Honda CB HORNET 160R 2015 Shop Manual Download Page 187

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11-15

CRANKCASE/TRANSMISSION/KICKSTARTER

THRUST
WASHER
(17 mm)

SET RING
(20 mm)

SPLINE
WASHER
(20 mm)

SPECIAL WASHER
(17 mm)

THRUST
WASHER
(20 mm)

COLLAR
(20 mm)

CHAMFERED SIDE

SHARPED
EDGE SIDE

COUNTERSHAFT

C1 BUSHING
(20 mm)

C1 GEAR
(40 T)

C4 GEAR
(32 T)

C3 GEAR
(26 T)

C5 GEAR
(22 T)

C2 BUSH

(20 mm)

C2 GEAR
(34 T)

COUNTERSHAFT

Summary of Contents for CB HORNET 160R 2015

Page 1: ...SHOP MANUAL CB HORNET 160R CB HORNET 160R...

Page 2: ...ice safety precautions are given below However we cannot warn you of every conceivable hazard that can arise in performing service and repair procedures Only you can decide whether or not you should p...

Page 3: ...1 2 3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 5 Your safety and the safety of others is very important To help you make informed decisions we have provided safety messages and other information...

Page 4: ...rning U S A Multi purpose M 2 manufactured by Mitsubishi Oil Japan Replace the part s with new one s before assembly Use recommended engine oil unless otherwise specified Use molybdenum oil solution m...

Page 5: ...SSION CONTROL SYSTEMS 1 22 SERVICE RULES 1 Use genuine HONDA or HONDA recommended parts and lubricants or their equivalents Parts that do not meet Honda s design specifications may cause damage to the...

Page 6: ...1 2 GENERAL INFORMATION MODEL IDENTIFICATION This manual covers 2 type of CBF 160 models STD and CBS...

Page 7: ...V I N is stamped other right side of the steering head Vehicle Identification Number ME4KC23 XXXXXXXXXX Engine Serial Number The Engine Serial Number is stamped on the lower left side of the crankcas...

Page 8: ...rom vertical Bore and stroke 57 3 x 63 096 mm 2 25 x 2 48 in Displacement 162 71 cm Compression ratio 10 01 Valve train Chain driven OHC with rocker arm Intake valve Opens at 1 08 mm 0 04 in lift 10 B...

Page 9: ...uum 53 3 kPa 400 mm Hg Page 5 20 CYLINDER HEAD VALVES SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Page NO Cylinder compression at 650 min 1 rpm 1300 kPa 13 2 kgf cm 188 5 psi Page 7 4 Valve clearance I...

Page 10: ...060 0 0012 0 0024 0 10 0 004 Page 8 5 Second 0 015 0 050 0 0006 0 0020 0 10 0 004 Page 8 5 Cylinder to piston clearance 0 005 0 030 0 0002 0 0012 0 09 0 004 Page 8 4 Connecting rod small end I D 14 0...

Page 11: ...4 0 785 Page 11 7 M4 19 968 19 980 0 7861 0 7866 19 94 0 785 Page 11 7 M5 16 968 16 980 0 6679 0 6686 16 93 0 666 Page 11 7 Bushing to shaft clearance C1 0 016 0 052 0 0006 0 0020 0 10 0 004 Page 11 7...

Page 12: ...d brake fluid DOT 3 or DOT 4 Page 14 5 Master cylinder I D 14 000 14 043 0 5512 0 5529 14 055 0 5533 Page 14 22 Master piston O D 13 957 12 984 0 5495 0 5529 13 945 0 5490 Page 14 22 Caliper cylinder...

Page 13: ...on pulse generator peak voltage 0 7 V minimum Page 16 4 Ignition timing F mark 8 BTDC at 1400 rpm Page 16 5 Throttle position sensor Input voltage 5 V Page 16 7 Resistance 200 C 680 F 4 0 6 0 W Page 1...

Page 14: ...10 Page 3 11 Page 3 13 LUBRICATION Oil pump plate screw Oil pump mounting bolt 93901 34120 95701 06035 00 1 2 4 6 3 0 3 2 2 12 1 2 9 Page 4 6 Page 4 6 FUEL SYSTEM Fuel tank mounting bolt SE valve lock...

Page 15: ...4 7 4 55 16 1 6 12 10 1 0 7 3 10 1 0 7 3 NOTE 1 NOTE 2 NOTE 2 NOTE 2 Page 10 5 Page 10 8 Page 10 17 Page 10 17 CRANKCASE CRANKSHAFT TRANSMISSION BALANCER DRIVE KICK STARTER Balancer Shaft Nut Right cr...

Page 16: ...ng bolt Lower Swing arm pivot bolt 90302 KTE 911 90105 KSP 870 90304 KTE 911 90305 KYJ 711 90304 KTE 911 90153 KYJ 900 90151 KSP 900 90121 KSP 900 1 4 4 1 2 1 1 1 6 8 10 16 10 10 10 14 10 1 0 7 3 42 4...

Page 17: ...Each dust seal lip Each oil seal lip Crankshaft hole cap threads Multi purpose grease Valve stem sliding surface Piston pin entire surface Clutch outer guide entire surface Clutch outer rotating area...

Page 18: ...od contacting area Brake caliper pin boot inner surface Brake caliper pin sliding surface Each dust seal lips Each bearing rotating area Each O ring Rear brake pedal equalizer pivot Multi purpose grea...

Page 19: ...signal light Ignition switch Front brakelight switch STARTER SWITCH WIRE LEFT POSITION LIGHT WIRE LEFT TURN SIGNAL LIGHT WIRE RIGHT TURN SIGNAL LIGHT WIRE RIGHT POSITION LIGHT WIRE HEADLIGHT 3P CONNEC...

Page 20: ...1 16 GENERAL INFORMATION LEFT HANDLEBAR SWITCH WIRE SELF STARTER SWITCH WIRE MAIN WIRE HARNESS SELF STARTER SWITCH HORN WIRE CHOKE KNOB CDI UNIT CLUTCH CABLE FRONT VIEW MAIN WIRE HARNESS GUIDE...

Page 21: ...1 17 GENERAL INFORMATION THROTTLE CABLE CBS TYPE SPARK PLUG WIRE FRONT BRAKE HOSE CBS FRONT BRAKE HOSE CLUTCH CABLE REAR BRAKE LIGHT SWITCH WIRE...

Page 22: ...1 18 GENERAL INFORMATION STD TYPE THROTTLE CABLE SPARK PLUG WIRE FRONT BRAKE HOSE REAR BRAKE LIGHT SWITCH WIRE CLUTCH CABLE...

Page 23: ...HOSE BATTERY NEGATIVE CONNECTOR BATTERY BOX BATTERY POSITIVE CONNECTOR NEUTRAL SWITCH WIRE CHOKE CABLE BATTERY TRAY TUBE FUEL TANK DRAIN TUBE CARBURETOR DRAIN TUBE CONNECTOR BOOT IGNITION PULSE GENERA...

Page 24: ...1 20 GENERAL INFORMATION CRANKCASE BREATHER PIPE SECONDARY AIR SUCTION HOSE REAR BRAKE LIGHT SWITCH WIRE THROTTLE CABLE REGULATOR AND RECTIFIER WIRE...

Page 25: ...1 21 GENERAL INFORMATION BRAKE TAIL LIGHT CONNECTOR CONNECTOR BOOT REAR TURN SIGNAL LIGHT WIRE CONNECTOR LICENCE PLATE LIGHT CONNECTOR...

Page 26: ...n conditions they react to form photochemical smog when subjected to sunlight Carbon monoxide does not react in the same way but it is toxic Honda Motor Co Ltd utilizes appropriate carburetor settings...

Page 27: ...NG RESONATOR AIR CHAMBER PAIR CHECK VALVE EXHAUST PORT PAIR CONTROL VALVE FRESH AIR EXHAUST GAS OXIDATION CATALYTIC CONVERTER This motorcycle is equipped with an oxidation catalytic converter The oxid...

Page 28: ...r pollution caused by fuel vapour diffused into the air No adjustment to the canister or the one way valve is required AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW 1 Rem...

Page 29: ...pe gasket with a new one after loosening or removing the exhaust pipe joint nuts When installing the exhaust system loosely install all of the exhaust pipe muffler fasteners always tighten the exhaust...

Page 30: ...d left garnish by removing screws 2 nos from both side and tabs carefully Remove the number plate stay by removing screws 4 nos Installation is in the reverse order of removal COVER HEADLIGHT RR REMOV...

Page 31: ...the reverse order of removal Be careful not to damage the side cover boss GROMMET RIGHT SIDE COVER TRIM CLIP TRIM CLIP TRIM CLIP PAN SCREW LEFT SIDE COVER REMOVAL INSTALLATION Remove the left side cov...

Page 32: ...emove the following Socket bolt 3 nos from fuel tank cap Screw 1 nos from fuel tank center cover rear side Trim clip 2 nos from fuel tank center cover front side Unlock the fuel tank cap by using igni...

Page 33: ...REWS PAN SCREWS INNER BOLT WASHER FRONT FENDER RUBBER FR FENDER MOUNTING COLLAR A FR FENDER FRONT FENDER REMOVAL INSTALLATION Remove the front wheel page 12 9 Remove the pan screws 2 nos from both sid...

Page 34: ...both side Remove the screw 1 no from the bottom side of the rear garnish from both side Installation is in the reverse order of removal MOUNTING BOLTS REAR GRIP LEFT REAR GRIP RIGHT SCREWS REAR GARNI...

Page 35: ...wire connectors Remove wire harness clamps 2 nos Remove the bolts 5 nos and rear fender Installation is in the reverse order of removal MOUNTING BOLTS REAR COWL ASSEMBLY REAR COWL CENTER BRAKE TAIL LI...

