Honda CRF50F 2004-2015 Service Manual Download

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Summary of Contents for CRF50F 2004-2015

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Page 3: ...s if YefY Oriportant To help OU makil inb med 08eiI 0nI we have pfOYlded safety messages and oth r inlormallon truOl ghou tho mat tlfll 01 course 1 not 1 f8ctlC81 Of possible to warn you a bout all tile hazards IISSOC1ated wolh servleir g musvehicle You must use your own good judgemafll You writ lind impo tanl safety inlorrnallOO in variety of Iorms inclUding Safllrv LaDe on the vetude Safety Mass...

Page 4: ...m disulfide grease containing more than 3 molybdenum disulfide NLGI 2 or equivalent Example MoIykoteil BA 2 plus manufactured by Dow Corning U S A Multi purpose M 2 manufactured by Mitsubishi Oil Japan Use molybdenum disulfide paste containing more than 40 molybdenum dIsulfide NLGI 2 or equivalent Example MolykoteQII G n Paste manufactured by Dow Corning U S A Honda Moly 60 U S A only Rocol ASP ma...

Page 5: ...N SPECiFiCATIONS 1 7 CLUTCH GEARSHIFT LINKAGE SPECIFICATIONS 1 7 ALTERNATOR CAM CHAIN TENSIONER SPECiFiCATIONS 1 7 CRANKSHAFT TRANSMISSION KICKSTARTER SPECIFICATIONS 1 8 FRONT WHEEL BRAKE SUSPENSION STEERING SPECIFICATIONS 1 8 REAR WHEEl BRAKE SUSPENSION SPECIFICATIONS 1 8 IGNITION SYSTEM SPECIFICATIONS 1 9 TORQUE VALUES 1 10 LUBRICATION SEAL POINTS 1 13 CABLE HARNESS ROUTING 1 14 EMISSION CONTROL...

Page 6: ... interchangeable with English fasteners 4 Install new gaskets O rings cotter pins and lock plates when reassembling 5 When tightening bolts or nuts begin with the larger diameter or inner bolt first Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified 6 Clean parts in cleaning solvent upon disassembly Lubricate any sliding surfaces before r...

Page 7: ...l number is stamped on the lower left side of the crankcase The model identification label U S A or the safety Certification label Canada is located on right side of the steering head The carburetor identification number is stamped on the right side of the carburetor body as shown GENERAL INFORMATION 1 3 ...

Page 8: ...le Emission Control Information label is attachad to the leh fronl fork U S A or both front forks Canada AFTER 07 EMISSION CONTROL INFORMATION LABEL Canada EMISSION CONTROL INFORMATION LABElIU 5A and Canada The color label is allached on the left side of the main frame When P ordering color coded parts always specify the deslgnaled color code 1 4 ...

Page 9: ...al 1 mm 0 04 in tift at 1 mm 0 04 in lift at mm 0 04 iollift at 1 mm 0 04 in Jift 2nd 3 d GENERAL INFORMATION mm 581 mm 22 9 in 774 mm 30 5 in 911 mm 35 9 in 548 mm 21 6 in 209 mm 8 2 in 146 mm 5 8 in 50 kg 110 Ibs Telescopic fork 87 mm 3 4 in Swingarm 70 mm 2 8 in Conventional type oil damper 2 50 1033J 2 50 1033J Front Rear C 183A Internal expanding shoe Internal expanding shoe 25 00 32 mm 1 3 i...

Page 10: ...ATION SYSTEM SPECIFICATIONS Canada or equivalent mOler oil API service classification SG or higher JASOT MA FUEL SYSTEM SPECIFICATIONS number PA42A 2rd groove from top CYLINDER HEADIVALVES SPECIFICATIONS valve guide I I 1 6 I I ...

Page 11: ...E UMIT I CLUTCH GEARSHIFT LINKAGE SPECIFICATIONS Clutch disc Ih d t l unil m in Clutch I ALTERNATOR CAM CHAIN TENSIONER SPECIFICATIONS Unit mm in n IT EM Ii STA fND A Ri1iD S ER V IC E L 1MWIT h C m h le nsTOner Push rod D D 11 985 12 000 OA71B 0 4724 11 94 0 470 __ Spring _f e e le g l h _ 1 11 3 4 381 100 3 9 1 7 ...

Page 12: ...um tire tread depth Cold tire pressure 125 kPa 1 25 kgf cm 18 psi Axle runout Wheel rim Io hub distance 25 1 0 to 0 04 Wheel rim runout Radial f Orive chain Axial Sizellink DID420MBKlfla Slack 15 25 9116 1 Brake Brake pedal free play 10 20 318 13 16 Brake drum I D 80 3 1 B ake lIning thickness 3 5 0 14 1 8 I I I Unit mm In t ERVICE LIMIT 3 0 0 12 0 20 O OO8 2 0 0 08 2 0 0 08 r 80 5 3 17 2 0 O OB ...

Page 13: ...GENERAL INFORMATION IGNITION SYSTEM SPECIFICATIONS 1 9 ...

Page 14: ...r 05 Oil drain bolt Valve adjuster hole cap Valve adjuster lock nut Cluten adjuster lock nut LUBRICATION ITEM Oil pump mounting screw Oil pump cover screw ENGINE REMOVAL INSTALLATION ITEM Drive sprocket fixing plate bolt CYLINDER HEAD VALVES ITEM Cylinder head cover nut cap nul Cylinder head right side cover bolt Cam sprocket bolt CYLINDER PISTON ITEM Cam d1ain guide roller pin bolt 1 10 O TY THRE...

Page 15: ...d pivot bolt 1 10 page 2 7 Muffler mounting bolt 1 8 26 2 7 20 Exhaust pipe protector bolt 3 6 15 1 5 11 Exhaust pipe cover screw 5 5 9 0 6 4 3 MAINTENANCE ITEM OTI THREAD TORQUE REMARKS DIA mml N m kgf m Ibf ftj Fuel valve mounting bolt 2 6 9 8 10 7 FUEl SYSTEM NEW ITEM OTI THREAD TORQUE REMARKS DIA mml N m kgf m Ibf ft Connectin boot band screw 1 to 0 1 0 7 ENGINE REMOVAl INSTALLATION ITEM OTI T...

Page 16: ...5 NOTE 3 Driven sprocket nut 4 8 32 3 3 24 NOTE 3 Rear brake arm nut 5 5 9 0 6 4 3 NOTE 4 Swingarm pivot nut 10 39 4 0 29 NOTE 2 3 Shock absorber mounting nul I 2 0 34 3 5 25 NOTE 3 Drive chain slider nut 6 12 1 2 9 NOTE 3 IGNITION SYSTEM r TH REA D TORauE ITEM Q lY DIA lmml N m kgf m Ibf f t l t R E M A R K S 1 nition coil mounting bolt 1 5 I 5 9 0 6 4 3 _ 1 12 ...

Page 17: ...rface Kickstarter spindle sliding surface Other rotating and sliding area Each bearing rotating area Each oil seal lips Each O ring FRAME pour 1 2cm3 Fill with 1 2 cmJ page 10 7 Fill with 0_5 cm l O C A JI O N t M A JERIAl R E M A R K S __ J Air cleaner housing cover mating groove Multi purpose grease Thronle grip pipe flange Steering head bearing and race sliding surface I Wheel hub dust seal lip...

Page 18: ... HARNESS ROUTING 1 14 AFTER 07 ONLY CLAMP LEFT ii 7 FUEL HOSE BRAKE CABLE iP lllJ L U 0 3mmIO O 12 fnl FUel TANK t o J BREATHER HOSE FUel HOSE PAINT MARKS THROTTLE CABLE WIRE BANOS ENGINE STOP SWITCH WIRE FUEL HOSE BRAKE CABLE ...

Page 19: ... A iI WIRE CLAMP ENGINE STOP SWITCH WIRE UP IGNITION SWITCH WIRE GENERAL INFORMATION IGNITION SWITCH SPARK PLUG WIRE IGNITION SWITCH WIRE ENGINE STOP SWITCH WIRE _ ALTERNATOR WIRE ENGINE STOP SWITCH WIRE CRANKCASEBAEATHER STORAGE TANK AlTEANATOA WIRE CRANKCASE BREATHER DRAIN HOSE CARBURETOR DRAIN HOSE 1 15 ...

Page 20: ...GENERAL INFORMATION IGNITION CDr RIOL MODULE oeM MAIN WIRE HAFINE S 1 16 ...

Page 21: ...he same way but it is toxic Honda Motor Co Ltd utilizes various systems to reduce carbon monoxide oxides of nitrogen and hydrocarbons EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of appropriate carburetor setting no adjustments should be made except for high altitude setting and idle speed adjustment with the throttle stop screw The exhaust emission control syste...

Page 22: ...CONSTITUTE TAMPERING ARE THE FOLLOWING ACTS 1 Removal of or puncturing of the muffler baffles header pipes or any other component which conducts exhaust gases 2 Removal of or puncturing of any part of the intake system 3 Lack of proper maintenance 4 Replacing any moving parts of the vehicle or parts of the exhaust or Intake system with parts other then those specified by the manufacturer FUEL PERM...

Page 23: ...2 FRAME BODY PANELS EXHAUST SYSTEM SERVICE INFORMATION 2 2 NUMBER PLATE 2 5 TROUBLESHOOTING 2 2 FRONT FENOER 2 5 SEAT 2 3 EXHAUST SYSTEM 2 5 FUEL TANK 2 4 SIDE STAND 2 6 2 1 ...

Page 24: ...osely install all of fasteners Always tighten the exhaust pipe joint nuts first then tighten the mounting fastener If you tighten the mounting fasteners first the exhaust pipe may not seat properly Always inspect the exhaust system for leaks after installation TORQUE VALUES Side stand pivot bolt Muffler mounting bolt Exhaust pipe protector bolt Exhaust pipe cover screw TROUBLESHOOTING Excessive ex...

Page 25: ...ts Pull the seat assembly back and remove it INSTALLATION Install the seal assembly by inserting the prongs into the retainers on the frame Install the bolts and screws and tighten them Install the trim clips and lock them by pushing the center pin flush SEAT ASSEMBLY PRONGS CLIPS SCREWS RETAINERS 2 3 ...

