectthe No 4 hose California type Bluw air inlu l11e inner air vent hose California No 7 with the ignition switch OFF Blow air into the outer air vent hose California No 4 with the ignition switch ON Air should flow through the solenoid valve and out the air vent hose Califo...

Page 119: ...itch to RUN and let the fuel flow into the beaker for 5 seconds then turn the ignition switch OFF Multiply the amount in the beaker by 12 to deter mine the fuel µump flow capacity per minute FUEL PUMP FLOW CAPACITY minimum 700 cm3 23 7 US oz 24 6 Imp oz minute SECONDARY AIR SUPPLY SYSTEM SYSTEM INSPECTION Start the engine and warm it up to normal operating temperature Remove the air cleaner housin...

Page 120: ...ck that the air supply hose stops drawing air and that the vacuum does not bleed SPECIFIED VACUUM 400 mm Hg 15 7 in Hg If the air is drawn in or if the specified vacuum is not maintained install a new PAIR control valve If afterburn occurs on deceleration even when the secondary air supply system is normal check the air cut off valve PAIR CHECK VALVE INSPECTION Remove the radiator without disconne...

Page 121: ...connect ttie air uµµly hu es and vacuum tube to remove the PAIR control valve Installation is in the reverse order of removal EVAPORATIVE EMISSION CONTROL SYSTEM California type only NOTE Refer to the Vacuum Hose Routing Diagram Label and Cable Harness Routing page 1 18 for the tube connections and routing EVAPORATIVE EMISSION EVAP CANISTER REMOVAL INSTALLATION Disconnect the No 1 No 4 and No 2 tu...

Page 122: ...1t1 control valve SPECIFIED VACUUM 250 mm Hg 9 8 in Hg The specified vacuum should maintained Replace the EVAP purge control valve if vacuum is not maintained Connect a pressure pump to the No 4 tube fitting input port that goes to EVAP canister CAUTION Damage to the EVAP purge control valve mav result from use of a high pressure air source Use a hand operated air pump only While applying the spec...

Page 123: ...ect the No 8 and No 4 hoses Blow air into the No 4 hose fitting that goes to the EVAP canister with the ignition switch OFF Blow air into the No 8 hose fitting with the ignition switch ON Air should flow through the EVAP CAV solenoid valve and out the air vent port No 4 hose fitting that goes to the air vent control solenoid valve FUEL SYSTEM BOLT STAY EVAP CAV SOLENOID VALVE No 4 HOSE FITTING Fro...

Page 124: ...COOLING SYSTEM 6 0 SIPHON TUBE RADIATOR RESERVE TANK CYLINDER HEAD CYLINDER CARBURETO THERMOSTAT WATER PUMP ...

Page 125: ...re wear of water pump seals or blockage of radiator passage Using tap water may cause engine damage Add coolant at the reserve tank Do not remove the radiator cap except to refill or drain the system All cooling system service can be done with the engine in the frame Avoid spilling coolant on painted surfaces After servicing the system check for leaks with o cooling system tester Refer to section ...

Page 126: ...water jacket Air in system Faulty cooling fan motor Faulty fan motor switch Faulty water pump Engine temperature too low Faulty temperature gauge or thermosensor Thermostat stuck open Faulty fan motor switch Coolant leaks Faulty water pump mechanical seal Deteriorated 0 rings Faulty radiator cap Damaged or deteriorated cylinder head gasket Loose hose connection or clamp Damaged or deteriorated hos...

Page 127: ... a hydrometer STANDARD COOLANT CONCENTRATION 50 Look for contamination and replace the coolant lf necessary Coolant temper ature 0 F 0 5 10 15 20 32 41 50 59 68 Coolant ratio 1 042 1 040 t 049 1 047 1 062 1 060 1 058 1056 1 1J 68 oaG t 064 1 078 1 076 1 074 1 072 1 0Bl fi 082 t 080 1 0 17 COOLING SYSTEM 25 30 35 40 45 50 77 86 95 104 113 122 0 999 0 997 I 1 007 j 005 1 014 1 012 1 021 1 019 1 028 ...

Page 128: ...s rinse them with water and consult a doctor immediately If any coolant is swallowed induce vomiting gargle and consult a physician immediately If any coolant gets on your skin or clothes rinse thoroughly with plenty of water KEEP OUT OF REACH OF CHILDREN CAUTION Using coolant with silicate corrosion inhibitors may cause premature wear of water pump seals or blockage of radiator passage Using tap ...

Page 129: ... Remove the radiator cap Remove the drain bolt on the water pump and drain the coolant from the system Remove the radiator without disconnecting the water hoses page 3 6 Remove the drain bolt on the cylinder and drain the coolant from the cylinder Remove the reseve tank cap Slide the heat guard rubber out of the way discon nect the siphon tube and drain the coolant from the reserve tank Connect th...

Page 130: ... the system 3 Stop the engine and add coolant up to the filler ncck 4 Install the radiator cap Fill the reserve tank to the upper level line and install the reserve tank cap Install the right air intake duct page 2 6 lm itall Lhe siue fairinys µage 2 4 THERMOSTAT REMOVAL 6 6 1 M Ori T 1e lilngine nm st bli cool befo e se1vici11g lfle cuvl ing system or severe scalding may result Drain the coolant ...

Page 131: ...r to check its operation NOTE Do not let the thermometer or thermostat touch the pan or you will get false readings THERMOSTAT BEGINS TO OPEN 73 77 C 163 171 F VALVE LIFT 8 mm 0 3 in minimum at 90 C 194 F Replace the thermostat if the valve responds at temperature other than those specified INSTALLATION Install a new seal rubber over the thermostat tlange Apply coolant to the seal rubber and insta...

Page 132: ...m by removing the drain bolt on the water pump page 6 5 Disconnect the fan motor 2P Black connector Disconnect the horn connectors Remove the horn bolt and horn Disconnect the water hoses and tubes from the ldUidlUI Remove the radiator mounting bolts washers and nut Remove the radiator from the mounting boss of the frame Remove the air guide rubber from the engine Installation is in the reverse or...

Page 133: ... radiator Disconnect the fan motor switch connector Remove the fan motor assembly by removing the three bolts and ground terminal Remove the nuts and the cooling fan from the fan motor Remove the fan motor connector from the shroud and the motor wire from the clamp Remove the nuts and the fan motor COOLING SYSTEM 6 9 ...

Page 134: ...the fan motor onto the shroud as shown Install and tighten the nuts Install the fan motor connector onto the shroud and secure the wire with the clamp Install the cooling fan onto the motor shaft by align ing the flat surfaces Install and tighten the nut AIR GUIDE RUBBER FAN MOTOR SHROUD ...

Page 135: ... page 6 8 RADIATOR RESERVE TANK REMOVAL INSTALLATION Drain the coolant from the reserve tank p ioe 6 5 _ Remove the breather tube from the reserve tank stay Remove the mounting bolt and the reserve tank and heat guard rubber from the stay Align the locating Installation is in the reverse order of removal pin with the hole in the stay NOTE noute the tubes properly page 1 18 Fill the reserve tank wi...

Page 136: ... leakage the mechanical seal is defective and replace the water pump as an assembly REMOVAL Drain the coolant from the system by removing the drain bolt on the water pump page 6 5 Disconnect the water tube and hoses from the water pump cover Remove the 0 ring Disconnect the water hoses Remove the pump body from the crankcase ...

Page 137: ...r pump shaft groove with the oil pump shaft end by turning the pump shaft Align the bolt holes in the water pump and crankcase and make sure the water pump is secure ly installed Connect the water hoses to the pump body Install a new 0 ring into the groove in the water pump body Install the water pump cover and tighten the bolts with a new sealing washer TORQUE 12 N m 1 2 kgf m 9 lbf ft Connect th...

Page 138: ...ENGINE REMOVAL INSTALLATION 54 N m 5 5 kgf m 40 lbf ft 7 0 ...

Page 139: ...AL 4 N m 0 4 kgf m 2 9 lbf ft 54 N m 5 5 kgf m 40 lbf ftl 39 N m 4 0 kgf m 29 bf ft 7 2 7 3 ENGINE INSTALLATION 7 6 39 N m 4 0 kgf m 29 lbf ft Ill 2 N m 0 2 kgf m 1 4 lbf ft 10 N m 1 0 kgf m 7 bf ft 54 N m 5 5 kgf m 40 lbf ft Q 10 x ob mm 10 X 50 mm 10 X 60 mm 7 1 ...

Page 140: ...n cylinder section 12 When installing the engine be sure to tighten the engine mounting fasteners to the specified torque in the specified sequence If you mistake the tightening torque or sequence loosen all mounting fasteners then tighten them again to the specified torque in the correct sequence SPECIFICATIONS TORQUE VALUES Front engine hanger bolt Center engine hanger bolt Ctmlt r 1 1r19in1 1 t...

Page 141: ...page 5 15 pulse secondary air injection PAIR control valve page 5 39 EVAP canister California only page 5 39 direct ignition coil connectors Remove the two bolts and radiator stay Remove the cable holder bolt and disconnect the clutch cable from the clutch arm Remove the two bolts and thermostat housing Remove the 0 ring ENGINE REMOVAL INSTALLATION 7 3 ...

Page 142: ...e switch wire by removing screw starter motor cable by removing terminal nut ground cable by removing motor mounting bolt thermosensor connector alternator 3P White connector side stand 2P Green connector gearshift arm by removing bolt neutral switch connector Remove the two bolts sprocket cover and guide plate SPROCKET COVER AND GUIDE PLATE ...

Page 143: ...lts shock link brackets from engine and shock link four dowel pins Support the Loosen the left and right swingarm pivot lock nuts win9C1 1m f li u1t 1 y pi ll Jtl 14 13 Remove the pivot nut and washer and the pivot bolt Place a floor jack or other adjustable support under the engine NOTE The jack height must be continually adjusted to relieve stress for ease of bolt removal Remove the following fr...

Page 144: ...LLATION 7 6 NOTE When tightening the lock nut with the lock nut wrench refer to torque wrench reading informa tion on page 7 2 SERVICE INFORMATION The jack height must be continually adjusted to relieve stress from the mounting fasteners Route the wires and cables properly page 1 18 CAUTION Be sure to tighten all engine mounting fasteners to the specified torque in the specified sequence described...

Page 145: ...4 N m 5 5 kgf m 40 lbf ft Indicated 49 N m 5 0 kgf m 36 bf ft 6 Set the right spacer F between the frame and engine Temporarily install the rear hanger bolt C to align the spacer Install the adjusting bolt F until it just contacts to the spacer Remove the hanger bolt C and tighten the rear adjusting bolt F to the specified torque then turn it out 180 TORQUE 4 N m 0 4 kgf m 2 9 lbf ft 7 Install the...

Page 146: ...ock link Install the bracket and shock link to bracket nuts Tighten the bracket nuts then the shock link to bracket nut TORQUE Bracket nut 39 N m 4 0 kgf m 29 Ibf ft Shock link to bracket 44 N m 4 5 kgf m 33 Ibf ft Install with the Install the drive sprocket with the drive chain onto sprocket s mark the countershaft 7 8 facing out Install the washer and bolt and tighten the bolt TORQUE 64 N m 6 6 ...

Page 147: ...er motor cable TORQUE 10 N m 1 0 kgf m 7 bf ft ground cable oil pressure switch wire TORQUE 2 N m 0 2 kgf m 1 4 lbf ft speed sensor 3P Black connector ignition pulse generator 2P Red connector thermosensor connector Install a new 0 ring into the thermostat housing groove Install the thermostat housing onto the cylinder head and tighten the two bolts ENGINE REMOVAL INSTALLATION GEARSHIFT ARM PUNCH ...

Page 148: ... Install the following direct ignition coil connectors EVAP canister California only page 5 39 pulse secondary air injection PAIR control valve page 5 39 carburetor page 5 30 exhaust system page 2 7 radiator reserve tank page 6 11 radiator page 6 8 Adjust the following drive chain slack page 3 10 clutch lever free play page 3 23 Fill the crankcase with recommended engine oil page 3 12 ...