Page 36: ...stallation is in the reverse order of removal TORQUE 22 N m 2 2 kgf m 16 lbf ft BOLTS SARI GUARD EXHAUST PIPE MUFFLER Remove the following Exhaust pipe joint nuts Muffler mounting bolts 1 no flange bo...

Page 37: ...or towards engine to take it out Installation is in the reverse order of removal The muffler protector can be serviced with the muffler installed on the engine Always check for the condition of the ru...

Page 38: ...MEMO...

Page 39: ...e running to do some work make sure the area is well ventilated Never run the engine in an enclosed area The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may...

Page 40: ...r Head cover bolt 31916 KRM 841 90206 250 000 90084 MN8 010 90087 KSP 860 90131 KRM 840 93700 05012 0A 90305 KYJ 711 93903 25580 90102 K43 900 90084 041 000 90107 GN1 010 90304 KTE 911 96001 06035 00...

Page 41: ...I Page 3 14 EVAPORATIVE EMISSION CONTROL SYSTEM I I Page 3 15 DRIVE CHAIN I EVERY 1000 Kms 600 mi I L Page 3 16 BATTERY VOLTAGE I I I I I I I I I Page 3 18 BRAKE FLUID NOTE 4 I I I I I I I I 2 YEARS P...

Page 42: ...e fuel valve OFF Remove the fuel strainer cup and drain the contents of the cup into a suitable container Remove the O ring and strainer screen Wash the strainer screen and cup in clean non flammable...

Page 43: ...the lock nut and reposition the dust cover Recheck the throttle operation Major Adjustment Major adjustment are made with the lower adjusting nut at the carburetor end Remove the right side cover pag...

Page 44: ...vent to remove dust and also do not use forced air on it The viscous oil will be lost and filter becomes dry As the base filter paper is coarse it cannot block fine dust when it becomes dry Replace th...

Page 45: ...rain hose from the air cleaner housing and drain deposits into a suitable container Reinstall the drain hose SPARK PLUG REMOVAL Disconnect the spark plug cap Clean around the spark plug base with comp...

Page 46: ...0 8 0 9 mm 0 03 0 04 in If necessary adjust the gap by bending the side electrode carefully by using the wire gauge INSTALLATION Install and hand tighten the spark plug to the cylinder head then tigh...

Page 47: ...ge from the center toward the outside VALVE CLEARANCE IN 0 08 0 02 mm 0 003 0 001 in EX 0 24 0 02 mm 0 010 0 001 in Adjust by loosening the valve adjusting lock nut and turning the adjusting screw unt...

Page 48: ...cap dipstick and wipe the oil from the dipstick with a clean shop towel Reinstall the oil filler cap dipstick but do not screw it Remove the oil filler cap dipstick Check the oil level If the oil leve...

Page 49: ...d draining Place a clean container under the engine Remove the oil drain bolt and sealing washer Drain the engine oil completely Install the oil drain bolt with a new sealing washer and tighten it to...

Page 50: ...nd flange side facing up as shown Install the right crankcase cover page 9 5 ENGINE OIL CENTRIFUGAL FILTER Remove the right crankcase cover page 9 3 Remove the screws 3 Nos of oil filter by using gear...

Page 51: ...oil through to the oil filter rotor cover While pressing the oil through from the reverse side install the clip Check the oil through operates freely without binding Install a new gasket on to the oi...

Page 52: ...trol valve This charged of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and wa...

Page 53: ...the engine via one way valve and the carburetor when the engine is running The device helps in avoiding the air pollution caused due to fuel vapours diffused into the air The evaporative emission cont...

Page 54: ...dge of the adjusting slots Adjust the drive chain at minimum slack point Tighten the rear axle nut to the specified torque TORQUE 88 N m 8 8 kgf m 65 lbf ft Tighten both adjusting nuts and lock nuts R...

Page 55: ...k plate and drive chain Clean the chain with non flammable or high flashpoint solvent and wipe it dry Be sure the chain has dried completely before lubricating Lubricate the drive chain Wipe off the e...

Page 56: ...open end opposite to the direction of chain travel BATTERY Remove the left side cover page 2 3 It is not necessary to check the battery electrolyte level or add distilled water as the battery is a mai...

Page 57: ...pecified torque TORQUE 1 5 N m 0 1 kgf m 1 1 lbf ft REAR BRAKE CBS BRAKE FLUID LEVEL INSPECTION Support the motorcycle on its center stand Check the rear brake fluid level mounted in rear step pillion...

Page 58: ...pedal is released Recheck the free play and adjust the brake light switch page 3 22 1 Make sure the cut out on the adjusting nut is seated on the brake arm pin when adjusting the free play 2 Push the...

Page 59: ...SHOES DRUM Check the wear indicator position when the brake is applied If the arrow on the indicator plate aligns with the reference mark on the brake panel inspect the brake drum page 14 30 Replace...

Page 60: ...he front brake light switch does not require adjustment Adjust the rear brake light switch Remove the right side cover Adjust the brake light switch so that the brake light comes on just prior to the...

Page 61: ...uspension parts impair motorcycle stability and control REAR SUSPENSION INSPECTION Check the action of the rear shock absorber by pressing the rear end several times Check the entire shock absorber as...

Page 62: ...to side Replace the bearings if any looseness is noted Refer to each bearing replacement Rear wheel bearings page 13 6 Driven flange bearing page 13 10 NUTS BOLTS FASTENERS Check that all chassis nuts...

Page 63: ...front wheel off the ground Check that the control cables do not interfere with handlebar rotation Check that the handlebar moves freely from side to side Check that the fork leg moves freely from forw...

Page 64: ...4 0 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM CRANKSHAFT COUNTERSHAFT MAINSHAFT CAMSHAFT ROCKER ARM OIL FILTER ROTOR OIL PUMP...

Page 65: ...you handle 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 ITEM STANDARD SERVICE LIMIT Engine oil capacit...

Page 66: ...creen rubber with engine oil and install it at original direction Install the right crankcase cover page 9 5 OIL PUMP REMOVAL Remove the right crankcase cover page 9 3 Remove the oil pump driven gear...

Page 67: ...EM Remove the dowel pins 2 nos DISASSEMBLY Remove the oil pump cover screw 1 no and oil pump cover Remove the inner rotor Remove the outer rotor from the oil pump body OUTER ROTOR SCREW DOWEL PINS INN...

Page 68: ...move both side shroud pan screw 1 no Temporarily install the outer rotor inner rotor and rotor shaft into the oil pump body Measure the oil pump body clearance SERVICE LIMIT 0 25 mm 0 010 in BODY CLEA...

Page 69: ...ROTOR SHAFT OIL PUMP ASSEMBLY DRIVEN GEAR PUMP BODY OUTER ROTOR INNER ROTOR PUMP COVER Apply clean engine oil to the outer rotor and install it into the oil pump body OUTER ROTOR INNER ROTOR Apply cle...

Page 70: ...ER INSTALLATION Install two dowel pins into the crankcase Install the oil pump and tighten the mounting bolts to the specified torque TORQUE 12 N m 1 2 kgf m 9 lbf ft Apply clean engine oil to the oil...

Page 71: ...MEMO...

Page 72: ...5 0 FUEL SYSTEM 27 N m 2 8 kgf m 20 Ibf ft COMPONENT LOCATION...

Page 73: ...red for more than one month drain the float chamber Fuel left in the float chamber may cause clogged jets resulting in hard starting or poor driveability SPECIFICATIONS TORQUE VALUES ITEM PART NO QTY...

Page 74: ...contaminated Flooded carburetor Engine stall hard to start rough idling Fuel line restricted Ignition system malfunction page 16 3 Fuel mixture too lean rich pilot screw adjustment Fuel contaminated...

Page 75: ...her and air vent from the frame clamps Disconnect the RR brake switch 2P connector as well as remove the wire routing from the frame clamp Disconnect the crank case breather hose Disconnect the ASV ho...

Page 76: ...g from right side BOLT BOLT AIR CLEANER HOUSING AIR CLEANER HOUSING BOLTS BAND SCREW Install the mounting bolts 2 nos from right side Connect the crankcase breather hose Connect the air cleaner connec...

Page 77: ...TCH STARTING ENRICHMENT SE VALVE REMOVAL INSTALLATION Remove the fuel tank right cover page 2 4 Loosen the air cleaner connecting boot band screw and insulator band screw from carburetor Loosen the st...

Page 78: ...ect the SE valve page 5 5 Disconnect the air vent hose and the throttle sensor 3P connector page 16 7 Turn the fuel valve OFF and disconnect the fuel hose from the carburetor DRAIN SCREW DRAIN HOSE Lo...

Page 79: ...throttle cable stay VACUUM CHAMBER Remove the two screws and vacuum chamber cover Remove the compression spring and diaphragm vacuum piston from the carburetor body Take care of the spring as the comp...

Page 80: ...et needle from the vacuum piston Check the following Jet needle for stepped wear Vacuum piston for wear or damage Diaphragm for pin holes deterioration or damage Spring for wear or damage Needle holde...

Page 81: ...crew spring washer and O ring Check the each jet for wear of damage Check the pilot screw spring washer and O ring for wear or damage Replace the damaged parts if necessary STARTING ENRICHMENT SE VALV...

Page 82: ...CARBURETOR BODY 2 1 N m 0 2 kgf m 1 6 lbf ft DRAIN SCREW 1 5 N m 0 2 kgf m 1 1 lbf ft SE VALVE COVER VACUUM CHAMBER COVER STAY SPRING O RING O RING O RING FLOAT PIN FLOAT FLOAT VALVE FLOAT CHAMBER GA...