Page 26: ...hose from the number plate Turn the fuel valve OFF and disconnect the fuel hose from the fuel valve Remove the two bolts washer and collar For fuel stramer 5er Remove the fuel tank Vice see page 34 Installation is in the reverse order of removal 2 4 SIDE COVERS REAR FENDER BREATHER HOSE BOlT vVASHER BOlT COLLAR tl 1f FUEL TANK FUEL HOSE ...

Page 27: ...T SYSTEM REMOVAL For spark arrester mamtenance refer to page 3 19 Remove the seat assembly page 2 3 Remove the exhaust pipe joint nulS Remove the mounting bolt and the muffler Remove the exhaust pipe joint gasket INSTALLATION Install a new joint gasket inlO the exhaust port Set the exhaust pipe onto the engine by aligning the exhaust pipe flange with the cylinder head studs then install the joint ...

Page 28: ...ST PIPE PROTECTOR 15 N m 1 5 kgf m 11Ibf ft 5 9 N m 0 6 kgf m 4 3 Ibf ft SIDE STAND REMOVAL JOINT NUTS EXHAUST PIPE caVEA GASKET fI Support the motorcycle securely with a hoist or r T i ljTeiQlTI equivalent 2 6 Retract the side stand and remove the following Return spring Pivot nut Pivot bolt Side stand ...

Page 29: ...ing sur faces Install the side stand with the pivot bolt Tighten the pivot bolt TORQUE 9 8 N m 1 0 kgf m 7 Ibf ft loosen the pivot bolt 45 90 Install the pivot nut and tighten it while holding the pivot bolt Install the return spring Check the side stand operation for freedom of movement 2 7 ...

Page 30: ...NE OIL 3 10 ENGINE OIL STRAINER SCREEN 3 12 ENGINE OIL CENTRIFUGAL FILTER 3 12 ENGINE IDLE SPEED 3 13 3 MAINTENANCE DRIVE CHAIN 3 13 DRIVE CHAIN SLIDER 3 15 BRAKE SHOE WEAR 3 15 BRAKE SYSTEM 3 16 CLUTCH SYSTEM 3 17 SIDE STAND 3 17 SUSPENSION 3 18 SPARK ARRESTER 3 19 NUTS BOLTS FASTENERS 3 19 WHEELS TIRES 3 20 STEERING HEAD BEARINGS 3 20 3 1 ...

Page 31: ...losed area SPECIFICATIONS Spark plug Engine oil capacity Recommended engine oit Valve clearance Tire size I I Tire air pressure Minimum tire tread depth TORQUE VALUES Fuel valve mounting bolt Spark plug 04 and OS Spark plug After OS Val e adjuster hole cap Valve adjuster lock nut Oil drain boh Clutc n adjuster lock nut Rear axle nut Spoke nipple 3 2 equivalent motor oil APi service classification ...

Page 32: ...mm 0770 0020100 or equivalent commercially avail able in U S A Valve adjusting wrench 8 x 9 mm 07708 0030100 or equivalent commercially avail able in U S A MAINTENANCE Valve adjuster B 07708 0030400 or 07908 KE90200 U S A only 3 3 ...

Page 33: ...KE 1f w I l rs z I_ S CTER COMES FIRST l NOTE NOrE NOTE 1 c MAINTE NANCE mi km 1 L REGULAR MAINTENANCE INTERVAL 14 c C C L ev m e m I REFER TO PAGE 3 3 7 3 9 3 13 3 15 3 19 3 20 Should be serviced by an authorized Honda dealer unless the owner has proper tools and service data and is mechanically qualified In the interest of safety we recommended these items be serviced only by an authorized Honda...

Page 34: ...150 1 I R I I L I I REGULAR MAINTENANCE INTERVAL 600 1 200 1 800 2 400 1 000 2 000 3 000 4 000 6 _ _ 12 18 24 I I I c c c I C I I I I I I I I I R R R R C C C C 1 I I I 1 r rL Every 300 mi SOD km or 3 months 1 1 I I I I I I I I I I I I I I I II SPARK ARRESTER c Every 1 000 mi 1 600 km or every 100 operating hours t I I I I I I I I I NUTS BOLTS FASTENERS WHEEtSfT IR E St STEERING HEAD BEARINGS T I I...

Page 35: ...screen in non flammable or high flash solven Check the D ring is In good condition reinstall the fuel valve TIghten the fuel valve mounting bolts to the speci fied torque m TORQUE 9 8 N m 10 kgf m 7lbf ftj After Installation check for fuellsaks THROTTLE OPERATION 3 6 Check for smooth throttle grip full opening and automatic full closing in all steering positions Check the throttle cable and replac...

Page 36: ...ration AIR CLEANER Remove the two screws and the air cleaner housing cover MAINTENANCE DUSTCQVER SCREWS COVER Remove the air cleaner element holder and element from the housing ELEMENT HOLDER Wash the element in non flammable or high flash s q u e e e point solvent and let it dry thoroughly Squeeze out solvent thoroughly out Soak the element in Pro Honda Foam Filter Oil or excess Oil equivalent an...

Page 37: ...ect or replace as described in the maintenance schedule page 3 4 INSPECTION PROJECTION GROOVE ELEMENT Check the following and replace if necessary rec ommended spark plug page 3 2 CENTER ELECTRODE 3 8 Insulator for damage Electrodes for wear Burning condition coloration Dark to light brown indicates good condition Excessive lightness indicates malfunctioning ignition system or lean mixture Wet or ...

Page 38: ...lve clearance while the engine IS cold below 95 F 35 CI Remove the left crankcase cover page 10 4 Turn the crankshaft counterclockwise and align the T mark on the flywheel with the index notch on the left crankcase Make sure the piston at TOe Top Dead Center on the compression stroke This position can be obtained by confirming that there is slack in the rocker arm If there is no slack rotate the c...

Page 39: ...kgf m Slbf ft Install the left crankcase cover page 10 8 ENGINE OIL 3 10 OIL LEVEL INSPECTION Support the motorcycle in an upright position on level ground Start the engine and let it idle for 3 5 minutes Stop the engine and wait 2 3minutes Hold the motorcycle in an upright pOSition Remove the oil filler cap dipstick and wipe it clean Check the oil level by inserting the oil filler cap dip stick i...

Page 40: ...n the indicated range Reinstall the filter cap dipstick ENGINE OIL CHANGE Warm up the engine Stop the engine and remove the oil filler cap dip stick Remove the drain bolt and sealing washer Drain the all completely Check that the sealing washer on the drain bolt is in good condition replace if necessary Install and tighten the drain bolt TORQUE 25 N m 2 5 kgf m 18 Ibf ft MAINTENANCE I 80 20 o 20 4...

Page 41: ...thout screwing it in Make sure there are no oil leaks ENGINE OIL STRAINER SCREEN CLEANING Remove the right crankcase cover page 9 5 Remove the oil strainer screen and clean it Check the screen for damage and the sealing rubber for damage or deterioration Reinstall the oil strainer screen and right crankcase cover page 9 19 ENGINE OIL CENTRIFUGAL FILTER CLEANING Remove the right crankcase cover bal...

Page 42: ...required to obtain the specified idle speed IDLE SPEED 1 700 100 rpm DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION Turn off the engine place the motorcycle on its side stand and shift the transmission into neutral Check the slack in the drive chain lower run midway between the sprockets CHAIN SLACK 15 25 mm 9 16 1in NOTICE Excessive chain slack 40 mm 1 112 in or more 111 may damage the frame ADJUSTMENT...

Page 43: ... Carefully remove the retaini ng clip with pliers Remove the link plate master link and drive chain Clean the chain with non flammable or high flash N O NO F LA M M A B L E O R H G H point solvent and wipe it dry FLASH POINT SOLVENT Be sure the chain has dried completely before lubri canting Lubricate the drive chain with 80 90 gear oil 0 _ Wipe off the excess gear oil CLEAN 4 WIPE AND DRY LUBRICA...

Page 44: ...l t he drive chain onto the sprockets Install the master link and link plate Install the retaining clip so that its open end is oppo site the normal rotation of the chain DRIVE CHAIN SLIDER Check the drive chain slider for wear or damage Replace the drive chain slider if the wear limit guide lug is worn out or it has been damaged BRAKE SHOE WEAR Check t he brake shoes and brake drum if the arrow o...

Page 45: ...ver FREE PLAY 10 20 mm 3 8 13 16 in Mak e sure the cut Adjust the brake lever free play by turning the our on the adjusting adjusting nut nUlls seared on the lomt pm REAR BRAKE Check the brake pedal free play FREE PLAY 10 20 mm 3 8 13 16 in 3 16 10 20 mm 3 8 13 16 in JOINT PIN 10 20mm 3 8 13 16 in ...

Page 46: ...ting bolt counterclockwise unlil resistance is felt Turn the adjusting bolt 118 turn clockwise from this position and tighten the lock nut while holding the adjusting bolt TORQUE 12 N m 1 2 kgf m 9 Ibf ft Check that the clutch is not slipping and is properly disengaging by operating gearshift pedal SIDE STAND Support the motorcycle on a level surface Check the side stand spring for damage or loss ...

Page 47: ...old the swingarm and move the rear wheel side ways with force to see if the wheel bearings are worn Check for worn or loose suspension pivot compo nents by grabbing the swingarm and attempting to move the swingarm back and forth Check each fastener of the swingarm and shock absorber if any are looseness is noted Also check the pivot bushings for wear or damage Check the action of the shock absorbe...

Page 48: ...ee of breaks and holes Replace if necessary MAINTENANCE SCREEN MESH Install the spark arrester with a new gasket into the r G AC S K C E C T C muffler IIiijjjIII Tighten the three bolts securely NUTS BOLTS FASTENERS Check that all chassis nuts and bolts are tightened to their correct torque values page 1 10 Check that all safety clips clamps and cable stays afe in place and properly secured ARREST...

Page 49: ...ce the tires when the tread depth reaches the following limits MINIMUM TREAD DEPTH FRONT REAR 3 0 mm 0 12 in Tighten any loose spokes to the specified torque TOOL Spoke wrench 4 1 4 5 mm 07701 0020100 Equivalent com merciallyavail able in U S A TORQUE 2 0 N m 0 2 kgf m 1 4Ibf ft STEERING HEAD BEARINGS Check that the con Support the motorcycle securely and raise the front r trof cables do not w hee...

Page 50: ...4 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM 4 2 TROUBLESHOOTING 4 3 SERVICE INFORMATION 4 3 OIL PUMp 4 4 4 1 ...

Page 51: ...LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM ROCKER ARM PISTON 4 2 II I II OIL AOTOR OIL STRAINER ...