Page 149: ...MEMO ...

Page 150: ...CYLINDER HEAD VALVE 10 N m 1 0 kgf m 7 lbf ft 47 N m 4 8 kgf m 35 bf ft 8 0 ...

Page 151: ... the cylinder head cover and cylinder head SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Cylinder compression at 350 rom 1 226 kPa 12 5 kaf cm2 178 osi Valve clearance IN 0 20 o o3 fo oo8 0 001 I FX 0 28 t 0 01 0 011 0 001 Camshaft Cam 49 state Canada IN 36 600 36 760 1 4409 1 4472 36 57 1 440 lobe _ y_Ee EX 35 380 35 540 1 3929 1 3992 35 35 1 392 height California type IN 34 640 34 720 1 ...

Page 152: ...ng surface Apply oil to the threads and seating surface Apply locking agem to the threads 07780 0010200 or equivalent commercially available in U S A 07780 0010100 07780 0013300 07780 0012500 07780 0014500 07780 0014202 07781 0010500 Engine top end problems usually affect engine performance These can be diagnosed by a compression test or by tracing top end noise with a sounding rod or stethoscope ...

Page 153: ...m reading is usually reached within 4 7 seconds COMPRESSION PRESSURE 1 226 kPa 12 5 kgf cm2 178 psi Low compression can be caused by blown cylinder head gasket improper valve adjustment valve leakage worn piston ring or cylinder High compression can be caused by carbon deposits in combustion chamber or on fJblun head CYLINDER HEAD COVER REMOVAL Remove the carburetor page 5 15 Disconnect the igniti...

Page 154: ...er page 8 3 Remove the cam chain tensioner lifter sealing bolt and coaling waohor Turn the cam chain tensioner lifter shaft clockwise fully and secure it with a stopper tool This tool can easily be made from a thin 1 mm of thickness piece of steel as shown below 15mm 19mm 3mm 15mm 1 8 5mm MATERIAL THICKNESS 1 0 mm 4 5 mm Remove the two bolts and cam chain guide plate from the camshaft holder ...

Page 155: ...t holder bolts in a crisscross pattern in several steps from the outside to inside to prevent damage the camshaft holder and camshafts Remove the comshaft holder Remove the camshafts NOTE Do not forcibly remove the dowel pins from the cr1mshr1ft holder Remove the valve lifters and shims NOTE Be careful not to damage the valve lifter bore Shims may stick to the inside of the valve lifter Do not all...

Page 156: ...IMIT 0 05 mm 0 002 in Measure each cam lobe height using a micrometer SERVICE LIMITS 49 state Canada type IN 36 57 mm 1 440 in EX 35 35 mm 1 392 in California typA IN 34 61 mm 1 363 in EX 33 89 mm 1 334 in CAMSHAFT JOURNAL Check the camshaft journal surfaces of the cam shaft holders and cylinder head for scoring scratches or evidence ot insufficient lubrication CAM CHAIN GUIDE PLATE Check the guid...

Page 157: ...r area gradually in the sequence 6 5 8 7 until the dowel pins on the camshaft holder inserts into the pin holes in the cylinder head properly The clearance between the holder and head is 1 5 llllll Next tighten the all bolts in numerical order cast on the camshaft holder 1 thru 20 in several steps TORQUE 12 N m 1 2 kgf m 9 lbf ft Remove the camshaft holder and measure the compressed plastigauge at...

Page 158: ... 9 mm cylinder head bolts in a criss cross pattern in 2 or 3 steps and remove them Remove the cylinder head Rcmovo tho gockct and dowel pine CYLINDER HEAD DISASSEMBLY Remove the spark plugs from the cylinder head Install the tappet hole protector into the valve lifter bore TOOL Tappet hole protector 07HMG MR70002 DOWEL PINS ...

Page 159: ...valve springs valve stem seal spring seats NOTE Mark all parts during disassembly so they can be placed back in their original locations INSPECTION CYLINDER HEAD Remove the carbon deposits from the combustion chamber hAing f irAf11I nnt tn rfam igA thA gaskP t surface Check the spark plug hole and valve areas for cracks Check the cylinder head for warpage with a straight edge and feeler gauge SERV...

Page 160: ...es or damage Measure the each valve lifter O D SERVICE LIMIT 25 97 mm 1 022 in VALVE SPRING Measure the valve spring free length SERVICE LIMITS IN 38 27 mm 1 507 in EX 34 73 mm 1 367 in VALVE VALVE GUIDE Check that the valve moves smoothly in the guide ChP ck the valve for bending burning or abnormal wear Measure each valve stem O D and record it SERVICE LIMITS IN 3 965 111111 0 1561 i11 EX 3 955 ...

Page 161: ... mm 0 0033 in If the stem to guide clearance exceeds the service limit determine if a new guide with standard dimen sions would bring the clearance within tolerance If so replace any guides as necessary and ream to fit If the stem to guide clearance exceeds the service limit with a new guide also replace the valve NOTE Inspect and reface the valve seats whenever the valve guides are replaced page ...

Page 162: ...130 140 C 275 290 F with a hot plate or oven Wear heavy gloves to avoid burns when handling the heated cylinder head CAUTION Using a torch to heat the cylinder head may cause warpage Support the cylinder head and drive the valve guides out of the cylinder head from the combus tion chamber side TOOL Valve guide driver 07JMD KY20100 While the cylinder head is still heated drive new valve guides in t...

Page 163: ...s Apply a light coating of Prussian Blue to each valve seat Tap the valve against the valve seat several times without rotating the valve to check for proper valve seat contact Remove the valve and inspect the valve seat face The valve seat contact should be within the speci fied width and even oil around the eircurnfcrcnce STANDARD IN EX 0 90 1 10 mm 0 035 0 043 in SERVICE LIMIT IN EX 1 5 mm 0 06...

Page 164: ...careful not to grind the seat more than neces sary If the contact area is too high on the valve the seat must be lowered using a 32 flat cutter If the contact area is too low on the valve the seat must be raised using a 60 interior cutter Using a 45 seat cutter remove any roughness or irregularities from the seat TOOLS Seat cutter 27 5 mm 07780 0010200 Seat cutter 24 5 mm 07780 0010100 Cutter hold...

Page 165: ...780 0014500 07780 0014202 07781 0010500 or equivalent commercially available in U S A Using a 45 seat cutter cut the seat to the proper width After cutting the seat apply lapping compound to the valve face and lap the valve using light pres sure CAUTION Excessive lapping pressure may deform or dam age the seat Change the angle of lapping tool frequently to prevent uneven seat wear Do not allow lap...

Page 166: ...ough oil oil passagos in the cylinder hood with compressed air Install the spring seats and new stem seals Lubricate the valve stem sliding surtace with molyb denum oil solution Insert the valve into the guide while turning it slow ly to avoid damage to the stem seal Install the valve spring with the tightly wound coils facing the combustion chamber Install the spring retainer VALVE GUIDE ...

Page 167: ...7757 0010000 07959 KM30101 To prevent loss of tension do not compress the valve springs more than necessary to install the cotters Support the cylinder head so that the valve heads will not contact anything that cause damage Tap the valve stems gently with two plastic hammers as shown to seat the cotters firmly Install and tighten the spark plugs TORQUE 12 N m 1 2 kgf m 9 lbf ft CYLINDER HEAD INST...

Page 168: ...attern in 2 or 3 steps TORQUE 47 N m 4 8 kgf m 35 lbf ft Install and tighten the two 6 mm bolts If the engine is out Install a naw 0 ring into tha thermostat housing of the frame do groove not install the Install thermostat housing onto the cylinder head thermostat yet and tighten the two bolts R 1R Turn the cam chain tensioner lifter shaft clockwise fully to retract the tensioner lifter and secur...

Page 169: ...der bolts for correct torque value Install the valve shims in their original locations Coat the outer surfaces of the valve lifters with mo lybdenum oil solution Install the valve lifters in their original lifter bores being careful not to damage the sliding surfaces of the lifters and bores Apply molybdenum oil solution to the camshaft journals and cam lobes The camshafts Install the camshafts on...

Page 170: ...the holder is parallel with the cylinder head resume tightening the bolts in the sequence specified above Once the clearance is within 2 3mm begin tightening all the bolts in numerical order 1 2 3 20 1 4 to 1 2 turn at a time until the holder is fully seated against the cylinder head TORQUE 12 N m 1 2 kgf m 9 lbf ft Be careful not to Tum the crankshaft clockwise and align T mark jam the cam chain ...

Page 171: ...e turn and tighten the other sprocket bolts to the same torque Install the cam chain guide plate and tighten the two bolts Remove the stopper tool from the cam chain ten sioner lifter and install the sealing bolt with a new sealing washer Install the timing hnle r ir r ige 11 Install the cylinder head cover CYLINDER HEAD COVER INSTALLATION Install a new gasket in the head cover groove Apply sealan...

Page 172: ...head properly Tighten the bolts in 2 or 3 steps TORQUE 10 N m 1 0 kgf m 7 lbf ft Connect the air suppiy hoses and the vacuum tube to install the PAIR control valve Install the direct ignition coils onto the spark plugs The cylinder Connect each 2P connector to the correct ignition numbers are coil printed on each ignition coil wire Install the carburetor page 5 30 8 22 Fill and bleed the cooling s...

Page 173: ...MEMO ...

Page 174: ...CLUTCH GEARSHIFT LINKAGE 15 N m 1 5 kgf m 11 lbf ft µ 127 N m 13 0 kgf m 94 lbf ft 12 N m 1 2 kgf m 9 lbf ft 9 0 ...

Page 175: ...tch Sarina free lenath 46 5 1 83 45 2 1 78 Disc thickness 2 92 3 08 0 115 0 121 2 6 0 10 Plate waroaqe I 0 30 0 012 Clutch outer guide l D 25 000 25 021 0 9843 0 9851 25 03 0 985 O D 34 975 34 991 1 3770 1 3776 34 97 1 377 Mainshaft O D at clutch outer auide 24 980 24 993 0 9835 0 9840 24 96 0 983 TORQUE VALUES Clutch center lock nut Clutch bolt Oil pump driven sprocket bolt Gearshift cam bolt Gea...

Page 176: ...ed Clutch slips No clutch lever free play Worn clutch discs Weak clutch springs Clutch lifter sticking Engine oil level too low or oil additive used Hard to shift Improper clutch operation Incorrect engine oil viscosity Incorrect clutch adjustment Bent or damaged gearshift spindle Damaged gearshift cam Bent fork shaft or damaged shift forks and shift drum section 11 Transmission jumps out of gear ...

Page 177: ... lifter arm Disconnect the ignition pulse generator 2P connec tor Remove the crankcase cover bolts The lifter arm Remove the crankcase cover while turning the spindle is engaged clutch lifter arm counterclockwise to disengage the with the clutch lifter arm spindle from the lifter piece lifter piece inside the right crankcase cover Remove the four dowel pins Clean any sealant from the crankcase cov...

Page 178: ... damage Check the lifter arm oil seal and needle bearings for wear or damage Install the clutch lifter arm with the spring and washer as shown DISASSEMBLY Remove the right crankcase cover pogo 9 3 Remove the clutch bolts springs and pressure plate Hemove the clutch litter piece Remove the seven clutch discs and six plates NOTE The two discs 8 on both ends are different from the five discs A Do not...

Page 179: ...ds Hold the clutch center with the special tool and re move the clutch center lock nut TOOL Clutch center holder 07724 0050002 or equivalent commercially available in u A Remove the special washer plain washer and clutch center Remove the thrust washer CLUTCH GEARSHIFT LINKAGE 9 5 ...

Page 180: ...e oil pump driven sprocket drive chain and drive sprocket as a set Remove the clutch outer guide INSPECTION LIFTER BEARING Turn the inner race of the lifter bearing willr yuur finger The bearing should turn smoothly and quietly Also check that the outer race of the bearing fits tightly in the pressure plate Replace the bearing if the inner race does not turn smoothly quietly or if the outer race f...