Page 83: ...the float valve where it contacts the valve seat for stepped wear or contaminated Replace the valve if the tip is worn or contaminated Check the operation of the float valve Inspect the float valve s...

Page 84: ...3 0 mm 0 51 in TOOL Carburetor float level gauge 070MJ 001 I110 The float cannot be adjusted Replace the float assembly if it the float level is out of specification Install a new O ring into the floa...

Page 85: ...ges and piston grooves should be fitted after turning Install the diaphragm vacuum piston into the carburetor body by aligning the tab of the diaphragm with the groove of carburetor body Lift the bott...

Page 86: ...two screws TORQUE 3 4 N m 0 4 kgf m 2 5 lbf ft INSTALLATION Install the carburetor to the connecting hose and insulator Loosely tighten the insulator band screw and air cleaner connecting boot band s...

Page 87: ...ew is correctly adjusted at the factory As the adjustment of the pilot screw is very critical for the emission of CO and HC gases such an adjustment shall be carried out very carefully Place the motor...

Page 88: ...r comp Turn the pilot screw clockwise until it seats lightly and then back it out to the specification given INITIAL OPENING 2 1 8 turns out 4 Warm up the engine for 10 minutes at idle speed Do not wa...

Page 89: ...is out of specification adjust the idle speed by turning the throttle stop screw with the PAIR system stopped 9 Turn the pilot screw and adjust the CO concentration CO measurement at idle secondary a...

Page 90: ...the engine and adjust the idle speed with the throttle stop screw IDLE SPEED 1 400 100 min 1 rpm 6 Turn the pilot screw in or out slowly to obtain the highest engine speed 7 Lightly open the throttle...

Page 91: ...e If the air is not drawn in check the air suction hose for clogging With the engine running gradually apply vacuum to the PAIR control valve vacuum hose Check that the air suction hoses stop drawing...

Page 92: ...tion is in the reverse order of removal VACUUM HOSE AIR SUPPLY HOSE VACUUM HOSE SMALLER DIA ONE WAY VALVE BOLTS AIR SUCTION HOSE EVAPORATIVE EMISSION CONTROL SYSTEM The evaporative emission control sy...

Page 93: ...or not in reverse direction The canister must be installed at its original position to avoid damage of performance Do not bend twist or kink the tube STARTER MOTOR CABLE HOSE HOSE CANISTER CANISTER Re...

Page 94: ...h compressed air O RING FUEL VALVE FUEL STRAINER FUEL STRAINER FUEL STRAINER REMOVAL Drain the fuel from the fuel tank into the approved gasoline container Remove the left side cover page 2 3 Remove t...

Page 95: ...he fuel tank O RING FUEL VALVE FUEL STRAINER LOCK NUT Tighten the fuel valve lock nut and apply the specified Torque TORQUE 22 N m 2 2 kgf m 16 lbf ft Install the fuel tank page 2 4 Install the fuel v...

Page 96: ...6 0 ENGINE REMOVAL INSTALLATION COMPONENT LOCATION 45 N m 4 5 kgf m 33 Ibf ft 12 N m 1 2 kgf m 9 Ibf ft 54 N m 5 5 kgf m 40 Ibf ft...

Page 97: ...2 Alternator page 10 1 The following components require engine removal for service Crankcase transmission kickstarter page 11 1 SPECIFICATIONS TORQUE VALUES ITEM SPECIFICATIONS Page NO Engine oil capa...

Page 98: ...7 Clutch cable page 9 6 Carburetor page 5 6 ASV air supply hose page 3 14 Disconnect the neutral switch wire connector ignition pulse generator wire connector alternator 2P white connector and VS sen...

Page 99: ...t and gear shift pedal Remove the bolts 2 nos of choke cable stay Remove the bolts 2 nos of left crankcase rear cover and remove it with bracket PEDAL PINCH BOLT BOLTS CHOKE CABLE STAY DRIVE SPROCKET...

Page 100: ...n frame to save from scratches ENGINE INSTALLATION Place the jack or other adjustable support under the engine The jack height must be continually adjusted to relieve stress for ease bolt installation...

Page 101: ...ft Rear engine hanger nut 54 N m 5 5 kgf m 37 6 lbf ft Install the drive chain onto the drive sprocket Install the drive sprocket to the counter shaft Install the fixing plate Rotate the fixing plate...

Page 102: ...he bolts 2 nos Install the gear shift pedal and tighten the pinch bolt Install the kickstarter pedal by aligning mark on the kick spindle Install and tighten the pinch bolt Connect the 2 terminals of...

Page 103: ...nect and install the following ASV air supply hose page 3 14 Exhaust pipe muffler page 2 8 Carburetor page 5 14 Spark plug cap page 3 7 Inspect the following Drive chain slack page 3 15 Clutch lever f...

Page 104: ...7 0 CYLINDER HEAD VALVES COMPONENT LOCATION 10 N m 1 0 kgf m 7 3 Ibf ft 12 N m 1 2 kgf m 9 Ibf ft 30 N m 3 0 kgf m 22 Ibf ft 9 N m 0 9 kgf m 6 6 Ibf ft 9 N m 0 9 kgf m 6 6 Ibf ft...

Page 105: ...d through oil passages in the cylinder head stud bolt hole camshaft holder and cylinder head cover Clean the oil passages before assembling them Unit mm in SPECIFICATIONS ITEM STANDARD SERVICE LIMIT P...

Page 106: ...Excessive smoke Worn valve stem or valve guide Damaged stem seal Cylinder piston problem Excessive noise Incorrect valve adjustment Sticking valve or broken valve spring Excessive worn valve seat Wor...

Page 107: ...G 0010100 Valve spring compressor 070 GE 001 I100 Flat cutter 27 mm 32 EX 07780 0013300 Flat cutter 30 mm 32 IN 07780 0012200 Valve Seat cutter 27 5 mm 45 EX 070GH 0031180 Valve Seat cutter 29 mm 45 I...

Page 108: ...stion chamber and or the piston crown If compression is low pour 3 5 cc 0 1 0 2 oz of lean engine oil into the cylinder through the spark plug hole and recheck the compression If the compression incre...

Page 109: ...emove the air supply pipe and O ring INSTALLATION Apply clean engine oil to a new O ring Install the new O ring to the air supply pipe Install the air supply pipe to the cylinder head cover Install an...

Page 110: ...Choke cable stay page 10 2 Cylinder head cover page 7 4 Remove the head cover cylinder L side by removing bolts 3 nos Make sure the piston is at TDC Top Dead Center on the compression stroke page 3 9...

Page 111: ...rankcase Remove the camshaft retainer bolt 1 no NOTE Do not hammer the cam shaft out as it can damage the camshaft Remove the camshaft CAMSHAFT FLANGE CAM CHAIN SPROCKET RETAINER BOLT CAMSHAFT CAMSHAF...

Page 112: ...bearings do not turn smoothly quietly or if they fit loosely on the camshaft CAM LOBE Measure the height of each cam lobe SERVICE LIMITS IN 32 96 mm 1 298 in EX 32 85 mm 1 293 in Inspect the cam lobe...

Page 113: ...nder head cover page 7 5 Choke cable stay page 10 3 Spark plug page 3 8 Install the head cover cylinder L side by installing the bolts 3 nos BOLTS RUBBER SEALS Install the cam chain on cam sprocket In...

Page 114: ...s 2 nos of the intake manifold from cylinder head Remove flange bolts 2 nos Loosen the nut 4 nos and loosen the stud bolt 4 nos STUD BOLTS NUTS FLANGE BOLTS STUD BOLTS NUTS BOLTS CAUTION Place a shop...

Page 115: ...er arms from the cylinder head INSPECTION ROCKER ARM SHAFT Inspect the sliding surface of each rocker arm and shaft for wear or damage Check the each rocker arm roller for scoring scratches or evidenc...

Page 116: ...SSEMBLY While compressing the valve spring using the special tool remove the valve cotters TOOL Valve spring compressor 070GE 001 I100 Loosen the valve spring compressor and remove the following Cotte...

Page 117: ...ul not to damage the gasket surface VALVE Inspect the valve for trueness burning scratches or abnormal stem wear Measure the valve stem O D SERVICE LIMITS IN 4 92 mm 0 194 in EX 4 90 mm 0 193 in Inser...

Page 118: ...plate or oven Do not heat the cylinder head beyond 150 C 300 F Use temperature indicator sticks available from welding supply stores to be sure the cylinder head is heated to the proper temperature We...

Page 119: ...seat VALVE SEAT INSPECTION Clean the intake and exhaust valves thoroughly to remove the carbon deposits Apply light coating of Prussian Blue to the valve seats Tap the valves and seats using a rubber...

Page 120: ...g a 60 degree inner cutter Use a 45 degree cutter to remove the roughness or irregularities from the seat TOOLS Seat cutter 27 5 mm EX 07780 0010200 Seat cutter 29 mm IN 07780 0010300 Cutter holder 07...

Page 121: ...l a 45 degree finish cutter and cut the seat to proper width Make sure that all pitting and irregularities are removed Refinish if necessary STANDARD SEAT WIDTH 0 9 1 1 mm 0 035 0 043 in 60 45 OLD SEA...

Page 122: ...aust valve into the valve guides Install the valve springs and retainers The springs tightly wound coils should face toward the combustion chamber To avoid damage to the seal turn the valve slowly whe...

Page 123: ...tallation To prevent loss of tension do not compress the valve spring more than necessary Do not allow dust and dirt to enter the engine If required replace the old intake manifold O ring with a new o...

