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Honda CR125R 1992-1997, Service Manual

The Honda CR125R 1992-1997 Service Manual is a comprehensive guide for owners and enthusiasts of this iconic motocross bike. This manual provides detailed instructions and diagrams for maintenance, repair, and troubleshooting. Download this essential manual for free at manualshive.com and unleash the full potential of your Honda CR125R.

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Summary of Contents for CR125R 1992-1997

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Page 3: ...tion of components t hat may be required to perform service described in the following sections Sections 4 through 15 describe parts of the motorcycle grouped according to location Find the section you want on this page then turn to the table of contentS on the first page of the section If you are not familiar with the Honda Power Port system refer to Section 16 Technical Feature If you don t know...

Page 4: ...rease NlGI 2 or equivalent Use molybdenum disulfide grease containing more than 3 molvbdenum disulfide NLGI 2 or equivalent Example Molvkotee BR 2 plus manufactured by Dow Corning U S A M 2 manufactured by Mitsubishi Oil J pan Use molybdenum disulfide paste containing more than 40 molybdenum disulfide NLGI 2 or equivalent Example Molykotee G n Paste manufactured bV Dow Corning U S A Honda Moly 60 ...

Page 5: ...ne and ex haust system have cooled before handling these parts 1 General Information Tools 1 14 Lubrication Seal Points 1 16 Cable Harness Routing 1 1 B Optional Parts List 1 21 Used EnginelTransmission Oil Used engine oil lor transmission oil in two strokes may cause skin cancer if repeatedly left in contact with the skin fOf prolonged periods Although this is unlikely un less you handle used oil...

Page 6: ...ock absorber could lead to an explosion that could result in serious injury Failure to release the pressure from a shock absorber before disposing of it may lead to a possible explosion and serious injury if it is heated or pierced To prevent the possibility of an explosion release the nitro gen by pressing the valve core Then remove the valve stem from the shock absorber reservoir Dispose of the ...

Page 7: ...n 1 The frame serial number is stamped on the right side Ii head NUMBER i on the left side of the carburetor body General Information 2 ENGINE NUMBER 2 The engine senal number IS stamped on the side of the crankcase 1 3 r ...

Page 8: ...ogen filled reservoir Front tire size 80 100 2 1 51M Rear tire size 110 100 1859M Tire brand Dunlop Front K990 Rear K990 J Front brake Hydraulic single disc Front brake swept area 306 cm2 47 4 in2 Rear brake Hydraulic single disc Rear brake swept 8 ea 303 cm2 47 0 in2 Caster angle 26 00 Trail length 08 mm 14 3 in Fuel tank capacity 7 5 liters 12 0 US gal 1 6 Imp gal Engine Bore and stroke 54 x 54 ...

Page 9: ...system Wire operated Transmission 6 speeds constant mesh Primary reduction 3 150 1 63 20 Final reduction 3 923 1 51 13 Gear ratio 1st 2 357 1 33 14 Gear ratio 2nd 1 867 1 28 15 Gear ratio 3rd 1 526 1 28 19 Gear ratio 4th 1 285 1 27 21 Gear ratio 5th 1 130 1 25 23 Gear ratio 6th 1 000 1 24 24 Gearshift pattern Left foot operated return system l N 2 3 4 5 6 Electrical Ignition system COl 1 5 ...

Page 10: ...ow jet Standard Jet needle clip position Standard Air screw initial opening Float level Throttle grip free play PJ15E 172 58 3rd groove 2 turns out 16 0 0 63 3 5 1 8 1 4 r Cooling System r Recommended coolant Coolant capacity Radiator cap relief pressure Use only a high quality ethylene glycol based anti freeze containing corrosion inhibitors specifically recommended for use in aluminum engines A ...

Page 11: ...2 125 0 2 1253 53 968 53 976 2 1247 2 12501 IN mark toward the intake side 53 933 53 940 12 1233 2 1236 53 925 53 93312 1230 2 1233 20 mm 0 79 in from the bottom 15 002 15 008 0 5906 0 5909 0 035 0 050 0 0014 0 0020 14 994 15 000 0 5903 0 5906 0 002 0 0 14 0 0001 0 0006 0 045 0 080 0 0018 0 0031 0 40 0 55 0 016 0 022 Mark facing up 19 002 1 9 014 0 748 1 0 7486 0 4 0 8 0 02 0 03 0 022 0 034 0 0009...

Page 12: ... 20 000 0 7866 0 7874 24 979 25 000 0 9834 0 9843 20 000 20 02 1 0 7874 0 7782 17 000 17 018 10 6693 0 6700 22 000 22 021 0 B661 0 8670 0 040 0 082 0 0016 0 0032 0 020 0 062 0 0008 0 0024 0 020 0 062 W 0008 0 0024 19 959 19 980 0 7858 0 7866 21 959 21 980 10 8645 0 86541 16 983 16 994 0 6686 0 6691 0 020 0 062 0 0008 0 0024 0 006 0 035 0 0002 0 0014 0 020 0 062 0 0008 0 00241 4 93 5 00 0 194 0 197...

Page 13: ...djuster standard position Rebound damping adjuster standard position Max Min 1 Max Min 512 0 20 16 With the tapered end facing up Pro Honda Suspension Fluid SS 7M or equivalent 106 4 2 92 3 6 123 4 81 571 cc 19 31 US oz 20 04 Imp oz 585 cc 19 78 US oz 20 53 Imp oz 553 cc 18 70 US oz 19 41 Imp oz o kg cm2 5 clicks out from full in 12 clicks out from full in 504 5 19 86 0 2 0 01 Rear Suspension Shoc...

Page 14: ...d NIPPONOENSO Optional CHAMPION Optional NGKI Optional NtPPONOENSO primary at 20 C 68 F fSecondary with plug cap Secondary without plug cap Alternator exciter coil resistance At 20 C 68 F Pulse generator resistance At 20 C 68 F 1 10 Standard DOT 4 3 0 O 12 1 000 11 043 10 4330 0 4347 10 957 10 984 10 4314 0 4324 27 000 27 050 1 0630 1 0650 26 900 26 950 11 0590 1 061 0 DOT 4 4 5 0 18 12 700 12 743...

Page 15: ... hose clamp 0 8 0 08 0 6 Water pump cover bolt 6 1 0 1211 2 9 Water pump impeller 1 0 12 1 2 9 Coolant drain bolt 6 1 0 1011 0 7 Fuel System Carburetor insulator 6 1 0 12 n 2 9 Cylinder Head CylinderIH P P Cylinder head nut 8 1 25 2712 7 20 Cylinder mounting nut 8 1 25 2712 7 201 Cylinder stud bolt 8 1 25 12 1 2 9 Note 1 H P P valve guide bolt 6 1 0 9 0 9 6 5 H P P pinion holder socket bolt 5 x O ...

Page 16: ...ing stem adjusting nut 26 x 1 5 2 0 2 1 4 Fork tube pinch bolt ITop B x 1 25 2212 2 16 IBottom 8 x 1 25 22 2 2 16 Fork cap 48 x 1 5 3513 5 25 Fork cap lock nut 12 x 1 0 2212 2 16 Fork center bolt 27 x 1 0 80 8 0 58 Fork protector mounting bolt 6 x 1 0 13 1 3 9 5 Note 1 Brake lever pivot nut 6 x 1 0 6 0 6 4 3 Clutch lever pivot bolt 6 x 1 0 2 0 2 1 5 Clutch lever pivot lock nut 6 x 1 0 10 1 0 7 Clu...

Page 17: ... disc guard mounting screw 6 x 1 0 710 7 5 11 Note 1 Front brake caliper mounting bolt 8 1 25 3113 1 221 Note 1 Brake caliper pad pin 10 x 1 0 1811 8 13 Brake caliper pad pin plug 10 x 1 0 2 5 0 25 1 8 Brake caliper pin bolt 8 x 1 25 13 1 3 9 Note 1 Brake caliper pin bolt A Front 8 1 25 23 2 3 17 Note 1 Read 12 1 25 28 2 8 201 Note 1 Rear brake master cylinder mounting bolt 6 x 1 0 15 1 5 11 Note ...

Page 18: ...ssembly tool set 07965 1660101 assembly tool shaft 07965 1660200 assembly collar 07965 1660301 Bearing remover 17 mm 07936 3710300 or equivalent commercially available in U S A remover handle 07936 37 10100 remover weight 07741 0010201 or 07936 3710200 Thread adaptor 07965 KA30000 Front SuspenSion Steering Searing race remover 07953 4250002 or 07953 MJ1000A Steering stem socket 079 16 KA50100 Oil ...

Page 19: ...ench body 07710 0010401 Bearing retainer wrench B 07710 0010200 Bearing remover head 17 mm 07746 0050500 Bearing remover shah 07746 0050100 Bearing remover head 20 mm 07746 0050600 Attachment 32 x 35 mm 07746 0010100 Attachment 42 x 47 mm 07746 0010300 Pilot 17 mm 07746 0040400 Pilot 20 mm 07746 0040500 Front SuspensionfSteering Driver 07749 0010000 Attachment 42 x 47 mm 07746 0010300 Attachment 5...

Page 20: ...rter spindle gear sliding surface Governor steel balls H P P valve pinion sliding surface H P P valve drive shaft sliding surface H P P valve lever and pinion sliding surface H P P valve cylinder head upper cover surface Water pump gear teeth Each bearings Honda GN4 4 Stroke Oil or Governor bearing equivalent Governor shaft sliding surface Oil seal lips Multi purpose grease Water seal lips Cylinde...

Page 21: ...ge bearings Swingarm bearings Brake pedal pivot sliding surface Dust seal lips Brake lever pivot bolt sliding surface Silicone grease Brake lever adjusting bolt Fork protector mounting bolt Honda Anaerobic Thread Lock or Front brake caliper mounting bolt equivalent Brake disc mounting bolt Rear brake hose guide screw Rear brake disc guard mounting screw Brake caliper pin bolt Brake caliper pin bol...

Page 22: ...e Harness Routing 11 THROTTLE CABLE 2 WIRE BANDS 4 CLUTCH CABLE FRO T BRAKE HOSE 5 ENGINE STOP A rrTC 12 WIRE 1 18 THROTTLE CABLE CLUTCH CABLE CARBIJRE TO R RIGHT I VENT TUBE 9 CARBURETOR OVERFLOW TUBE CRANKCASE BREATHER TUBE ...

Page 23: ...General Information 2 IGNITION COIL 1 GROUND POINT_ CLUTCH CABLE 151 SPSRK r c y WIRE PRIMARY WIRE 6 ENGINE STOP BU rTON CABLE 11 REAR BRAKE RESERVOIR HOSE 10 REAR BR KE HOSE 1 19 ...

Page 24: ...DIATOR OVERFLOW TUBE 13 CABLE CLAMP 12 CLUTCH CABLE 1 20 2 RADIATOR UPPER JOINT TUBE 31 SPARK PLUG WIRE m 4 THROTTLE CABLE 5 CLUTCH CABLE B CARBURETOR RIGHT AIR VENT TUBE 19 CARBURETOR OVERFLOW TUBE 0 CRANKCASE BREATHER 11 CARBURETOR LEFT AIR VENT TUBE ...