Page 181: ... Replace the clutch Check the clutch discs for signs of scoring or discs and plates discoloration as a set_ Measure the clutch disc thickness SERVICE LIMIT 2 6 mm 0 10 in CLUTCH PLATE Replace the clutch Check the plates for discoloration discs and plates Check the plate warpage on a surface plate using a as a set feeler gauge SERVICE LIMIT 0 30 mm 0 012 in CLUTCH GEARSHIFT LINKAGE CLUTCH CENTER 9 ...

Page 182: ... outer guide SERVICE LIMIT 24 96 mm 0 983 in CLUTCH OUTER Check the slots in the clutch outer for nicks indentation or abnormal wear made by the clutch dlSCS Check the needle bearing for wear or damage Replace the bearing if necessary Press the needle bearing out of the clutch outer us ing the special tools TOOLS Driver 07749 0010000 Attachment 37 x 40 mm 07746 0010200 Pilot 35 mm 07746 0040800 ...

Page 183: ...mp drive sprocket with the pins facing out drive chain and driven sprocket as a set with the OUT mark on the driven sprocket facing out Apply locking agent to the oil pump driven sprocket bolt threads Install the bolt with lht i washt ir am I Lil Jhlt in it TORQUE 15 N m 1 5 kgf m 11 Ibf ft Be careful not to Align the gear teeth of the scissors gears primary bend the ignition drive gear and sub ge...

Page 184: ...r with the OU I mark on the special washer tacing out Apply engine oil to the threads and seating surface of a new clutch center lock nut and install it onto the mainshaft Hold the clutch center with the special tool and tighten the lock nut TOOL Clutch center holder 07724 0050002 or equivalent commercially available in U S A TORQUE 127 N m 13 0 kgf m 94 lbf ftl Be careful not to Stake the clutch ...

Page 185: ... the disc 8 The two discs tabs into the 8 are installed onto both ends shallow slots of the clutch outer Install the clutch lifter piece into the lifter bearing Install the pressure plate and the clutch bolts with the springs Tighten the bolts in a crisscross pattern in 2 or 3 steps TORQUE 12 N m 1 2 kgf m 9 lbf ft Install the right crankcase cover page 9 14 CLUTCH GEARSHIFT LINKAGE DISC8 9 11 ...

Page 186: ...emove the gearshift spindle assembly and thrust washer Remove the gearshift cam bolt and gearshift cam Remove the dowel pin from the shift drum Remove the stopper arm bolt arm washer and re turn spring INSPECTION Check the gearshift spindle for bending Check the spindle plate for wear or damage Check the spindle return spring for fatigue or dam age ...

Page 187: ...per arm with a screwdriver and install the gearshift cam by aligning the pin hole in the cam with the dowel pin Apply locking agent to the gearshift cam bolt threads Install and tighten the bolt TORQUE 23 N m 2 3 kgf m 17 lbf ft Install the thrust washer onto the gearshift spindle and insert the spindle into the crankcase aligning the return spring ends with the spring pin CLUTCH GEARSHIFT LINKAGE...

Page 188: ...e clutch page 9 9 RIGHT CRANKCASE COVER INSTALLATION 9 14 Install the four dowel pins Apply sealant to the crankcase mating surfaces as shown firu 10 15 mm 0 4 0 6 in 10 15mm 0 4 0 6 in Apply sealant to the right crankcase cover mating surface Install the right crankcase cover while turning the lifter arm clockwise to engage the lifter arm groove with the lifter piece flange ...

Page 189: ...e water the cable holder with the bolt hose and engine Tighten the four cover bolts first in a numerical or der on the crankcase cover in 2 or 3 steps TORQUE 12 N m 1 2 kgf m 9 lbf ft Tighten the other cover bolts to the same torque Fill the crankcase with recommended engine oil page 3 12 Adjust the clutch cable page 3 23 Install the side fairing page 2 4 CLUTCH GEARSHIFT LINKAGE 9 15 ...

Page 190: ...ALTERNATOR STARTER CLUTCH 12 N m 1 2 kgf m 9 Ibf ft 10 0 ...

Page 191: ...servicing SPECIFICATIONS ITEM Starter driven gear boss O D TORQUE VALUES 14 N m 1 4 kgf m 10 lbf ft 12 N m 1 2 kgf m 9 lbf ft STANDARD 51 699 51 718 2 0354 2 0361 16 N m 1 6 kgf m 12 Ibf ft Apply locking agent to the threads Unit mm in SERVICE LIMIT 51 684 2 0348 Stator wire clamp bolt Alternator stator bolt Starter clutch bolt Flywheel bolt 103 N m 10 5 kgf m 76 lbf ft Apply oil to the threads an...

Page 192: ...ne and add the recommended oil to the specified level after installation Remove the gasket and dowel pin STATOR REPLACEMENT Remove the clamp bolt and clamp Remove the four bolts grommet and stator from the left crankcase cover Install a new stator onto the left crankcase cover Apply sealant to the grommet seating surface and install it into the cover groove properly Set the wire properly and insta...

Page 193: ...I if necessary page 3 11 FLYWHEEL REMOVAL Remove the left crankcase cover page 10 2 Remnwi thP starter reduction gear and shaft Hold the flywheel with the special tool and loosen the flywheel bolt TOOL Flywheel holder 07725 0040000 or equivalent commercially available in U S A Remove the flywheel bolt and special washer Remove the flywheel using the special tool TOOL Rotor puller 07733 0020001 or ...

Page 194: ...Remove the starter driven gear while turning it counterclockwise Hold the flywheel with the special tool and remove the starter clutch bolts TOOL Flywheel holder 07726 0040000 or equivalent commercially available in U S A Remove the starter clutch assembly from the fly wheel Remove the sprag clutch from the starter clutch out er ...

Page 195: ...engine oil to the sprag clutch contacting sur faces Install the sprag clutch into the starter clutch outer as shown Apply locking agent to the starter clutch bolt threads Install the starter clutch assembly onto the flywheel and install the bolts Hold the flywheel with the special tool and tighten the bolts TOOL Flywheel holder 07725 0040000 or equivalent commercially available in U S A TORQUE 16 ...

Page 196: ...from the tapered portion of the crank shaft and flywheel Install the woodruff key in the crankshaft key groove Install the flywheel aligning the kev way in the fly wheel with the woodruff key on the crankshaft Apply engine oil to the flywheel bolt threads and seating surface Install the special washer and flywheel bolt Hold the flywheel with the special tool and tighten the bolt TOOL Flywheel hold...

Page 197: ...Apply oil to the starter reduction gear and gear shaft Install the reduction gear and shaft Install the left crankcase cover page 10 2 ALTERNATOR STARTER CLUTCH 10 7 ...

Page 198: ...CRANKCASE TRANSMISSION 39 N m 4 0 kgf m 29 lbf ft 12 N m 1 2 kgf m 9 lbf ft 59 N m 6 0 kgf m 43 lbf ft 10 N m 1 0 kgf m 7 lbf ft 11 0 ...

Page 199: ...ATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Shift fork l D 12 000 12 021 0 4724 0 4733 12 03 0 474 Claw thickness 5 93 6 00 0 233 0 236 5 9 0 23 Shift fork shaft 0 D 11 957 11 968 0 4707 0 4712 11 95 0 470 Transmission Gear l D M5 M6 28 000 28 021 1 1024 1 1032 28 04 1 104 C2 C3 C4 31 000 31 025 12205 1 i 1 31 04 1 222 Gear bushing O D I M5 M6 27 959 27 980 1 1007 1 1016 27 94 1 100 C2 30 955 30...

Page 200: ...ft drum cam grooves Bent gearshift spindle Transmission jumps out of gear Worn gear dogs Worn gear shifter groove Bent shift fork shaft Broken shift drum stopper arm Worn or bent shift forks Broken drum stopper arm spring Broken gearshift spindle return spring Exoel l ive engine noil o Worn or damaged transmission gears Worn or damaged transmission bearings 11 2 12 N m 1 2 kgf m 9 lbf ft 12 N m 1 ...

Page 201: ...rank case with the speed sensor installed Do not use the Remove the bolt washer and ignition pulse genera ianition pulse tor rotor generator rotor Remove the washer bolt and cam chain guide tangs to hold it in Remove the cam chain and timing sprocket place while Remove the pivot bolt cam chain tensioner and removing the bolt washer Remove the three bolts and bearing set plate Loosen the seven 6 mm...

Page 202: ... 3 steps Remove the bolts Separate the lower crankcase from the upper crank case Remove the dowel pins and oil orifices Clean any sealant from the crankcase mating sur faces SHIFT FORK SHIFT DRUM REMOVAL Jeparate the crankcaae halvea page 11 3 Remove the bearing set bolts Remove the shift fork shaft and shift forks Remove the shift drum and bearing 11 4 ...

Page 203: ...e the shift fork claw thickness SERVICE LIMIT 5 9 mm 0 23 in Measure the shift fork shaft 0 0 SERVICE LIMIT 11 95 mm 0 470 in Check the shift drum guide groove for abnormal wear or damage Check the shift drum bearing for smooth rotation INSTALLATION Install the shift drum and bearing into the lower crankcase CRANKCASE TRANSMISSION 11 5 ...

Page 204: ... fork shaft Apply locking agent to the bearing set bolt threads Install the set bolts and tighten them TORQUE 12 N m 1 2 kgf m 1 9 lbf ft Assemble the crankcase halves page 11 11 TRANSMISSION DISASSEMBLY 11 6 Separate the crankcase halves page 11 3 Remove the mainshaft and countershaft assem blies Disassemble the mainshaft and countershaft Clean all disassembled parts in solvent thoroughly Check t...

Page 205: ... gear to bushing clearance SERVICE LIMITS MS MG 0 10 mm 0 004 in C3 C4 0 11 mm 0 004 in C2 0 10 mm 0 004 in Measure the gear bushing l D SERVICE LIMITS MS 25 016 mm 0 9849 in C2 28 021 mm 1 1032 in Check the mainshaft and counters haft for abnormal wear or damage Measure the mainshaft O D at the MS gear SERVICE LIMIT 24 96 mm 0 983 in Measure the countershaft 0 D at the C2 gear SERVICE LIMIT 27 96...

Page 206: ...es not turn smoothly quietly or if the inner race fits loosely on the shaft NOTE The countershaft ball bearing cannot be replaced If the countershaft bearing is faulty replace the coun tershaft MAINSHAFT BEARING REPLACEMENT Press the mainshaft out of the bearing Install with the Press a new bearing onto the mainshaft with the groove side facing special tools up TOOL Inner driver C 077 16 0030100 A...

Page 207: ...ves and bushings Assemble the mainshaft and countershaft MAINSHAFT M5 BUSHING 0 CRANKCASE TRANSMISSION WASHER AND SNAP RING UIHtCl IUN M5 GEAR M3 M4 GEAR 17 19T Y M6 SPLINE BUSHING M6 GEAR 123T fJ NEEDLE BEARING COUNTERSHAFT WASHER AND SNAP RING DIRECTION C2 GEAR 33Tl C B GEAR 26Tl 11 9 ...

Page 208: ... Install the snap ring so that its end gap aligns with the groove in the splines Make sure that the snap ring is fully seated in the shaft groove after installing it Install thP mainsh ift issP mhly hy ilionino thP hole in the needle bearing outer race with the dowel pin Install the countershaft assembly by aligning the hole in the needle bearing outer race with the dowel pin and the ring groove w...

Page 209: ...ear shifter grooves Apply engine oil to the 8 mm bolt threads and seat ing surfaces Install the 10 mm bolt ten 8 mm bolts and eight 6 mm bolts and tighten them in a crisscross pattern in 2 or 3 steps TORQUE 10 mm bolt 39 N m 4 0 kgf m 29 Ibf ft 8 mm bolt 25 N m 2 6 kgf m 19 lbf ft Install the sealing Install the five 8 mm bolts and seven 6 mm bolts washers indicated with new sealing washers by the...