Page 124: ...kcase cover Make sure the piston is at TDC Top Dead Center on the compression stroke Be careful not to jam the cam chain and timing sprocket on the crankshaft when rotating the crankshaft Cover the ca...

Page 125: ...2 nos and choke cable stay PAN SCREW CHOKE CABLE STAY BOLTS Install and tighten the intake manifold bolts 2 nos as per the specified torque TORQUE 12 N m 1 2 kgf m 9 lbf ft Install the following Cover...

Page 126: ...h the stopper tool to retract the tensioner lifter then insert the stopper fully to hold the tensioner lifter in the fully retracted position Install a new gasket on the cam chain tensioner lifter TOO...

Page 127: ...MEMO...

Page 128: ...8 0 CYLINDER PISTON COMPONENT LOCATION...

Page 129: ...of piston rings cored or scratched piston or cylinder wall Abnormal noise piston Worn piston pin or piston pin hole Worn cylinder piston or piston rings Worn connecting rod small end TOOLS ITEM STAND...

Page 130: ...the cylinder wall for scratches and wear Measure and record the cylinder I D with bore gauge at three levels in both the X and Y axes Take the maximum reading to determine the cylinder wear SERVICE L...

Page 131: ...at the clearance for an oversize piston rings is 0 005 0 030 mm 0 0002 0 0012 in Check the cylinder for warpage with a straight edge and feeler gauge across the studs and bolt holes as shown SERVICE L...

Page 132: ...ect the ring grooves for excessive wear and carbon buildup Measure the piston O D at a point 10 mm 0 4 in from the bottom and 90 to the piston pin hole SERVICE LIMIT 57 20 mm 2 252 in Calculate the cy...

Page 133: ...rely into the cylinder and measure the end gap using a feeler gauge SERVICE LIMITS Top 0 40 mm 0 016 in Second 0 40 mm 0 016 in Oil 0 85 mm 0 033 in FEELER GAUGE PISTON PIN CONNECTING ROD PISTON RING...

Page 134: ...the ends too far Be careful not to damage the piston when the piston ring installation Do not confuse the top and second rings After installing the rings they should rotate freely without sticking Sp...

Page 135: ...iston 070SRTKSP008 Install the new piston pin clips Always use new piston pin clips Reinstalling used piston pin clips may lead to serious engine damage Set the piston pin clip in the groove properly...

Page 136: ...ugh the cylinder and install the cylinder over the piston while compressing the piston rings with your fingers TOOL Slider base piston 070SRTKSP008 Insert the cam chain guide into the cylinder and cra...

Page 137: ...MEMO...

Page 138: ...LUTCH GEARSHIFT LINKAGE COMPONENT LOCATION 12 N m 1 2 kgf m 9 0 Ibf ft 83 N m 8 3 kgf m 61 Ibf ft 83 N m 8 3 kgf m 61 Ibf ft 12 N m 1 2 kgf m 9 Ibf ft 64 N m 6 4 kgf m 47 Ibf ft 9 N m 0 9 kgf m 6 6 Ib...

Page 139: ...984 0 6680 0 6687 16 95 0 667 ITEM PART NO QTY THREAD DIA mm TORQUE N m kgf m lbf ft REMARKS PAGE NO Clutch center lock nut Clutch lifter plate bolt Oil filter rotor lock nut Shift drum stopper arm bo...

Page 140: ...lips Clutch lifter sticking Worn clutch discs Weak clutch springs No clutch lever free play Check for oil additive Hard to shift Misadjusted clutch cable Damaged or bent shift fork Bent shift fork sha...

Page 141: ...nuts 2 nos Loosen the right crankcase cover bolts 12 nos in a crisscross pattern in 2 or 3 steps and remove the right crankcase cover bolts clutch cable holder and right crankcase cover LIFTER ARM CLU...

Page 142: ...ary ASSEMBLY Apply grease to a new kickstarter spindle dust seal lip and install it into the right crankcase cover Apply grease to a new clutch lifter arm dust seal lip and install it into the right c...

Page 143: ...rm groove by aligning the groove with the lifter piece hole INSTALLATION Clean off any gasket material from the mating surfaces of the right crankcase and cover Install the dowel pins and new gasket C...

Page 144: ...r then loosen the clutch center lock nut using the special tool TOOL Clutch center holder 070SRTKSP011 CLUTCH REMOVAL Remove the following Right crankcase cover page 9 3 Oil filter rotor cover page 3...

Page 145: ...er Remove the following Clutch center Clutch disc A Clutch plates and discs B Pressure plate Remove the following Washer Clutch outer Remove the clutch outer guide DISC A DISCS B PLATES DISC A CLUTCH...

Page 146: ...oes not turn smoothly quietly or if the outer race fits loosely in the clutch lifter plate CLUTCH SPRING Check the clutch spring for fatigue or damage Measure the clutch spring free length SERVICE LIM...

Page 147: ...E Check the slots in the clutch outer for nicks indentations or abnormal wear made by the clutch discs Check the primary driven gear teeth for wear or damage Measure the clutch outer I D SERVICE LIMIT...

Page 148: ...ll it onto the mainshaft Apply clean engine oil to the gear primary drive Install the oil pump driven gear Install the clutch outer and washer Coat the clutch discs with clean engine oil Assemble clut...

Page 149: ...clutch center lock nut to the specified torque using special tool TOOL Clutch center holder 070SRTKSP011 TORQUE 83 N m 8 3 kgf m 61 lbf ft CLUTCH CENTER ASSEMBLY DISC A OUTSIDE SHALLOW SLOT OUTER CLU...

Page 150: ...lock nut to the specified torque using the special tools TOOLS Gear holder 07006 KRBT900 TORQUE 83 N m 8 3 kgf m 61 lbf ft Install the following Oil filter rotor cover page 3 13 Right crankcase cover...

Page 151: ...stall the return spring washer stopper arm and bolt and tighten the bolt to the specified torque TORQUE 12 N m 1 2 kgf m 9 lbf ft Hook the return spring to the stopper arm groove STOPPER ARM WASHER GE...

Page 152: ...ft Apply clean engine oil to the gearshift spindle journal rotating area Install the thrust washer to the gearshift spindle and insert the spindle into the crankcase Install the gearshift spindle by a...

Page 153: ...age 9 10 BALANSER DRIVE GEAR PRIMARY DRIVE GEAR Align Align BALANCER DRIVE GEAR REMOVAL Remove the primary drive gear page 9 14 Remove the balancer drive gear INSTALLATION Apply clean engine oil to th...

Page 154: ...10 0 ALTERNATOR 74 N m 7 5 kgf m 55 Ibf ft COMPONENT LOCATION...

Page 155: ...15 8 SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Starter driven gear boss O D 45 660 45 673 1 7976 1 7981 45 60 1 795 Starter motor brush length 10 00 10 05 0 394 0 396 6 5 0 26 TORQUE VALU...

Page 156: ...and choke cable stay Remove the dowel pins 2 nos and gasket Remove the left crankcase rear cover page 6 3 Loosen the left crankcase cover bolts in a crisscross pattern in several steps Remove the lef...

Page 157: ...ied torque TORQUE 9 N m 0 9 kgf m 6 6 Ibf ft Route the neutral switch wire to the left crankcase grooves Install the left crankcase rear cover page 6 5 NEUTRAL SWITCH WIRE CHOKE CABLE STAY BOLTS ALTER...

Page 158: ...er 070SRTKSP015 Remove the flywheel using the flywheel puller TOOL Flywheel puller 070SRTKSP014 FLYWHEEL HOLDER FLYWHEEL PULLER SHAFT COLLAR STARTER IDLE GEAR NUT WASHER FLYWHEEL Remove the collar sha...

Page 159: ...t to the specified torque TOOL Flywheel holder 070SRTKSP015 TORQUE 74 N m 7 4 kgf m 55 Ibf ft Install the flywheel with the oneway clutch assy while aligning the woodruff key on the crankshaft When in...

Page 160: ...turning the driven gear counterclockwise Remove the starter clutch bolts while holding the flywheel with a flywheel holder Tool Flywheel holder 070SRTKSP015 Remove the starter clutch assembly from the...

Page 161: ...roller for wear or damage Check the roller contacting surface of the starter driven gear for abnormal wear or damage Measure the starter driven gear boss O D SERVICE LIMIT 45 60 mm 1 795 in FLYWHEEL...

Page 162: ...oil to the starter driven gear teeth Install the starter driven gear to the flywheel while turning the driven gear counterclockwise Make sure that the starter driven gear turns counter clockwise smoo...

Page 163: ...ring from the starter motor DISASSEMBLY INSPECTION Remove the starter motor case bolts and O rings Remove the following Rear cover assembly Seal ring Shims Armature Remove the following Front cover a...

Page 164: ...ontinuity between the cable terminal and the insulated brush There should be continuity Check for continuity between the cable terminal and rear cover There should be no continuity Remove the followin...

Page 165: ...ollowing Nut Washer Insulators O ring Insulator plate Brush terminal Check the bushing in the rear cover for wear or damage BUSHING INSULATOR NUTS BUSHING O RING BRUSH TERMINAL INSULATOR INSULATOR PLA...

Page 166: ...pects the commutator bars of the armature for discolouration Check for continuity between pair of commutator bars There should be continuity Check for continuity between each commutator bar and the ar...

Page 167: ...NG INSULATOR PLATES REAR COVER O RING INSULATOR WASHER O RINGS FRONT COVER SEAL RING ARMATURE SHIMS NUTS SHIMS LOCK WASHER INSULATED WASHER BRUSH TERMINAL MOTOR CASE SEAL RING NUT NUTS BUSHING O RING...

