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Honda Gold Wing GL1100, Service Manual

The Honda Gold Wing GL1100, a legendary touring motorcycle, comes with a comprehensive Service Manual that allows riders to maintain and repair their bikes with ease. This invaluable manual is available for free download from our website, ensuring you have all the information you need to keep your Gold Wing running smoothly.

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Summary of Contents for Gold Wing GL1100

Page 1: ...will be called out in the text or a note Variations between the different model years are also called out Sections 1 3 apply to the whole motorcycle while sections4 18 describe parts of the Gl11 00 grouped according to location Section 19 Accessories covers torque specifications and removal installation of accessories Be sure to refer to the Maintenance Schedule Section 31 whenever a motorcycle is...

Page 2: ...General Information Service Safety 1 2 Model Identification 1 3 Emission Control System 1 4 Metric Conversions 1 6 N P S Part Numbers 1 7 Tools III III IlII lj III it 8 ...

Page 3: ...ase of contact flush thoroughly with water and call a doctor if your eyes were exposed 1Ft V generates hYldr lge n gas which can be v espe ciailly while it explosive Do not smoke or allow flames or sparks near the 1M SAFETY NOTICE Detailed of standard principles and service are not included It is imlJortarlt to note that this manual contains some and cautions some service methods which could PERSO...

Page 4: ...the head The frame serial number is stamr ed on the t p n nn head side of the The serial number is sta mr ed on the top the crankcase side of GEAR SERIAL NUMBER The final drive serial number is on the left side of the case near the The carburetor identification number is on the left side of the carburetor 1 3 ...

Page 5: ...erated and maintained according to the instructions provided with the terms ohhe Distributer s Warranties for Honda Emission Control is necessary in order to keep the emission control system warranty in effect Exhaust Emission Control System The GL1100 is with a crankcase emission control system which routes crankcase emissions thnou lh the air filter and into the combustion chamber Condensed cran...

Page 6: ...ncorporated into any new vehicle forthe purpose of noise control prior to its sale or to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW Removal 01 or the muffler baffles header or any other component which condu...

Page 7: ...3 3 281 0 03937 0 3048 25 40 0 6214 1 609 14 22 0 0703 To Obtain Foot pounds Newton meters N m Feet ft Inohes lin Meter Millimeter Mile mi Kilometer km Pounds Sq inch psi Kilogram Sq centimeter 1I 1i Im j Volume Cubic centimeter inches 32 1 8 0 2642 1 0568 0 9463 3 785 0 061 16 39 2 205 0 03527 0 4536 28 3495 Fahrenheit Gallon gal Quart qt Liter I Liter I Cubic inches in Cubic centimeters Pounds P...

Page 8: ...Number Method of Manufacture of thread Normal DIameter under the head Material Surface Treatment Semi Standard Numbers Front Wheel Dust Seal Function Detail Number Product Number first Classification Manufacturer 92120 060420Z 92 1 20 06 042 o Z n Irinlos bearings 91251 300 003 91 2 51 300 00 3 Sp 9cial Numbers Non interchangeable Left Side Cover Function Product Classification Color Code 83700 37...

Page 9: ...230000 Valve wrench 0479782 M937B 021 XXXXX Vacuum gauge kit 0400747 M982X 350 XXXXX Kit adaptor 6 2 required 0400754 M983X 350 XXXXX Kit adaptor 2 2 0719575 07908 4220100 Carburetor wrench 0630681 07999 3710001 inspection plug H 0413070 07925 3710200 Timing holder 0688150 07757 0010000 Valve compressor 0724906 07942 6570100 Valve driver 6 6 mm or or 0487215 07942 6110000 0724898 07984 6570100 Val...

Page 10: ...99373 07910 3710000 07924 3710000 07965 3710100 07749 0010000 or 07949 6110000 07945 330100 07910 4630100 07973 4630200 07973 46301 00 07935 MBOoooo 07746 0010400 07947 46301 00 07716 0020203 KS HBA 08 469 07916 3710100 07946 MBOooOO 07946 3710500 07946 3110701 01749 001 0000 or 07949 6110000 07746 0010200 07914 56701 00 07947 3710101 07953 4250002 07936 3710100 07936 3710200 07936 8890300 Final g...