Page 210: ... bolt with the washer and tighten it TORQUE 59 N rn 6 0 kgf m 43 lbf ft Install the cam chain Apply locking agent to the pivot bolt threads Install the cam chain tensioner washer between the tensioner and crankcase and pivot bolt Tighten tho bolt TORQUE 10 N m 1 0 kgf m 7 lbf ft Install the cam chain guide and washer bolt Tighten the bolt TORQUE 12 N rn 1 2 kgf rn 9 lbf ft Install a new 0 ring int...

Page 211: ...the following oil pressure switch page 4 3 oil pump oil cooler oil strainer pressure relief valve and oil pan section 4 water pump section 6 starter motor section 18 flywheel section 10 gearshift linkage and clutch section 9 cylinder head camshafts and head cover sec tion 8 engine section 7 CRANKCASE TRANSMISSION 11 13 ...

Page 212: ...CRANKSHAFT PISTON CYLINDER 12 0 25 N m 2 6 kgf m 19 lbf ft d I I I ...

Page 213: ...0 0 012 Crankoin bearinq oil clearance 0 028 0 052 0 0011 0 0020 0 06 0 002 Main journal be d g oil clearance 0 020 0 038 0 0008 0 0015 0 05 0 002 Runout 0 05 0 002 Piston Piston O D at 15 0 6 from bottom 66 965 66 985 2 6364 2 6372 66 90 2 634 piston pin Piston oin hole l D 17 002 17 008 0 6694 0 6696 17 02 0 670 piston ring Piston pin 0 D 16 994 17 000 0 6691 0 6693 16 98 0 669 _f iston to 2i to...

Page 214: ...rn stuck or broken piston ring Worn or damaged cylinder and piston Compression too high overheating or knocking Excessive carbon built up on piston head or combustion chamber Excessive smoke Worn cylinder piston or piston rings Improper installation of piston rings Scnrecl or scrritchAcl pistnn or cylinclAr wall Abnormal noise Worn piston pin or piston pin hole Worn cu1me1 lir1y ruu rnall end Worn...

Page 215: ...e assembly Tap the side of the cap lightly if the bearing cap is hard to removed Remove the connecting rod bearing cap nuts and bearing caps Lower the pistons to the top dead center to avoid damaging the crankshaft by the connecting rod bolto Remove the crankshaft INSPECTION Hold the crankshaft both end Set a dial indicator on the center main journal of the crankshaft Rotate the crankshaft two rev...

Page 216: ...the stoppers on the reverse side of the sub gear are pushing against the gear springs Install with the Install a new snap ring into the ring groove in the large tab facing crankshaft securely with the end gap at right angle the right and the to the crankshaft cut outs by aligning the large tab chamfered side edge with the sub gear groove as shown facina the gear 12 4 STARTER CLUTCH NEEDLE BEARING ...

Page 217: ...ecting rod bolts and bearing cap nuts It may cause the cap nuts to be tightened to an incorrect torque value Apply molybdenum oil solution to the main journal bearing sliding surfaces on the upper crankcase and the crankpin bearing sliding surfaces on the connecting rods Apply molybdenum oil solution to the thrust sur faces of the crankshaft as shown Lower all the pistons to the top dead center to...

Page 218: ...p nuts Tighten the nuts in 2 or 3 steps TORQUE 25 N m 2 6 kgf m 19 lbf ft Assemble the crankcase halves page 11 11 MAIN JOURNAL BEARING Remove the crankshaft page 12 3 BEARING INSPECTION Check the bearing inserts on the upper and lower crankcases for unusual wear or peeling Check the bearing tabs tor damage OIL CLEARANCE INSPECTION Do not rotate the Clean off any oil from the bearing inserts and m...

Page 219: ...est point on each main journal to determine the oil clearance SERVICE LIMIT 0 05 mm 0 002 in If the oil clearance exceeds the service limit select the correct replacement bearings BEARING SELECTION Record the crankcase bearing support 1 0 code let ters NOTE Letters A 8 or Cl on the left side of upper crank case are the codes tor the bearing support 1 0 s from left to right Record the corresponding...

Page 220: ...ERT THICKNESS A Black 1 506 1 509 mm 0 0593 0 0594 in B Brown 1 503 1 506 mm 0 0592 0 0593 in C Green 1 500 1 503 mm 0 0591 0 0592 in D Yellow 1 497 1 500 mm 0 0589 0 0591 in E Pink 1 494 1 497 mm 0 0588 0 0589 in CAUTION After selecting new bearings recheck the oil clear ance with plastigauge Incorrect oil clearance can cause major engine damage BEARING INSTALLATION Clean the bearing outer surfac...

Page 221: ...il to the connecting rod bcoring cop nut threads and seating surfaces and install them Tighten the cap nuts in 2 or 3 steps TORQUE 25 N rn 2 6 kgf m 19 Ibf ft Remove the bearing caps and measure the compressed plastigauge at its widest point on the crankpin to determine the oil clearance SERVICE LIMIT 0 06 mm 0 002 in If the oil clearance exceeds the service limit select the correct replacement be...

Page 222: ...HICKNESS Brown 1 244 1 248 mm 0 0490 0 0491 in Green 1 240 1 244 mm 0 0488 0 0490 in Yellow 1 236 1 240 mm 0 0487 0 0488 in CAUTION After selecting new bearings recheck the oil clear ance with plastigauge Incorrect oil clearance can cause major engine damage BEARING INSTALLATION Clean the bearing outer surfaces bearing cap and connecting rod Install the crankpin bearing inserts onto the bearing ca...

Page 223: ... the piston pin clips with the pliers Push the piston pin out of the piston and con necting rod and remove the piston PISTON RING REMOVAL CAUTION Dv 11ot damage tlle pi tou ring by sµreauiuy the ends too far Spread each piston ring and remove it by lifting up at a point opposite the gap Clean carbon deposits from the piston CAUTION Clean carbon deposits from the ring grooves with a ring that will ...

Page 224: ...ring into the bottom of the cylin der squarely using the piston Mea ure tile ring em gap SERVICE LIMITS Top 0 4 mm 0 02 in Second 0 5 mm 0 02 in Oil side rail 1 0 mm 0 04 in MAasurn the piston pin 0 D at piston ancl c nn necting rod sliding areas SERVICE LIMIT 16 98 mm 0 669 in Measure the piston pin hole l D SERVICE LIMIT 17 02 mm 0 670 in Calculate the piston to piston pin clearance SERVICE LIMI...

Page 225: ...0 mm 0 004 in Calculate the cylinder taper and out of round at three levels in an X and Y axis Take the maximum reading to determine the taper and out of round SERVICE LIMITS Taper 0 10 mm 0 004 in Out of round 0 10 mm 0 004 in The cylinder must be rebored and an oversize piston 0 25 mm fitted if the service limits are exceeded The cylinder must be rebored so that the clearance for an oversize pis...

Page 226: ...m each other Stagger the side rail end gaps as shown PISTON INSTALLATION RING SECOND RING Apply molybdenum oil solution to the connecting rod small end inner surfaces and piston pin outer iurfocc i Install the piston Install the piston pin into the piston and connecting so that the JN rod mark facing the Install new piston pin clips into the grooves of the same a1rectt0n as piston pin hole the oil...

Page 227: ...age the piston rings and the cylinder wall by the connecting rod Install the connecting rod piston from the top of the cylinder with the IN mark toward the intake side using a commercially available piston ring com pressor tool Install the crankshaft page 12 5 CRANKSHAFT PISTON CYLINDER 12 15 ...

Page 228: ...FRONT WHEEL SUSPENSION STEERING 12 N m 1 2 kgf m 9 lbf ft 22 N m 2 2 kgf m 16 lbf ft 30 N m 3 1 kgf m 22 bf ft 13 0 ...

Page 229: ...Steerina head bearina preload TORQUE VALUES Handlebar weight mounting screw Front brake disc bolt Fru11L 1xle bull Front axle holder bolt Front fender bolt Fork socket bolt Fork cap Fork top bridge pinch bolt Fork bottom bridge pinch bolt Steering bearing adjustment nut Steering stem nut Front brake hose clamp bolt steering stem Front master cylinder mounting bolt Front brake caliper mounting bolt...

Page 230: ...over attachment B Steering stem driver TROUBLESHOOTING Hard steering 07947 KA50100 07965 MA60000 07VMF KZ30200 07VMF MATO100 07VMF MAT0200 07VMF MAT0300 07VMF MAT0400 07946 MBOOOOO Steering bearing adjustment nut too tight Worn or damaQed steering head bearings Bent steering stem Insufficient tire pressure Steers one side or does not trook straight Damaged or loose steering head bearings Bent fork...

Page 231: ...event air from entering the hydraulic system Remove the two bolts holder and master cylinder from the handlebar Remove the two screws and handlebar switch throttle housing Loosen the pinch bolt Remove the stopper ring and the handlebar from the fork Remove the throttle grip pipe from the handlebar RIGHT HANDLEBAR INSTALLATION Apply grease to the throttle grip pipe flange and in stall the throttle ...

Page 232: ...he rear screw Install the front brake master cylinder and holder with the UP mark facing up Align the end of the master cylinder with the punch mark on the handlebar and tighten the upper bolt first then the lower bolt TORQUE 12 N m 1 2 kgf m 9 lbf ft Connect the front brake light switch connectors Install the handlebar weight onto the inner weight aligning the bosses and grooves each other Instal...

Page 233: ...d the handlebar from the fork LEFT HANDLEBAR INSTALLATION Install the handlebar onto the fork aligning its boss with the groove in the fork top bridge Install the stopper ring and tighten the handlebar pinch bolt Clean the inside surface of the left handlebar grip and the outside surface of the left handlebar Apply Honda Bond A or equivalent to the inside surface of the left handlebar grip and to ...

Page 234: ... Install the clutch lever bracket and bracket holder with the UP mark facing up Align the end of the clutch lever bracket with the punch mark on the handlebar and tighten the upper bolt first then the lower bolt Connect the clutch switch connectors FRONT WHEEL REMOVAL 13 s Support the motorcycle securely using a hoist or equivalent and raise the front wheel off the ground Remove Lt1e four bolt and...

Page 235: ...n the left front axle holder bolts Remove the front axle and the front wheel Remove the side collars INSPECTION AXLE Set the front axle in V blocks Turn the front axle and measure the runout using a dial indicator Actual runout is 1 2 the total indicator reading SERVICE LIMIT 0 2 mm 0 01 in FRONT AXLE 13 7 ...

Page 236: ...iscard the bearings if the races do bearings in pairs not turn smoothly and quietly if they fit loosely in the hub DISASSEMBLY Remove the dust seals from the wheel hub Remove the disc bolts and brake discs from the wheel hub Replace the wheel Install the bearing remover head into the bearing bearings in pairs From opposite side install the bearing remover Do not reuse old shaft and drivethe bearin...

Page 237: ...ng side facing up until it is fully seated TOOLS Driver Attachment 42 x 47 mm Pilot 20 mm 07749 0010000 07746 0010300 07746 0040500 Do not get grease on the brake disc or stopping power will be reduced Install Lhe ur1 1ke discs with the arrow mark facing in the normal rotating direction Install new disc bolts and tighten them in a criss cross pattern in 2 or 3 steps TORQUE 20 N m 2 0 kgf m 14 lbf ...

Page 238: ...e mark a paint dot on the side wall must be located next to the valve stem Remount the tire if necessary Mount the wheel tire and brake disc assembly on an inspection stand Spin the wheel allow it to stop and mark the lowest heaviest part of the wheel with chalk Do this two or three times to verify the heaviest area If wheel is balanced it will not stop consistently in the same position To balance...

Page 239: ...he left side Install the front axle bolt and tighten it while holding the axle TORQUE 59 N m 6 0 kgf m 43 lbf ft Tighten the right axle holder bolts TORQUE 22 N m 2 2 kgf m 16 lbf ft Install the brake calipers with new mounting bolts and tighten the bolts TORQUE 30 N m 3 1 kgf m 22 lbf ft Install the front fender Install the four fender bolts with the brake hose clamp 3 way joint and reflectors an...