Page 168: ...e shaft Install the shims properly as noted during removal Apply a thin coat of grease to the armature shaft end Install the brushes into the brush holder Spread the brushes Install the armature into...

Page 169: ...e bearing in the front cover Install the lock washer onto the front cover Install the front cover being careful not to damage the dust seal lip Align the index lines on the front cover and motor case...

Page 170: ...ENERATOR REMOVAL Remove the left crankcase cover page 10 2 Remove the flange bolts 3 nos wire guide and ignition pulse generator Remove the grommet Remove the three flange bolts and stator from the le...

Page 171: ...sealant to the wire grommet seating surface and install the wire grommet into the groove Install the wire guide and ignition pulse generator Apply a locking agent to the three bolt threads Install th...

Page 172: ...11 0 CRANKCASE TRANSMISSION KICKSTARTER 64 N m 6 5 kgf m 47 Ibf ft 55 N m 5 5 kgf m 44 Ibf ft 12 N m 1 2 kgf m 9 0 Ibf ft 10 N m 1 0 kgf m 7 Ibf ft COMPONENT LOCATION...

Page 173: ...0 20 018 0 7874 0 7882 20 05 0 789 M5 17 000 17 018 0 6692 0 6699 17 05 0 671 C1 20 500 20 521 0 8071 0 8079 20 55 0 809 C2 23 020 23 041 0 9063 0 9071 23 07 0 908 C3 20 020 20 038 0 7881 0 7888 20 07...

Page 174: ...SHOOTING Excessive engine noise Worn seized or chipped transmission gears Worn or damaged transmission bearings Worn or damaged connecting rod big end bearing Worn crankshaft bearing Hard to shift Imp...

Page 175: ...0 Remover weight 070MCKPLI300 Driver 070GD004I100 Pilot 12 mm 070GD004I130 Oil seal remover 070SRTKSP002 Assembly collar 070MFKPLI110 Pilot 17 mm 070GD004I150 Fork seal driver 070SRTKSP001 Remover hea...

Page 176: ...move cam chain tensioner guide Remove the cam chain Remove the bolt and push plug plate Hold the gear balancer drive and gear balancer driven using gear lock Remove the driven balancer gear and weight...

Page 177: ...rankcase bolts in a criss cross pattern in two or three step and remove them BALANCER BOLT BOLTS Place the crankcase assembly with the right side down Carefully separate the left crankcase from the ri...

Page 178: ...page 11 4 Carefully remove the balancer shaft Pull out the shift fork shafts MAINSHAFT SHIFT FORKS SHAFT BALANCER DRIVE SHAFT SHIFT FORKS SHAFT SHIFT DRUM COUNTERSHAFT Remove the shift forks and shift...

Page 179: ...2 0 10 mm 0 004 in Measure I D of each bushing C1 17 04 mm 0 6 71 in C2 20 07 mm 0 790 in MAINSHAFT COUNTERSHAFT Check the spine grooves and sliding surfaces for abnormal wear or damage Measure the O...

Page 180: ...n SHIFT FORK SHAFT Check the shift fork shafts for damage and straightness Measure the shift fork shaft for O D SERVICE LIMITS 9 93 mm 0 391 in CRANKSHAFT REMOVAL Remove both crankcase page 11 5 Remov...

Page 181: ...amage Remove the timing sprocket if necessary When installing the timing sprocket while align the center of the timing sprocket teeth with the center of the crank pin CRANKSHAFT BALANCER BEARING INSPE...

Page 182: ...ght crankcase with following tools TOOLS Remover shaft 17mm 07936 3710330 Remover handle 07936 3710100 Remover weight 070MC KPLI300 Remove the countershaft dust seal and gear shift spindle dust seal f...

Page 183: ...0 Pilot 17 mm 070GD 004I150 Mainshaft bearing Driver 070GD 001I100 Attachment 37x40 mm 070GD 002I150 Pilot 17 mm 070GD 004I150 LEFT CRANKCASE Mainshaft bearing Driver 070GD 001I100 Attachment 32x35 mm...

Page 184: ...ECTION Turn the inner race of bearing with your finger The bearing should turn smoothly and quietly Also check that bearing outer races fit tightly in the crankcase Replace bearing if the inner race d...

Page 185: ...ach gear teeth Apply molybdenum oil solution to the bushing sliding surface to ensure initial lubrication Assemble all parts into their original positions Check the gears for freedom of movement or ro...

Page 186: ...STARTER SPLINE WASHER 20 mm SET RING 20 mm EACH GEAR TEETH BUSHING AND SPLINE WASHER SPECIAL WASHER 12 X 23 mm THRUST WASHER 17 mm M4 GEAR 30 T M3 GEAR 20 T MAINSHAFT 13 T M2 GEAR 19 T M5 GEAR 24 T CH...

Page 187: ...ET RING 20 mm SPLINE WASHER 20 mm SPECIAL WASHER 17 mm THRUST WASHER 20 mm THRUST WASHER 20 mm COLLAR 20 mm CHAMFERED SIDE SHARPED EDGE SIDE COUNTERSHAFT C1 BUSHING 20 mm C1 GEAR 40 T C4 GEAR 32 T C3...

Page 188: ...together into the right crankcase Be sure to install the three end washers mainshaft left only countershaft both ends Each shift fork has an identification marks R L right and left C center Install t...

Page 189: ...CRANKCASE ASSEMBLY Clean the oil passages of crankcase using the compressed air Clean the left and right crankcase mating surface thoroughly being careful not to damage them and check for damage Appl...

Page 190: ...ten the bolts in a crisscross pattern in 2 3 steps Install the tighten the right crankcase bolt LEFT CRANKCASE RIGHT CRANKCASE BOLT Install the dowel pins DOWEL PINS Do not force the crankcase halves...

Page 191: ...cer shaft Install the balancer driven weight A on to the balancer shaft by aligning its keyway Install and tighten the balancer driven gear nut and washer to the specified torque using the below menti...

Page 192: ...tighten the tensioner guide plate bolts 2 nos Install the removed parts in the reverse order of removal Apply molybdenum oil solution to the push plug Install the push plug and spring CAM CHAIN PUSH...

Page 193: ...atchet Remove the following Snap ring Washer Drive gear Spindle INSPECTION Check the following Starter ratchet and kickstarter drive gear for excessive wear or damage Spindle for vent or damage Measur...

Page 194: ...l the washer and snap ring Apply molybdenum oil solution to the starter ratchet inner surface and install it by on the kickstarter spindle KICKSTARTER SPINDLE RETAINER KICK SPINDLE SNAP RING KICKSTART...

Page 195: ...denum oil solution to the kickstarter drive gear teeth Install the kickstarter assembly and insert the ratchet stop into the right crankcase groove Hook the return spring to the crankcase right Rotate...

Page 196: ...12 0 FRONT WHEEL SUSPENSION STEERING COMPONENT LOCATION 74 N m 7 5 kgf m 55 Ibf ft 22 N m 2 2 kgf m 16 Ibf ft 22 N m 2 2 kgf m 16 Ibf ft 32 N m 3 3 kgf m 24 Ibf ft 59 N m 6 0 kgf m 44 Ibf ft...

Page 197: ...SERVICE LIMIT Minimum tire thread depth 1 5 0 06 Cold tire pressure Driver only 175 kPa 1 75 kgf cm 25 psi Driver and passenger 175 kPa 1 75 kgf cm 25 psi Axle runout 0 2 0 01 Wheel rim runout Radial...

Page 198: ...746 0040300 Driver 07749 0010000 Piston remover front cushion 070SRTKSP003 Ball race remover 070SRTKSP005 Bearing remover shaft 07746 0050100 Fork seal driver 070SRTKSP001 Steering cone installer Fram...

Page 199: ...Unevenly assembled left and right fork legs Unequal oil quantity in each fork leg Front wheel wobbling Bent rim Worn or damaged wheel bearings Faulty tire Axle not tightened properly Wheel turns hard...

Page 200: ...t switch connectors Remove the bolts holder and brake master cylinder Remove handlebar throttle housing screws 2 nos on right hand side Remove the starter switch housing screws and remove the housing...

Page 201: ...e the screws and separate the left handlebar switch housing CLUTCH WIRE CONNECTOR THROTTLE GRIP HANDLEBAR Pull out the handle bar grip with twisting movement in outward direction Remove the clutch cab...

Page 202: ...ark on the handlebar with the mating surface of the lower holder Tighten the forward bolts first then the rear bolts TORQUE 22 N m 2 2 kgf m 16 lbf ft Slide and Install the clutch lever bracket by ali...

Page 203: ...housing with the hole in the handlebar Align SCREWS HANDLEBAR THROTTLE GRIP Install the screw and tighten the forward screw first then the rear screw Connect the clutch wire connector Apply grease to...

Page 204: ...o the handlebar Install the starter switch housing on the handlebar while aligning it s locating pin Install and tighten the starter switch housing screws SCREWS Install the right handlebar switch hou...

Page 205: ...or mounting nuts to the specified torque TORQUE 34 N m 3 5 kgf m 26 Ibf ft Check adjust the throttle grip free play Page 3 5 Adjust the clutch lever free play Page 3 22 WIRE BAND REARVIEW MIRROR ADAPT...

Page 206: ...LIMIT 0 2mm 0 01 in WHEEL BEARING Turn the inner race of each bearing with your finger Also check that the bearing outer race fits tightly in the hub Remove and discard the bearings if the inner race...

Page 207: ...all must be located next to the valve stem Remount the tire if necessary Note the rear direction marks on the tire and upon tire installation always fit the tire so the marks face the same direction D...

Page 208: ...hub with the arrow mark facing out Install and tighten new brake disc mounting bolts to the specified torque in a crisscross pattern in 2 or 3 steps TORQUE 42 N m 4 3 kgf m 31 lbf ft Apply grease to a...