Page 25: ...ER TAPER ANGLE 5 TA ANG LE F iwq A 2 5 mm S 0 0 Jet needle clip standard position 3rd groove Slow jet Standard 58 Optional 52 62 in increments of 2 or 3 Frame Item Remarks Maintenance Work stand Provides support in an upright position Air pressure gauge For checking tire air pressure Pin spanner Pin spanner A x 2 For shock absorber spring installed length preload adjustment two reQuired Seat Stand...

Page 26: ...4 kg mm 19 04 Ib in 4 coils m Standard 0 36 kg mm 20 16 Ib inl 3 coils m Heavy 0 38 kglmm 21 28 Ib in 1 coil Rear Shock Absorber Spring Type Spring Rate Identification Mark light 4 4 kglmm 246 4 Ib in Brown paint Standard 4 8 kg mm 1268 8 Ibtin White paint Heavy 5 2 kglmm 1291 2 tb in Red paint 1 22 ...

Page 27: ...he working area or where gasoline is stored can cause a fire or explosion This section covers removal and installation of the frame body panels fuel tank and exhaust system Always replace the exhaust chamber gasket when removing the exhaust chamber f rom the engine Always inspect the exhaust system for leaks alter installation Torque Values Seat mounting bolt Sub frame mounting bolt Troubleshootin...

Page 28: ...e fuel tank Also align the seat side prongs with the sub frame tabs Install and tighten the seat mounting bolts Torque 22 N m 12 2 kg m 16 ft lbl Side Covers Removal In5 tallation Remove the seat Remove the flange bolt and side cover Installation is in the reverse order of removal 2 2 0 BOLT EACH SIDE 2 SEAT 1 BOLT EACH SIDE 2 SEAT 121 S I D COV PRONGS l ...

Page 29: ... radiator shroud bolts and washers 2 RADI HIOR S IR UIJ Remove the fuel tank mounting bolts unhook the band and re MOUNTING BOLT WASHEA EACH SIDE move the fuel tank Remove the bolts and radiator shroud Installation is in the reverse order of removal NOTE After installation make sure there are no fuel leaks InSlall the breather tube into the stem nut as shown Perform fuel filter maintenance See Own...

Page 30: ...age 2 21 Remove the silencer case mounting bolt silencer case and joint rubber Check the joint rubber for wear or damage Replace the joint rubber if necessary Check the glass wool packing maintenance see page 3 14 Installation is in the reverse order of removal Expansion Chamber Removal Installation Remove the seat and right side cover page 2 2 Loosen the chamber bracket bolts Unhook and remove th...

Page 31: ...osely attach the upper and lower ends of the sub frame to the main frame while connecting the expansion chamber to the Silencer pipe with the joint rubber and the air filter connecting tube to the carburetor Tighten the screw on the connecting tube clamp Tighten the sub frame mounting bolts and nut to the specified torque Torque 27 N m 12 7 kg m 20 ft lb Frame Body Panels Exhaust System 2 TUBE CLA...

Page 32: ...MEMO ...

Page 33: ...ipple Rim lock 3 6 Brake System 3 6 Clutch System 3 8 Control Cables 3 8 Expansion Chamber Silencer 3 8 Suspension 3 9 Swingarm Shock Linkage 3 10 Nuts Bolts Fasteners 3 11 WheelsfTires 3 11 Steering Head Bearings Standard I At draining 0 57 liter O 60 US qt 0 50 Imp qt At disassembly 0 65 liter 0 69 US qt 0 57 Imp qt Honda GN4 4 Stroke Oil or equivalent API Service Classification SF or SG SAE 10W...

Page 34: ...ss wool packing replacement Right side cover 4 Caliper Pad wear 14 Wheel IDamage runout corrosion loose spokes 151 Tire Wear damage air pressure 16 Brake Hose Fitting oil leaks 17 Shock Linkage Damage lubrication 18 Brake Pedal Air in system height adjustment 3 2 5 Throttle Grip Operation 6 Radiator Leakage damage 7 Master Cylinder Oil level fluid replacement 8 Brake Lever Air in system free play ...

Page 35: ...l tank 17 Piston Piston Ring Wear damage Seat fuel lank 18 Transmission Oil Drain Bolt Oil change Maintenance 5 Cylinder Head Decarbonizing Seat fuel tank 6 Throttle Cable Damage lubrication 7 Swingarm Damage lubrication B Air Filter Contamination clogging Seat 9 Driven Sprocket Wear damage loose nuts 10 Drive Chain Slider Wear damage 1 1 Drive Chain Wear damage lubrication 12 Drive Chain Roller W...

Page 36: ... Oil R Drive Chain I L R Drive Chain Sliders 1 Drive Chain Rollers 1 Drive Sprocket 1 Driven Sprocket 1 Brake Fluid Note 2 1 Brake Pads Wear 1 Brake System 1 Clutch System 1 Control Cables I L Expansion Chamber Silencer 1 Suspension 1 Swingarm Shock Linkage L Fork Oil Note 3 R Nuts Bolts Fasteners 1 WheelsfTires 1 Steering Head Bearings 1 Refer to page 3 6 3 6 3 8 3 8 3 8 7 3 8 5 7 8 7 8 9 3 9 3 1...

Page 37: ...5 16 in Front rear brake pad Wear Minimum thickness 1 mm 0 04 in Sub frame mounting bolts Fatigue or damage Chain guide plate Wear or damage Side cover Damage Front number plate Damage Front rear fender Damage Clutch lever holder Play or damage Brake lever Play or damage Handlebar Bent or cracked Throttle hOUSing Damage Grip rubber Damage Gearshift pedal Damage Brake pedal Damage Chain adjuster bo...

Page 38: ...ing Slide the rubber protector down and loosen the lock nut Tighten the lock nut Major adjustments are made at the carburetor end of the cable Turn in the adjuster at the throttle grip in all the way Pull the carburetor rubber cap up loosen the lock nut and turn the adjuster Tighten the lock nut and reinstall the rubber cap Check that the throttle grip turns smoothly and returns com pletely in all...

Page 39: ...l or an equivalent Apply air filter oil to the entire surface of each element and rub it with both hands to saturate the element with oil Gently squeeze out excess oil Apply thin coat of Honda white lithium grease or an equivalent to the sealing surface Assemble the air filter element and holder and put the air filter retaining bolt through the assembly Install the assembly into the air filter cas...

Page 40: ...rk Plug Gap 0 5 0 6 mm 0 0 20 0 024 in Radiator Coolant Check the coolant level with the engine cold it should be up to the filler neck Add coolant as required page 5 3 Cooling System Remove the radiator shrouds Inspect the hoses for cracks and deterioration Use low pressure water and a soft brush to rinse off any dirt that may be stuck on the radiator core Replace jf necessary Check the tight nes...

Page 41: ...g to ensure consistent performance and maximum service life of both transmission and clutch components Warm up the engine before draining the oil This ensures complete and rapid draining If the engine must be running to do some work make sure the ar8a Is well ventilated Never run the engine in an enclosed area The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness ...

Page 42: ... cleaned and lubricated each outing Stop the engine and shift the transmission into neutral Place a work stand or box under the engine Carefully remove the master link clip with pliers Remove the master link and the drive chain Clean the drive chain in high flash point solvent and wipe it dry Inspect the chain for possible wear or damage replace any chain that has damaged roliers or loose fitting ...

Page 43: ... nut Drive Chain Sliders Inspect the drive chain slider for excessive wear Service Limit 5 mm 0 2 in from upper surface Check the chain guide and chain guide slider for wear or damage Replace the chain guide if it is damaged or worn Replace the chain guide slider if the chain is visible through t he wear inspection window Drive Chain Rollers Inspect the drive chain rollers for excessive wear or bi...

Page 44: ...N Brake fluid wit damage painted plastic or rubber parts Place a rag over these parts whenever the system is serviced 00 not mix different types of fluid as they are not com patible Front Remove the cover diaphragm and plate and fill the reservoir with DOT 3 or 4 brake fluid to the upper level mark Check the entire system for leak Rear Remove the cap diaphragm and plate and fill the reservoir with...

Page 45: ...the grip After adjustment hold the adjuster and tighten the lock nut to the specified torque Torque 6 N m 0 6 kg m 4 3 ft Ibl If the brake lever free play exceeds 20 mm 0 8 in there is air in the system that must be bled Refer to page 13 3 for brake system bleeding NOTE Apply grease to the contact faces of the adjuster bolt and piston Brake Pedal Height Adjust the brake pedal to the desired height...

Page 46: ...er Tighten the lock nut If proper free play cannot be obtained using both procedures or the clutch slips during the test ride disassemble and inspect the clutch See section 9 Control Cables Remove the throttle cable end cover Disconnect the throttle cable upper end from the throttle grip Disconnect the clutch cable upper end from the clutch lever Thoroughly lubricate the cable pivot points with a ...

Page 47: ...age the glass wool packing Apply muffler sealant high temperature silicone in the area shown Inser the inner pipe and packing into the silencer case and align the bolt holes Install and tighten the silencer case bolts Wipe off the excess sealant Suspension Front Check the action of the fork by compressing the suspension several times Check the entire fork assembly for signs of leaks damage or loos...

Page 48: ... fork is fully extended with the front tire off the ground Loosen the pressure release screws fully then tighten them se curely Rear Bounce the rear of the motorcycle up and down to check for proper operation Push and pull the rear wheel side ways inalignment with the axle to check for play in the swingarm Remove the sub frame page 2 5 Check the damper rod is not bent or oil leaking from the seals...

Page 49: ...s and related seals each 3 races or about 7 5 hours of running page 12 23 through 12 29 Lubricate and reassemble Nuts Bolts Fasteners Check that all chassis nuts and bolts are tightened to their COf rect torque values Check that all cotter pins and clips are in place and properly secured Wheels Tires Check the lire for cuts embedded objects or excessive wear Tire Pressure Front and Rear 100 kPa 11...

Page 50: ...d and check that the fork rotates freely Check that the control cables do not interfere with fork rotation If the handlebar moves unevenly binds or has vertical move ment adjust the steering head bearings by turning the steering head adjusting nut page 24 3 18 ...

Page 51: ...MEMO ...

Page 52: ...Fuel System 4 0 ...

Page 53: ...the suitable container under the carburetor remove the plug and drain the carburetor After removing the carburetor wrap the intake port of the engine with a shop towel or cover it with piece of tape to pre vent any foreign material from dropping into the engine NOTE If the vehicle is to be stored lor more than one month drain the float bowl Fuel left in the float bowl may cause clogged jets result...

Page 54: ...n malfunction Low compression Rich mixture Lean mixture Air filter clogged Intake air leak Fuel contaminated 4 2 Lean Mixture Fuel jets clogged Fuel tank breather tube clogged Fuel filter clogged Fuel line restricted Float valve faulty Float level too low Air vent tube clogged Advanced ignition timing Intake air leak Worn crankshaft seal lalternator side Rich Mixture Choke valve in ON position Flo...