Page 52: ...oil pump is worn beyond the specified service limits replace the oil pump as an assembly After the oil pump has been installed check that there are no oil leaks and thai oil pressure is correct SPECIFICATIONS TORQUE VALUES Oil pump mounting screw Oil pump cover screw TROUBLESHOOTING Engine oil level too low high oil consumption Normal oil consumption External oil leak c o r equivalent motor 1 A cl...

Page 53: ...ly Remove the rotor shaft collar from the crankcase OISASSEMBLY Remove the three screws and oil pump cover Remove the oil pump shaft then remove the inner and outer rotors from the oil pump body INSPECTION Temporarily install the outer and inner rotors into the oil pump body Install the oil pump shaft Measure the tip clearance between the inner and outer rotors SERVICE LIMIT 0 20 mrn 0 008 in Meas...

Page 54: ...mm 0 008 in ASSEMBLY OIL PUMP SHAFT INNER ROTOR OIL PUMP COVER Install the inner and outer rotors into the oil pump body Install the oil pump shaft aligning the flat surfaces of the shaft and inner rotor Fill the oil pump with 0 5 1 cm3 of engine oil LUBRICATION SYSTEM OIL PUMP BODY 4 5 ...

Page 55: ...nstall the rotor shaft collar into the crankcase Install a new gasket onto the oil pump body Install the oil pump into the crankcase while align ing the pump shaft groove with the cam chain guide spindle lug Install and tighten the three screws to the specified torque TORQUE 1 4 N m 0 75 kgf m 5 5 Ibf ft Install the clutch assembly page 9 14 COVER ...

Page 56: ... INFORMATION 5 3 TROUBLESHOOTING 5 4 AIR CLEANER HOUSING 5 5 CARBURETOR REMOVAL 5 5 5 FUEL SYSTEM CARBURETOR DISASSEMBLY 5 7 CARBURETOR ASSEMBLY 5 9 CARBURETOR INSTALLATION 5 1 1 AIR SCREW ADJUSTMENT 5 13 CRANKCASE BREATHER 5 14 5 1 ...

Page 57: ...FUEL SYSTEM COMPONENT LOCATION 1 0 N m 0 1 kgf m 0 7 IbHt 5 2 ...

Page 58: ...e 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 SPECIFICATIONS ITEM Carburetor identification 04 and 05 U S A number 04 07 Canada 06 and 07 U S A After 07 Main jet Slow at Jet neadle clip position 04 and 05 U S A 04 07 Canada Air screw initial opening Float level Idle speed Thronla grip free I TORQUE VALUES Connec...

Page 59: ...ch mixture Choke lever in CLOSE position Float valve faulty Float level 100 high Air jets clogged Air cleaner element contaminated Flooded carburetor Engine stalls hard to start idles roughly Fuel line restricted Ignition malfunction Fuel mixture too lean rich Fuel contaminated deteriorated Intake air leak Idle speed misadjusted Float level misadjusted Fuel tank breather hose clogged Air screw mis...

Page 60: ...bolt and the air cleaner housing assem bly At installation Installation is in the reverse order of removal secure the ground eyelet with the iJlr cleaner housing mountmg boll CARBURETOR REMOVAL THROTILE VALVE Remove the seat shrouds side cover rea r fender assemblv page 2 3 Loosen the carburetor lop FUEL SYSTEM ALIGN H O U S I N G C O V E R HOLDER ELEMENT AIR CLEANER HOUSING 5 5 ...

Page 61: ...he carburetor Remove the throttle cable from the throttle valve while compressing the throttle valve spring Remove the jet needle retainer and jet needle Check the throttle valve and jet needle for scratches wear or damage JET NEEDLE THROTILE VALVE RETAINER JET NEEDLE ...

Page 62: ...carburetor body Loosen the carburetor connecting boot band screw Remove the carburetor mounting bolts carburetor and insulator CARBURETOR DISASSEMBLY Remove the drain hose Remove the screws and float chamber Remove the screw Remove the float pin float and float valve Inspect the ftoat for deformation or damage FLOAT CHAMBER FUEL SYSTEM DRAIN HOSE FLOAT FLOAT VALVE 5 7 ...

Page 63: ...ontaminated Check the operation of the float valve Remove the following Main jel NeedleJsl Thronls stop screw and spring Turn the air screw in and carefully count the num ber of turns until it seats lightly Make a nole of this to use as a reference when reinstalling the air screw Remove the air screw and spring Ahfl 07 canD TOOLS 5 8 Pilot screw wrench 0 type Pilot screw wrench guide 07KMA MS60101...

Page 64: ...r scratched After 05 U S A Blow open each air and fuel passage in the carbure tor body with compressed air Install the following Throttle slop screw and spring Needle jet Main Jet Install the air screw with the spring and return it to its original position as noted during removal After W Canada TOOLS Pilot screw wrench 0 type 07KMA MS60101 or 07KMA MN9A100 U S A onlv Pilot screw wrench guide 07PMA...

Page 65: ...easure the float level with the special tool as shown TOOL Carburetor float level gauge 07401 0010000 FLOAT LEVel 12 7 mm 10 50 in The float cannot be adjusted If the float level is OUI of specification Inspect the float valve and valve seat If the float valve and valve seat are normal replace the float assembly If the floal valve and valve seat are abnormal replace them and recheck the float leve...

Page 66: ... the mani fold and carburetor then install the mounting bolts Tighten the connecting boot band screw TORQUE 1 0 N m 0 1 kgf m O 7Ibf ft Tighten the mounting boilS Connect the fuel hose and air vent hose THROTILE VALVE Install the needle clip on the jet needle 04 07 Canada STANDARD POSITION 2rd groove from top AhBf 05 USA Aher 07 CAn 18 After 05 U S A and After 07 Canada models can not adjust the n...

Page 67: ... in good condition replace if necessary Install the throttle valve spring onto the throttle cable Connect the throttle cable to the throttle valve while compressing the throttle valve spring Install the throttle valve into the carburetor body aligning its cut out with the throttle stop screw THFlOTTL VALVE RETAINER JET NEEDLE ...

Page 68: ... 07 CanM2 Adjust the air screw using the following lools TOOLS Pilot screw wrench 0 type 07KMA MS60101 or 07KMA MN9A100 U S A only Pilot sc rew wrench guide 07PMA MZ20110 FUEL SYSTEM o m ge 10 IIHJ fir SCffIW Hal WJI occur If the aJr screw IS IJf htened msr the SUI 1 Turn the air screw clockwise until it seats lightly 1 rl H ST B and then back it out to the specification given INITIAL OPENING 1 1 ...

Page 69: ...5 14 Remove the crankcase breather hose plug and empty any deposits if the deposit level can be seen in the breather hose Install the crankcase breather hose plug and secure it with the clip securely CRANKCASE BREATHER DAAINHOSE PLUG ...

Page 70: ...6 ENGINE REMOVAL INSTALLATION COMPONENT LOCATION 6 2 ENGINE REMOVAL 6 4 SERVICE INFORMATION 6 3 ENGINE INSTALLATION 6 6 6 1 ...

Page 71: ...ENGINE REMOVAL INSTALLATION COMPONENT LOCATION 12 N m 1 2 kgf m 9Ibf ft 31 N m 3 2 kgf m 23 Ibf ft 26 N m 2 7 kgf m 20 Ibf ft 6 2 ...

Page 72: ...ator cam chain tensioner page 10 3 Clutch page 9 6 Cylinder piston page 8 3 Cylinder head valves page 7 3 Gearshift linkage page 9 16 Oil pump page 4 4 The crankshaft transmission and kickstarter require engine removal for service page 11 3 SPECIFICATIONS ITEM ine dry weight Engine oil capacity at disassembly TORQUE VALUES Drive sprocket fixing plate bolt Engine hanger nut Muffler mounting boll SP...

Page 73: ... the spark plug Disconnect the ignition pulse generator and alterna tor connectors Disconnect the crankcase breather hose from the crankcase Remove the following from the clamp Carburetor drain hose Crankcase breather hose loosen the rear axle nut and drive chain adjusters to loosen the drive chain page 3 13 Remove the following Fixing plate bolts Fixing plate Drive sprocket SPROCKET ...

Page 74: ...footpeg bar cycle securely Remove the engine hanger nuts Place a floor jack or other adjustable support under the engine During engme Remove the hanger bolts and the engine from the assembly removal frame hold the engine securely and be careful nor 0 dam age the frame and engme ENGINE REMOVAL INSTALLATION 6 5 ...

Page 75: ...s are installed from left side The jack height must be continually adjusted to relieve stress from the hanger bolts Tighten the hanger nuts to the specified torque TORQUE 31 N m 3 2 kgf m 23 Ibf ftl Install the four bolts and footpeg bar InslaUthe brake pedal return spring Replace the intake manifold O ring with a new one Install and tighten the intake manifold bolts ...

Page 76: ...ack page 3 13 Connect the crankcase breather hose to the crank case Connect the ignition pulse generator and alternato r connectors Connect the spark plug cap to the spark plug Install the following Exhaust system page 2 5 left crankcase cover page 10 8 fill the recommended engine oil page 3 11 ENGINE REMOVAL INSTALLATION 6 7 ...

Page 77: ...7 CYLINDER HEAD VALVES COMPONENT LOCATION 7 2 SERVICE INFORMATION 7 3 TROUBLESHOOTING 7 5 CYLINDER COMPRESSiON 7 6 CAMSHAFT REMOVAL 7 6 CYLINDER HEAD 7 7 CAMSHAFT INSTALLATION 7 18 7 1 ...

Page 78: ...CYLINDER HEADIVALVES COMPONENT LOCATION 04 and 05 12 N m 1 2 kgf m 9Ibf ft After 05 16 N m 1 6 kgf m 12Ibf ft 7 2 8 8 N m 0 9 kgf m 6 5 Ibf ftJ ...

Page 79: ...ing solvent and dry them by blowing them off with compressed air before inspection Camshaft lubricating oil is fed through oil passages in the cylinder head Clean the oil passages before assembling cyl inder head Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head Refer to page 10 6 for cam chain tensioner service SPECIFICATIONS valve guide TORQUE V...