Page 11: ...02 07347 0010100 07923 4610000 or 07923 3710000 07716 0020203 07945 3710101 077 0 0010200 07710 0010100 07710 0010401 07749 0010000 07746 0010300 07746 0010400 07746 0040300 07772 0020201 077 00 holder Piston base Piston tool set Vee blocks Clutch center holder Locknut socket wrench Clutch outer driver Retainer wrench attachment front Retainer wrench attachment Retainer wrench Driver Attachment 42...

Page 12: ...s listed here are those that Tool Used In Sections Feeler gauges blad and wire types wrench 0 140 N m 100 Floor or ri Ulr tvr pressure gauge indicator om nrc ion tester Vernier calipers scale micrometer or bore gauge Outside micrometers a mm 25 50 mm 50 75 mm 75 100 mm 4 7 8 9 10 12 4 6 7 8 9 10 12 13 16 17 19 3 6 12 3 12 14 18 3 13 14 3 7 7 9 10 12 13 17 3 12 16 17 7 8 12 13 7 8 10 12 13 16 pan a...

Page 13: ...Specifications General fl IlIi iW III It Jl 0 III III II IIIIl III III iii 2 2 Electrical 2 5 Standards Service Limits 2 6 ...

Page 14: ... Curb Frame Type F suspension travel and air pressure 1980 1982 1983 Double cradle Telescopic 47 mm 5 8 in 100 150 kPa 1 0 1 5 14 21 Telesc opilc 140 mm in 100 150 kPa 1 0 1 5 14 21 R suspension travel and air pressure 110 90 19 62 H 225 kPa kg cm2 32 psi 120 90 18 65H M120 90 18 225 kPa kg cm2 32 psi Sw inmHm 80 mm 3 1 in 200 300 kPa 3 0 28 42 psi SwinOlHm 80 mml 200 400 kPa 4 0 28 57 psi 1980 19...

Page 15: ......

Page 16: ...C SAE 80 below SoC 41 Electrical Transistorized NO X22ES U X22ESR U X22EPR U9 X24ES U X24 ESR U X24EPR U9 X27ES U X27ESR U X27EPR U9 NGK D7EA DR7ES DPR7EA 9 08EA DRSES L DPR8EA 9 09EA DR8ES DPR9EA 9 at 950 rpm at 950 rpm at 3 000 rpm St lrtirln motor generator 12V 300W 5 OOO rpm mark 1980 1981 1982 timing 1980 981 for 1 982 cold climate 1980 1981 optional for 1 1982 For extended speed riding 1980 ...

Page 17: ...Force damper 26 mm 1 02 in 55 175 kg al 20 mm 386 Ib at 0 787 in t 12 13 mm 0 47 0 51 in 5 5 mm Ill 560 680 gr 19 7 24 0 all 400 gr 14 0 Ol Brush length Service limit Brush tension Service limit Fan Motor type 12V DC Speed 2800 rpm Current without 1 4 A Blade rotation Clockwise from rider s position Rated current and speed 4 6 0 5 A 2 500 300 rpm Switch 7A Starter Switches Instruments Oil pressure...

Page 18: ...05 1 065 0 140 0 0055 24 91 0 980 25 05 0 986 0 140 10 or more than 1 0 kg cm2 15 variation between cylinders Rocker Arms Rocker arm 1 0 And Shafts Rocker shaft D O Camshaft holder rocker shaft hole 0 0 Valve Outer free Inner free 14 00 14 02 0 551 0 552 13 97 13 98 0 549 14 00 14 02 0 551 43 8 1 40 2 1 14 05 0 553 13 94 0 548 14 05 0 553 42 5 1 67 39 0 1 Outer51 5 3 6kgat 28 mm 113 5 7 9 ib at 1 ...

Page 19: ...0 141 35 5 1 23 8 at 23 mm 52 4 Ib at 0 905 0 3 0 012 3 20 1 34 2 1 21 8 at 23 mm lb at 0 905 in 31 050 1 30 900 1 2165 0 150 0 0059 28 060 1 1 27 900 1 0984 0 160 0 0063 31 060 1 30 900 1 2165 0 160 0 0063 25 060 0 9866 0 150 0 0059 28 060 1 1 047 27 900 1 0984 0 160 0 0063 0 200 0 0097 0 120 0 0047 31 000 31 025 1 2205 1 2215 30 950 30 975 1 2185 1 2195 0 025 0 075 0 0001 0 0030 28 000 28 033 1 ...