Page 55: ...n of a slightly rich mixture and an idle speed that s set too high may lead to plug fouting when shutting off for tight sections of the track Reduce idle speed of this occurs Major Carburetor Adjustment For Temperature and Altitude Check that the carburetor is adjusted to the standard settings NOTE For the following recommendations to be accurate you must use these standard settings as a baseline ...

Page 56: ...correction factors will get you very close to the ideal jetting However because of differences in pressure and humidity you may need to fine tune the carburetor for race day conditions Just off idle Engine blubbers rich turn out the air screw 4 turn Engine surges Oeanl turn in the air screw 1 4 turn NOTE The minimum to maximum range of air screw adjustments is 1 to 3 turns out If you must exceed t...

Page 57: ...the track has a very long straightaway steep climbs a high percentage of sand or the track is muddy Go leaner on the main jet by one number when it is very humid or raining or it is very hot above 45 C 1113 FI Jet Needles Under normal circumstances the standard jet needle can be adjusted to fit most situations However a peculiar condition may require replacement of the standard jet needle But befo...

Page 58: ... and connecting tube clamp screw and turn the carburetor to the left Remove the carburetor top and pull out the throttle valve Remove the carburetor Disassembly Remove the throttle cable from the cable holder Remove the throttle valve spring from the carburetor top Push down on the cable holder and turn it 90 degree Remove the cable holder set collar spring and jet needle Remove the following Floa...

Page 59: ...s until it seats lightly Air screw spring washer O ring Unscrew the lock nut and remove the choke idle speed knob Check the valve seat and needle for damage Carburetor Assembly Installation 3 SLOW JET 6 1 MAIN JET 2 BAFFLE PLATE 11 CHOKE IDLE SPEED KNOB 2 VALVE SEAT Assembly 1 CHOKE IDLE SPEED KNOB 4 FLOAT 11 3 SLOW JET 6 THROTTLE VALVE 2 AIR SCREW 5 MAIN JET Fuel System 4 AIR SCREW IIII 4 7 ...

Page 60: ...w jet Baffle plate Main jet Install the float valve float and float pin Measure the float level Specification page 6 Install a new float chamber a ring Install the float chamber and tighten the screws securely NOTE Install the air vent tube guide as shown Install the carburetor tubes as shown 4 8 KNOB 13ISLO 5 MAIN JET 4 BAFFLE PLATE 121 T 111 AT VALVE 111 I VENT TUBES 2 FUEL TUBE ...

Page 61: ...cable holder Push the cable holder in and turn it 90 degrees Assemble the throttle cable carburetor top rubber cap and throttle valve spring Installation Looselv install the carburetor Move the carburetor to the left and slide the throttle valve into the carburetor body Fuel System 3 THROTTLE VALVE 1 NEEDLE CLIP 2 JET NEEDLE I 14 CABLE HOLDER 2 JET NEEDLE L ___ __ 5 SET COLLAR 3ICABLE 2 r kl 1 SET...

Page 62: ... replace the reed valve as an assembly Disassembling or bending the reed stopper can cause engine trouble Installation Check the insulator and O ring for damage and replace them if necessary Reed valve installation is in the reverse order of removal NOTE After installation check for secondary air leaks around the reed cage and insulator Air Filter Case Removal Remove the sub frame page 2 5 Remove ...

Page 63: ...Installation Air filter case installation is in the reverse order of removal 4 CONNECTING TUBE CLAMP It AIR FILTEA CASE 3 MOUNTING BOLT Fuel System 2 AIR FtLTER ELEMENT 4 11 ...

Page 64: ...Cooling System o 10 l O 7 1 0 12 1 2 9 0 121 1 2 9 5 0 ...

Page 65: ...ine in the frame Specifications Item Specifications Recommended coolant Use only a high quality ethylene glycol based anti freeze containing Coolant capacity Radiator cap relief pressure Torque Values Water pump impeller Coolant drain bolt Water pump cover bolt Tools Special Water seal driver Bearing remover set 12 mm remover handle assembly remover weight Bearing remover 7 mm Bearing driver 7 mm ...

Page 66: ...ystem Troubleshooting Engine Temperature Too High Faulty radiator cap Insufficient coolant Passages blocked in radiator hoses or water jacket 5 2 Coolant Leaks Faulty water pump oil seal Deteriorated water seal ...

Page 67: ...A 1 I CYLINDER DRAIN Check the drain bolt sealing washers are in good condition then Install and tighten the drain bolts to the specified torque Torque 10 N m 1 0 kg m 7 ft lbl Add the recommended coolant mixture to the radiator filler I RA DL TOR CAP neck page 1 61 Capacity 750 cc 125 4 US oz 26 3 Imp azl lean the machine approximatelv 20 right and left several times to bleed air trapped In the c...

Page 68: ...tor to cylinder head radiator to water pump Remove the radiator mounting bolts and radiator Installation Installation is essentially the reverse order of removal Add the recommend coolant mixture up to the filler neck and bleed the air page 5 31 After installation check the radiator and radiator hoses for leak NOTE Note the direction of the hose clamps 5 4 111 RADIATOR HOSE 12 ou _ 11 RADIATOR RAD...

Page 69: ... gasket Impeller and plain washer Right crankcase cover page 9 2 Water pump shaft from the right crankcase cover Check the water pump shaft and gear to be sure they are not bent or damaged Bearing Replacemen Right Crankcase Cover Side Remove the bearing using the special tools EJ Bearing remover set 12 mm Bearing remover handle Remover weight 07936 1660001 Not available in U S A 07936 1660101 0774...

Page 70: ...40200 Remove the bearing using the special tool as shown Searing remover 7 mm 07931 KA30000 Drive in the new bearing into the right crankcase 7 00 1 Bearing driver 7 mm 07946 KA30100 Water Seal Replacement Remove the water pump bearing from the right crankcase cover page 5 5 Remove the oil seal Drive out the worn or damaged water seal from the right crankcase cover 5 6 ...

Page 71: ...ter seal lips Instatl a new bearing and oil seal Assembly Instatl the following Water pump shaft gear into the right crankcase cover Right crankcase cover page 9 2 Install the plain washer and impeller on the water pump shaft then tighten the impeller to the specified torque Torque 12 N m 11 2 kg m 9 ft Ib 1211 2 9 Cooling System sToo l 1 WATER SEAL DRIVER 10 1 0 7 C12 1 2 9 14 WATER PUMP SHAFT CR...

Page 72: ...ate Install the new outer gasket onto the water pump cover Install the water pump cover and lighten the mounting bolts to the specified torque Torque 12 N m 11 2 kg m 9 ft Ib Add the recommend coolant mixture up to the filler neck and bleed the air page 5 3 5 8 1 PUMP COVER ...

Page 73: ...MEMO ...

Page 74: ...Engine Removal Installation 0 90 9 0 0 2712 7 201 fij 0 4 0 4 2 9 6 0 ...

Page 75: ... Crankshaft transmission Section 10 Shift forks shift drum Section 10 Specifications Item Engine dry weight Recommended transmission oil Transmission oil capacity Coolant capacity Torque Values Engine mounting bolt Engine hanger plate bolt Swingarm pivot bolt Sub frame mounting bolt Alternator cover screw Specifications 7 6 kg 138 8 Ibs Honda GN4 4 Stroke Oil or equivalent SAE 10 W 40 API service ...

Page 76: ...e clamp Alternator wire connector Pulse generator wire connector Drive chain Spark plug cap Radiator hoses from cylinder head Remove the alternator cover and disconnect the clutch cable Remove the following Engine upper bracket bolts and hanger bracket Engine mounting bolts Swingarm pivot bolt NOTE Note the direction of the engine mounting bolts and swingarm pivot bolt for reassembly page 6 0 6 2 ...

Page 77: ... kg m 20 ft Ib NOTE Route the wires and cables properly page 1 14 through 1 18 After installing the engine perform the follOwing inspections and adjustments Transmission oil level Throttle grip free play adjustment Rear brake pedal height Drive chain slack Clutch lever free play Check that exhaust gas is not leaking past the expansion chamber connection Engine Removal Installation 3 BRACKET 3 CLUT...

Page 78: ...Cylinder Head Cylinder Piston C27 2 7 20 C 27 2 7 20 C2 5 0 25 1 8 C 12 1 2 9 fill Gasket 7 0 ...

Page 79: ...system decarbonizing disassembly and assembly The cylinders and pistons are select fitted Use new cylinders and pistons with the same 1 0 and 0 0 codes when replac ing the cylinder andlor piston Specifications Unit mm jin Item Specification Service Limit Cylinder head warpage 0 05 W 002 Cylinder 1 0 A 53 976 53 983 j2 1250 2 1253 54 013 2 1265 B 53 968 53 976 2 1247 2 1250 54 006 12 12621 Taper 0 ...

Page 80: ...Ibl g N m 10 9 kg m 6 5 ft Ibl 5 5 N m 0 55 kg m 4 0 ft Ibl Compression Too Low Hard Starting Or Poor Performance At Low Speed Abnormal Noise Piston Worn or cracked piston Worn cylinder and piston Blown cylinder head gasket Loose spark plug Worn stuck or broken piston ring Worn or damaged cylinder and piston Faulty reed valve Worn crankshaft seals Compression Too High Overheating Or Knocking Exces...

Page 81: ... bolts and hanger brackets Remove the five cylinder head flange nuts Remove the cylinder head CAUTION To avoid warping the cylinder head use a crisscross pat tern to loosen each nut about 1 4 turn then remove the nuts Remove the cylinder head gasket Inspection Clean the head gasket surface of any gasket material Remove the carbon deposits from the combustion chamber CAUTION Use care not to scratch...

Page 82: ... head on the cylinder Install the five cylinder head flange nuts and tighten to the specified torque Torque 27 N m 2 7 kg m 20 ft lb NOTE Tighten the nuts in a crisscross pattern in 2 or 3 steps Install the engine upper hanger brackets and bolts NOTE Route the clutch cable between the hanger plates Tighten the mounting bolts to the specified torque Torque 27 N m 2 7 kg m 20 ft lbl Install the fuel...

Page 83: ...e clamp screws at the cylinder and remove the hose Remove the two right radiator mounting bolts and loosen the upper mounting bolt as shown loosen the radiator lower joint hose clamp screws and remove the lower joint hose then swing the right radiator forward Remove the following Bolts and screw Right exhaust valve cover Gasket and grommet H P P valve rod NOTE Be careful not to drop the B clip and...

Page 84: ... the H P P valve system page 8 4 Piston Removal CAUTION Do not let the clip fall into the crankcase Always support the piston w hen pressing out the pin Remove the following Piston pin clip Piston pin Piston NOTE Under racing condition the piston and piston ring should be replaced according to the maintenance schedule See page 3 4 Spread the piston ring and remove by ritting it up at a point just ...