Page 240: ...eration Tighten the left axle holder bolts TORQUE 22 N m 2 2 kyf m 16 lbf ft REMOVAL Rt move the front vvheel pdyt 13 6 Remove the wire band s Loosen the handlebar pinch bolt and remove the stopper ring from the fork When the fork is ready to be disassembled loosen the fork cap but do not remove it yet Remove the handlebar assembly and secure it ...

Page 241: ...SEMBLY Remove the fork cap from the fork tube Hold the rebound damping adjuster and remove the fork cap from the damping adjuster Remove the 0 ring CAUTION Do not remove the rebound damping adjuster from the damper rod or fork damping force will change Remove the joint plate joint collar and spring seat Remove the 0 ring 13 13 ...

Page 242: ...mes Hold the fork slider in a vise with a soft jaws or shop towel and remove the socket bolt NOTE If the fork damper turns together with the socket bolt temporarily install the fork spring spring seat joint collar and fork cap Remove the fork damper from the fork tube Remove the dust seal and the fork protector FORK DAMPER t FORK PROTECTOR ...

Page 243: ... slider Remove the oil seal back up ring and guide bushing from the tork tube NOTE Do not remove slider bushing unless it is necessary to replace it with a new one Carefully remove the slider bushing by prying the slit with a screwdriver until the bushing can be pulled off by hand Remove the oil lock piece from the fork slider Remove the 0 ring OIL LOCK PIECE SLIDER BUSHING 13 15 ...

Page 244: ... V blocks and measure the fork tube runout with a dial indicator Actual runout is 1 2 the total indicator reading SERVICE LIMIT 0 20 mm 0 008 in Visually inspect the slider and guide bushings Replace the bushings if there is excessive scoring or scratching or if the teflon is worn so that the copper surface appears on more 3 4 of the entire surface Check the back up ring replace it if there is any...

Page 245: ...ING SEAT FORK SPRING SOCKET BOLT OIL LOCK PIECE FORK DAMPER Install a new slider bushing if it has been removed CAUTION Be careful not to damage the coating of the bushing Do not open the bushing more than necessary NOTE Remove the burrs from the bushing mating surface being careful not to peel off the coating Coat new 0 ring with fork tluld and install It into the groove in the oil lock piece Ins...

Page 246: ...old bushing or equivalent tool on top of the guide bushing Drive the bushing into place and remove the old bu hino or P q11iv ilent tool Wrap vinyl tape around the fork tube top end to avoid damaging the oil seal lip Coat a new oil seal with fork fluid and install it over the fork tube with the marked side facing up Drive the oil seal until the stopper ring groove is visible TOOLS Fork seal driver...

Page 247: ...cm 16 1 U 08 us oz 16 0 09 OZ Pump the damper rod several times until the fork fluid flows out of the oil hole in the rebound damp ing adjuster Slowly pump the fork tube several times to remove trapped air Cornf m i lhe fork tube fully Measure the oil level from the top of the fork tube OIL LEVEL 118 mm 4 6 in Pull up the damper rod fully Install the fork spring with the tightly wound end facing d...

Page 248: ...the fork tube NOTE Tighten the fork cap after installing the fork tube into the fork bridges INSTALLATION Route the cables Install the fork tube into the fork bridges so that the wire harnesses height from the top bridge upper surface to the fork and hoocopropcr tube end is 33 mm 1 3 in ly page 1 18 Tighten the fork top bridge pinch bolt TORQUE 23 N m 2 3 kgf m 17 bf ft Tighten the fork bottom bri...

Page 249: ... Right fork Secure the handlebar switch wire with the wire band I Aft fork SAc ure the handlebar switch and horn wires with the wire bands page 1 18 Install the front wheel page 13 11 STEERING STEM REMOVAL Remove the front wheel paqe 13 6 Remove the left air intake duct page 2 6 Release the wire band and disconnect the ignition switch 4P White connector Remove the bolt and front brake hose clamp D...

Page 250: ...dges Loosen the steering stem nut Remove the forks stem nut and fork top bridge Straighten the lock washer tabs Remove the steering bearing adjustment nut lock nut and lock washer Remove the steering bearing adjustment nut using the special tool TOOL Steering stem socket 07916 3710101 or 07916 3710100 FORKS STEERING STEM NUT ...

Page 251: ...replace Replace the steering bearing outer races using the thA hARring f lnd b ill race remover set races as a set TOOLS Ball race remover set Driver attachment A 1 Driver attachment B 2 Driver shaft assembly 3 Bearing remover A 4 Bearing remover B 5 Assembly base 6 07946 KM90001 07946 KM90100 07946 KM90200 07946 KM90300 07946 KM90401 07946 KM90500 07946 KM90600 3 NUTS r 1 2 4 5 13 23 ...

Page 252: ...turn nut A gradually to remove the upper bearing outer race Note the installa Install the ball race remover into the steerinQ head tion direction of pipe as shown the assembly base Align bearing remover S with the groove in the steering head 13 24 Lightly tighten nut 8 While holding the driver shaft turn nut A gradually to remove the lower bearing outer race NUTS REMOVERAJ SHAFT ATIACHMENTA ATIACl...

Page 253: ...f the steering head This will allow you to install the upper bearing outer race Install a new lower bearing outer race and the ball race remover as shown While holding the driver shaft turn nut A gradually unit the groove in driver attachment B aligns with thP lowP r P nd of the steering head This will allow you to install the lower bearing outer race ATTACHMENT A BASE NUTA SHAFT __ ATTACHMENT B A...

Page 254: ... attachment A with the groove in the steering head While holding the installer shaft with the wrench turn the upper nut gradually to remove the upper bearing outer race Install the pl cial t nl into thE stE ering head pipe as shown Align remover attachment B with the groove in the steering head While holding the Installer shaft with the wrench turn the lower nut gradually to remove the lower beari...

Page 255: ...e spe cial tools as shown While holding the installer shaft with the wrench turn the upper nut gradually until the groove in installer attachment B aligns with tho lower end of the steering head This will allow you to install the lower bearing outer race UPPERNUT n INSTALLER ATTACHMENT A UPPER BEARING OUTER RACE INSTALLER SHAFT _ i INSTALLER ATTACHMENTB d 1 OIL SEAL DRIVER FORK SEAL URIVER WEIGHT ...

Page 256: ...ease to a new dust seal lip and install it to the steering stem Press a new lower bearing inner race onto the steering stem using the special tool TOOL Steering stem driver 07946 M800000 INSTALLATION Route the cables Apply grease to the steering bearings and bearing wires and hose races properly Install the lower bearing onto the steering stem page 1 18 Install the steering stem into the steering ...

Page 257: ... tabs down into the grooves in the adjustment nut Install and finger tighten the lock nut all the way Hold the steering adjustment nut and further tighten the lock nut within 90 to align its grooves with the tabs of the lock washer Bend up the lock washer tabs into the grooves of the lock nut Install the fork top bridge and steering stem nut Temporarily install the forks into the fork bridges Tigh...

Page 258: ...rt tho motorcyclo oocuroly uoing oofoty stands or a hoist and raise the front wheel off the ground Position the steering stem to the straight ahead po sition Hook a spring scale to the fork tube between the fork top and bottom bridges Make sure that there is no cable wire harness or hose interference Pull the spring scale keeping it right angle to the steering stem Rtiad the scale at tl1e poi11l w...

Page 259: ...MEMO ...

Page 260: ...REAR WHEEL SUSPENSION 44 N m 4 5 kgf m 33 Ibf ft Fnrtiohtening procedure see page 14 17 14 0 ...

Page 261: ...pecification later in the text gives both actual and indicated Wher1 installing the swin Jarrr1 l Je sure lu lighltm lhe swiri Jarrn pivot fasteners to the specified torque in the specified se quence If you mistake the tightening torque or sequence loosen all pivot fasteners then tighten them again to the speci fied torque in the correct sequence Refer to section 15 for brake system service SPECIF...

Page 262: ... 07946 MJ00100 Driver head Needle bearing remover 07946 MJOOZOO 07HMC MR70100 TROUBLESHOOTING Soft suspension Weak shock absorber spring Incorrect suspension adjustment Oil leakage from damper unit Insufficient tire pressure Hard suspension Incorrect suspension adjustment n im io ri rear suspenc ion pivot bearings Bent damper rod Incorrect swingarm pivot fasteners tightening Tire pressure too high...

Page 263: ... washer Push the rear wheel forward and derail the drive chain from the final driven sprocket Remove the rear axle and the rear wheel NOTE Do not operate the brake pedal after removing the rear wheel Remove the side collars INSPECTION AXLE Place the axle in V blocks and measure the runout Actual runout is 1 2 the total indicator reading SERVICE LIMIT 0 2 mm 0 01 in REAR WHEEL SUSPENSION 14 3 ...

Page 264: ...in the hub Replace the wheel Remove and discard the bearings if the races do bearings in pairs not turn smoothly and quietly or if they fit loosely in the hub 14 4 DRIVEN SPROCKET Check the condition of the driven sprocket teeth Replace the sprocket if worn or damaged NOTE If the driven sprocket requires replacement inspect the drive chain and drive sprocket Never install a new drive chain on a wo...

Page 265: ...e bearing remover head into the bearing bearings in pairs From opposite side install the bearing remover Do not reuse old shaft and drive the bearing out of the wheel hub bearings Remove the distance collar and drive out the other bearing TOOLS Bearing remover shaft Bearing remover head 20mm 07746 0050100 or equivalent commercially available in U S A 07746 0050600 or equivalent commercially availa...

Page 266: ...Remove tho driven flange bearing ASSEMBLY NOTE Refer to page 13 10 for wheel balance BRAKE DISC WHEEL DEARING 0204 DUST SEAL DISTANGE COLLAR Press the driven flange collar in a new driven flange bearing until it is fully seated TOOLS Driver 07749 0010000 Attachment 28 X 30 mm 07946 1870100 Pilot 20 mm 07746 0040500 DRIVEN FLANGE BEARING 63 22 ...

Page 267: ...ully seated TOOLS Driver 07749 0010000 Attachment 42 X 47 mm 07746 0010300 Pilot 20 mm 07746 0040500 Install the damper rubbers into the left wheel hub Coat a new 0 ring with grease and install it into the hub groove Apply grease to the mating surface of the wheel hub side surface and final driven flange Install the driven flange assembly into the left wheel hub When the driven sprocket is replace...

Page 268: ...ll it un til it is flush with the hub INSTALLATION Apply grease to the groove in the side collar inner surface Install the side collars Make sure that the rear brake caliper is in position Place the rear wheel in the swingarm and install the drive chain over the driven sprocket Insert the rear axle from the left side through the swingarm wheel and caliper bracket Install the washer and axle nut Ad...

Page 269: ...eck the needle bearing pivot collar and dust seals for wear or damage NEEDLE BEARING REPLACEMENT Remove the dust seals Set the lower joint Press the needle bearing out of the lower joint us in a hydraulic ing the special tools press with the rebound damping TOOLS adjuster facing up Driver attachment handle 07949 3710001 when pressing in Attachment 22 X 24 mm 07746 0010800 and out tf1f Pilot 17 mm ...

Page 270: ... pressure Do not drill the side of the reservoir or the damper case or you may drill into the oil chamber bladder oil escaping under high pressure may cause serious personal injury Always wear eye protection to avoid getting metal shavings in your eyes when the gas pres sure is released The plastic bag is only intended to shield you from the escaping gas Hold the bag around the drill motor and bri...

Page 271: ... swing arm nut and bolt shock arm to shock link nut and bolt shock arm plates shock link to bracket nut and bolt shock link NOTE If the shock link can not be removed loosen the shock link bracket nuts to get the clearance be tween the shock link and brackets page 7 5 INSPECTION Remove the pivot collars Check the needle bearings pivot collars and dust seals for wear or damage Check the shock arm pl...