Page 209: ...l the front wheel between the fork legs so that the brake disc is positioned between the pads Install the front axle from left side SIDE COLLAR AXLE NUT Install and tighten the axle nut to the specifi...

Page 210: ...mbled loosen the fork socket bolts FRONT AXLE PINCH BOLT Tighten the front axle pinch bolt to the specified torque TORQUE 22 N m 2 2 kgf m 16 lbf ft Check the brake operation BOLTS FRONT FENDOR FORK S...

Page 211: ...AT FORK CAP O RING DISASSEMBLY Remove the dust seal and stopper ring Be careful not to scratch the fork pipe Remove the following Fork bolt O ring Spring collar Spring seat FORK SPRING Remove the fork...

Page 212: ...ver front cushion 070SRTKSP003 FORK PIPE FORK SLIDER OIL LOCK PIECE FORK PIPE OIL SEAL BACK UP RING GUIDE BUSHING Do not overtighten the vise on the piston remover front cushion If the fork piston tur...

Page 213: ...r for score marks scratches or excessive or abnormal wear Place the fork pipe on V blocks Turn the fork pipe and measure the runout using a dial indicator Actual runout is 1 2 of the total indicator r...

Page 214: ...fully remove the slider bushing by prying the bushing gap with a screwdriver until the bushing can be pulled off by hand NOTE Do not remove the slider bushing unless it is necessary to replace with a...

Page 215: ...onto the fork tube OIL SEAL BACK UP RING GUIDE BUSHING REBOUND SPRING FORK PISTON FORK PISTON FORK PIPE FORK PIPE Install the rebound spring to the fork piston and install them into the fork pipe Inst...

Page 216: ...t of recommended fork fluid into the fork pipe RECOMMENDED FORK FLUID Honda ULTRA CUSHION OIL No 10 or equivalent FORK FLUID CAPACITY 310 2 5 cm3 11 0 0 08 US oz 11 5 0 09 UK oz Slowly pump the fork p...

Page 217: ...olt Loosely install the fork bolt by pushing it to the fork pipe INSTALLATION Install the fork leg through the bottom bridge and top bridge while aligning index line of fork pipe with the top surface...

Page 218: ...page 1 15 Install the front brake caliper bracket assembly and tighten new brake caliper mounting bolts to the specified torque TORQUE 30 N m 3 1 kgf m 22 lbf ft Install the following Front fendor pa...

Page 219: ...tool TOOL Socket wrench steering 070SRTKSP004 Hold the steering stem and remove the adjusting nut Remove the following top cone race Be careful not to loose the steel balls SOCKET WRENCH STEERING UPPE...

Page 220: ...Steering cone installer 070SRTKSP006 BOTTOM BALL RACE BOTTOM CONE RACE BOTTOM CONE RACE REMOVER BOTTOM CONE RACE INSTALLER BOTTOM CONE BOTTOM CONE RACE REPLACEMENT Remove the dust seal Remove the bot...

Page 221: ...G STEM BOTTOM BALL RACE UPPER STEEL BALLS 18 LOWER STEEL BALLS 18 Apply grease properly to bottom cone race top ball race and all other bearing area Install the steel balls in the bottom cone race and...

Page 222: ...QUE Actual 2 5 N m 0 25 kgf m 1 8 Ibf ft Check that there is no vertical play and that the steering stem rotates smoothly Refer to torque wrench reading information on page 12 1 Service information In...

Page 223: ...Loosen the bottom pinch bolts when tighten the stem nut STEERING STEM NUT STEERING BEARING PRELOAD Jack up the motorcycle to raise the front wheel off the ground Position the steering stem to the str...

Page 224: ...13 0 REAR WHEEL SUSPENSION COMPONENT LOCATION 88 N m 8 8 kgf m 65 lbf ft 44 N m 4 4 kgf m 33 lbf ft 44 N m 4 4 kgf m 33 lbf ft 54 N m 5 4 kgf m 40 lbf ft...

Page 225: ...he help of bid breaker Demount the tyre using a tyre demounting machine In nail hole puncture case drill the puncture hole to make the inner surface of the puncture hole smooth to remove contamination...

Page 226: ...Page 13 6 Axial 0 3 0 04 Page 13 6 Drive chain Size link 428 132 Page 3 17 Slack 25 35 0 984 1 37 50 1 96 Page 3 16 ITEM PART NO QTY THREAD DIA mm TORQUE N m kgf m lbf ft REMARKS PAGE NO Rear brake ar...

Page 227: ...Soft suspension Incorrect suspension adjustment Weak shock absorber springs Oil leakage from damper unit Insufficient tire pressure Hard suspension Incorrect suspension adjustment Bent shock absorber...

Page 228: ...emove the brake disc mounting bolts collar and brake disc Remove the dust seal DRUM TYPE REMOVAL Remove the rear brake adjusting nut Push the brake pedal down and remove the brake rod from the joint p...

Page 229: ...ring TOOLS Bearing remover head 15 mm 07746 0050400 Bearing remover shaft 07746 0050100 AXLE Set the axle in V blocks Trun the axle and measure the runout using a dial indicator Actual runout is 1 2 t...

Page 230: ...in a turning stand Spin then wheel by hand and read the runout using a dial indicator SERVICE LIMITS Runout 0 10 mm 0 004 in WHEEL BALANCE Carefully check balance before installing the wheel The wheel...

Page 231: ...HER SWINGARM WASHER REAR DISC ASSEMBLY OF DISC BRAKE BEARING BEARING BEARING DAMPER RUBBER DAMPER RUBBER DRIVEN SPROCKET ASSEMBLY DRIVEN SPROCKET ASSEMBLY DUST SEAL COLLAR COLLAR COLLAR AXLE NUT AXLE...

Page 232: ...ps Install the side collar and dust seal RUBBER DAMPERS BRAKE DISC DUST SEAL SIDE COLLAR BOLTS Install the wheel rubber dampers AXLE SHAFT AXLE NUT RIGHT ADJUSTING PLATE Carefully hold and slide the r...

Page 233: ...RIGHT ADJUSTING PLATE Hold the wheel up and Install rear Axle shaft from left hand side Install Adjusting Plates and screw axle nut to specified torque TORQUE 88 N m 8 97 kgf m 64 9 Ibf ft Install rod...

Page 234: ...a worn chain on new sprockets Both chain and sprocket must be in good condition or the replacement chain or sprocket will wear rapidly NUTS DRIVEN SPROCKET Drive out the driven flange bearing BEARING...

Page 235: ...ring cavities with grease Drive in a new bearing squarely until it is fully seated TOOLS Driver 070GD 001I100 Attachment 42 x 47 mm 070GD 002I160 Pilot 15 mm 07746 0040300 DRIVEN SPROCKET Install the...

Page 236: ...0 Fuel tank page 2 3 Remove rear wheel page 13 4 Remove the shock absorber lower mounting nut and bolt MOUNTING NUT BOLT NUT BUSHES SHOCK ABSORBER SHOCK ABSORBER Remove the shock absorber upper mounti...

Page 237: ...Tighten the lower mounting nut to the specified torque TORQUE 44 N m 4 5 kgf m 33 Ibf ft Install the following Fuel tank page 2 3 Drive chain case page 13 0 Rear wheel page 13 8 SWINGARM Remove the re...

Page 238: ...BLY Remove the chain slider while releasing the bosses 3 nos from the tabs PIVOT NUT PIVOT BOLT BOLT NUT SHOCK ABSORBER Remove the shock absorber lower mounting nut and bolt Remove the swingram pivot...

Page 239: ...wear or damage The chain slider must be replaced if it is worn to the wear limit cutout Remove the dust seal Remove the collars COLLARS Inspect the swingarm dust seal collar Check the swingarm for any...

Page 240: ...needle bearings Press the needle bearings into the swingarm so that the needle bearing surface is 7 mm 0 3 in from the end of swingarm pivot using the special tools and a hydraulic press TOOLS Driver...

Page 241: ...the dust seal Install the dust seal DUST SEAL Install the chain slider while aligning the bosses 3 nos with tabs INSTALLATION Install the swingram pivot bolt and nut Tighten the pivot nut to the speci...

Page 242: ...kgf m 33 Ibf ft BOLT NUT SHOCK ABSORBER BOLTS REAR BRAKE HOSE BOLTS DRIVE CHAIN UPPER CASE DRIVE CHAIN LOWER CASE Install the rear brake caliper hose and tighten the bolts 2 nos Install the drive cha...

Page 243: ...MEMO...

Page 244: ...gf m 9 lbf ft COMPONENT LOCATION 17 N m 1 7 kgf m 13 lbf ft 34 N m 3 5 kgf m 25 lbf ft STD CBS FRONT BRAKE CBS REAR BRAKE 34 N m 3 5 kgf m 25 lbf ft 5 4 N m 0 6 kgf m 4 0 lbf ft Calliper bleeder valve...

Page 245: ...motorcycle This section covers service of the combi brake components of the brake system SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Page NO FRONT BRAKE AND MASTER CYLINDER Specified brake f...

Page 246: ...between brake arm and serrations Brake lever hard or slow return Worn broken return spring Improperly adjusted brake Sticking brake drum due to contamination Worn brake shoes at cam contact area Brak...

Page 247: ...e caliper to bleed valve Loosen the bleed valve and pump the brake lever until no more fluid flows out of the bleed valve Tighten the bleed valve BLEED HOSE BLEED VALVE Cover the painted parts and the...