Page 85: ...k or equivalent Tighten the studs to the specified torque Torque 12 N m 1 2 kg m 9 ft Ib If necessary remove the bolts and water hose joint from the cylinder Discard the O ring and install a new one Install the water hose joint in the reverse order of removal Measure the bore diameter at four positions top middle Al middle B and the bottom With the exception of the bottom measure both X and Y axis...

Page 86: ... 003 in Remove the carbon deposits from the piston ring groove Measure the piston ring to groove clearance Service limit 0 09 mm 0 004 In Measure the piston pin bore 1 0 Service limit 15 022 mm 0 5914 in Check the piston pin for wear and excessive discoloration Measure the piston pin 0 0 Service limit 14 980 mm 0 5898 in Insert the piston ring into the cylinder Use the piston to push the ring squa...

Page 87: ...the excessive play If it feels loose measure the connect ing rod small end I D Service limit 19 022 mm 0 7489 in Piston Installation Clean the piston ring groove Lubricate the piston ring and piston ring groove with clean 2 stroke oil Install the piston ring on the piston with the mark facing up locate the piston end gap on the pin in the ring groove Clean off any gasket material from the cylinder...

Page 88: ...e CAUTION Use new piston pin clips Never reuse old clips Do not let the piston pin clips fall into the crankcase Cylinder Installation Align the ring end gap with the piston ring pin Place the cylinder base gasket and dowel pins on the crankcase lubricate the piston with clean 2 stroke engine oil and slip the cylinder over the piston while compressing the piston ring CAUTION Do not rotate the cyli...

Page 89: ...nk cover Install the grommet and link cover Install the cover using the five mounting bolts and one screw Tighten the bolts and screw to the specified torque Torque Bolts 12 N m 11 2 kg m 9 ft Ib Screw 2 5 N m 0 25 kg m 1 8 ft Ib Connect the radiator lower joint hose and tighten the hose clamp screws Install the right radiator bolts and tighten the all mounting bolts Cylinder Head Cylinder Piston ...

Page 90: ... Install the following Expansion chamber page 2 4 Cylinder head page 7 3 Fuel tank and seat page 2 3 Pour the recommended coolant mixture into the radiator up to the correct level page 5 3 Check for the following Compression leaks Abnormal engine noise Secondary air leak Coolant leaks 7 12 CLAMP ...

Page 91: ...MEMO ...

Page 92: ...H P P Honda Power Port 0 12 1 2 9 0 27 2 7 20 0 10 1 0 0 10 1 0 7 8 0 ...

Page 93: ...pecial Bearing remover 7 mm Bearing driver 7 mm Common Driver Attachment 24 x 26 mm Troubleshooting Poor Performance At l ow Speed Exhaust valve does not close fully Improper adjustment Faulty governor Broken pinion lever spring Bent valve rod 27 N m 2 7 kg m 20 ft lb 27 N m 2 7 kg m 20 ft lb 12 N m 1 2 kg m 9 ft lb Apply a locking agent 27 N m 2 7 kg m 20 ft lb 10 N m 1 0 kg m 7 fHb 12 N m 1 2 kg...

Page 94: ...ck that the al e is fully colsed In this position the E ctip of the al e should be in contact with the al e guide NOTE Before each race be sure that the val e is fully closed If there is any clearance between the E clip and val e guide disassemble and decarbonize the al es See Decarbonizing page 8 5 Adjustment Loosen the both side pinion shaft holder socket bolts and turn the pinion lever to conta...

Page 95: ...ing on the valve guide pinion lever Torque 5 5 N m 10 55 kg m 4 0 ft Ib Loosen right socket bolt and torque the socket bolt using same procedure as for the left side Check the clearance between the end of the pinion lever retu rn spring and pinion lever as shown Clearance 0 5 2 0 mm 0 02 0 08 in H P P Honda Power Port 2 PINION LEVER __ 0 1 SOCKET BOLT 2 PINION LEVER LEFT SIDE RIGHT SIDE 1 SPRING E...

Page 96: ...bolts and screw to the specified torque Torque Bolts 12 N m 11 2 kg m 9 ft Ibl Screw 2 5 N m 0 25 kg m 1 8 ft Ibl Disassembly Remove the following Right and left exhaust valve cover Gaskets grommet Pinion holder socket bolt Cylinder upper cover Pinion holder Pull the exhaust valve out and remove the valve lever from the exhaust valve Remove the pinion shaft assembly from the cylinder 8 4 1 DRIVE S...

Page 97: ...n gear valve lever pinion lever spring and pi nion shaft for wear or damage Check the following item Sliding surface of valve Sliding surface of valve guide Groove of attaching E clip Pinion shaft Assembly Apply recommended 2 stroke engine oil to the valve guide and valve Install the valve guides into the cylinder Install the lock plate aligning its tab with the groove of the valve guide 1 LOCKING...

Page 98: ... PLATE o o o o x x OJ VALVE GUIDE The valve levers have the identification marks for right side R 1 LEFT VALVE LEVER 2 LEFT PINION GEAR and left side L The left pinion gear has an identification groove on its teeth NOTE Install the valve lever with the identification mark facing up Assemble the valve lever pinion lever spring pinion gear and valve lever as shown 8 6 r 5 RIGHT VALVE LEVER 4 PINION ...

Page 99: ...the cylinder upper cover gaskets and covers then tighten the bolts Adjust the exhaust valve page 8 2 Exhaust Valve Drive Shaft Disassemblv Remove the B clip and setting collar then remove the valve rod from the drive shaft lever Check the smooth operation of the drive shaft If the operation is not smooth remove the drive shaft as follow H P P Honda Power Port 11 EXHAUST VALVE 3 PINION SHAFT y 2 VA...

Page 100: ...he each bearing inner race with your finger The bearing should turn smoothly and quietly Also check that the bearing outer race has not been spinning in its seat Discard the bearing if the race does not turn smoothly and quietiV or if they have been spinning in its seal Drive Shaft Bearing Replacement Remove the bearing using the special tools Is 7 000 I Bearing remover 1 mm 01931 KA30000 8 8 13 I...

Page 101: ...t Ibl Install the exhaust valve link and cover lpage 7 111 GovernorlValve Linkage Removal Remove the following Exhaust valve cover and link page 7 6 Right crankcase cover page 9 2 Remove the pinion gear by removing the retaining screw washer and grommet Remove the governor assembly by pulling it off the shaft Inspection Inspect the pinion gear teeth for excessive wear or damage Inspect the governo...

Page 102: ...r 7 mm 07946 KA30100 Right Crankcase Cover Side Remove the bearing by thermally expanding the case Slowly and uniformly heat the case with a heat gun industrial dryer To avoid burns wear insulated gloves when handing the heated parts CAUTION Using 8 torch to heat the case may cause warping Drive in the new bearing into the right crankcase I_Tooc Driver Attachment 24 II 26 mm 8 10 07749 0010000 077...

Page 103: ... center of valve rod joint lines up with the edge of the cutout Install the washer and selting screw Tighten the screw to the specified torque Torque 9 N m 10 9 kg m 6 5 ft Ib Install the grommet with its tab facing outside as shown Install the following Right crankcase cover page 9 2 Exhaust valve rod and cover page 7 11 H P P Honda Power Port 2 GROMMET 1 r G f om t 4 W SHER 3 RETAINING SCREW 1 J...

Page 104: ...Clutch Kickstarter Gearshift L Inkage C 27 2 7 20 9 0 12 1 2 9 o 1 0 7 ...

Page 105: ... Clutch center holder Troubleshooting Hard To Shift Incorrect clutch adjustment Loose stopper plate bolt Damaged stopper plate and pin Damaged gearshift spindle Transmission Jumps Out Of Gear Worn shift drum stopper arm Weak or broken shift arm return spring Loose stopper plate bolt Gearshift Pedal Will Not Return Standard 10 20 3 8 3 4 39 4 1 55 2 92 3 08 0 114 0 121 10 N m 1 0 kg m 7 ft Ib 60 N ...

Page 106: ...ght exhaust valve cover and exhaust valve rod page 7 4 Disconnect the radiator hoses from the right crankcase cover Remove the crankcase cover bolts and right crankcase cover Remove the gasket and dowel pins Installation Place a new gasket on the right crankcase cover and cut the end of the gasket flush with the end as shown Install the dowel pins and new gasket 9 2 m LINK ROD C I i I 111 U If 111...

Page 107: ...e 2 4 Brake pedal page 13 14 Install the kickstarter pedal Clean the kickstarter pedal bolt thread and apply Honda Anaerobic Thread Lock or equivalent Tighten the bolt to the specified torque Torque 27 N m 2 7 kg m 20 ft Ib Fill the transmission with recommended oil to the correct level Add the radiator coolant mixture Into the radiator up to the cor rect level page 5 31 Check and adjust the reaf ...

Page 108: ...d clutch lifter rod NOTE To avoid losing the steel ball be careful when you remove the clutch lifter Remove the seven clutch friction discs and six clutch plates Bend the tabs of the lock washer away from the lock nut Hold the clutch center with the clutch center holder Remove the lock nut lock washer and thrust washer Clutch center holder 07724 0050001 Remove the tool and clutch center 9 4 l CLUT...

Page 109: ...4 6 Remove the return spring and clutch lifter lever from the left crankcase Inspect the following Clutch lifter lever for damage Oil seal for wear or damage Clutch Lifter lever Installation Coat the clutch lifter lever with grease then install the clutch lifter lever and return spring Installation is in the reverse order of removal After installation check the following Ignition timing page 14 8 ...

Page 110: ...ST WASH R 5 NEEDLE BEARING 3 THRUST W S IER 1 CLUTCH DISC 1151 SPFIING PLATE Install the clutch outer guide and needle bearing onto the mainshaft Install the clutch outer and thrust washer 9 6 6 GUIDE eLlJl eH OUTER 8 CLUTCH CENTER ROD STEEL BALL 14 PRESSURE PLATE ...

Page 111: ... specified torque while holding the clutch center with the clutch center holder 1 7 00 1 Clutch center holder 07724 0050001 Torque 60 N m 16 0 kg m 43 ft Ibl Bend the tabs of the lock washer up against the clutch center nut Coat the clutch plates with clean transmission oiL Install the seven friction discs and six clutch plates alternately starting with a disc Clutch Kickstarter Gearshift Linkage ...

Page 112: ...e clutch lifter Install the clutch pressure plate Install the five springs and spring bolts Tighten the bolts in a crisscross pattern in 2 or 3 steps Torque 10 N m 11 0 kg m 7 ft Ibl Check that the clutch cover a ring is in good condition and in stall the clutch cover Install and tighten the clutch cover bolts Torque 10 N m 11 0 kg m 7 ft Ib Install the brake pedal page 13 14 9 8 3 CLUTCH LIFTER ...

Page 113: ...y removing the following Thrust washer and collar Return spring Ratchet spring and starter ratchet Snap ring thrust washers and pinion gear Assembly Clutch Kickstarter Gearshift Linkage 2 COLLAR 3 RETURN SPRING OF 9 KJCKSTARTER SPINDLE 8 PINION GEAR 5 STARTER RATCHET __________ lJ 1 THRUST WASHERS 0tJ J 7 THRUST WASHER 6 SNAP RING 4 RATCHET SPRING 141 T RATCHET 3 THRUST WASHERS 2 COLLAR 5 RATCHET ...