Page 80: ...Valve spring compressor attach ment 07959 KM30101 Valve seat cutter 24 mm 45 IN 07780 0010600 or equivalent commercially avail able in U S A Flat cutter 24 mm 32 IN 07780 0012500 or equivalent commercially avail able in U S A Valve guide reamer 5 0 mm 07984 MA60001 or 07984 MA6000D U S A only Valve seal cutter 20 5 mm 45 EX 07780 0011000 or equivalent commercially avail able in U S A Interior cutt...

Page 81: ...ing Uneven valve seating Cylinder head Leaking or damaged head gasket Warped or cracked cylinder head Worn cylinder piston or piston rings page 8 5 Compression t oo high overheating or knocking Excessive carbon build up on piston crown or on combustion chamber Excessive smoke Cylinder head Worn valve stem or valve guide Damaged stem seal Worn cylinder piston or piston rings page 8 5 Excessive nois...

Page 82: ...eposits in combustion chamber or on piston head CAMSHAFT REMOVAL Drain the engine oil page 3 11 Remove the following Valve adjuster hole caps page 3 9 left crankcase cover page 10 4 Sealing bolt tensioner spring and tensioner push rod to loosen the cam chain tensioner page 10 6 Disconnect the spark plug cap Loosen the cylinder head side cover 6 mm bolt Tap the head of the 6 mm bolt and release the...

Page 83: ...er The outer race should turn smoothly and quietly Also check that the bearing inner race fits tightly on the camshaft Replace the camshaft assembly if the outer race does not turn smoothly and quietly or if it fits loosely on the camshaft Using a micrometer measure each cam lobe height SERVICE LIMITS IN 19 66 mm 0 774 in EX 19 65 mm 0 774 in CYLINDER HEAD REMOVAL Remove the following Muffler page...

Page 84: ...he cylinder head mounting bolt and cylin der head Remove the following Gasket Dowel pins Collar O ring DISASSEMBLY Remove the spark plug page 3 8 Remove the bolts and cylinder head right side cover Temporarily install a B mm bolt to the rocker arm shaft and remove the rocker arm shafts and rocker arms BOLTS B bolt ROCKER ARMS ...

Page 85: ...e following mg disassembly so thev can be placed back In thelf ongmal locations Spring retainer Valve spring Valve Valve spring seat Stem seal INSPECTION CYLINDER HEAD Remove carbon deposits from the combustion chamber Avoid damaging the Check the spark plug hole and valve areas for gasket slJrfiICe cracks Check the cylinder head for warpage with a straight edge and feeter gauge SERVICE LIMIT 0 05...

Page 86: ... LIMIT tN EX 10 10 mm 0 398 in Inspect the rocker arm shaft for wear or damage Measure the O O of the rocker arm shaft SERVICE LIMIT IN EX 9 91 mm 0 390 in VALVE SPRING Measure the free length of the valve springs SERVICE LIMIT IN EX 31 8 mm 1 25 in Replace the springs if they ere shorter than the ser vice Jimit VALVE Inspect each valve for bending burning or abnor mal stem wear Check valve moveme...

Page 87: ... so replaced page 7 12 replace any guides as necessary and ream to fit Do not use a torch to heat the cylinder head rt may cause warping If the stem to guide clearance is out of specification with a new guide also replace the valve VALVE GUIDE REPLACEMENT Chill new valve guides in the freezer section of a refrigerator for about an hour Heat the cylinder head to 212 302 O F t100 150 e with a hot pl...

Page 88: ...I ND I A1 NGi 6 remove carbon deposits The valves cannof be ground If 8 valve face is burned or Apply a light coaling of Prussian Blue to the valve seat lap the valves and seats using a rubber hose or other hand lapping 1001 Remove and inspect the valves Inspect the width of each valve seat badlywom 01 rf If STANDARD 1 0 _ 1 3 mm 0 04 0 05 in COOfacrs rM sear SERVICE LIMIT 2 0 mm 0 08 in uneven re...

Page 89: ...ter 24 mm 320 IN Flat cutter 21 5 mm 320 EX Cutter holder 5mm 07780 0012500 07780 0012800 07781 0010400 or equivalent commercially available in U S A SEATWIDTH 30 I Use a 50 cutter remove 1 4 of the existing valve _ seat material lD SEAT WIDTH TOOLS Intenor cutter 22 mm 60 IN EX 07780 0014202 Cutter holder S mm 07781 0010400 or equivalent commercially available in U S A L J 60 Using a 45 seat cutt...

Page 90: ...valve face and lap the valve using light pressure Excessive lapping pressure may deform or damage the sea Do not Change the angle of lapping tool frequently to pre al ow appmg conr vent uneven seat wear pound to emer the gUides After lapping wash all residual compound off the cylinder head and valve ASSEMBLY CYLINDER HEAD RIGHT SIDE COI ER 9 8 N m 1 0 7 Ibf ft GASKET ROCKER ARM SHAFT ROCKER ARM I ...

Page 91: ...alve coners using the special tool as lenSlon do nor compress the valve spnng more than necessary shown TOOLS Valve spring compressor 07757 0010000 Valve spring compressor attachment 07959 KM30101 Support the cylm Tap the valve stems gently w ith two plastic ham der head above the mers as shown to seat the valve coners firmly NOr bench so that the valve heads will not COflfact any thing that cause...

Page 92: ...tall the right side cover onto the cylinder head Install the right side cover bolts to the specified torque TOROUE 9 8 N m 11 0 kgf m 7 IbUt INSTALLATION Clean off the gasket material from the cylinder sur face Install the following New O ring Collar Dowel pins New gasket c RING COLLAR BOLTS ...

Page 93: ...ts new sealing washers Nut new sealing washer Note the position of the washers and nuts Tighten the cylinder head cover nuts to the specified torque TORQUE 1 N m 1 1 kgf m 8 Ibf ft Install and tighten the cylinder head mounting bolt If the cylinder was removed tighten the cylinder mounting bolt ARROW Install a new O ring into the groove in the intake manifold Install and tighten the intake manifol...

Page 94: ...urn the crankshaft counterclockwise and align the T mark on the flywheel with the index notch on the left crankcase Install the dowel pin and cam sprocket i i Install the cam sprocket with its a mark with the index notch on the cylinder head NOTCH Install and tighten the cam sprocket bolts to the specified torque TORQUE 8 8 N m 0 9 kgf m 6 5 IbUt Install the cylinder head left side cover onto the ...

Page 95: ...linder head and tighten it Tighten the two right side cover bolts if the cylinder head was disassembled TORQUE 9 8 N m 1 0 kgf m 7 Ibf ftJ Install the spark plug cap Install the tensioner push rod spring and sealing bolt page 10 7 Adjust the valve clearance page 3 10 Pour the recommended engine oil page 3 1 1 CYLINDER HEADIVALVES SEALING BOLT 7 19 ...

Page 96: ...INDER PISTON COMPONENT LOCATION 8 2 PISTON REMOVAL 8 4 SERVICE INFORMATION 8 3 CYLINDER PISTON INSPECTION 8 5 TROUBLESHOOTING 8 3 PISTON INSTALLATION 8 8 CYLINDER REMOVAL 8 4 CYLINDER INSTALLATION 8 8 8 1 t ...

Page 97: ...CYLINDER PISTON COMPONENT LOCATION 9 8 N m 1 0 kgf m 7lbHt 8 2 ...

Page 98: ... m 1 0 kgf m 7 Ibf ft TROUBLESHOOTING If the performance is poor at low speeds check for white smoke in the crankcase breather hose if the hose is smoky check for a seized piston ring Cylinder compression is too low or engine is hard to start Blown cylinder head gasket Worn stuck or broken piston ring Worn or damaged cylinder or piston Cylinder compression is too high or engine overheats or knocks...

Page 99: ...move the mounting boll and cylinder Remove the following Rubber packing Gasket Dowel pins PISTON REMOVAL Do no leI the P S ton pm clip fall mID the crankcase Remove the piston pin clip with pliers Press the piston pin Qut of the piston and remove the piston Do not damage the Remove the piston rings PIS on rings dunng removal 8 4 CYLINDER GUIDE ...

Page 100: ...of round at three levels in X and Y axis Take the maximum reading to determine them SERVICE LIMITS Taper Out of round 0 10 mm 0 004 in 0 10 mm 0 004 in The cylinder must be rebored and an oversize pis ton fined if the service limits are exceeded The following oversize pistons are available 0 25 mm 0 010 in 0 50 mm 0 020 in The piston to cylinder clearance for the oversize pis ton must be 0 010 0 0...

Page 101: ...5 in Second 0 12 mm 0 005 in Inspect the piston for wear or damage Measure the diameter of the piston at B mm 0 3 in from the bottom of skirt and 90 degrees to the pis ton pin hole SERVICE LIMIT 38 90 mm 1 531 in Measure the piston pin bore SERVICE LIMIT 13 06 mm 0 514 in Measure the 0 0 of the piston pin SERVICE LIMIT 12 98 m m 0 511 in Calculate the piston ta piston pin clearance SERVICE LIMIT 0...

Page 102: ...nd Oil side rail 0 5 mm 0 02 in 0 5 mm 0 02 in 1 1 mm 0 04 in PISTON RING INSTALLATION Clean the piston ring grooves thoroughly and install the piston rings Apply oil to the piston rings Avoid piston and piston ring damage during installation Install the piston rings with their marking facing up 00 not confuse the top and second rings Space the piston ring end gaps 120 degrees apart Do not align t...

Page 103: ...he piston cut out Do not let the piston pin clips fall into the can ke8se fI CLIP CYLINDER INSTALLATION 8 8 Install the dowel pins new gasket and new rubber ItiijIIII Apply engine oil to a rubber packing_ packing Coat the cylinder bore piston outer surface and pis CYLINDER Ion ring grooves with clean engine oil Route the cam chain through the cylinder and install the cylinder while compressing the...

Page 104: ...inner surface Install the cam chain guide roller new sealing washer and pin bolt Tighten the cam chain guide roller pin bolt to the specified torque TORQUE 9 8 N m 1 0 kgf m 7 Ibf ft Install the cylinder mounting bolt but do not tighten it yet Install the cylinder head page 7 1 6 CYLINDER PISTON 1 GUIDE 8 9 ...

Page 105: ...CLUTCH GEARSHIFT LINKAGE COMPONENT LOCATION 9 2 SERVICE INFORMATION 9 3 TROUBLESHOOTING 9 4 RIGHT CRANKCASE COVER REMOVAL 9 5 CLUTCH 9 6 GEARSHIFT LINKAGE 9 16 RIGHT CRANKCASE COVER INSTALLATION 9 19 9 1 ...