Page 272: ...arking side 5 2 5 7 mm 0 20 0 22 in using the same tools facing up 14 1 Apply grease to new dust seal lips and install them into the shock link pivots until they are seated Install the pivot collars INSTALLATION Install the shock link into the link brackets and the bolt from the left side Install tt11 1 11ut Install the shock arm plates with the arrow facing the left and front side and the bolts f...

Page 273: ...mps Remove the rear brake caliper bracket assembly from the swingarm Support the swingarm securely Remove the shock arm to swingarm nut and bolt Loosen the left and right pivot lock nuts TOOL Lock nut wrench 07908 4690003 or 07908 4690002 Remove the swingarm pivot nut and washer Remove the pivot bolt REAR WHEEL SUSPENSION 14 13 ...

Page 274: ...ng bolts and remove the swingarm DISASSEMBLY emove the two bolts and drive cha m sl ider H 111 1 essary Remove the pivot collars and dust seals PIVOT BEARING REPLACEMENT Remove the snap ring Drive ball bearings and distance collar out of the right pivot ...

Page 275: ...t 20 mm 07746 0040500 Install the snap ring Apply grease to the needle rollers of a new bearing Press in the Carefully press the needle bearing into the left piv bearing with the ot until the depth from the swingarm outer surface marking side is 5 6 mm 0 20 0 24 in using the special tools facing up TOOLS Driver 07749 0010000 Attachment 37 x 40 mm 07746 0010200 Pilot 28 mm 07746 0041100 SHOCK ARM B...

Page 276: ...s shock arm pivot and swingarm right pivot dust seals until they are flush with swingarm outer sur face left pivot outer dust seal until it is seated onto bearing left pivot inner dust seal until depth from swing arm outer surface is 4 mm 0 2 in Install the pivot collars as shown Install the drive chain slider if removed aligning the hole with the boss of the swingarm Install new slider bolts and ...

Page 277: ...2 Obtain a spare pivot bolt P N 5210 1 MBW OOO for this model or use a 20 mm 0 8 in O D shaft Set the swingarm into the frame and the shock arm plates and temporarily insert the spare pivot bolt or 20 mm 0 D shaft from the left side to support the swingarm Be sure that the swingarm is properly aligned 3 Tighten the right adjusting bolt TORQUE 12 N m 1 2 kgf m 9 lbf ft Loosen the right adjusting bo...

Page 278: ...sting bolt and retighten it to the specified torque TORQUE 7 N m 0 7 kgf m 5 1 bf ft 7 Install the left lock nut Hold the left adjusting bolt and tighten the left lock nut TOOL Lock nut wrench 07908 4690003 or 07908 4690002 TORQUE Actual 64 N m 6 5 kgf m 47 lbf ft Indicated 58 N m 5 9 kgf m 43 lbf ft 8 Push in the pivot bolt until it is seated Install the pivot nut with the washer and tighten it T...

Page 279: ...33 Ibf ft Install the brake caliper bracket assembly onto the boss of the swingarm Install the brake hose clamps with the bolts Install the chain cover by aligning the hole with the boss of the swingarm and tighten the two bolts Install the rear wheel paQe 14 8 REAR WHEEL SUSPENSION 14 19 ...

Page 280: ...12 N m 1 2 kgf m 9 Ibf ft 34 N m 3 5 kgf m 25 bf ft 9 N m 0 9 kgf m 6 5 bf ft TfJ 26 N rn 2 7 kgf m 20 lbf ft 3 N m 0 3 kgf m 2 2 lbf ft 23 N m 2 3 kgf m 17 lbf ft 15 0 1N m10 1 kgf m f ttl 30 N m 3 1 kgf m 22 lbf ft 18 N m 1 8 kgf m 13 lbf ft ...

Page 281: ...luid from a sealed container when servicing the system Do not mix different types of flu id as they may not be compatible Always check brake operation before riding the motorcycle SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Front Specified brake fluid DOT4 Brake disc thickness 4 4 4 6 0 17 0 18 3 5 0 14 Broke disc runout 0 30 0 012 Master cylinder l D 15 870 15 913 0 6248 0 6265 15 925 0...

Page 282: ...evel Clogged fluid passage Warped deformed brake disc Sticking worn caliper piston Sticking worn master piston Bent brake lever pedal Brake lever pedal hard Clogged restricted hydraulic system Sticking worn caliper piston Sticking worn master piston Caliper not sliding properly Bent brake lever pedal 1fi 6 N m 0 6 kgf m 4 3 lbf ft 18 N m 1 8 kgf m 13 Ibf ft 3 N m 0 3 kgf m 2 2 lbf ft 34 N m 3 5 kg...

Page 283: ...e the reservoir cap set plate and diaphragm page 3 20 for front page 3 21 for rear Connect the bleed hose to the bleed valve Loosen the bleed valve and pump the brake lever or pedal until no more fluid flows out of the bleed valve BRAKE FLUID FILLING BLEEDING Close the bleed valve Fill the reservoir with DOT 4 brake fluid from a sealed container Connect a commercially available brake bleeder to th...

Page 284: ...lt Connect a bleed hose to the bleed valve and bleed the system as follows 1 Squeeze the brake lever or depress the brake pedal open the bleed valve 1 2 turn and then close it NOTE Do not release the brake lever or pedal until the bleed valve has been closed 2 Release the brake lever or pedal slowly and wait several seconds after it reaches the end of its travel Repeat the steps 1 and 2 until air ...

Page 285: ...e Remove the pad pins while pushing in the pad spring then remove the pad spring and brake pads Install new brake pads and the pad spring with the arrow focing up Install the pad pin while pushing in the pad spring Install the front brake caliper so the disc is posi tioned between the pads being careful not to dam aQe the pads Install and tighten new mounting bolts TORQUE 30 N m 3 1 kgf m 22 Ibf f...

Page 286: ...ssure NOTE Check the brake fluid level in the brake reservoir a this operation causes the level to rise Remove the pad pin plug and loosen the pad pin Remove the rear brake caliper bolt Pivot the caliper up and remove the pad pin and brake pads Be careful not to Install new brake pads so that their ends are lose the pad spring positioned on the retainer on the caliper bracket as shown ...

Page 287: ...edal to seat the caliper piston against the pads BRAKE DISC INSPECTION Visually inspect the disc for damage or cracks Measure the brake disc thickness at several points SERVICE LIMITS Front 3 5 mm 0 14 in Rear 4 0 mm 0 16 in Measure the brake disc warpage with a dial indica tor SERVICE LIMIT 0 30 mm 0 012 in Check the wheel bearing for excessive play if the warpage exceeds the service limit Replac...

Page 288: ...Y Drain the brake fluid from the front brake hydraulic system page 15 3 Disconnect the front brake light switch connectors Disconnect the brake hose from the master cylinder by removing the oil bolt and sealing washers Remove the master cylinder holder bolts holder and the master cylinder Remove the pivot nut bolt and brake lever assem bly Remove the screw and front brake light switch Remove the p...

Page 289: ...linder and master piston with clean brake fluid INSPECTION Check the cups for wear deterioration or damage Check the spring for damage Check the master cylinder and piston for scoring scratches or damage Measure the master cylinder 1 0 SERVICE LIMIT 15_9 5 mm 0_6 70 in Measure the master piston 0 0 SERVICE LIMIT 15 815 mm 0 6226 in HYDRAULIC BRAKE SN 7 P RING 15 9 ...

Page 290: ... and master piston into the master cylinder CAUTION Do not allow the piston cup lips to turn inside out Install the snap ring into the groove in the master cylinder using the special tool TOOL Snap ring pliers 07914 SA50001 CAUTION Be certain the snap ring is firmly seated in the groove 1 RESERVOIR CAP I SET PLATE DIAPHRAGM MASTER CYLINDER I BRAKE LIGHT SWITCH ...

Page 291: ...ke light switch with the screw TORQUE 1 N m 0 1 kgf m 0 7 lbf ft Install the master cylinder and holder with the UP mark facing up Align the end of the master cylinder with the punch mark on the handlebar and tighten the upper bolt first then tighten the lower bolt TORQUE 12 N m 1 2 kgf m 9 lbf ft Connect the brake hose to the master cylinder with the oil bolt and new sealing washers and tighten t...

Page 292: ...n the brake fluid from the rear brake hydraulic system page 15 3 Disconnect the brake hose from the master cylinder by removing the oil bolt and sealing washers Remove the screw and reservoir hose joint from the master cylinder Remove the 0 ring Loosen the master cylinder mounting bolts Remove the footpeq bracket bolts and footpeg bracket assembly Remove the rear brake light switch spring and brak...

Page 293: ...nt pin and master cylinder from the brake pedal Remove the boot from the master cylinder Remove the snap ring using the special tool TOOL Snap ring pliers 07914 SA50001 Remove the master piston cup and spring Clean the master cylinder and master piston in clean brake fluid INSPECTION Check the cups for wear deterioration or damage Check the spring for damage HYDRAULIC BRAKE 15 13 ...

Page 294: ...CE LIMIT 13 945 mm 0 5490 in ASSEMBLY MASTER CYLINDER 15 14 SPRING CUP MASTER PISTON AP RING BOOT Coat the master piston and piston cups with clean brake fluid Install the spring cup and master piston into the master cylinder CAUTION Do not allow the piston cup lips to turn inside out Apply silicone grease to the push rod contacting area of the master piston PUSH ROD PUSH ROD JOINT ...

Page 295: ...is reintalled adjust the push rod length so that the distance from the center of the master cylinder lower mounting hole to the cen ter of the joint pin hole is 100 mm 3 9 in After ad justment tighten the joint nut TORQUE 18 N m 1 8 kgf m 13 lbf ft Connect the master cylinder push rod joint to the brake pedal with the joint pin and a new cotter pin Apply grease to the brake pedal pivot Install the...

Page 296: ...t Tighten the master cylinder mounting bolts TORQUE 9 N m 0 9 kgf m 6 5 Ibf ft Apply brake fluid to a new 0 ring and install it onto the reservoir hose joint Install the hose joint into the master cylinder Apply locking agent to the hose joint screw Install the screw and tighten it Connect the brake hose to the master cylinder with the oil bolt and new sealing washers and tighten the oil bolt TORQ...

Page 297: ...brake hose from the front brake cali per by removing the oil bolt and sealing washers Remove the brake pads page 15 5 Install a corrugated cardboard or soft wood sheet between the pistons Apply small squirts of air pressure to the fluid inlet to remove the pistons MM W Hil Do not use high pressure air or bring the nozzle too close to the inlet Remove the four caliper assembly bolts and sepa rate t...

Page 298: ... piston sliding surface Clean the seal grooves caliper cylinders and piston with clean brake fluid INSPECTION Check the caliper cylinders and pistons for scoring scratches or damage Measure the caliper cylinder 1 0 SERVICE LIMITS Cylinder A 34 02 mm 1 339 in CylinderB 32 09 mm 1 263 in Measure the caliper piston 0 0 SERVICE LIMITS Piston A 33 87 mm 1 333 in Piston B 31 94 mm 1 257 in ...

Page 299: ...seal grooves in the caliper Coat the caliper pistons with clean brake fluid and install them into the caliper cylinders with the open ing toward the pads Install a new joint seal into the fluid passage groove in the caliper body Assemble the caliper body halves Apply locking agent to the caliper assembly bolt threads Install and tighten the assembly bolts TORQUE 23 N m 2 3 kgf m 17 Ibf ft 15 19 ...

Page 300: ... CALIPER 15 20 CAUTION Avoid spilling fluid on painted plastic or rubber parts Place a rag over these parts whenever the system is serviced DISASSEMBLY Drain the brake fluid from the rear brake hydraulic system page 1b 3 Disconnect the brake hose from the rear brake caliper by removing the oil bolt and sealing washers Remove the rear brake pads page 15 6 Remove the rear brake caliper from the brac...

Page 301: ...e inlet Push the dust seal and piston seal in and lift them out CAUTION Be careful not to damage the piston sliding surface Clean the seal grooves caliper cylinder and piston with clean brake fluid INSPECTION Check the caliper cylinder and piston for scoring scratches or damage Measure the caliper cylinder l D SERVICE LIMIT 38 24 mm 1 506 in Measure the caliper piston 0 D SERVICE LIMIT 38 09 mm 1 ...