Page 114: ...nion gear Install the thrust washer and snap ring NOTE Seat the snap ring in the groove of the spindle with the sharp edge facing towards the outside Align the punch marks and install the starter ratchet Install the ratchet spring and thrust washer Install the kickstarter spindle and hook the return spring end to the crankcase 9 10 121 SPfliNe HOOK 3 SNAP I _ V 7 r 1 111 PINI O GEAR 141 GROO 2 THR...

Page 115: ...2 Clutch page 9 31 Remove the gearshift pedal and pull the gearshift spindle out Remove the shifter collar Remove the guide plate bolts the remove the guide plate and drum shifter as an assembly NOTE Do not let the ratchet pawls fall when removing the guide plate and drum shifter Remove the bolt stopper arm and return spring Remove the shift drum center pin and shift drum center Clutch Kickstarter...

Page 116: ...per arm and tighten the stopper arm bolt to the specified torque Torque 12 N m 11 2 kg m 9 ft lb Check the stopper arm for proper operation Install the dowel pin into the shift drum Move the stopper arm out of the way using a screwdriver Align the shift drum center hole with the dowel pin and slip it into place Install and tighten the shift drum center pin Torque 22 N m 12 2 kg m 16 ft Ib 9 12 4 R...

Page 117: ...hten the guide plate bolts Install the shifter collar onto the drum shi fter Assemble and install t he gearshift spindle NOTE Do not forget to install the trust washer onto the gear shift spindle Check that the shift drum turns smoothly Install the gearshift pedal Install the following Clutch page 9 6 Right crankcase cover page 9 2 Clutch Kickstarter Gearshift Linkage 121 ARSf IF T SPINDLE 9 13 ...

Page 118: ...h ft Transmission Crankcase Cranks a o10 1 0 71 10 0 30 3 0 221 10 1 0 7 10 1 0 7 I 0 27 2 7 20 Gasket O rings ...

Page 119: ...5 M6 22 959 22 980 0 9039 0 9047 0 0 Cl 19 979 20 000 0 7866 0 7874 C2 C3 C4 24 979 25 000 0 9834 0 9843 Transmission gear bushing M5 20 000 20 021 0 7874 0 7782 1 0 Cl 17 000 17 018 0 6693 0 6700 C2 C4 22 000 22 02 1 0 8661 0 8670 Gear to bushing clearance M5 M6 0 040 0 082 0 0016 0 0032 Cl 0 020 0 062 0 0008 0 0024 C2 C4 0 020 0 062 0 0008 0 0024 Mainshaft 0 0 at M5 gear 19 959 19 980 0 7858 0 7...

Page 120: ...orn or bent shift forks Broken shift linkage return spring 10 2 45 N m 14 5 kg m 33 ft lbl 27 N m 12 7 kg m 20 ft Ibl 10 N m 11 0 kg m 7 It lb Apply a locking agent 10 N m 11 0 kg m 7 ft Ib 07937 4300000 07631 0010000 or equivalent commercially available in U S A 07965 1660100 Not available in U S A or 07965 16601 01 07965 1660200 07965 1660300 or 07965 1660301 07936 3710300 or equivalent commerci...

Page 121: ... cone spring washer and drive sprocket erankcase Crankshaft Transmission 2 SPROCKET GUARD Temporarily instal the clutch outer guide needle bearing and 2 GEAR H ILCIE clutch outer onto the mainshaft Insert the gear holder between the primary drive and driven gear Remove the primary drive gear bol t then remove the washer and drive gear Gear holder 07724 0010100 or Equivalent commerciallv available ...

Page 122: ...t plV the crankcase halves apart with a screwdriver s 7 00L I Crankcase puller Threaded adaptor 07937 4300000 07965 KA30000 Remove the gasket and dowel pins Transmission Disassembly Separate the crankcase halves page 0 3 Remove the shift fork shafts and shift forks Remove the shift drum Remove the mainshaft and countershaft assemblies as a set Disassemble the mainshaft and countershah Inspect the ...

Page 123: ...with the crankshaft remove the bearing using the bearing puller and discard the bearing 1 j 7 001 I UNIVERSAL BEARING PULLER Universal bearing puller 07631 0010000 or Equivalent commercially avaitable in U S A Crankcase Bearing Replacement Crankcase Bearing Oil Seal l ocations 1 CRANKSHAFT OIL SEAL 121 CRANKSHAFT BEARINGS RIGHT CRANKCASE SIDE 3 MAIN SHAFT BEARINGS 4 COUNTERSHAFT BEARINGS 9 CLUTCH ...

Page 124: ...Left Crankcase Remove the countershaft oil seal 07749 0010000 07749 0010400 Remove the set plates and the countershaft bearing Remove the mainshaft bearing using the following tools TOOL Bearing remover 17 mm Remover handle 07936 3710300 or Equivalent commercially available in U S A 07936 3710100 Remover weight 07741 0010201 or 07936 371 0200 Remove the shift drum bearing 10 6 DRIVER 1 MAINSHAFT B...

Page 125: ...and countershaft bearings Remove the shift drum bearing set pla tes and drive out the shift drum bearing Drive new bearings into the right crankcase using special tools Mainshaft bearing Driver Attachment 52 x 55 mm Pilot 25 mm Countershaft bearing Driver Attachment 37 x 40 mm Pilot 17 mm Shift drum bearing Driver Attachment 37 x 40 mm Pilot 25 mm 07749 0010000 07746 0010400 07746 0040600 07749 00...

Page 126: ...n 2 stroke oil of the recommended type Install the threaded adaptor onto the crankshaft Threaded adaptor 07965 KA30000 Install the crankshaft into the right crankcase using the special tool Crankcase assembly tool set Assembly sheft Assembly collar 07965 16601 00 or 07965 1660101 Not available in U S A 07965 1660200 07965 1660300 or 07965 1660301 Transmission Assembly Assemble the transmission 1 M...

Page 127: ...EA 7 C2 2ST 3 SPLINE WASHER 4 LOCK WASHEA 5 C3 SPLINE BUSHING Coat each gear with clean transmission oil and check for smooth movement Engage the mainshaft and countershaft gears and place the transmission assembly into the right crankcase Install the shift forks into the shifter gear grooves NOTE Install the shift forks with their marks facing toward the right crankcase n A MAAK 2 L MARK RIGHT Ii...

Page 128: ...kcase breather onto the left crankcase Place the left crankcase onto the right crankcase using the crankcase assembly tool Crankcase assembly tool set Assembly shaft Assembly collar 07965 1660100 or 07965 1660101 Not available in U S A 07965 1660200 07965 1660300 or 07965 1660301 Pack multi purpose grease into the cavity of the oil seal lips Press the oil seals into the crankcase using the crankca...

Page 129: ...ntershaft Install the drive sprocket onto the countershaft as described below and at right CAUTION Install the drive sprocket with its flat side facing the outside Install the cone washer with the OUTSIDE mark facing out Hold the drive sprocket with the universal holder and install and tighten the sprocket bolt to the specified torque Universal holder 07725 0030000 or Equivalent commercially avail...

Page 130: ... Attach the gear holder between the primary drive and driven gear 7 000 Gear holder 07724 0010100 or Equivalent commercially available in U S A Install and tighten the primary drive gear bolt to the specified torque Torque 45 N m 14 5 kg m 33 h lbJ Install the remaining parts in the reverse order of removal NOTE Refer to Service Information page 10 1 for installation of parts referenced 10 12 2 WA...

Page 131: ...MEMO ...

Page 132: ...Front Wheel Suspension Steering 22 2 2 161 C35 3 5 25 118 n 1 8 85 22 2 2 161 C 3 9 51 C20 12 0 14 31 13 1 22 87 18 7 63 C80 18 0 581 11 0 ...

Page 133: ...ormation Section 1 for details A box Or work stand is required to support the motorCVcle For optimum fork performance the fork should be completelv disassembled and cleaned after the first three hours of riding Thereafter it should be disassembled and cleaned on a regular basis to ensure maximum performance and service life from the internal partS Refer to the section 13 for brake system informati...

Page 134: ... 17 mm Bearing remover shaft Spanner C 5 8 x 6 1 mm 11 2 20 N m 2 0 kg m 16 ft Ibl 87 N m 8 7 kg m 63 ft Ib 20 N m 12 0 kg m 16 ft Ibl 3 8 N m 0 38 kg m 2 8 ft lbl 13 N m 11 3 kg m 9 5 ft lbl 22 N m 2 2 kg m 16 ft Ibl 10 N m 1 0 kg m 7 ft lbl 10 N m 1 0 kg m 7 ft Ibl 2 N m 0 20 kg m 1 5 ft lbl 10 N m 1 0 kg m 7 ft Ib 10 N m 11 0 kg m 7 ft Ib 1 5 N m 0 15 kg m 1 1 ft Ibl 1 5 N m 10 15 kg m 1 1 h Ib...

Page 135: ... swingarm pivot components Front Wheel Wobbling Bent rim Worn front wheel bearings Bent spokes Faulty tire Axle not tightened properly Front Wheel Suspension Steering Soft Suspension Insufficient fluid in fork Fork oil viscosity too thin Weak fork springs if free length is OK go to optional stiffer spring Hard Suspension Fork oil level too high too much aiD Fork oil viscosity too thick Fork tube s...

Page 136: ...t depress the brake lever after the front wheel is removed The caliper piston will move out and make reassembly difficult Disassembly Remove the following Left side collar Dust seal Brake disc bolts and disc Wheel hub cover Right side collar Oust seal If necessary remove the tire tube ri m band and the rim lock 11 4 1 AXLE AXLE BOLTS 1 I4IBRAKE DIS I II SEAL ...

Page 137: ... by hand and read the runout using a dial indicator Actual runout is 112 the total indicator reading Service limit Radial 2 0mm 0 08 in Axial 2 0 mm 0 08 in Check the spokes and tighten any that are loose Spoke nipple wrench 07JMA MR60 00 or Equivalent commercially available in U S A Torque 3 8 N m fO 38 kg m 2 8 ft Ibl Remove the wheel bearings and distance collar from the wheel hub Bearing remov...

Page 138: ...stance from the hub left end surface to the side of rim is 20 00 mm 0 787 in as shown Torque the spokes in 2 or 3 progressive steps Is l Spoke nipple w rench 07JMA MR60 100 or Equivalent commercially available in U S A Torque 3 8 N m O 38 kg m 2 8 ft Ibl Check the rim runout page 11 5 Install the rim lock rim band tube and tire Tighten the rim lock nut to the specified torque Torque 13 N m 11 3 kg...

Page 139: ...b with the minimum thickness and DRIVE markings facing out Clean and apply Honda Anaerobic Thread Lock or equivalent to the brake disc bolt threads Tighten the brake disc mounting bolts to the specified torque Torque 20 N m 12 0 kg m 14 ft Ib Pack the left dust seal tip with grease and install the left dust seat Install the left side collar Pack the right dust seal lip with grease and install the ...