Page 106: ...CLUTCH GEARSHIFT LINKAGE COMPONENT LOCATION 17 N m 1 7 12Ibf ft 13 N m 1 3 42 N m 4 3 kgf m 31 Ibf ft 9 2 ...

Page 107: ...ew Clutch lock nut Clutch assembly screw Shift drum stopper arm bolt Shift return spring pin bolt Gearshift cam plate bolt TOOLS Lock nut wrench 20 x 24 mm 07716 0020100 4 4 N m 0 45 kgf m 3 3 Ibf ft 42 N m 4 3 kgf m 31 IbHt 5 9 N m 0 6 kgf m 4 3 Ibf ft 13 N m 1 3 kgf m 9 Ibf h 29 N m 3 0 kgf m 22 Ibf ft 17 N m 1 7 kgf m 12Ibf ft Extension bar 07716 0020500 or equivalent commercially avail able in...

Page 108: ...rect clutch adjustment Clutch plate warped Faulty clutch lifter Faulty clutch weight Incorrect engine oil weight 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 w ill not return Weak or ...

Page 109: ...er pedal Unhook the brake pedal return spring loosen the rear brake pedal adjusting nut and lower the brake pedal Remove the eight bolts and right crankcase cover Remove the gasket and dowel pins Remove the clutch adjusting nut washer and 0 ring Remove the clutch lifter adjusting boft assembly CLUTCH GEARSHIFT LINKAGE 9 5 ...

Page 110: ...for damage replace if necessary REMOVAL Remove the right crankcase cover page 9 5 Remove the ball retainer and spring Remove the clutch lifter lever Remove the oil through and sprig Remove the clutch lifter cam plate Remove the screws and clutch outer cover and bearing ...

Page 111: ...ools as shown TOOLS Flywheel holder 07725 0040000 Equivalent com merciallyavailable in U S A Lock nut wrench 20 x 24 mm 07716 0020100 Extension bar 07716 0020500 Equivalent com merciallyavailable in U S A Remove the lock washer B 14 mm lock washer and CLUTCH GEARSHIFT LINKAGE clutch assembly 1 1 Remove the primary drive gear 9 7 ...

Page 112: ...ring and primary driven gear from the mainshaft Remove the collar from the crankshaft DISASSEMBLY Remove the following Set ring Clutch plate B Clutch disc A Clutch disc B Clutch disc A Free springs Clutch plate A Remove the clutch center and drive gear outer SET I CLUTCH CENTER ...

Page 113: ...t center ring INSPECTION Clutch lifter bearing Turn the inner race of the litter bearing with your finger The bearing should turn smoothly and freely with out excessive play Also check that the bearing fits tightly in the clutch outer cover Replace the bearing if necessary CLUTCH GEARSHIFT LINKAGE SCREWS WASHERS DRIVE PLATE ASSEMBLY CllJTCHWEIGHT CENTER RING STC P R R NG BEARING 9 9 ...

Page 114: ... Clutch disc B Clutch plate 2 3 mm 0 09 in 3 0 mm 0 12 in Check each disc plate for warpage on a surface plate using a feeler gauge SERVICE LIMIT 0 20 mm 0 008 in Primary drive gear clutch center guide Check the primary drive gear and clutch center guide for excessive wear or damage Measure the LO of the primary drive gear SERVICE LIMIT 21 05 mm 0 829 in Measure the 0 0 and I D of the clutch cente...

Page 115: ...uter clutch center Check t he drive gear outer and clutch center for excessive wear or damage ASSEMBLY STelPPI R RING CLUTCH GEARSHIFT LINKAGE CLUTCH CENTER DRIVE GEAR OUTER CLUTCH WEIGHTfCENTER RING DRIVE OUTER FREE SPRING CLUTCH DISC A cum H PLATE B CLUTCH OUTER CLUTCH C TER eu le H DISC B SET RING 9 11 ...

Page 116: ...all the clutch springs onto the clutch outer holes Install the drive plate assembly into the clutch outer aligning its bosses with the clutch springs Install the plain washers and screws Tighten the screws in a crisscross pattern in 2 3 steps TORQUE 5 9 N m 0 6 kgf m 4 3 Ibf ft Install the damper springs as shown CLUTCH WEIGHTfCENTER RING _ t q 1 J _ I p l _ t 1 d I STOPPER RING DRIVE PLATE A SEME...

Page 117: ... Clutch disc A Clutch plate B Install the clutch disc A with its flat surface facing the clutch disc B Install the clutch plate B with its chamfered side facing the clutch disc A Install the clutch set ring with its chamfered side facing the clutch plate 8 DRIVE SET CLUTCH GEARSHIFT LINKAGE OUTER SPRINGS A DISCB PLATE B 9 13 ...

Page 118: ... gear onto the mainshaft and secure it with the snap ring Apply engine oil to the clutch center guide and install it onto the crankshaft Install the primary drive gear Install the clutch assembly onto the crankshaft Install a new 14 mm lock washer by aligning its short tabs with the grooves in the drive plate ...

Page 119: ...000 IEquivalent com merciallyavailable in U S A 07716 0020100 07716 0020500 IEquivalent com merciallyavailable in U S A TORQUE 42 N m 14 3 kgf m 3llbf ft If the lock nut groove does not align with the lock washer tab further tighten the lock nut and align Bent up the tab of the 14 mm lock washer into the groove of the lock nut Clean the inside of the clutch outer and outer cover page 3 12 Install ...

Page 120: ...am plate Install the oillhrough spring and oillhrough Install the spring ball retainer and clutch lifter lever Install the right crankcase cover page 9 19 GEARSHIFT LINKAGE REMOVAL Remove the clutch and primary driven gear page 9 6 Clean the gearshift Remove the pinch bolt and gearshift pedal spmdle end 0 pre vent din from amm mg rhe crankcase 9 16 G RSHFTPEDAL ...

Page 121: ...per arm and return spring Pull down the gearshift arm then pull out the gear shift spindle from the crankcase Remove the bolt and shift cam plate Remove the dowel pins and gearshift drum pins CLUTCH GEARSHIFT LINKAGE 9 17 ...

Page 122: ...plate by aligning the pin hole with the dowel pins and aligning the drum pin with the denl Install the cam plate and tighten the bolt to the spec ified torque TORQUE 17 N m 1 7 kgf m 12 Ibf ft InSlall the gearshift spindle into the crankcase by aligning the return spring ends with the spring pin w hile pushing down the gearshift arm and set the gearshift arm to the shift drum pins ...

Page 123: ...e pinch bolt and tighten it Install the primary driven gear and clutch assembly page 9 14 RIGHT CRANKCASE COVER INSTALLATION Install the clutch lifter plate adjusting bolt into the right crankcase cover by aligning its pin w ith the hole in the crankcase cover Coat a new O ring with engine oil and install it into the cover groove properly Install the washer and lock nut CLUTCH GEARSHIFT LINKAGE WA...

Page 124: ...ht cover bolts in a criss cross pattern several steps Install the kickstaner pedal as shown and tighten the bolt Hook the return spring to the brake pedal and spring holding pin as shown Install the footpeg bar page 6 6 Adjust the brake pedal free play page 3 16 Pour the recommended engine oil page 3 11 Adjust the clutch page 3 17 ...

Page 125: ...10 ALTERNATOR CAM CHAIN TENSIONER COMPONENT LOCATION 10 2 SERVICE INFORMATION 10 3 TROUBLESHOOTING 10 3 FLYWHEEL STATOR REMOVAL 10 4 CAM CHAIN TENSIONER 10 6 STATOR FLYWHEEL INSTALLATION 10 8 10 1 ...

Page 126: ...ALTERNATOR CAM CHAIN TENSIONER COMPONENT LOCATION 16 N m 1 6 kgf m 121bHt 23 N m 2 3 17 Ibf ft 41 N m 4 2 kgf m 30 Ibf ft 10 2 ...

Page 127: ... o 41l7 24 IC t 11 94 I O 4 70 1 1 Spring free lengt h__ 1 1 1 3 4 38 ___ 00 3 9 1__ TORQUE VALUES Flywheel nut Cam chain tensioner sealing bolt Cam chain tensioner pivot bolt TOOLS Universal holder 07725 0030000 TROUBLESHOOTING Excessive engine noise Worn or damaged cam chain tensioner 41 N m 4 2 kgf m 30 Ibf ft 23 N m 2 3 kgf m 17 Ibf h 16 N m 1 6 kgf m 12 Ibf h Flywheel puller 07933 GEOOOOO Not...

Page 128: ...ge 3 11 Disconnect the alternator and ignition pulse genera tor connectors Remove the bolt and gearshift pedal Remove the three bolts and left crankcase cover Hold the flywheel using the universal holder and remove the flywheel nul TOOL Universal holder 07725 0030000 Remove the washer ...

Page 129: ...woodruff key Remove the bolt and wire clamp 07933 GEOOOOO Not available in U S A or 07933 0010000 U S A ONLY Release the wire grommet from the crankcase groove Remove the ignition pulse generator mounting bolts and wire clamp Remove the stator mounting bolts Remove the ignition pulse generator and stator as an assembly 10 5 ...

Page 130: ...e Remove the O rings from the crankcase Remove the O rings from the stator base CAM CHAIN TENSlONER REMOVAL 10 6 Remove the stator base page 10 4 Remove the sealing bolt washer lensioner spring and push rod Remove the pivot bolt lensioner arm and tensioner r rolter ...

Page 131: ...h rod a D SERVICE LIMIT 11 94 mm 0 470 in INSTALLATION Install the cam chain tensionar railer tensioner arm J and pivot boll Tighten the pivot bolt to the specified torque TORQUE 16 N m 1 6 kgf m 12 IbHt Check the sealing washer is in good condition replace if necessary Install the push rod spring washer and seating bolt Tighten the sealing bolt to the specified torque TORQUE 23 N m 2 3 kgf m 17 I...

Page 132: ...her and bolt Tighten the bolt securely_ STATOR FLYWHEEL INSTALLATION Check the stator base oil seal for damage replace if necessary Apply engine oil to the lip of the oil seal Apply engine oil to new O rings install them into the crankcase grooves Apply engine oil to new D ring install it into the sta tor base groove Be careful not fO Install the stator base and tighten the screws damage rheOlfsea...