Page 302: ...e caliper Coat the caliper piston with clean brake fluid and in stall it into the caliper cylinder with the opening to wan J lt11 1 µalh i Install the pad spring onto the caliper body as shown Check the caliper boot and replace it if it is hard de teriorated or damaged Apply silicone grease to the inside of the boot Install the boot and collar into the caliper CALIPER PISTON ...

Page 303: ... of the boot and install the caliper onto the bracket Install the rear brake pads page 15 6 Connect the brake hose to the brake caliper with the oil bolt and new sealing washers and tighten thP nil bnlt TORQUE 34 N m 3 5 kgf m 25 lbf ft fill and bleed the rear brake hydraulic system page 15 3 HYDRAULIC BRAKE 15 23 ...

Page 304: ...CHARGING SYSTEM y y y ALTERNATOR Y Yellow G Green R Red W White 11 n MAIN FUSE 30A REGULATOR RECTIFIER rR WMAIN FUSE 30A BATTERY y y y G R W Rl GULA I OR Rl C I IfIER G L ...

Page 305: ...ove the sealing caps rom the cells may damage the battery The battery can be damaged if overcharged or undercharged or if left to discharge for long period These same conditions contribute to shortening the life span of the battery Even under normal use the performance of the battery deteriorates after 2 3 years Bauery voltage rnay rnvuv1 11 arLt n u 1lli 1y d1a1yi11g but undi r heavy load the bat...

Page 306: ...n the battery so that the actual battery condition of the load can be meas ured Recommended battery tester BM 210 AH BM 210 or BATTERY MATE or equivalent CAUTION For battery charging do not exceed the charging current and time specified on the battery Using excessive current or extending the charging time may damage the battery SPECIFICATIONS ITEM SPECIFICATIONS Battery acit 12V BAH Current leakag...

Page 307: ...rect I i Correct Faulty regulator rectifier _______ Shorted wire harness Faulty ignition switch Check the alternator charging coil page 16 6 Incorrect Faulty charging coil STANDARD 0 1 1 0 Q 20 C 68 F Correct Measure and record the battery voltage using a _Correct Faulty battery digital multimeter page 16 4 Start the engine Measure the charging voltage page 16 5 Compare the measurements to result ...

Page 308: ... positive I cable first then con nect the negative cable After connecting the battery cables coat the terminals with grease VOLTAGE INSPECTION Open the battery case cover Measure the battery voltage using a commercially available digital multimeter VOLTAGE 20 C 68 F Fully charged 13 0 13 2 V Undercharged Below 12 3 V BATTERY CHARGING The battery gives off explosive gases keep sparks flames and cig...

Page 309: ...switch OFF check for current leak age NOTE When measuring current using a tester set it to a high range and then bring the range down to an appropriate level Current flow higher than the range selected may blow out the fuse in the tester While measuring current do not turn the ignition switch ON A sudden surge of current may blow out the fuse in the tester SPECIFIED CURRENT LEAKAGE 0_ 1 mA m oix_ ...

Page 310: ...components With the headlight on Hi beam restart the engine Measure the voltage on the multitester when the engine runs at 5 000 rpm STANDARD Measured battery voltage page 16 4 Measured charaina volfa JA sAA ahovA 155 V ALTERNATOR CHARGING COIL INSPECTION Remove the left side fairing page 2 4 Disconnect the alternator 3P white connector Measure the resistance between the wire terminals of the alte...

Page 311: ...en the red white wire ter minal and ground There should be battery voltage at all times GROUND LINE Check the continuity between the green wire termi nal and ground There should be continuity at all times CHARGING COIL LINE Measure tho rcsistonoo between tho yellow wire tor minals STANDARD 0 1 1 0 Q 20 C 68 F Check for continuity between each yellow wire ter minal and ground There should not be r ...

Page 312: ... G Green NEUTRAL SWITCH Lg Light green R Red W White Y Yellow 3 iii I iii No COILS 1 SPARK PLUGS1 13ATTERY I I 3 3 3 I iii SIDE STAND SWITCH R SWITCH FUSE 10A 3 ENGINE STOP SWITCH a Bl W 0 81 y gIGNITION PULSE GENERATOR Y W Y Bu SENSOR y B l THROTTLE n iii 3 a I 3 _ 0 I3 1 I S a 0 a 3 _ ow GNmON CONTROL MODULJ CM y SIDE NEUTRAL STAND SWITCH SWITCH ...

Page 313: ...ording to the engine speed The throttle sensor signals the ICM to compensate the ignition timing according to the throttle opening The lCM may be damaged if dropped Also if the connector is disconnected when current is flowing the excessive voltage may damage the ICM Always turn off the ignition switch before servicing A faulty ignition system is often related to poor connections Check those conne...

Page 314: ...nimum IQnition pulse qenerator peak voltaae 0 7 V minimum J_g_nitior i timina F mark 10 BTDC at irllP Throttle I Resistance 20 C 68 F 4 6kQ sensor I Input voltaqe TORQUE VALUE Timing hole cap TOOL Peak voltage tester U S A only or Peak voltage adaptor 17 4 7 5 3V 18 N m 1 8 kgf m 13 Ibf ft Apply grease to the threads 07HGJ 0020100 not available in U S A with commercially available digital multimet...

Page 315: ...or 4 Faulty ICM when the initial voltage is normal while disconnecting ICM connector 1 Incorrect peak voltage adaptor connections 2 Battery is undercharged large voltage drops when the engine is started 3 No voltage between the black and ground of the ICM connector or loose or poorly connected ICM 4 Poor connection or open circuit in green ground wire of the ICM 5 loose or poor connections or open...

Page 316: ...eak voltage adaptor 07HGJ 0020100 with commercially available digital multimeter impedance 10 M Q DCV minimum IGNITION PRIMARY PEAK VOLTAGE NOTE Check all system connections before this inspec tion Poor connected connectors can cause incorrect readings Check the cylinder compression at each cylinder and check that the spark plugs are installed correctly in each cylinder Disconnect the direct ignit...

Page 317: ...ecks described in the troubleshooting on page 17 3 Shift the transmission into neutral Crank the engine with the starter motor and meas ure the ignition coil primary peak voltage PEAK VOLTAGE 100 V minimum Avoid touching the spark plugs and tester probes to prevent electric shock NOTE Although measured values are different for each ignition coil tht1y are normal as long as voltage Is higher than t...

Page 318: ...normal measure the peak voltage at the pulse generator connector Remove the right side fairing page 2 4 Disconnect the clutch cable page 9 3 Disconnect the ignition pulse generator 2P red connector and connect the peak voltage adaptor or tester probes to the connector terminals of the ignition pulse generator side In the same manner as at the ICM connector meas ure the peak voltage and compare it ...

Page 319: ...ght operation Start the engine let it idle and check the ignition timing The ignition timing is correct if the F mark on the ignition pulse generator rotor aligns with the index notch on the right crankcase cover at idle as shown Coat a new 0 ring with grease and install it onto the timing hole cap Apply grease to the timing hole cap threads Install and tighten the timing hole cap TORQUE 18 N m 1 ...

Page 320: ...are abnormal replace the throttle sensor Connect the ICM connector Turn the ignition switch ON Measure the input voltage between the yellow bla k aml blue yreen wire terminals of the wire harness side throttle sensor connector STANDARD 4 7 5 3 V If the input voltage is abnormal or if there is no input voltage check for open or short circuit in the wire harness or loose or poor ICM connector contac...

Page 321: ...ensor position so that the resis tance between terminals A and 8 is 490 510Q and tighten the torx screws Connect the throttle sensor connector Install the removed parts in the reverse order of re moval IGNITION SYSTEM 17 9 ...

Page 322: ...TRAL SWITCH SIDE STAND SWITCH STARTER RELAY SWITCH STARTER RELAY SWITCH EB 8 MAIN FUSE BATTERY 30A IGNITION CLUTCH SWITCH G R Y R SWITCH FUSE ioA G Ri I L R O R BI G R L_ Bl STARTER SWITCH ENGINE STOP SIDE STAND SWITCH OIODEt Y R Bl W 0 SWITCH _1_ lg i_ NEUTRAL SWITCH Bl Black G Green Lg Light green R Red W White Y Yellow ...

Page 323: ...flow chart page 18 2 A weak battery may be unable to turn the starter motor 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 section 10 for starter clutch servicing See section 19 for following components Ignition switch Engine stop switch Starter switch ...

Page 324: ...tarter motor cable motor cable and open circuit in starter motor ca Open circuit in starter cable ble Normal With the ignition switch ON and engine stop Clicks switch at RUN push the starter switch and check for a Click sound from the starter relay switch No clicks Connect the starter motor terminal directly to the battery positive terminal Because a large amount of current flows do not use a thin...

Page 325: ...al Faulty starter relay switch 10 I Normal Loose or poor starter relay switch 4P connector contact Starter motor turns slowly Weak battery Poorly connected battery cable Poorly connected starter motor cable Faulty starter motor Starter motor turns but engine dues nut turn Faulty starter clutch section 10 Starter relay switch clicks but engine does not turn over Crankshaft does not turn due to engi...

Page 326: ... page 6 5 Disconnect the water hose from the water pump Remove the rubber cap terminal nut and starter motor cable Pull the water hose aside Remove the two mounting bolts and the starter mo tor from the crankcase Remove the 0 ring from the starter motor DISASSEMBLV Remove the starter motor case bolts Remove the 0 rings from starter motor case bolts Record the Remove the following location and fron...

Page 327: ...g in the rear cover for wear or damage Check the oil seal and needle bearing in the front cover for deterioration wear or damage Check the commutator bars of the armature for discoloration NOTE Do not use emery or sand paper on the commu tator ELECTRIC STARTER 18 5 ...

Page 328: ...uity Check for continuity between each 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 Check for continuity between the cable terminal and motor case There should be no continuity ...

Page 329: ...ove the following nut washer insulator washers O ring brush holder brushes Measure the brush length SERVICE LIMIT 6 5 mm 0 26 in ASSEMBLY REAR COVER BRUSH HOLDER ELECTRIC STARTER BRUSH HOLDER ARMATURE 18 7 ...

Page 330: ...y be damaged if the magnet pulls the armature against the case Install the same number of shims in the same loca tions as noted during disassembly Install a new seal ring onto the motor case Apply thin coat of grease to the armature shaft end Install the reor cover while pushing in the brushes into the brush holder and aligning the brush holder tab with the motor case groove Install the shims and ...

Page 331: ...tarter motor into the crankcase Install the ground cable and mounting bolts and tighten the bolts securely Connect the starter motor cable Install and tighten the terminal nut TORQUE 10 N m 1 0 kgf m 7 bf ft Install the rubber cap securely Connect the water hose to the water pump Install the fuel tank page 2 3 Fill and bleed the cooling system page 6 4 ELECTRIC STARTER WATER HOSE 18 9 ...

Page 332: ...side stand is retracted the ground circuit is normal In n utral ther is a slight resistance due to the di ode STARTER RELAY VOLTAGE Connect the starter relay switch 4P connector Shift the transmission into neutral Measure the voltago between tho yolfow rod wiro terminal and ground If the battery voltage appears only when the starter switch 1s pushed with the 1gnit1on switch UN and en gine stop swi...

Page 333: ... the fuse box cover and remove the clutch di ode Check for continuity between the diode terminals When there is continuity a small resistance value will register If there is continuity in one direction the diode is normal ELECTRIC STARTER A OC B c A 18 11 ...

Page 334: ...LIGHTS METERS SWITCHES FRONT BRAKE LIGHT SWITCH IGNITION WITCH CLUTCH SWITCH 19 0 FUEL RESERVE SENSOR I SPEED SENSOR _u Q SIDE STAND SWITCH REAR BRAKE LIGHT SWITCH ...