Page 140: ...sert the axle from the right side Install and tighten the axle nut to the specified torque Torque 87 N m 8 7 kg m 63 ft tb Tighten the left axle pinch bolts Torque 20 N m 2 0 kg roo 14 ft Ibl With the front brake applied pump the front suspension up and down several times to seat the axle and check frOnt brake operation Be sure the fork legs are parallel then tighten the right axle pinch bolts to ...

Page 141: ...r around the center bolt before disassemble the fork CAUTION Be careful not to scratch the slider and not to damage the dust seal Install the oil level spacer on t he axle holder of the slider IsTooc l Fork slider spacer 07KMZ KZ30101 Hold the outer tube remove the fork cap from the outer tube and slide the outer lUbe down onto the slider spacer Hold the lock nut and remove the fork cap hom the da...

Page 142: ...and fork oil wilt leak from the slider Remove the lock nut and spring guide Pour out the fork oil Remove the distance collar rebound needle and spring from the damper rod Set the lower end iaxle holder of the slider in a vise with a piece of wood or soft jaws to avoid to damage CAUTION I 00 not over tighten the axle holder Loosen and remove the center bolt and sealing washer NOTE If the center bol...

Page 143: ...s are normal check the outer tube In Quick successive motions pull the slider and guide bushing out of the outer tube Carefully remove the slider bushing by prying the slot with a screwdriver until the bushing can be pulled off by hand CAUTION Do not damage the slider bushing especially the sliding surface To prevent loss of tension do not open the bushing more than necessary Remove the following ...

Page 144: ...ide bushings with a nylon brush and fOrk oil Center Bolt Check the center bolt lor damage Replace the O rings and sealing washer with a new one Fork Cap Rebound Adjuster Check that the O ring on the fork cap is in good condition Check that the rebound adjuster needle is not bent or damaged CAUTION If the needle is bent or damaged the rebound damping force will be impaired 11 12 OJ BUSHING 2 BACK U...

Page 145: ...TE Clean the disassembled parts thoroughlv with non flammable or high flash point solvent before assembly 2 SU DER 111 OAIMPE R t AIR RELEASE SCREW 31 FORK CAP 4 OUTER TUBE 2 O RING 1201 SPRING 19 LOCK NUT 1181 SPRING GUIOE C 17 DISTANCE COLLAR 16 FORK SPRING lSI REBOUND NEEDLE 14 VALVE SPRING 113 FORK DAMPER L I I I r Front Wheel Suspension Steering 3 OUTER TUBE 2 OIL LOCK VALVE 51 SUDER I s ___ ...

Page 146: ...ing Tape or tie the dust seal and stop ring so they won t gel in Ihe way Coat Ihe slider and guide bushings with recommended fork oil and install the slider into the outer tube Drive the guide bushing with the back up ring into the outer tube first using the special 1001 Drive the oil seal into outer tube using the special tool Oil seal driver Oil seal driver attachment 11 14 07KMD KZ30100 07NMD K...

Page 147: ...e tool 5 TOOl I Fork Slider spacer 07KMZ KZ30101 Install the fork damper Into the slider Hold the axle holder in a vise protected with a piece of wood or soft jaws CAUTION I Do not oV8nighten the axle holder Install the center bolt with a new sealing washer and tighten the boh to the specified torque Torque 80 N m 18 0 kg m 58 ft Ibl NOTE If the center bolt turns together with the fork damper temp...

Page 148: ...mended fork oil into the fork leg Bleed the air as follows 1 Extend the fork Co er the top of the outer tube with your hand and compress the fork slowly CAUTION The fork 011 will spill out of the oil hole in the slider Do not pull up the outer tube more than 250 mm 9 8 inl from the axle holder to eJttend the fork 2 With the damper rod fully pushed in add the recommended fork oil into the rod untit...

Page 149: ...123 mm level capacity 1 4 84 inl Slightly softer as it nears 553 cc full compression 19 410z1 For the detail of the oil level adjustment refer to Owner s Manual Attach a 60 mm 2 feet length of mechanic s wire to the lock nut on the damper rod Wipe off any excess oil from fork spring then install it over wire into the slider with tapered side facing up Pull the mechanic s wire up and hold the dampe...

Page 150: ... nut and tighten the fork cap to the specified torque Torque 22 N m 12 2 kg m 15 ft lb Temporarily install the lork cap in the outer tube Installation Install the fork leg Standard position Align the groove of the top bridge with the groove 9 mm lOA in below the top of the outer tube For alternate position see Owner s Manual Tighten the bottom bridge Torque 22 N m 2 2 kg m 16 ft lb 11 18 LOCK NUT ...

Page 151: ... to the specified torque Torque 13 N m 1 3 kg m 9 5 ft Ibl Clean and apply a Honda Anaerobic Thread Lock or equivalent to the caliper bracket bolt Install the caliper and tighten the bolt to the specified torque Torque 31 N m 3 1 kg m 22 ft Ibl InstaU the handlebar assembly page Install the front wheel page 11 81 Handlebar Removal 11 21 Disconnect the engine stop switch wire connectors Unhook the ...

Page 152: ...e screws Slide the rubber protector off and loosen the lock nut and adjuster 111 M ST ERCYUNDER SCREWS HOIJS G COVER Disconnect the throttle cable from the throttle grip by remov 1 THROTTLE CABLE ing the lock nut and adjuster Loosen the throttle housing mounting bolts and remove the _ throttle grip from the handlebar Remove the handlebar holder bolts upper holders and handlebar 11 20 12 3 THROTILE...

Page 153: ... the slit of the hOUSing with the punch mark on the handlebar Tighten the upper bolt first then the lower bolt Torque 10 N m 1 0 kg m 7 ft Ib Install the throttle housing cover and tighten the screws securely Torque 1 5 N m 0 15 kg m 1 1 ft Ibl Set the brake master cylinder on the handlebar Install the master cylinder holder with the UP mark up and align the end of the holder with the punch mark o...

Page 154: ...Attach the engine stop button wires to the handlebar using the wire bands Route the fuel cap breather tube Hook the number plate tab onto the handlebar Steering Stem Removal Remove the following Handlebar page 11 19 Front wheel page 11 4 Front fender mounting bolts and collar Front fender Brake hose guide Remove the steering stem nut and washer Remove the fork legs page 1 1 9 Remove the fork top b...

Page 155: ... roller bearing and steering 1 UPPER DUST UPPER BEARING stem from the head pipe Bearing Replacement Remove the lower laper roller bearing and dust seal from the steering stem NOTE Avoid damaging the steering stem threads temporarily install the stem nut Remove the upper and lower bearing outer races from the head pipe TOOl Ball race remover 07948 4630100 31 LOWER DUST SEAL III STEM NUT 2 LOWER BEA...

Page 156: ... roller bearings with grease Apply grease to the all bearing area Install the upper taper roiler bearing in the steering head pipe Slide the steering stem through the steering head pipe from the bottom Install the dust seal washer and steering head adjusting nut Tighten the steering head adjusting nut with the steering stem socket Is7 OOI I Steering stem socket Torque 2 N m 10 2 kg m 1 4 ft lb 077...

Page 157: ...e top bridge Install and tighten the stem nut to the specified torque Torque 118 N m 111 8 kg m 85 ft Ibl Recheck the steering stem adjustment before installing the removed parts Install the removed parts in the reverse order of removal Front Wheel Suspension Steering 11 25 ...

Page 158: ...Rear Who liS e uspenslon 0 12 11 2 9 12 0 0 63 6 3 46 0 2612 6 19 0 90 9 0 65 C22 12 2 16 0 63 6 3 46 0 6316 3 46 1 J 1 1 ...

Page 159: ...strength for these applications Also take note of the installatIon dIrection of these bolts sInce they must be installed correctly For optimum suspension performannce and linkage component service life the swingarm and shock linkage pivot bearings along with related seals and bushingsI should be disassembled cleaned inspected for wear and lubricated wlh multi purpose grease NLGI No 2 Imolybdenum d...

Page 160: ...g Oil leakage from damper unit Hard Suspension 95 N m 9 5 kg m 69 ft Ib 30 N m 3 0 kg m 24 ft Ib 45 N 4 5 kg m 33 ft Ib 43 N m 4 3 kg m 3 1 ft Ib 27 N 2 7 kg m 20 ft Ibl 20 N m 2 0 kg m 14 ft Ib 90 N m 9 0 kg m 65 ft Ibl 22 N m 2 2 kg m 16 ft Ibl 63 N m 6 3 kg m 46 It fbl 63 N m 6 3 kg m 46 ft Ibl 63 N m 6 3 kg m 46 ft Ibl 90 N m 9 0 kg m 65 it fbI 12 N m 1 2 kg m 9 ft Ib 07JMA MR60100 or equivale...

Page 161: ...eful not to damage the brake pads with the disc NOTE Do not depress the brake pedal after the rear wheel is removed The caliper piston will move out and make reassembly difficult Disassembly Remove the following Left side coliar Driven sprocket Dust seal Right side collar Brake disc Dust seal If necessary remove the tire tube rim band and the rim lock Inspection Axle Set the exle in V blocks and m...

Page 162: ...dicator Actual runout is 1 2 the total indicator reading Service Limit Radial 2 0 mm 0 08 Inl Axial 2 0 mm 0 08 in Check the spokes and tighten any that are loose IsTOOL Spoke nipple wrench 07JMA MR60100 or Equivalent commercially available in U S A Remove the bearing retainer using the special tools IsTOOL I Ratainer wrench B Retainer wrench body 07710 0010200 07710 0010401 Remove the wheel beari...

Page 163: ...g with new spokes Adjust the hub position so that the distance from the hub left end surface to the side of rim is 47 0 mm 11 85 in as shown Torque the spokes in 2 or 3 progressive steps 100 1 Spoke nipple wrench 07JMA MR60100 or Equivalent commercially available in U S A Torque 3 S N m 10 38 kg m 2 S ft lb Check the wheel runout Install the rim lock rim band tube and tire Tighten the rim lock nut...

Page 164: ...07749 0010000 07746 0010300 07746 0040500 Then drive the lett wheel bearings into the hub using same tools Apply grease to the bearing retainer and install it into the hub using the special tools Retainer wrench 8 Retainer w rench body 07710 0010200 07710 0010401 Peen the edge of the retainer as shown 12 6 2 LEFT WHEEL BEARINGS 1 DISTANCE COLLAR RElrA ER WRENCH B ...

Page 165: ...all the bolts washers and nuts and tighten the nuts to the specified torque Torque 33 N m 3 3 kg m 24 ft Ibl NOTE It is important to hold the bolts while tightening the nuts to achieve proper torque Pack the dust seal lip with grease and install the left dust seal _____ Install the left side co llar Installation Install the rear brake caliper by aligning the bracket with the slide rail on the swin...