Page 133: ...ll the stator mounting bolts Set the wire grommet into the crankcase groove Install the wire clamp and tighten the bolt Clean any oil from the tapered portion of the crank shaft and flywheel Install the woodruff key into the crankshaft groove Install the flywheel by aligning the key way in the flywheel with the woodruff key on the crankshaft Install the washer 10 9 ...

Page 134: ...t to the specified torque TOOL Universal holder 07725 0030000 TORQUE 41 N m 4 2 kgf m 30 Ibf ft Install the left crankcase cover and tighten the three bolts Install the gearshift pedal so that it is same height as the footpeg Install the pinch bolt and tighten it Connect the ignition pulse generator and alternator connectors ...

Page 135: ...KSHAFTITRANSMISSION KICKSTARTER COMPONENT LOCATION 11 2 SERVICE INFORMATION 11 3 TROUBLESHOOTING 11 4 CRANKCASE SEPARATION 11 5 CRANKSHAFT 11 6 TRANSMISSION 11 8 KICKSTARTER 11 14 CRANKCASE ASSEMBLY 11 16 11 1 ...

Page 136: ...CRANKSHAFTITRANSMISSION KICKSTARTER COMPONENT LOCATION 12 N m 1 2 kgf m 9Ibf ft 11 2 ...

Page 137: ...ed before separating the crankcase Alternator cam chain tensioner page 10 4 Clutch gearshift linkage page 9 6 Cylinder head page 7 7 Cylinder piston page 8 4 Engine page 6 4 Oil pump page 4 4 SPECIFICATIONS clearance Radial clearance I I TORQUE VALUE Shift drum bott TOOLS Driver 07749 0010000 12 N m 1 2 kgf m 9Ibf ft Anachment 37 x 40 mm 07746 0010200 Pilol 17 mm 07746 0040400 J 11 3 ...

Page 138: ...djustment Bent shift fork Bent fork claw Damaged shift drum cam groove Incorrect transmission oil weight Transmission jumps out of gear Worn gear dogs or slots 8enl shift fork Broken shift drum stopper Excessive noise Worn crankshaft big end bearing Worn crankshaft journal bearing 11 4 ...

Page 139: ...arating the crankcase Remove the snap ring from the kickstarter spindle Unhook the return spring and remove the retainer and return spring Remove the rubber cap Remove the shift drum bolt and washer Remove the cam chain Loosen the seven crankcase bolts in a crisscross pattern in 2 3 steps and remove them Remove the damp CLAMP BOLTS 11 5 ...

Page 140: ...left side down Separate the right and left crankcase halves Remove the gasket and dowel pins CRANKSHAFT REMOVAL 11 6 Remove the crankshaft from the left crankcase If necessary remove the cam chain guide spindle and guide sprocket RIGHT CRANKCASE DOWEL PINS CRANKSHAFT ...

Page 141: ...cal points as shown SERVICE LIMIT 0 05 mm 0 002 in Turn the outer race of the crankshaft bearing with your finger The bearing should turn smoothly and quietly Also check that the inner race of the bearing fits tightly on the crankshaft Check the timing sprocket for wear or damage If you are replacing the timing sprocket align the valley of the sprocket teeth with the center of woo druff key groove...

Page 142: ...stall the guide sprocket and guide spindle Pour 1 2 cm3 of engine oil into the connecting rod big end bearing Install the crankshaft into the left crankcase being careful not to interfere the connecting rod with the crankcase Assemble the crankcase halves page 11 16 TRANSMISSION REMOVAL 11 8 Remove the kickstarter spindle page 11 1 4 Remove the mainshaft countershaft and shift drum as an assembly ...

Page 143: ...and 0 0 of Cl gear bushing SERVICE LIMITS 0 0 22 93 mm 0 903 in 1 0 20 08 mm 0 791 in Calculate the C1 gear la bushing clearance SERVICE liMIT 0 10 mm 0 004 in Check the shifter groolle of the shifter gear for excessive wear or damage Measure the 0 0 of the mainshaft and counlershaft SERVICE LIMITS AT M2 gear 16 95 mm 0 667 in AT C1 gear 19 94 mm 0 785 in Calculate the M2 gear la shaft clearance S...

Page 144: ...36T M3 MAIINSI AFT llTJ GEARSHFT ORUM DISASSEMBLY Gear sliding surface gear teeth and shifter groove COUNTEASHAFT Remove the guide pin clips Remove the guide pins then remove the shift forks CLIP 11 10 Inspect the shift drum grooves for wear or damage Measure the 0 0 of the shift drum SERVICE LIMIT 33 93 mm 1 336 in GUIDE PIN ...

Page 145: ...shift fork I D SERVICE LIMIT 34 14 mm 1 344 in Measure the shift fork claw thickness SERVICE LIMIT 4 60 mm 0 181 in SHFT DRUM ASSEMBLY T HIFTDRUM CRANKSHAFTITRANSMISSION KICKSTARTER ClIP SHIFT FORK GUIDE PIN 11 11 ...

Page 146: ...nd bend the tab to lock the washer TRANSMISSION BEARING REPLACEMENT Turn the inner race of each bearing with your finger The bearings should turn smoothly and quietly Also check that the bearing outer race fits tightly in the crankcase Remove and discard the bearing if the race does not turn smoothly quietly or fils loosely in the crank case Remove the countershaft oil seal Drive the mainshaft bea...

Page 147: ... 17 mm 07746 0040400 Drive new countershaft bearing into the crankcases using the same tools Apply engine oil to a new countershaft oil seal lip Install the countershaft oil seal TRANSMISSION INSTALLATION Apply clean engine oil to the transmission gears and shift drum Set the right fork into the M3 gear and the left fork into the C2 gear to assemble the mainshaft countershaft and shift drum as sho...

Page 148: ...he transmission operation Install the kickstarter spindle page 11 15 KICKSTARTER REMOVAL 11 14 Separate the right and left crankcase page 11 5 Remove the kickstarter spindle from the right crank case DISASSEMBLY Remove the washer Remove the snap ring and starter ratchet spring Remove the snap ring washer and starter pinion gear IC SPINDLE RATCHET SNAP RING ...

Page 149: ...ASSEMBLY Assembly is in the reverse order of disassembly KICKSTARTER SPINDLE PINION GEAR STARTER RA HET SI R iG KICKST AR r ER SPINDLE PINION GEAR WASHER SNAP RING FRICTION SPRING STARTER RATCHET INSTALLATION Install the kickSlarter spindle by aligning its friction spring with the groove in the left crankcase as shown Assemble the crankcase halves ALIGN SNAP RING KICKSTAATER SPINDLE ...

Page 150: ... pins and a new gasket onto the leh crankcase Make sure thSI the Install the right crankcase over the left crankcase gasket slays In place 11 16 Install the seven bolts with the clamp and tighten them in a crisscross pattern in 2 3 steps Apply engine oil to the cam chain and install it Install the washer and bolt to the shift drum then tighten the bolt to the specified torque TORQUE 12 N m 1 2 kgf...

Page 151: ...er spindle Temporarily install the kickstarter pedal Install the spring ends onto the retainer and crank case lug as shown and press the retainer to set its edge against the stepped part of the crankcase while turning the pedal countercl ockwise Install the snap ring into the groove in the kick starter spindle securely 11 17 ...

Page 152: ...12 FRONT WHEEL BRAKE SUSPENSION STEERING COMPONENT LOCATION 12 2 FRONT WHEEL 12 8 SERVICE INFORMATION 12 3 FRONT BRAKE 12 13 TROUBLESHOOTING 12 5 FORK 12 1 5 HANDLEBAR 12 6 STEERING STEM 12 18 12 1 ...

Page 153: ...FRONT WHEEL BRAKE SUSPENSION STEERING COMPONENT LOCATION 74 N m 7 5 54 Ibf ft 20 N m 2 0 kgf m 141bf ft 47 N m 4 8 kgf m 35 Ibf ft 9 8 N m 1 0 kgf m 7 Ibf ftj 12 2 ...

Page 154: ...rim ta hub distance Wheel rim runout Radial Axial Brake Brake lever free play I Brake drum 1 0 I Brake lining thickness Fork Spring free length TORQUE VALUES Handlebar mounting nut Engine stop switch holder screw Brake lever pivot ball Brake lever pivot nut Spoke nipple Front axle nut Unit mm in STANDARD SERVICE UMIT 3 0 0 12 lOa kPa 1 00 kgf cm 15 psi 0 2010 00B 6 3 0 0 25 0 04 2 0 0 08 I 2 0 0 0...

Page 155: ...er 07702 0020001 Steering stem driver 07946 GC40000 or Steering stem driver 07946 MBOOOOO with Steering stem driver attachment 07946 GC4000A U S A only 12 4 Bearing remover shaft 07746 0050100 Attachment 32 x 35 mm 07746 0010100 Ball race remover 07944 1150001 Bearing remover head 12 mm 07746 0050300 Pilot 12 mm 07746 0040200 Attachment 37 x 40 mm 07746 0010200 ...

Page 156: ...eel wobbling Bent rim Worn front wheel bearings Faulty tire Unbalanced tire and wheel Wheel turns hard Faulty wheel bearings Bent front axle Brake drag Soft suspension Weak fork springs Tire pressure too low Stiff suspension Bent fork sliders Front Suspension noisy Damaged or bent fork sliders Loose fork fasteners Improper brake performance Incorrect adjustment of lever Contaminated brake shoes Wo...

Page 157: ... the number plate from the steering stem nut Remove the wire bands Remove the two screws and engine SlOp switchl throttle housing from the handlebar ENGINE STOP SWITCHfTHROTTLE HOUSING 12 6 Disconnect the throttle cable and remove the throt tle grip Remove the left handlebar grip Remove the two nuts and handlebar GRtP ...

Page 158: ...surface of the left handlebar Wait 3 5 minutes and install the grip GRIP Allow the adneslve Rotate t he grip for even application of the adhesive 10 dry for an hour before uSlflg ApplV grease to the throttle grip pipe flange and install the throttle grip onto the right handlebar GRIP Connect the throttle cable to the throttle grip pipe flange Install the engine stop switchlthrottle housing onto th...

Page 159: ...peration and free play page 3 6 FRONT WHEEL REMOVAL 12 8 Support the motorcycle securely using a safety stand or a hoist Remove the brake cable from the cable holder on the fork protector Remove the two socket bolts and fork protector Disconnect the brake cable from the brake arm Remove the axle nut axle and front wheel Remove the side collar from the right side wheel hub and the brake panel from ...