Page 20: ... 0 007 0 17 Gear Backlash Assembly preload Pinion preload 0 3 2 Front fork Air pressure Fluid capacity 1980 1981 982 Fluid capacity 980 1981 982 free length free length 1980 1982 1983 Slider 1 0 Tube D O Guide i 0 A B 1 0 1 5 14 21 220 cc oz 270 cc ozl 240 Cc oz 290 cc ozl 111 7 4 40 466 2 1 472 2 18 59 40 040 40 080 1 5764 1 38 950 38 975 1 5335 1 39 02 39 11 1 536 1 540 106 0 7 442 0 1 7 40 462 ...

Page 21: ...57 13 984 V J 15 827 15 854 42 85 42 90 1 687 1 30 23 30 28 1 190 1 1 42 772 42 822 1 6839 1 30 148 30 198 1 187 1 1 15 870 15 913 v u u 15 827 15 854 cylinder LO 980 1982 983 cylinder piston 0 0 980 1982 1983 1 0 1980 1981 1982 Caliper piston 0 0 980 1981 1982 Disc thickness 9S0 Standard and Interstate 19S 2 Asiperlcal Je Disc runout Pad thickness Master 1 0 Master cylinder piston 0 0 Caliper 1 0...

Page 22: ...chronize 3 16 Carburetor Idle Speed 3 17 R iator Coolant Hoses and Core 3 17 rive Shaft Joint 3 18 Final Drive lubricant 3 19 Battery 3 20 Brake Fluid 3 20 Brake Pad VVear 3 21 Brake System 3 21 Brake light Switch 3 22 Headlight Aim 3 23 Clutch 3 23 Side Stand 3 24 SuspensionlSteering Head Bearings 3 25 VVheels Tires 3 27 Ignition Timing Check 3 29 Compression Test 3 30 Oil Pressure Test 3 30 Oil ...

Page 23: ... 50 mm 2 Hg Clutch free 0 20 mm COimpres sicln pressure Standard Service Limit 12 10 1 0 difference between cvllnders Coolant 50 ettivl me 50 water base antifreeze UI IIlI IJ system CalJaclty 3 4 US qt Drive shaft grease NlGI 2 lithium based mUIU uqpmle grease with mCllyt delnum OISUlp mCle additive order Final drive lubricant Idle 1980 1981 1982 marks 1 3 2 4 gear oil API GL 5 Over 5 C 41 F SAE 9...

Page 24: ...81 1982 09ES DR9ES OPR9EA 9 X27ES U X27ESR U X27EPR U9 Cold climate 1980 1981 1982 D7ES DR7ES DPR7EA 9 X22ES U X22ESR U X22EPR U9 up to 200 Ib load up to vehicle load 14 21 28 42 57 0 57 psi 1 0 1 5 2 0 3 0 2 0 4 0 0 4 0 Front Rear 1981 1 982 198 Aspe nc lde 1BaS STD Interstate Recommended air pressure Front Rear 1980 Tire pressure Valve clearance below 35 C Intake Exhaust 0 10 mm 0 13 mm cont d 3...

Page 25: ...8Q 1982 35 25 1983 22 16 Front axle nut 58 42 Front brake disc bolt nut 30 22 Front mount bolt 1980 1982 35 25 1 40 29 23 17 Front bolt 198Q 1981 18 13 1982 23 17 pivot bolt 1983 28 20 Front master cylinder holder bolt 10 7 Brake hose bolt 30 22 Brake hose joint bolt 12 9 Rear wheel axle nut 1980 1982 90 65 1983 95 69 Rear brake disc bolt nut 30 22 Rear torque link 22 16 Rear master cylinder bolt ...

Page 26: ...18 13 Air pressure sensor 10 7 Air hose 10 6 4 Air hose 12 11 8 Air hose bolt 6 mm 10 7 Air hose bolt 10 10 7 Connector 6 4 lock nut 14 10 mount bolt 8 22 16 mount bolt 10 mm 35 25 Exhaust nut 18 13 bracket 60 43 Rear bolt 40 29 Muffler mount bo t 40 29 Gearshift bolt 10 7 Rear fender mount bolt 14 10 case mount bolt 22 16 Side stand bolt 22 16 Center stand bolt 22 16 Exhaust muffler bolt 22 16 3 ...