Page 166: ...table gas can cause a fire or ellplosion resulting in serious injury The rear shock absorber contains nitrogen gas under high pressure Do not allow fire or heat near the shock absorber Before disposal of the shock absorber release the nitrogen by pressing the valve core Then remove the valve from the shock absorber Raise the rear w heel off the ground by placing the box or work stand under the eng...

Page 167: ... pressure before disassembly other wise the chamber cap will be under significant pressure and could cause reverse injury or death Wear protective clothing and adequate eye protection to protect against injury and prevent debris from getting in your eyes Point the valve away from you to prevent debris getting in your eyes Remove the valve core Put a suitable t ool on the chamber cap and push il in...

Page 168: ...ole then pull the damper rod all the way Install the valve core securely Remove the chamber cap and bladder following the procedure below Wrap a shop towel around the chamber cap 1 Compress the damper rod slowly to force the chamber cap out The chamber cap will be removed with hydraulic pressure so its force can be significant considering the air in the bladder Wear protective clothing and a face ...

Page 169: ...g to the groove of the reservoir securely Temporarily fill the reservoir with 7 1 psi 49 kPa of air slowly until the chamber cap seats against the stop ring Be sure the stop ring is seated in the ring groove all the way around or the chamber ca p can come apart when riding the motorcycle Then make sure that chamber cap face is equal height level with reservoir face If the chamber cap does not seat...

Page 170: ...pe or tie it to the bump rubber so it won t get in the way Push in the damper seal until you have good access to the stop ring You ll need two small screwdrivers to remove the stop ring The stop ring groove in the damper case is ramped towards the inside to give the stop ring a square shoulder on which to seat securely To remove the stop ring first push one end of the stop ring out of its groove t...

Page 171: ... with the sleeve collar Sleeve collar Slider guide attachment Damper Rod Disassembly CAUTION 07974 KA30201 07974 KA50101 To keep lint or dirt from getting onto damper rod parts do not wear gloves while working on the damper rod Be careful to grind the end nut so that the 0 0 of the rod end is about 10 mm O 04 in Be careful too not to over grind Unstake the damper rod end nut with a grinder as show...

Page 172: ...s to ensure correct reassembly Keep dust and abrasives away from all damper rod parts Thoroughly clean the valves in solvent and blow them dry with compressed air If they have been disassembled and separated Be careful not to get solvent on the O ring piston ring The valve arrangement and number of valves shown is typical Remove the compression valves washers and valve stopper Wrap the top threads...

Page 173: ... one Visually inspect the rod guide case metal If the metal is worn so that the copper surface appears replace the rod guide case with a new one Remove the O ring from the rod guide case and replace it with a new one Damper Rod Inspection Inspect the damper rod sliding surface for damage or distortion Rear WheeIfSuspension 2 MFTAL 1 REBOUND RUBBER 11 SEAL 2 ROD GUIDE CASE 11 O RING 8 mm W 3 in 8 m...

Page 174: ...ngement and number of valves may differ from those shown 1 I SPHERICAL BEARING 20 DAMPER CASE i t5 191BLADDER 18 LOCK NUT 0 171 ADJUSTING NUT 16 CHAMBER CAP 15 SPRING 141 REBOUND VALVES Hold the lower shock mount in a vise with soft jaws or a shop towel Clamp in a vise with soft jaws or use a shop towel around the lower mount Remove the burrs from the damper rod end with a file and COf rect the th...

Page 175: ...he damper rod NOTE The valve arrangement and number of valves shown is typical nstall the piston onto the damper rOd Install the rebound valves with its polished surface fac ing down Install the valve stopper NOTE Do not install the end washer except using the new damper rod Note the installation direction of the piston and valves Be careful not to bind the valves when installing the piston onto t...

Page 176: ...on Fluid 55 7 or equivalent Check the rod guide case by sliding it up and down fully to be sure there is no restriction Coat the damper case inner surface piston ring and O ring with Honda Suspension Fluid 55 7 01 equivalent and insert the damper rod assembly carefully Install the stop ring into the groove in the damper case NOTE After assembling check that the stop ring is seated in the groove of...

Page 177: ...ted against the stop ring by pulling the damper rod out all the way Remove the damper unit from the vise Postion the damper the damping adjuster hole facing up Turn the damper unit as shown to bleed the air from the reservoir completely NOTE When bleeding air from the reservoir be careful to hold the damper at the angles shown so the filler hole points p NOTE 1 Do not let oil flow out of the reser...

Page 178: ...the damper rod can lead to premature failure of the oil seal Check for oil leaks Release the 7_1 psi of air that was in the reservoir at precompression Fill the reservoir with 142 psi 981 kPa 10 0 kg cm2 of nitrogen gas The shock absorber is fitted w ith a gas filled reservoir Use only nitrogen gas to pressurize t he shock absorber The use of an unstable gas can cause a fire or explosion in seriou...

Page 179: ... rider weight and setting damping for riding conditions and rider skill Spherical Bearing Replacement Check the spherical bearing for wear or damage If it is worn or damaged it must be replaced Remove the upper collars and dust seals Assemble the following items for the bearing replacement Metal tubing for the base holder 1 0 26 5 mm over Metal tubing for the driver 0 0 23 x 20 mm length Flange bo...

Page 180: ...ot allow it to tilt Disassemble the bolt nut washer and tubes Install the new stop ring into the groove of the upper mount securely Assemble the items onto the upper mount as shown Tighten the bolt and nut to press the spherical bearing into the upper mount until it seats against the stop ring end Apply grease to the lip of the new dust seals and install them Install the collars 12 22 1 4 1 WASH R...

Page 181: ...oller Swingarm caps Shock absorber lower mounting bolt Shock arm bolt swingarm side Shock link bolt frame side Shock linkage assembly Disassemble the shock arm and shock link Rear Wheel Suspension 11 REI 1 ru mR LOWER MOUNTING BOLT 2 UPPER M lLH TINC BOLT NUT 4 SHOCK ARM 2 LOWER MC U TIf G BIJLT Remove the side collars pivot coliars dust seals and washers i 2 2 p vvomT CmU 14 liS E C O Li iL A RRS...

Page 182: ...Pack the new needle bearings with grease Carefully press the needle bearings into the shock link side pivot to 7 0 7 5 mm 0 28 0 30 in below the surface of the pivot on both side NOTE Install the bearings with the marks facing out IsTOOl Driver Attachment 24 x 26 mm Pilot 20 mm Shock Arm Spherical 8earing 07749 0010000 07946 0010700 07746 0040500 Remove the stop rings and press the spherical beari...

Page 183: ...E Install the bearings With the marks facing out Is 7 00L 1 Driver Attachment 24 II 26 mm Pilot 20 mm 07749 0010000 07946 0010700 07746 0040500 Apply multi purpose grease NLGI No 2 molybdenum disulfide additive to the shock linkage collars bearings and dust seal lips Install the washers dust seals pivot collars and side collars NOTE Make sure that the needle bearing rollers are in position before ...

Page 184: ...t Torque 43 N m 14 3 kg m 3 1 ft Ibl Install the lower chain guide roUer and tighten the bolt Torque 22 N m 12 2 kg m 16 ft Ibl Swingarm Removal Raise the rear wheel off the ground with a box or workstand under the engine Remove the following Rear wheel page 12 3 Shock linkage page 12 23 Brake pedal page 13 14 Remove the brake hose guide and brake hose Disconnect the carburetor tubes from the clam...

Page 185: ... the inside bearing into the swingarm pivot Is 7 00L 1 Needle bearing driver Oriver head 07946 MJ001 00 07946 KM40701 First carefully press the inner needle bearing then press in the outer bearing and bushing NOTE Install the bearings with the marks facing out Ism 1 Needle bearing driver Driver head Attachment 32 C 35 mm Pilot 22 mm 07946 MJOO 100 07946 KM40701 07746 0010100 07746 0041000 Rear Whe...

Page 186: ...UIDE Apply grease to the needle bearing and the inside of the dust seals and collars Install the drive chain guide and chain slider Installation Install the swingarm onto the frame and tighten the pivot nut to the specified torque Torque 90 N m 9 0 kg m 65 ft Ib 12 28 1 PIVOT COLLAR I 1 SWINGARM ...

Page 187: ...ube Route the brake hose and install the brake hose guide Install the following Shock linkage page 12 26 Rear wheel page 12 71 Rear brake pedal page 13 14 Drive chain Adjust the drive chain slack page 3 10 Rear Wheel Suspension 21 BRAKE PEDAL 12 29 ...

Page 188: ...Brake System 18 1 8 13 2 5 0 25 1 8 13 0 6 0 6 4 3 3513 5 251 18 1 8 13 26 2 6 19 10 1 0 7 10 1 0 7 15 1 5 11 Piston seals Dust seals S r D rings Sealin washers ...

Page 189: ...servoir Avoid spilling brake Iluid on painted plastic or rubber parts Place a rag or shop towel over these parts whenever the system is serviced CAUTION Spilling fluid on painted plastic or rubber pans will damage them Place a clean shop towel over these pans whenever the system is serviced KEEP OUT OF REACH OR CHILDREN Alwavs check the brake operation belore riding the motorcycle Specifications U...

Page 190: ... worm caliper piston Sticking worn master cylinder piston Contaminated master cylinder Bent brake lever 13 2 35 N m 13 5 kg m 25 fI lb 6 N m 0 6 kg m 4 3 ft Ibl 5 N m 0 5 kg m 3 6 ft lbl 10 N m 1 0 kg m 7 ft Ib 31 N m 3 1 kg m 22 ft lb Apply a locking agent 6 N m 10 6 kg m 4 3 ft Ibl 7 N m 0 7 kg m 5 1 ft lbl 15 N m 1 5 kg m 11 ft Ibl 23 N m 2 3 kg m 17 ft Ib Apply a locking agent 28 N m 12 8 kg m...

Page 191: ...r reuse the con taminated fluid which has been pumped out during brake bleeding because this will impair the efficiency of the brake system Front FiU the master cylinder reservoir with DOT 3 or DOT 4 brake fluid form a sealed container to the top of the casting ledge Rear FiU the reservoir to the upper level line with DOT 4 brake fluid from a sealed container Connect the Mityvac Brake Bleeder No 6...

Page 192: ... end of its travel Repeat step 1 and 2 until bubbles cease to appear in the lIuid at the end of the hose Tighten the bleed valve to the specified torque Torque 6 N m 0 6 kg m 4 3 ft Ibl Front Fill the master cylinder reservoir with DOT 3 or DOT 4 brake fluid form a sealed container to the top of the casting ledge Reinstall the diaphragm and master cylinder cover Tighten the screws securely Rear Fi...

Page 193: ... assure even disc pressure Remove the pad pin plug and loosen the pad pin Pull the pad pin out of the caliper Remove the brake pad Insert new right side pad and push the caliper piston to allow clearance for that installation of the left side new pad Install new left side pad Install the pad pin by pushing the pads against the caliper to depress the pad spring Tighten the pad pin to the specified ...