Page 160: ...k that the bearing outer race fits tightly in the hub Always replace rhe Remove and discard the bearings if they do not turn beanngs mpmrs smoothly quietly or if they fit loosely in the hub Wheel rim runout Check the rim runout by placing the wheel in a turn I ing stand Spin the wheel by hand and read the runout using a dial indicator Actual runout is 112 the total indicator reading SERVICE LIMITS...

Page 161: ...er shaft 07746 0050100 ASSEMBLY RIGI iT WHEEL BEARING 6201 U DUST SEAL Never Install the old Pack each wheel bearing cavity with grease bearmgs Once the Drive in a new left bearing squarely with its sealed bearmgs flave been side facing out removed the bear Install the distance collar and drive in a new right mgs musl be bearing using the same tools replaced wnh new TOOLS OM 12 10 Driver Attachmen...

Page 162: ... 1 lC 4 5 mm 07701 0020100 Equivalent corn merciallvavail able in U S A TORQUE 2 0 N m 0 2 kgf m 1 4 Ibf ft Check the rim unout page 12 9 6 3 1 0 mm 0 25 0 04 in Apply grease to a new dust seal lips then install it into the right wheel hub INSTALLAnON Do not gel grease Make sure any grease is cleaned off the inside of the onto the mner sur brake drum and brake shoes face of the brake Install the b...

Page 163: ...ly tighten the axle nut Install the spring and joint pin and connect the brake cable Install the adjusting nut Adjust the front brake lever free play page 3 16 With the front brake applied pump the fork up and down several times to seallhe axle and check brake operation Tighten the axle nut to the specified torque TORQUE 47 N m 4 8 kgf m 35 Ibf ft Install the fork protector and tighten the socket ...

Page 164: ...eel page 12 8 INSPECTION Measure the front brake drum I D SERVICE LIMIT 80 5 mm 3 17 in Measure the brake lining thickness SERVICE LIMIT 2 0 mm 0 08 in DISASSEMBLY Remove the spring and brake shoes Remove the nUl bolt and brake arm Remove the wear indicator dust seal and brake cam CAM DUST SEAL 12 13 ...

Page 165: ...ES Apply grease to the brake cam spindle Inslall the brake cam into the brake panel Apply oil to a new dust seal and install it onto the brake panel Install the wear indicator plale onto the brake cam by aligning its wide tooth with the wide groove in the brake cam INDICATOR ALIGN BRAKE ARM NUT BOLTS ...

Page 166: ...ke cam slid ing surfaces Install the brake shoes and spring as shown Wipe any excess grease of the brake cam and anchor pin INSTALLATION Install the front wheel page 12 11 DISASSEMBLY Remove the front wheel page 12 8 Loosen the brake cable nul and remove the brake cable from the fork slider Remove the dust seal from the fork ou ter tube by sliding it down Remove the stopper ring Remove the fork to...

Page 167: ...wing from the fork slider Fork springfspring holders Slider piston Slider guide Back up ring Stopper ring Oust seal INSPECTION Visually inspect each part for excessive wear or damage Measure the fork spring free length SERVICE LIMIT 158 3 mm 6 23 in PISTON SUDER GUIDE BACK UP RING FORK SUOER DUST SEAL T P RING ...

Page 168: ...p 5 6g Back up ri ng Slider guide apply 5 6 9 of grease to the slider guide sliding surface of the fork slider BACK UP NG STOPPER RING Install the slider piston and fork spring holders as shown Align the pin holes in the piston fork slider and spring holder so that the locating pin on the upper spring holder is facing inside of the fork slider and drive the spring pin to secure them using a 4 mm p...

Page 169: ...the outer tube Install the stopper ring into the groove in the outer tube properly Install the dust seal over the outer tube Wipe any excess grease of the fork slider Install the brake cable onto the fork slider and secure it by tightening the cable nut Install the front wheel page 12 1 STEERING STEM REMOVAL 12 18 Remove the following Number plale page 2 5 Handlebar page 12 6 Front wheel page 12 8...

Page 170: ...ering stem Lower bearing BEARING REPLACEMENT Always rep ace the Drive out the upper and lower bearing outer races bearings and races using the special tool as a set TOOL Ball race remover 07944 1150001 Drive new upper and lower bearing outer races into the steering head pipe using the special tool as shown TOOLS Driver Attachment 37 x 40 mm 07749 0010000 07746 0010200 PIN SPANNER STEM 12 19 ...

Page 171: ... washer Install the washer over the steering stem Apply grease to a new dust seal lips and install it over the steering stem Install a new lower bearing inner race using a spe cial tool and a hydraulic press TOOLS Steering stem driver 07946 GC40000 or Steering stem driver 07946 MBOOOOO with Steering st8m driver attachment INSTALLATION 01946 GC4000A U S A only STEERING STEM DRIVER TOP THREAD t UPPE...

Page 172: ... kgf m 18 Ibf ft Move the steering stem right and left lock te lock several times to seat the bearings loosen the top thread Retighten the top thread to the specified torque TORQUE 2 9 N m 0 3 kgf m 2 2 Ibf ftl Install the top bridge Install the slem nut and fork top bolts with the washers and tighten them TORQUE 74 N m 7 5 kgf m 54 Ibf ft Make sure that the steering stem moves smoothly without pl...

Page 173: ...13 REAR WHEEL BRAKE SUSPENSION COMPONENT LOCATION 13 2 REAR BRAKE 13 10 SERVICE INFORMATION 13 3 SHOCK ABSORBER 13 12 TROUBLESHOOTING 13 4 SWINGARM 13 14 REAR WHEEL 13 5 BRAKE PEDAL 13 15 13 1 ...

Page 174: ...REAR WHEEL BRAKE SUSPENSION COMPONENT LOCATION 34 N m kgf m 25 IbUt J o 34 N m 3 5 kgf m 251bUt 47 N m 4 8 kgf m 35 Ibf fl 39 N m 4 0 kgf m 291bHt 13 2 ...

Page 175: ...ng agent When servicing the rear wheel support the motorcycle using a safety stand or hoist Use genuine Honda replacement bolts and nuts for all suspension pivots and mounting points SPECIFICATIONS TORQUE VALUES Spoke nipple Rear axle nut Driven sprocket nut Rear brake arm nut Swingarm pivot nut Shock absorber mounting nut Drive chain slider nut 2 0 N m 0 2 kgf m 1 4Ibf ft 47 N m 4 8 kgf m 35 Ibf ...

Page 176: ...ROUBLESHOOTING Soft suspension Weak shock absorber spring Qilleakage from damper unit Tire pressure too low Stiff suspension Bent damper rod Damaged swingarm pivot bushings Bent swingarm pivot Tire pressure lao high Steers to one side or does not track straight Bent fear axle Axle alignment chain adjustment nol equal on both sides Rear wheel w obbling Bent rim Worn fear wheel bearings Faulty tire ...

Page 177: ...t the rear brake rod from the brake arm and remove the joint pin and spring loosen the drive chain adjuster lock nuts and adjusting nuts Remove the axle nut and left chain adjuster Push the rear wheel forward and derail the drive chain from the driven sprocket Remove the axle from the right side and remove the fear wheel Remove the left side collar from the left wheel hub Remove the brake panel fr...

Page 178: ...sety in the hub Wheel rim runout Check the rim runout by placing the wheel in a turn 1 1 ing stand 13 6 Spin the wheel slowly and read the runc ut using 8 dial indicator Actual runcut is 112 the total indicator reading SERVICE LIMITS Radial 2 0 mm 0 08 in Axial 2 0 mm 0 08 in Driven sprocket Check the condition of the final driven sprocket teeth Replace the sprocket if worn or damaged If the final...

Page 179: ... side install the bearing remover shaft and drive the bearing out of the wheel hub Remove the distance collar and drive OUI the other bearing TOOLS Bearing remover head 12 mm 07746 0050300 Bearing remover shaft 07746 0050100 ASSEMBLY DISTANCE COLLAR BEARING 6201U 32 N m 3 3 kgf m 24 Ibf ft REAR WHEEl BRAKE SUSPENSION BEARING 6201 U DUST SEAL DRIVEN SPROCKET BOLTS 13 7 ...

Page 180: ... using the same tools Wheel center adjustment Place the rim on the work bench Place the hub with the left side down and begin lac ing with new spokes Adjust the hub position so that the distance from the hub right end surface to the side of rim is 25 1 10 mm 1 0 0 04 in as shown TOOL Spoke wrench 4 1 x 4 5 mm 07701 0020100 Equivalent com merciallyavall able in U S A TORQUE 2 0 N m 0 2 kgf m 1 4Ibf...

Page 181: ...ar wheel into the swingarm by aligning the brake panel groove with the swingarm boss Install the drive chain over the driven sprocket Apply thin layer of grease to the axle Install the axle with the right drive chain adjuster from the right side Install the left drive chain adjuster and axle nut REAR WHEEL BRAKE SUSPENSION 13 9 ...

Page 182: ...rive chain slack page 3 13 Tighten the axle nut to the specified torque TORQUE 47 N m 4 8 kgf m 35 IbUt REAR BRAKE INSPECTION 13 10 Remove the brake panel from the rear wheel page 13 5 Measure the rear brake drum 1 0 SERVICE LIMIT 80 5 mm 3 17 in Measure the brake lining thickness SERVICE LIMIT 2 0 mm O OS in DISASSEMBLY Remove the brake shoes and spring SHOES SPRING ...

Page 183: ... arm Remove the indicator plate dust seal and brake cam ASSEMBLY REAR WHEEL BRAKE SUSPENSION CAM NUT ARM BRAKE ARM WEAR INDICATOR PLATE BRAKE SHOES Apply grease to the brake cam spindle Install the brake cam into the brake panel tCc llJ 5 9 N m 0 6 kgf m 4 3 Ibf ft 13 11 ...

Page 184: ...t and nut as shown and tighten it to the specified torque TORQUE 5 9 N m 0 6 kgf m 4 3 IbUt Install the brake arm cover onto the arm Assemble the brake shoes and spring as shown and install them onto the brake panel Wipe any excess grease off the brake cam and anchor pin Install the rear wheel page 13 9 SHOCK ABSORBER REMOVAL 13 12 Support the motorcycle securely using a hoist or equivalent and ra...