Page 335: ...t to heat the water coolant mixture for the thermosensor inspection Keep all flammable materials away from the electric heating element Wear protective clothing insulated gloves and eye protection Note the following when repladng the halogen headlight bulb Wear clean gloves while replacing the bulb Do not put finger prints on the headlight bulb as they may create hot spots on the bulb and cause it...

Page 336: ... Oil pressure indicator 12V 1 1W Low fuel indicator LED Fuse Main fuse 30A Sub fuse 10A X 4 Thermosensor resistance At 80 C 176 F 47 57 Q At 120 c 248 F 14 18 Q Fan motor switch Starts to close ON 98 102 C 208 216 F Stops to ooen OFF 93 97 C 199 207 F TORQUE VALUES Thermosensor Fan motor switch 10 N rn 1 0 kgf m 7 llJf l Aµµly tl 1la11l lu Lhtl llntla b Ignition switch mounting bolt Neutral switch...

Page 337: ...use a bulb to break If you touch the bulb with your bare hands clean it with a cloth moistened with alcohol to prevent its early failure lm lall lilt rt r11uvt LI µarls i11 Lht rt vt rst urLlt r uf rt moval REMOVAL INSTALLATION Remove the front fairing page 2 5 Remove the four screws washers two clamps and the headlight unit Route the wires Install the headlight unit in the reverse order of re and...

Page 338: ...ht and tighten the screw REMOVAL INSTALLATION Front Remove the instrument panels page 2 b Rear Remove the seat page 2 2 Disconnect the turn signal light connectors Remove the nut setting plate and the turn signal light Install the turn signal light in the reverse order of re moval NOTE Route the turn signal light wire properly page 1 18 BRAKE TAILLIGHT BULB REPLACEMENT Remove the seat page 2 2 Tur...

Page 339: ...mp and washers number plate bracket from the rear fender two nuts lens lens cover and license light base from the number plate bracket While pushing the bulb in turn it counterclockwise to remove it and replace it with a new one Make sure that the seal rubber is installed in position and is in good condition and replace it with new one if necessary Install the removed parts in the reverse order of...

Page 340: ...clockwise damaged if the bulb is removed or Install a new bulb and turn it clockwise to lock it 1nsra11ea while rhe Install the bulb hole cap ignition switch is ON 19 6 Install the combination meter by aligning the two bosses with the grommets of the fairing stay Install the mounting bolt and bolt cap lnst ill thA instrumAnt p inAls p igA fi _ REMOVAL INSTALLATION Remove the combination meter from...

Page 341: ...ltage with the ignition switch ON If there is no voltage check for open circuit in Black brown wire BACK UP VOLTAGE LINE Measure the voltage between the Red wire terminal and ground There should be battery vollagtl dt all ti111tl If there is no voltage check for open circuit in red wire SENSOR GROUND LINE Check for continuity between the Green black wire terminal and ground There should be continu...

Page 342: ...lse voltage appears replace the printed circuit board If pulse voltage does not appear check for open or short circuit in Pink green wire If the Pink green wire is OK check the speed sensor SPEED SENSOR INSPECTION Raise the fuel tank page 2 3 Turn the ignition switch ON and measure the voltage between the Black and Green wire terminals of the speed sensor 3P connector with the connector connected ...

Page 343: ...reen wire COOLANT TEMPERATURE GAUGE THERMOSENSOR SYSTEM INSPECTION Check that the speedometer and tachometer func tion properly If they do not function perform the power ground line inspection of the combination meter page 19 7 If they function raise the fuel tank page 2 3 dis connect the thermosensor wire connector and ground it with a jumper wire Turn the ignition owitch ON and check the coolant...

Page 344: ...up to its threads with at least 40 mm 1 57 in from the bot tom of the pan to the bottom of the sensor Keep the temperature constant for 3 minutes be fore tooting cuddcn change of temperature will result in incorrect readings Do not let the ther mometer or thermosensor touch the pan Tern erature 80 C 176 F Resistance Replace the thermosensor if it is out of specifica tions by more than 10 at any te...

Page 345: ... switch ON and check the fan mo tor If the motor starts check the connection at the fan motor switch terminal If it is OK replace the fan motor switch If the fon motor docs not start measure the voltage between the Black blue and Green wire terminals at the fan motor 2P connector There should be battery voltage If there is battery voltage replace the fan motor If there is no voltage check for open...

Page 346: ...ge 4 3 If the indicator does not come on check for open circuit in Bu R wire Indicator stays on while the engine is running Remove the rubber cap and disconnect the oil pres sure switch wire by removing the terminal screw Check for continuity between the wire terminal and ground If there is continuity check for short circuit in Bu R wire If there is no continuity check the oil pressure page 4 3 If...

Page 347: ...hten the mount ing bolts TORQUE 25 N m 2 5 kgf m 18 lbf ft Install the removed parts in the reverse order HANDLEBAR SWITCHS Remove the left air intake duct page 2 6 Disconnect the right handlebar switch 3P and 4P Red connectors and left handlebar switch 13P connector Check for continuity between the connector termi nals in each switch position Continuity should exist between the color coded wires ...

Page 348: ...e switch terminals Tt1ere t1uulu IJe t u11Li11uily will1 ltH I rrunti rake lever squeezed and no continuity with the lever released REAR Remove the seat page 2 2 Disconnect the rear brake light switch 2P white connector and check for continuity between the con nector terminals There should be continuity with the rear brake ped al depressed and no continuity with the pedal re leased 0 W Lb W DIMMER...

Page 349: ...no continuity with the transmis sion in gear except neutral REMOVAL INSTALLATION Disconnect tho noutrol switch wire connector Remove the neutral switch from the crankcase Install the neutral switch with a new sealing wash er and tighten it TORQUE 12 N m 1 2 kgf m 9 lbf ft Connect the neutral switch wire connector SIDE STAND SWITCH Remove the left side fairing page 2 2 INSPECTION f isr nnnP d the s...

Page 350: ...urn the ignition switch ON and check the low fuel indicator If the indicator does not come on replace the fuel reserve sensor If the indicator comes on check for short circuit in Brown black wire Low fuel indicator does not come on Check that the speedometer tachometer and cool ant temperature gauge function properly If they do not function perform the power ground line inspeGtiu11 of Lhe GurntJin...

Page 351: ...e 2 3 Remove the fuel reserve sensor from the fuel tank Install a new 0 ring into the sensor groove properly and install the reserve sensor and tighten it TORQUE 23 N m 2 3 kQf m 17 Ibf ft Check for leakage from the reserve sensor Install the fuel tank page 2 3 Disconnect the wire connectors from the horn Connect a 12 V battery to the horn terminals The horn is normal if it sounds when the 12 V ba...

Page 352: ... the turn sig nal light by operating the turn signal switch If the light does not come on check for open cir cuit in Black brown and Gray wires If the light comes on check for continuity be tween the Green wire terminal and body ground If there is no continuity check for open circuit in green wire If there is continuity check the connector termi nals for loose or poor contact If the connector term...

Page 353: ...ONTTURNSlGNA1UGHT 12V3UlCI 2l 8Wl o r A o t JW Ll l LWW 1 G G SWITOlCONTINVrrY OlMMERSWJrCH HOflNSWrrCH Ill lO H l ltto BAT o I INI PUSH I o J u h HH 1rr 11 1 1 rr CLUTOJ SWITCH T W SIGNAL DIMMER HORN SWITCH TURN S GliAl SWTCH IGNITlONSWITCH j w R L IO PR Pl FAN IG BAT1 Y JJB CiW CONDITION OHOCKPIN ON NO H Off YES c _ LOO YES OUT I IGNITDNSWlTCH ENGl IE SfOl SWrTCH i i IDAn I I RUN IC 11 11 l Er f...

Page 354: ...NSJR Y IW 1111 G YtN l BtW Bl fll 4 BlW F e _ _ 1 8 YIW W 8 fM N1 MNNfUSE lOA C J Q M 3i I I I I I I _j_ _ _ 11 1111 1 I l ij J J 1 lll l n_ all 1 1 J i HORN m m 7 l grJ oi t 10 q f gm I m o ij ttt ill oY g OO N I tt m r j 0 0 CLUTCH SWITCH TURN SIGNAL DIMMER H RN SWITCH ALTERNATOR EGUtATORtflECTIFlER I I I I Bl BLACK Br BROWN Y YELLOW 0 ORANGE Bu BLUE lb UGHT BLUE G GREEN lg LlGHT GREEN R RED P P...

Page 355: ...ED SPARK PLUG CAP DIRECT IGNITION COIL The direct ignition coil is the spark plug cap with the built in ignition coil The spark plug wire is omitted and the light weight and compact size ignition device is accomplished by the direct ignition coil CONNECTOR SECONDARY COIL PLUG TERMINAL m 71 1 ...

Page 356: ...MEMO ...

Page 357: ...n system wires Faulty ignition pulse generator Faulty ignition coil Faulty ignition control module ICM Faulty engine stop switch Faulty ignition switch 3 Remove and inspect spark plugs Wet plug Flooded carburetor I Starting enrichment SE valve ON Good condition position open Dirty air cleaner j Throttle valve open 4 Start by followinq normal procedure Engine starts but stops Improper choke operati...

Page 358: ...gine speed does not Starting enrichment SE valve ON increase position open Tne speed wease g breather tube 5 Check ignition timing I Correct i Incorrect raulty ignition control module ICM Faulty ignition pulse generator 6 Test cylinder compression Incorrect 1 Valve clearance too small I Worn cylinder and piston rings Norm il r nmrrAs inn n imagArl r ylincfar he11rl Q Sket i Improper valve timing 7...

Page 359: ... fuel t Exct ssive 1 arl Ju11 l Juih l uµ iri 1 urnl Ju Engine does not knock tion chamber Ignition timing too advance Faulty ICM Lean fuel mixture POOR PERFORMANCE AT LOW AND IDLE SPEED Possible cause 1 Check carburetor pilot screw adjust Incorrect See section 5 ment I Correct i 2 Check for leaking carburetor insulator Leaking Loose carburetor insulator bands Damaged carburetor insulator No leak ...

Page 360: ...ot installed properly I Correct i 4 Check ignition timing I Correct i Incorrect 1 Faulty ignition control module ICM Faulty ignition pulse generator 5 Check valve spring Weak Faulty valve spring i Not weak POOR HANDLING Possible cause 1 If steering is heavy Steering stem adjustment nut too tight Damaged steering head bearings 2 If either wheel is wobbling Excessive wheel bearing play Bent rim Impr...

Page 361: ... 4 8 COMBINATION METER 19 6 OIL PRESSURE CHECK 4 3 COOLANT REPLACEMENT 6 4 OIL PRESSURE INDICATOR 19 12 COOLANT TEMPERATURE GAUGE OIL PUMP 4 6 THERMOSENSOR 19 9 OIL STRAINER PRESSURE RELIEF VALVE 4 4 COOLING FAN MOTOR SWITCH 19 11 PILOT SCREW ADJUSTMENT 5 33 COOLING SYSTEM 3 15 PISTON CYLINDER 12 10 CRANKCASE ASSEMBLY 11 11 RADIATOR COOLANT 3 14 CRANKCASE SEPARATION 11 3 RADIATOR RESERVE TANK 6 11...

Page 362: ...HROTILE OPERATION 3 4 THROTILE SENSOR 17 7 TOOLS 1 14 TORQUE VALUES 1 11 TnANSMISSION 11 6 TROUBLESHOOTING ALTERNATOR 10 1 BATIERY CHARGING SYSTEM 16 3 CLUTCH GEARSHIFT LINKAGE 9 2 COOLING SYSTEM 6 2 CRANKCASE TRANSMISSION 11 2 CRANKSHAFT PISTON CYLINDER 12 2 CYLINDER HEADNALVE 8 2 ELECTRIC STARTER 18 2 ENGINE DOES NOT START OR IS HARD TO TART 22 1 ENGINE LACKS POWER 22 2 FRAME BODY PANELS EXHAUST...

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Honda C8R600F4, Service Manual

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