Page 194: ...bolt cover the end of the hose to prevent contamination Secure the hose to prevent fluid from leaking out Drain the front brake hydraulic system page 13 3 Remove the pivot nut bolt and brake lever Remove the oil bolt and disconnect the brake hose Remove the master cylinder holder and master cylinde r Disassembly Remove the piston boot snap ring and washer from the master cylinder body IsTOOL Snap ...

Page 195: ...nstall the washer snap ring and boot IS 7 000 I Snap ring pliers Installation 07914 3230001 or Equivalent commercially available in U S A Place the master cylinder on the handlebar and install the holder and two mounting bolts with holder s UP mark fac ing up Align the end of the holder with the punch mark on the handlebar Torque the upper bolt first then the lower bolt Torque 10 N m 1 0 kg m 7 ft...

Page 196: ... page 13 14 Remove the rear master cylinder mounting bolts and rear master cylinder from the frame Remove the snap ring and disconnect the reservoir hose joint hom the master cylinder Snap ring pliers Disassembly Remove the rubber boot 07914 3 230001 or Equivalent commercially available in U S A Remove the snap ring and push rod from the master cylinder body CAUTION Be aware that the push rod will...

Page 197: ...the master cylinder piston cylinder and spring as a set Clean the master cylinder with compressed air Dip the piston cups in clean brake fluid before assembly Install the spring and master piston together Install the push rod and washer into t he master cylinder Install the snap ring Snap ring pliers Install the rubber boot 07914 3230001 or Equivalent commercially available in U S A I Brake System...

Page 198: ...eyelet joint with the notch in the master cylinder first then tighten the bolt After installing the brake hose to the master cylinder make sure it does not interfere with the movement of the shock absorber Tighten the brake oil bolt to the specified torque Torque 35 N m 3 5 kg m 25 ft Ibl Fill the brake system with DOT 4 brake fluid from a sealed con tainer and bleed the system of air page 13 3 Fr...

Page 199: ...damage Replace if necessary Assembly Coat the new oil and piston seals with clean brake fluid and in stall them in the seal grooves of the caliper Lubricate the caliper cylinders and pistons with clean brake Iluid and install the pistons into the caliper cylinders with the closed end of the piston facing the pad side Apply silicone grease to the pivot boots and install them mak ing sure that they ...

Page 200: ... 13 51 Rear Brake Caliper Removal CAUTION Avoid spilling fluid on painted plastic or rubber parts Place a shop towel over these parts whenever the system is serviced Drain the rear brake fluid hom the hydraulic system Remove the rear wheel page 12 31 Remove the brake pads page 13 51 Place a clean container under the caliper and remove the brake hose bolt sealing washer and eyelet joint from the ca...

Page 201: ...e to the pivot bOOtS and Install them mak ing sure that they are seated in the caliper and bracket grooves properly Coat the caliper caliper and bracket pins with silicone grease Install the pad retainer on the caliper bracket Install the pad spring on the caliper Assemble the caliper and bracket Install the disc guard With two screws and tighten them to the specified torque Torque 7 N m 10 7 kg m...

Page 202: ... Installation Install the brake pedal and joint pin and secure them with a new cotter pin Apply grease to the sliding surface of the pivot bolt and dust seals Install the dust seals into the brake pedal pivot Install and tighten the pivot bolt to the specified torque Torque 26 N m 2 6 kg m 19 ft Ibl InSlall Ihe return spring 13 14 3 BRAKE PEDAL 1 2 DUST ...

Page 203: ...MEMO ...

Page 204: ...Ignition System Alternator 14 0 5 ALTEf NA TOR PULSE GENERATOR WIRE IGNITION COIL I COl UNIT 14f SPARK PLUG m ROTOR 55 5 5 40 ...

Page 205: ...elated to poorly connected or corroded connectors Check those connections before proceeding Use a spark plug of the conect heat range Using a spark plug with an incorrect heat range can damage the engine Aeplace the pulse generator exciter coil and stator base as a set Specifications hem Standard Spark plug Standard CHAMPION QN84 NGK BA9EG NIPPONDENSO W27ESA V Optional CHAMPION QNS9G NGK BA9EV NIP...

Page 206: ...oorly connected COl unit L ___S p k _ _ r Poorly connected COl unit connector Correct it and conduct the spark test again No spark Disconnect COl unit connector d check related circuit at the connector Measure resistance of the secondary coil page 14 4 Abnormal I Check components individually Compare result with the value measured in test above Normal I 14 2 Normal Abnormal Faulty ignition coil Fa...

Page 207: ...ulse generator If all are OK replace the COl unit and recheck Measure the data between the connector terminals using the following chart Item Terminals Ignition primary coli Black Yellow and Green Pulse generator Blue Yellow and Green White Alternator excitor coil White and Blue Engine stop button Black Yellow and Green Ignition System Alternator Standard 20oC 68 F 0 4 0 6 n 180 2800 40 140n Conti...

Page 208: ...Measure the primary coil resistance of the ignition coil Standard 0 4 0 6 fI 20oC 68 F Disconnect the spark plug cap from the plug and measure the secondary resistance between the plug cap and Green terminal Standard 14 23 kO 20 C 68 F If the resistance is out of range remove the spark plug cap and measure the secondary coil resistance between the spark plug wire and Green terminal Standard 10 16 ...

Page 209: ...he resistance between the Blue Yellow and Green White terminals 1f the resistance out of the specification replace the stator as an assembly Excitor Coil Inspection Remove the seat and fuel tank page 2 2 Disconnect the excitor 2P connector from the COl unit Measure the resistance between the Blue and White terminals Standard 20 140 20 0 C 68 F If the resistance out of the specification replace the...

Page 210: ...the flywheel with the universal holder and remove the nut Universal holder 07725 0030000 or Equivalent commercially available in U S A Remove the flywheel using the flywheel puller Flvw heel puller 07733 0010000 Remove the stator mounting bolts then remove the stator 14 6 ...

Page 211: ...e flywheel by hand after assembled Hold the flywheel with the universal holder and tighten the flywheel nut to the specified torque IsTOOt I Universal holder 07725 0030000 or Equivalent commercially available in U S A Torque 55 N m 5 5 kg m 40 ft fb Connect the alternator wire connectors Install the wire band Check the ignition timing Check the alternator cover rubber gasket is in good condition I...

Page 212: ...riginal index mark aligns between the F marks the engine is timed correctly Remove the testing equipment and reassemble the motorcycle But if the stator s original index mark does not align between the F marks scribe a temporary index mark on the stator base that will align between the F marks at 5 000 rpm Stop the engine and do the following NOTE This procedure is to be done after replacing the C...

Page 213: ...ex mark should now align between the F marks on the flywheel Repeat the proceeding steps if the ignition timing is not correct Remove the flywheel and stator front setting bolt Scribe a new index mark on the stator base and grind off the old index mark Ignition System Alternator 1 Make a new mark here 2 MOUNTING BOLT 3 SETTING SCREW 14 9 ...

Page 214: ...MEMO ...

Page 215: ... G W I I L ___ _ I II GIWBulY c_ i i r1l I I II I I J I I I L lSIIW oc r SIIW I L G G I __ J I BIIY c e J BIIY jf G Ln J 6 IGNITION COIL I m SPARK PLUG 5 PULSE COIL 3 EXCITER COIL 4 ALTERNATOR ENGINE STOP SWITCH BUTTON IG E Bu Blue OUT BI Black PUSHED IN C W White WIRE COLOR BIIW G G Green Y Yellow 1 T1 _ l CO C _ Q CO Q 3 ...

Page 216: ...MEMO ...

Page 217: ...ase so that the engine can produce its best possible power ou tput at any given engine speed At low engine speed the 6 Chaust valves are dosed for mild eJlhaust port timing As the engine speed increases the exhaust valves begin to open to give maximum efficiency At high engine speeds the exhaust valves are fully open 12 PINION GEAR 111 GOVERNOR 1 VALVE GUIDE LOCK BOLT 2 EXHAUST VALVE 10 PINION GEA...

Page 218: ...r The governor moves out ward toward the right crankcase cover and applies force on the pinion which in turn pulls down the drive shalt lever linkage As the drive shaft lever linkage moves it also allows the valve levers to turn which in turn moves the exhaust valves At the highest engine speeds the weights move to their fur thest extreme and the exhaust valves are fully open NOTE This H P P valve...

Page 219: ...ry 6 Start with choke on Possible Cause Clogged fuel tube or fuel strainer screen Sticking float valve Clogged fuel tank cap breather Faulty spark plug Fouled spark plug Faulty COl unit Broken or shorted spark plug wire Broken or shorted ignition coil Faulty pulse generator Faulty excitor coil Faulty engine stop switch Loose or disconnected ignition system w ires Stuck piston ring Worn cylinder an...

Page 220: ...oes Not I ncrease Carburetor choke is on Engine Speed Increase I Clogged air deaner Restricted fuel flow Clogged exhaust chamber Pinched fuel tank cap breather Excessive carbon build up on the exhaust valve 5 Check ignition timing Incorrect _ Faulty COl unit Faulty pulse generator Correct t 6 Test cylinder compression _ lncorrect Faulty reed valve using kickstarter Worn cylinder and piston ring Le...

Page 221: ...el mixture Possible Cause 1 Check ignition liming ______ Incorrect _ Improper ignition timing Faulty COl unit Faulty alternator Correct 2 Check carburetor air screw lncorrect __ See section 4 adjustment Correct 3 Check lot leaking intake pipe Leaking _ _ Loose insulator clamp No Leak Damaged insulator and reed valve gasket 4 Perform spark test _ Weak or Intermittent Spark Carbon or wet fouled spar...

Page 222: ... the fuel check for clogged jets Not Clogged I 5 Check H P P system Incorrect Correct 6 Install a large carburetor main jet Condition Worse Poor Handling Exhaust pipe does not open fully Jet size w rong rejet in t he opposite direction Possible Cause 1 If steering is heavy ________________________ Steering stem adjusting nut too tight Damaged steering head bearings 2 If either wheel is wobbling __...

Page 223: ...level 8 Front end hops over bumps in smooth turns oo Lower fork oil level Decrease fork compression damping Use softer fork spring 9 Rear end hops over bumps white accelerating _ Decrease shock spring preload Decrease shock spring compression damping 10 Rear end hops over bumps while braking 0 Decrease rebound damping 11 Rear end gets poor traction white accelerating away from a bumpy corner _ Dec...

Page 224: ...MEMO ...

Page 225: ...8 9 9 1 16 4 3 4 3 1 3 3 17 1 2 1 5 4 3 8 13 12 13 14 13 8 12 13 4 10 18 Index Right Crankcase Cover 9 2 Seat 2 2 Service Access Guide 3 2 Service Information Brake System 13 1 Clutch Kickstarter Gea rshift linkage 9 1 Cooling System 5 1 CrankcasefCrankshaftfTransmission 10 1 Cylinder HeadfCylinder Piston 7 1 Engine Remollal lnstallation 6 1 Frame Body Panels Exhaust System 2 1 Front Wheel Suspens...

Page 226: ...MEMO 12241 ...

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