Page 185: ...leaks Bump rubber for wear or damage Mounting bushings for damage Replace the shock absorber assembly if necessary INSTALLATION Install the shock absorber into the frame and swingarm Install the upper and lower mounting bolts from the left side Install the nuts and tighten them to the specified torque TORQUE 34 N m 3 5 kgf m 25 Ibf ft REAR WHEEL BRAKE SUSPENSION DAIMP R ROD SPRING SHOCK ABSORBER 1...

Page 186: ...s and drive chain cover Remove the bolts and drive chain guard Remove the shock absorber lower mounting nut and bolt Remove the swingarm pivot nut bolt and swingarm Remove the nut and bolt and the drive chain slider INSPECTION Inspect the swingarm for wear or damage Inspect the pivot bushings for wear or damage NUT BOLT CHAIN SUI R ...

Page 187: ... the swing arm pivot nul to the specified torque TORQUE 39 N m 14 0 kgf m 29 IbUtl Tighten the shock absorber lower mounting nut to the specified torque TORQUE 34 N m 3 5 kgf m 25 Ibf ftJ Install the drive chain guard and tighten the bolts Install the drive chain cover and lighten the bolts Install the rear wheel page 13 9 Install the drive chain page 3 15 BRAKE PEDAL REMOVAL Remove the rear brake...

Page 188: ...d Unhook the brake pedal return spring from brake pedal Remove the cotter pin washer and brake pedal INSTALLATION the Apply grease to the pivot surface and install the brake pedal Install the washer and a new cotter pin to secure the brake pedal Install the return spring as shown ...

Page 189: ...t pin and secure it with a new cotter pin Install the spring onto the brake rod and the joint pin into the brake arm Install the rod to the joint pin with the adjusting nut Adjust the brake pedal free play page 3 16 REAR WHEEL BRAKE SUSPENSION 13 17 ...

Page 190: ... 2 SERVICE INFORMATION 14 3 TROUBLESHOOTING 14 4 IGNITION SYSTEM INSPECTION 14 5 IGNITION COIL 14 7 14 IGNITION SYSTEM IGNITION CONTROL MODULE 14 8 ENGINE STOP SWITCH 14 8 IGNITION SWITCH 14 9 IGNITION TIMING 14 10 14 1 ...

Page 191: ...NITION PULSE GENERATOR 14 2 ENGINE STOP SWITCH HJ IGNITION SWITCH HJ BIIW G BIIW G Wl SWITCH CONTINUITY ENGINE IGNmON STOP SWITCH SWITCH 1 OG 1 OG w Ie fa 1 0 f J BI BLACK G GREEN Y YELLOW R RED Bioi BLUE W WHITE n BIIW G BIIY BIIY G BIIR II111Y IGNITION CONTROL MODULE IGNITION COIL SPARK PLUG G o IGNITION PULSE GENERATOR o ALTERNATOR ...

Page 192: ...damage the module A faulty ignition system is often related to poor connections Check those connections before proceeding Use spark plug of the correct heat range Using spark plug with an incorrect heal range can damage the engine For alternator and ignition pulse generator removal and installation See page 10 3 SPECIFICATION TORQUE VALUES Ignition coil mounting bolt TOOLS Peak voltage adaptor wit...

Page 193: ...Faulty ignition switch or engine stop switch 4 Loose or poorly connected ICM connectors 5 Open circuit or poor connection in ground wire Green of the ICM 6 Faulty peak voltage adaptor 7 Faulty exciter coil Measure peak voltage 8 Faulty ignition pulse generator Measure peak voltage 9 Faulty ICM in case when above NO 1 8 are normal Peak voltage is normar but no spark 1 Faulty spark plug or leaking i...

Page 194: ...ARY PEAK VOLTAGE Check all system connections before inspection K C N C O c W C N c G O C O C D S C p C A C R C K c p C L C U C G If the system is disconnected incorrect peak volt age might be measured Check cylinder compression and check that the spark plug is installed correctly Disconnect the spark plug cap from the spark plug Connect a known good spark plug to the spark plug cap and ground the...

Page 195: ...and read the peak voliage PEAK VOLTAGE 0 7 V minimum leM CONNECTOR If the peak voltage measured at leM connector is riGNrnclNPlJUiEZ iffi miCmmECTc l abnormal measure the peak voltage at the pulse IGNITION PULSE GENERATOR generator connector Disconnect the ignition pulse generator connector Blue yellow and connect the peak voltage adaptor or tester probes to the connector terminal of the ignition ...

Page 196: ...tage at the alterna tor exciter coil connector Disconnect the alternator exciter coil connector Black red and connect the peak voltage adaptor or tester probes to the connector terminal of the exciter coil side and ground In the same manner as at the eM connector mea sure the peak voltage and compare it to the voltage measured at the leM connector If the peak voltage measured at the leM is abnor m...

Page 197: ...leM from the frame Installation is in the reverse order of removal ENGINE STOP SWITCH INSPECTION 14 8 Disconnect the engine slop switch connectors Check for continuity between the terminals There should be no continuity when the engine SlOp switch is in the OFF position and there should be ENGINE STOP SWITCH continuity when the engine stop switch is in the RUN position ...

Page 198: ...witch is in the OW posi tion and continuity when the ignition switch is in the OFF position REMOVAL INSTALLATION Disconnect the ignition switch connectors Release the tabs on the ignition switch body and remove the ignition switch At instal arIOn align Installation is in the reverse order of removal the gUide on the 19m ron SWITdI and groove on the frame IGNITION SYSTEM CONNECTORS 14 9 ...

Page 199: ...plug wire 1 0ns for tlmmg light operation 14 10 Start the engine and let it idle IDLE SPEED 1 700 100 rpm The ignition timing is correct if the F mark on fly wheel aligns with the index notch on the left crank case Increase the engine speed by turning the throttle stop screw and make sure the F mark begins to move clockwise Install the left crankcase cover page 10 8 ...

Page 200: ...15 WIRING DIAGRAM WIRING DIAGRAM 15 2 E 15 1 ...

Page 201: ...G BI BlACK Y YELLOW Bu BLUE IGNITION SWITCH IG E COLOR BWI G G GREEN R RED W WHITE IGNITION SWITCH OVW G I OW OIV or E IR o iv f n IGNITION CONTROL MODULE SPARK PLUG IGNITION COIL G o 01 0 n I IGNITION PULSE GENERATOR E E xl Z 2 Cl C 0 C Cl l l C s xl l s 01lA 01lA ALTERNATOR 0030Z GEL 7000 ...

Page 202: ...16 TROUBLESHOOTING ENGINE DDES NDT START OR POOR PERFORMANCE AT LOW IS HARD TO START 16 2 AND IDLE SPEED 16 5 ENGINE LACKS POWER 16 3 POOR PERFORMANCE AT HIGH SPEED 16 5 POOR HANDLlNG 16 6 16 1 ...

Page 203: ...stem wires YES GO TO STEP 3 3 Sparic Plug Inspection Remove and inspect spark plug Is the spark plug in good condition NO Flooded carburetor Choke valve closed Air cleaner dirty YES GO TO STEP 4 4 Engine Start Condition Start by following the normal procedure Does the engine start but then stop YES Improper choke operation Carburetor incorrectly adjusted Intake pipe leaking improper ignition timin...

Page 204: ...TEP 4 4 Engine Performance Inspection Accelerate lightly Does the engine speed increase NO _ Choke valve closed Clogged air cleaner Restricted fuel flow Clogged muffler Pinched fuel tank breather hose YES GO TO STEP 5 5 Ignition Timing Inspection Check the ignition timing Is the ignition timing normal NO _ Faulty ignition control module Faulty ignition pulse generator YES GO TO STEP 6 6 Cylinder C...

Page 205: ...ver and inspect lubrication Is the valve train lubricated properly NO _ Clogged oil passage Clogged oil control orifice YES GOTDSTEP1 11 Over Heating Inspection Check for engine over heating Is the engine over heating YES _ Excessive carbon build up in combustion chamber Use of poor quality fuel Clutch slipping lean fuel mixture Wrong type of fuel NO GOTO STEP 12 12 Engine Knocking Inspection Acce...

Page 206: ...enerator Loose or disconnected ignition system wires YES GO TO STEP 4 4 Ignition Timing Inspection Check the ignition timing Is the Ignition timing normal NO Improper ignition timing Faulty ignition control module POOR PERFORMANCE AT HIGH SPEED 1 Fuel line Inspection Disconnect the fuel hose at the carburetor Does the fuel flow freely NO _ Clogged fuel line Clogged fuel tank breather hose Faulty f...

Page 207: ...gth normal NO Faulty spring YES Not weak POOR HANDLING Steering is heavy Steering stem adjusting nut 100 tight Damaged steering head bearings Either wheel is wobbling ExcessivB wheel bearing play Bent rim Improper installed wheel hub Swingarm pivot bearing excessively worn Bent frame The motorcycle pulls to one side Faulty shock absorber Front and rear wheel not aligned Bent fork Bent swingarm Ben...

Page 208: ...STATOR REMOVAL 10 4 FORK 12 15 FRONT BRAKE 12 13 FRONT FENDER 2 5 FRONT WHEEL 12 8 17 INDEX FRONT WHEEUBRAKEISUSPENSION STEERING SPECiFiCATIONS 1 8 FUEL LINE 3 6 FUEL SYSTEM SPECIFICATIONS 1 6 FUEL TANK 2 4 GEARSHIFT LINKAGE 9 16 GENERAL SPECIFICATIONS 1 5 HANDLEBAR 12 6 IGNITION COIL 14 7 IGNITION CONTROL MODULE 14 8 IGNITION SWITCH 14 9 IGNITION SYSTEM INSPECTION 14 5 IGNITION SYSTEM SPECIFICATI...

Page 209: ... ELECTRICALSYSTEM 14 4 ENGINE DOES NOT START OR IS HARD TO START 16 2 ENGINE LACKS POWERT 16 3 17 2 FRAME BODY PANELS EXHAUST SYSTEM 2 2 FRONT WHEEUBRAKE SUSPENSIONI STEERING 12 5 13 4 FUEL SYSTEM 5 4 LUBRICATION SYSTEM 4 3 POOR HANDLING 16 6 POOR PERFORMANCE AT HIGH SPEED 16 5 POOR PERFORMANCE AT LOW AND IDLE SPEED16 5 VALVE CLEARANCE 3 9 WHEELSfTlRES 3 20 WIRING DIAGRAM 15 2 ...

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Honda CRF50F 2004-2015, Service Manual

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Summary of Contents for CRF50F 2004-2015

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