Page 248: ...the rear brake pedal until no more fluid flows out of the bleed valve Tighten the bleed valve Connect the bleed hose to the CBS bleed valve of the front brake caliper Loosen the bleed valve and pump t...

Page 249: ...he brake caliper bleed valve to the specified torque TORQUE 5 4 N m 0 6 kgf m 4 0 lbf ft BLEED HOSE BLEED HOSE NON CBS CBS BLEED VALVE BLEED VALVE Do not mix different types of fluid These are not com...

Page 250: ...bleeder from around the bleed valve threads seal the threads with teflon tape Repeat steps 1 and 2 until air bubbles do not appear in the bleed hose After bleeding the air completely tighten the brak...

Page 251: ...help of wrench Check the pad pin for abnormal wear or distortion Replace if necessary Remove the brake pads Clean the brake caliper inside especially around the piston Install new brake pads if found...

Page 252: ...e pads and caliper Drive the pad pin into the caliper TORQUE 17 2 N m 1 7 kgf m 12 lbf ft Be careful not to apply grease on brake pads PAD PIN CBS DISC FRONT BRAKE DISC INSPECTION Visually inspect the...

Page 253: ...ing the oil bolt and sealing washers Check the brake disc warpage using a dial indicator SERVICE LIMIT 0 10 mm 0 004 in Check the wheel bearings for excessive play if the warpage exceeds the service l...

Page 254: ...m the master cylinder body using snap ring pliers Remove the master piston and spring from the master cylinder BOOT SNAP RING SPRING MASTER CYLINDER MASTER PISTON SCREW BRAKE LIGHT SWITCH Clean the in...

Page 255: ...scoring scratches or damage Measure the master cylinder I D SERVICE LIMIT DISC 12 755 mm 0 5022 in BRAKE LIGHT SWITCH DIAPHRAGM DIAPHRAGM PLATE RESERVOIR CAP SPRING MASTER PISTON MASTER CYLINDER SNAP...

Page 256: ...master cylinder Be certain the snap ring is firmly seated in the groove SPRING MASTER CYLINDER MASTER PISTON BOOT SNAP RING Apply grease to boot and install it to the master cylinder NOTE If seal is f...

Page 257: ...ATION OF MASTER CYLINDER Place the master cylinder assembly on the handlebar Place the master cylinder holder with up mark facing forward and install the bolts Align the end of the master cylinder wit...

Page 258: ...If the bracket pin boot is hard or deteriorated replace it with a new one BOLTS SEALING WASHERS OIL BOLT CALIPER BRACKET PAD SPRING PAD RETAINER CALIPER PIN BOOT BRACKET PIN BOOT CALIPER BODY Place a...

Page 259: ...ER PISTON B CALIPER PISTON A CALIPER BODY BLEED VALVE PISTON SEALS BRACKET PIN BOOT BRACKET PIN PAD RETAINER BRACKET COLLAR PIN CALIPER PISTON DUST SEALS CALIPER PIN BOOT PAD SPRING HANGER PIN O RING...

Page 260: ...l the brake caliper to the right fork leg so that the disc is positioned between the pads Install and tighten new brake caliper mounting bolts to the specified torque TORQUE 30 N m 3 1 kgf m 22 lbf ft...

Page 261: ...the fluid inlet to remove the caliper pistons Push the dust seals and piston seals in and lift them out Clean the seal grooves caliper piston sliding surfaces and caliper pistons with clean brake flui...

Page 262: ...rd the pads PISTON SEAL DUST SEAL PISTON BRAKE PADS PAD SPRING BRAKE CALIPER SLIDE PIN CALIPER BRACKET CALIPER PIN BOOTS PISTON SEAL BLEED VALVE CALIPER PISTON CALIPER BODY PAD PIN FRONT BRAKE NON CBS...

Page 263: ...ke pads page 14 7 Fill the brake fluid and bleed the air for the hydraulic system page 14 4 REAR BRAKE REAR DISK BRAKE PAD REPLACEMENT Push the caliper pistons all the way in by pushing the caliper bo...

Page 264: ...holes in the pads and caliper Drive the pad pin into the caliper Tighten the rear brake pad pin to the specified torque TORQUE 17 2 N m 1 7 kgf m 12 lbf ft REAR BRAKE PAD PIN REAR BRAKE DISC INSPECTIO...

Page 265: ...brake hose oil bolt and joint hose from rear master cylinder Remove the split pin from the joint pin in the rear brake pedal joint and remove the joint pin Remove the master cylinder mounting bolts 2...

Page 266: ...heck the master cylinder and piston for abnormal scratches Measure the master cylinder I D SERVICE LIMIT CBS 12 775 mm 0 5029 in Measure the master cylinder O D SERVICE LIMIT CBS 12 645 mm 0 4978 in R...

Page 267: ...stall the boot After installing the snap ring always rotate it in its groove to be sure it is fully seated CIRCLIP BOOT BRAKE PEDAL HEIGHT If the push rod is disassembled adjust the push rod length so...

Page 268: ...ve the brake pads by removing pad pin from the caliper page 14 7 Remove the oil bolt sealing washers and brake hose eyelet joint Remove the rear wheel page 13 4 Remove the brake caliper JOINT PIN REAR...

Page 269: ...ng scratches or damage Measure the caliper cylinder I D SERVICE LIMIT 32 090 mm 1 2634 in Measure the caliper piston O D SERVICE LIMITS 31 94 mm 1 257 in Lightly apply compressed air to the fluid inle...

Page 270: ...ots and bracket pins and install them Make sure the boots are securely seated into the pin grooves Assemble the caliper bracket and caliper body If the caliper and bracket pin boots are hard or deteri...

Page 271: ...nd bleed the rear brake hydraulic system Lubricate the pad pin with silicone grease PAD SPRING BRACKET BRAKE PEDAL REMOVAL CBS Remove the right side step holder by removing swing arm pivot nut and rig...

Page 272: ...urn spring Hook the cotter pin from pin D joint and brake pad holder shaft REMOVAL STD Remove the rear brake rod page 13 4 Remove the right side cover page 2 3 Remove spring set from swing arm Remove...

Page 273: ...RAKE PEDAL JOINT PIN SPLIT PIN BRAKE PEDAL WASHER RIGHT STEP HOLDER Remove the split pin washer and brake pedal from the right step holder INSTALLATION Connect the brake rod to the brake pedal then in...

Page 274: ...ing set on to the brake rod and swing arm Install the rear brake rod page 13 9 SWING ARM BOLT BRAKE LIGHT STOP SWITCH RIGHT STEP HOLDER BOLT NUT SPRING SET SWING ARM SPLIT PIN BRAKE PEDAL WASHER RIGHT...

Page 275: ...et When the brake shoes are reused mark all parts before disassembly so they can be installed in their original locations Remove the brake arm nut bolt and brake arm SPRING BRAKE SHOES Do not apply gr...

Page 276: ...onto the brake cam by aligning its wide tooth with the wide groove on the brake cam Remove the indicator plate dust seal and brake cam BRAKE CAM BRAKE PANEL BRAKE CAM FELT SEAL Align BRAKE PANEL INDI...

Page 277: ...s as shown Install the shoe assembly onto the brake panel Wipe any excess grease off the brake cam and anchor pin Install the brake panel and then install the rear wheel page 13 9 If the brake shoes a...

Page 278: ...ONENT LOCATION SYSTEM DIAGRAM FUSE CDI UNIT REGULATOR RECTIFIER TO LIGHTING CIRCUIT W White Y Yellow R Red G Green B Black REGULATOR RECTIFIER BATTERY FUSE 20A BATTERY ALTERNATOR ALTERNATOR R R 4P BLA...

Page 279: ...two weeks For a battery remaining in a stored motorcycle disconnect the negative battery cable from the battery terminal The battery can be damaged if overcharged or undercharged or if left to discha...

Page 280: ...5 4 Compare the measurements to the results of the following calculation STANDARD Measured BV Measured CV 13 5V 14 5V BV Battery Voltage CV Charging Voltage Is the measured charging voltage within the...

Page 281: ...lt and open the battery band Remove the battery Install the battery in the reverse order of removal Connect the positive cable first and then the negative cable Connect the tester probes to the batter...

Page 282: ...n number According to the reference table given on page 15 3 To check voltage press V button VOLTAGE 20 C 68 F Fully charged More than 12 4 V Under charged Below 12 4 V BATTERY LOAD TEST To load test...

Page 283: ...eady to be used RESULT 2 Result indicator shows Orange light with LOW This means battery is weak Battery needs bench charging RESULT 3 Result indicator shows Red light with X This means battery is dea...

Page 284: ...tching ON the Power MAINS LED will glow instantly Main LED will be followed by Yellow LED For New Battery or Blue LED For Used Battery showing that the battery is getting charged properly Green LED in...

Page 285: ...ange 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...

Page 286: ...ical components Connect a tachometer according to the tachometer manufacturer s instructions Restart the engine With the headlight high beam in ON position measure the voltage on the multimeter when t...

Page 287: ...components of the charging system are normal and there are no loose connections at the regulator rectifier connector replace the regulator rectifier unit REMOVAL INSTALLATION Remove the right side co...

Page 288: ...16 0 IGNITION SYSTEM COMPONENT LOCATION FUSE CDI BATTERY SPARK PLUG IGNITION SWITCH IGNITION COIL SYSTEM DIAGRAM...

Page 289: ...t be adjusted since the CDI is factory preset A faulty ignition system is often related to poor connections Check those connections before proceeding Unit mm in TORQUE VALUES TOOL SPECIFICATIONS Peak...

Page 290: ...ire of the CDI 7 Faulty peak voltage adapter 8 Faulty ignition pulse generator Measure the peak voltage 9 Faulty CDI in case when above No 1 8 are normal Peak voltage is normal but no spark jumps at t...