Page 27: ...d Fue cap vent clogged Engine But Will Not Start Weather Choke too lean Ice in fuel lines carburetors fuel tank or fuel filter due to low temperature Incorrect oil Water pump iced antifreeze Maintenance Troubleshooting n ninlA Will Not Crank ch rqma system Starter or starter system seized Switches or accessory Engine But Will Not Start Engine Hot Fuel flow stclpp ed in lines carburetor or fuel pum...

Page 28: ...8 3 19 11 14 14 12 3 20 3 20 Whichever Comes First Year Radiator Core Speed Radiator Coolant COioling Sv te m Hoses it Should be serviced by an authorized HONDA dealer unless the owner has proper tools and service data and is m h nil lll l qualified In the interest of safety we recommend these items be serviced ONLY by an authorized HONDA dealer NOTES 11 Service more frequently when riding in dust...

Page 29: ...he left side and pull the fuel pump inlet line off Loosen the hose the fuel pump Remove the fuel filter bracket and loosen the hose at each end of the filter Pull the fuel lines off the filter and install a new filter with the arrow on the toward the fuel pump Install the fuel filter bracket on the filter and Route the fuel line under the fuel tank and connect it to the fuel pump Position the fiit...

Page 30: ...rottle operation is not smooth lubricate the throttle cables Make sure throttle grip free play is 2 6 mm throttle at the Make minor lrliw tmAnt5 with the adjluster at the throttle loosen the the lock adjustments with the rernovirlo the top compartment To make with either lock nut tum the adjuster as and Make throttle middle cable adj ustl9r Recheck throttle operation and install all removed parts ...

Page 31: ...e choke cable If operation is not Adjust if necessary by loc seninia the choke cable on the carburetor and the cable so the choke lever is closed the clamp Push the choke knob all the way down or the choke lever on the handlebar all the way to the sure the choke valve is open by for free in the cable between the lever and cable 1980 1982 The choke knob must move smoothly operation friction by and ...

Page 32: ...nt Install the air cleaner cover and nut tool tray and close the top compartment cover Crankcase Breather loosen transparent tube lower Remove the storage tank rnillmnnn bolt and remove the storage tank any depo lts from the tank and reinstall the storage tank NOTE Service more when in rain or at full or if the level can be seen in the transparent section of the drain tube 3 11 ...

Page 33: ... t981 0 6 0 7 mm 0 024 0 028 in 1982 0 8 0 9 mm 0 031 0 035 in car eflllly h rlrlirlf1 the side the gap necessary electrode washers on the and thread them into the CVllndl lr heads hand to avoid crclssthrea lin g hand then them an additional 1 2 tum with wrench to compress the washers Standard For Cold Climate For Extended High below 5 C 41 F Speed Riding D8EA D7EA D9EA NGK DR8E L DR7ES DRSES DPR7...

Page 34: ...n the mark hole the T 1 mark of the timing Make sure the No 1 is at TDC Dead the stroke the rocker arms If do not move rotate the generator rotor clockwise one comrllete turn and the T 1 mark with the index mark The rocker arms should now move that the No 1 piston is on the stroke Check valve clearance for these valves No Intake No 1 Exhaust No 3 Exhaust No 4 Intake Valve Clearance Intake 0 10 mm ...

Page 35: ...filter bolt and oil mark hole cap and Change drain oil with the its center stand to assure com lete 2 Intake Exhaust No 3 Intake No 4 Exhaust Remove oil filler cover Rotate the generator rotor clockwise one turn and the T l mark with the index mark Make the No 2 is at TDC on the stroke NOTE ChainQ Check valve clearance for these valves check that the drain condition and install the Reol lce the oi...

Page 36: ...dicated range there are no oil leaks and let it idle for a few minutes the make sure the oil level is at the upper level mark window the window if necessary viscosities average temperature eleictl iClJllly driven but the is mechan At the regular scheduled oil filter change interval the odometer a maintenance indicator from to Be sure to reset the indicator after each oil filter by inserting the ke...

Page 37: ...the idle speed to 950 1 VACUUM GAUGES HIC 047978 PIN M9371H121 XXXXX Check that the difference in vacuum gauge recldirlgs is 50 mm or less NOTE The No 3 carburetor cannot be adj Us1ted It is the base Recheck the syrlcrlrolliziati m and idle speed If adjustment is necessary loosen the lock nuts and turn the adj ust in9 screws with the adjustment wrench 071957 PIN 07908 42201 until the vacuum gauge ...