Page 291: ...ster TOOL Imrie diagnostic tester model 625 or Peak voltage adaptor 07HG J 0020100 With commercially available digital multimeter Impedance 10 M DCV minimum PEAK VOLTAGE ADAPTER KNOWN GOOD SPARK PLUG...

Page 292: ...bes to prevent electric shock IGNITION PULSE GENERATOR PEAK VOLTAGE Check the cylinder compression and make sure the spark plug is installed correctly in the cylinder head Remove the fuel tank page 2...

Page 293: ...one measured at the ignition pulse generator is normal the wire harness has an open or short circuit or loose connection If both peak voltages are abnormal follow the checks described in the troublesh...

Page 294: ...nstallation is in the reverse order of removal CDI CAPACITIVE DISCHARGE IGNITION SYSTEM INSPECTION Remove the fuel tank page 2 3 Disconnect the CDI 6P White connector Turn the ignition switch ON Check...

Page 295: ...ng the throttle grip CONNECTION Yellow Red Yellow Blue RESISTANCE 4 0 6 0 20 C 68 F Item Resistance Full close to full open Decreases Full open to full close Increases Item Resistance Full close to fu...

Page 296: ...0 4 kgf m 2 5 lbf ft Connect the throttle position sensor 3P Grey connectors Check the throttle operation page 3 5 Install the left side cover page 2 3 INITIALIZING PROCEDURE After replacing the CDI o...

Page 297: ...onnector and body ground CONNECTION Blue Yellow wire terminal Body ground Connect the positive terminal first and then the negative terminal Turn the ignition switch ON the tachometer should indicate...

Page 298: ...each step within 8 seconds Turn the throttle grip to the fully closed position the tachometer should indicate the 5 000 r min When the tachometer indicates soon about 7 000 r min the initializing pro...

Page 299: ...MEMO...

Page 300: ...SWITCHES COMPONENT LOCATION SYSTEM DIAGRAM SPARK PLUG IGNITION SWITCH NEUTRAL SWITCH REAR BRAKE LIGHT SWITCH HEADLIGHT SWITCH PASSING RELAY WINKER RELAY FRONT BRAKE LIGHT SWITCH HORN COMBINATION METER...

Page 301: ...bulb with your bare hands clean it with a cloth moistened with alcohol to prevent its early failure Be sure to install the dust cover after replacing the bulb Keep all flammable materials away from t...

Page 302: ...the new bulb while aligning the tabs of the bulb with the slots of the headlight unit Hook the bulb retainer into the headlight unit groove Install the dust cover with the mark facing up Connect the...

Page 303: ...LED UNIT REPLACEMENT Remove the LED brake tail light by following the disassembly procedure as given in chapter 2 page 2 5 Replace the LED tail light assy with a new one under warranty As per conditio...

Page 304: ...ect the turn signal light connector Remove the turn signal mounting nut and stay Remove the turn signal light assy Install the turn signal light by aligning the cut out of the turn signal light with c...

Page 305: ...e Measure the voltage between the Black wire terminal and body ground There should be battery voltage with the combination switch ON If there is no voltage check the fuse 15 Amp and open circuit in Bl...

Page 306: ...rews 3 nos and washers Remove the combination meter assembly from front cowl stay Installation is in the reverse order of removal DISASSEMBLY Remove the screws 6 nos meter lower cover and upper cover...

Page 307: ...16P CONNECTOR DUST COVER Turn the ignition switch to ON and measure the voltage between the Black and Green wire terminals at the harness side CONNECTION Black Green STANDARD 9 0 5 V If there is no v...

Page 308: ...Start the engine and measure the tachometer input peak voltage PEAK VOLTAGE 10 5 V minimum If the peak voltage is normal replace the combination meter assembly page 17 5 PEAK VOLTAGE ADAPTOR If the m...

Page 309: ...the display reaches the desired hour 5 After pressing the select button minute digit will start flashing To reset the tripmeter press and hold the reset button for more than 3 seconds when the display...

Page 310: ...e time adjustment mode the clock will be reset The clock will be reset at 1 00 hrs if the battery is disconnected COMBINATION SWITCH INSPECTION Remove the front cowl page 2 2 Disconnect the combinatio...

Page 311: ...the terminals in each switch position according to the table 3P BLACK CONNECTORS 3P BLACK CONNECTORS 6P WHITE CONNECTORS LIGHTING SWITCH HORN DIMMER SWITCH TURN SIGNAL SWITCH PASSING SWITCH DIMMER SW...

Page 312: ...d be continuity with the brake pedal squeezed and there should be no continuity when the brake pedal is released Continuity Green Yellow Black NEUTRAL SWITCH INSPECTION Remove the left side cover page...

Page 313: ...m if necessary Bending the drive piece by forcing or crushing the contact point will cause poor electricity connection Install the spring and drive piece O RING NEUTRAL SWITCH DRIVE PIECE SPRING DRIVE...

Page 314: ...el Level Sensor Inspection Remove the fuel tank page 2 3 Disconnect the fuel level sensor 3P White connector Measure the resistance at the fuel level sensor terminals Yellow White Green STANDARD 4 100...

Page 315: ...e continuity NO Open circuit in Yellow White or Green wire YES Check the Speedometer REMOVAL INSTALLATION Drain the fuel from the fuel tank into the approved gasoline container Remove the fuel tank pa...

Page 316: ...sconnect the wire connectors from the horn Remove the bolt and horn Installation is in the reverse order of removal WIRE CONNECTORS ADJUSTING SCREW PASSING RELAY REMOVAL INSTALLATION Remove the front...

Page 317: ...items in good condition NO Replace or repair the malfunction part s YES GO TO STEP 2 REMOVAL INSTALLATION Remove the front cowl page 2 5 Disconnect the turn signal relay 2P White connector from the r...

Page 318: ...ve the left side cover page 2 3 Unhook the fuse box by pulling the fuse box lock outside from the battery box Installation is in the reverse order of removal Don t pull the fuse box lock with excessiv...

Page 319: ...MEMO...

Page 320: ...ELECTRIC STARTER SYSTEM ELECTRIC STARTER COMPONENT SYSTEM DIAGRAM STARTER MOTOR NEUTRAL DIODE IGNITION SWITCH CLUTCH SWITCH HANDLEBAR SWITCH STARTER SWITCH STARTER RELAY NEUTRAL SWITCH VEHICLE SPEED S...

Page 321: ...ral switch page 17 12 Clutch switch page 18 5 TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK 1 Fuse Inspection Check for blown main fuse or sub fuse Is the fuse blown YES Replace the fuse NO GO TO STEP 2...

Page 322: ...ine normal YES GO TO STEP 9 NO Faulty ignition switch page 17 10 Faulty starter switch page 18 3 Loose or poor contact of the related connector terminal Open circuit in the wire harness 9 Starter Rela...

Page 323: ...3 Shift the transmission into neutral Turn the ignition switch to ON and push the starter switch The coil is normal if the starter relay switch clicks If you don t hear the switch click inspect the r...

Page 324: ...tarter relay switch cable terminals Connect the fully charged 12V battery to the starter relay switch connector terminals A and B terminals There should be continuity between the cable terminals while...

Page 325: ...tinuity with the clutch lever applied and there should be no continuity when the clutch lever is released RIGHT HANDLEBAR SWITCHES Remove the front cowl page 2 2 Disconnect the right handlebar switch...

Page 326: ...MEMO...

Page 327: ...19 WIRING DIAGRAM 19 1 STANDARD AND CBS CB HORNET 160R 19 1...

Page 328: ...lty spark plug Loose or disconnected ignition system wires Broken or shorted spark plug wire Faulty ignition coil Faulty ignition pulse generator Faulty ignition switch Faulty CDI Faulty regulator rec...

Page 329: ...4 4 Engine Performance Inspection Accelerate lightly Does the engine speed increase NO Fuel air mixture too rich or lean Clogged air cleaner Restricted fuel flow Clogged muffler Clogged fuel fill cap...

Page 330: ...S Valve clearance too small Valve stuck open Worn cylinder and piston rings Leaking damaged cylinder head gasket Seized valve Improper valve timing NO GO TO STEP 10 10 Carburetor Inspection Check carb...

Page 331: ...carburetor insulator bands Damaged insulator NO GO TO STEP 3 3 Spark Test Perform spark test Is there weak or no spark YES Faulty spark plug Fouled spark plug Loose or disconnected ignition system wir...

Page 332: ...GO TO STEP 4 4 Valve Timing Inspection Check the valve timing Is the valve timing correct NO Cam sprocket not installed properly YES GO TO STEP 5 5 Valve Spring Inspection Check the valve springs Are...

Page 333: ...MEMO...

Page 334: ...M 18 0 IGNITION SYSTEM 16 0 LIGHTS METER SWITCHES 17 0 LUBRICATION SYSTEM 4 0 CRANKCASE ASSEMBLY 11 17 CRANKCASE BREATHER 3 7 CRANKSHAFT 11 8 CRANKCASE SEPARATION 11 4 CYLINDER COMPRESSION 7 4 CYLINDE...

Page 335: ...CYLINDER HEAD VALVES 1 5 CYLINDER PISTON 1 6 ELECTRIC STARTER 1 9 FRONT WHEEL SUSPENSION STEERING 1 7 FUEL SYSTEM 1 5 HYDRAULIC BRAKE 1 8 IGNITION SYSTEM 1 9 LIGHTS METER SWITCHES 1 9 LUBRICATION SYST...

Page 336: ...Honda Motor Co Ltd 2015 82K43P0 Published by Honda Motorcycle Scooter India Pvt Ltd...

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