Page 38: ...and remove the tool tray Check the coolant level in the reserve tank with the engine at normal temperature It should be between the FULL and lOW level lines If necessary remove the reserve tank cap and fill to the FULL level line WARNING Avoid never remove the radiator cap when the is hot The coolant is under pressure Re install the top compartment cover Fill the radiator with coolant and install ...

Page 39: ...o them the radiator if the air flow is restricted over more than 20 of the surface M M the hoses for cracks and deterioration Rep ace necessary Check the of the hose radiator nuts Refer to Section 5 for coolant rej llac enlerlt Drive Shaft Joint Recommended grease NlGI 2 or lithium based mtlitil urpoise grease with m llyl de num disulfide additive Lubricate the drive shaft grease the grease pUlTlp...

Page 40: ...t With the on its center stand put a pan under the final drive Remove the filler cap and drain Rotate the wheel by hand to drain any residual oil Fill the gear case with the recommended gear oil Allow 2 3 minutes for the oil to flow around the gear teeth and hp lnl n and check level Install the filler cap Recommended Gear 011 Hypold gear oil API GL 5 Over 5 C SAE 90 Below 5 C SAl 80 140 160 cc 4 7...

Page 41: ...d In case of contact flush with water and call a doctor if your eyes were expose d Brake Fluid Check the front and rear brake fluid reservoirs are filled to the upper level mark If the level nears the lower level mark fill the reservoir with DOT 3 fluid to upper level mark Be sure to check the entire system for leaks if the fluid level is Refer to Section 13 for the brake bleeding fJILJL t ULIft C...

Page 42: ...disc pressure R I both brake pad reaches the 1980 1981 1982 brake so the is the spl cij jed distance below the upper surface of the fOQ1tpeig Brake System Brake Pedal HeiiQht Brake pedal 1980 1982 1983 CAUTION Incorrect brake 7 rnm 10 mm height can cause brake after adj ust ing switch next the brake loosen the lock nut and turn the master cyl m Jer push rod the lock nut To NOTE pedal 3 21 ...

Page 43: ...e hoses and for deterioration cracks and of lealkage any loose hoses and require d B light Switch the adlustma does not and switch so the brake comes on is and brake engagement NOTE The front brake holdirlg the switch nut Do not turn the switch ...

Page 44: ... lul ltioln the screw on the headiiigl1t rim Tum the screw clockwise to move the beam toward the rider s left lutch Make minor with the at the clutch lever back the dust cover loosen the lock nut and turn the the lock nut and reinstall the dust cover NOTE Do not expose more than 8 mm threads the lever holder measured of adJ ustl r 6 is 10 20 mm Normal clutch leverfree at the end of the lever Check...

Page 45: ...ch cable on the loosen the lock nut Turn the nut to obtain 15 mm free at the lower clutch lever the lock nut Make the final lnllw rtm nt with the adiuster at the clutch hand lever After be sure all lock nuts are un ny Test ride the and make sure the clutch engages and does not Side Stand Check the rubber for deterioration or wear If wear extends to the wear line with a pad marked Over 260lbs GOOD ...

Page 46: ...0 not ride a vehicle with faulty suspension components loose worn or damaged parts impair vehicle s lbillity and control Check front fork action by the front brake and nmrHA innthe forks several times The should Check the entire fork assembly for and of the air hoses for deterioration and cracks HetJlac e parts as reqluired all nuts and bolts Place the m ltOlrCyc e on its center stand Remove the f...

Page 47: ...full left to full Push and the sliders and check that there is no free or looseness Place the mCltorcvcle on the center stand the rear wheel from side to side If or looseness the W f tClan11 darna le and proper li lml nt 1 1 the air hoses for deterioration and cracks of leakage and bolts SW lmlanm tor rlBmilnp all the shock absorbers for damclge and Check valve cap and make sure air pressure is Re...

Page 48: ... light comes on and stays on while over 10 mph recheck the rear suspension air pressure and condition NOTE 1983 models are not eqljip ed with the rear suspen sion air pressure system Wheels Tires Check the wheel rim for visible damage ComStar W and cast wheels must be replaced if or deformed dial indicator measure both radial and axial runout while the wheel If either runout measurement is the seN...

Page 49: ...l tires on tubeless rims The beads may not seat and the tires could on the rims ca using tire deflation CAUTION Do not try to remove tubeless tires without tools and rim protectors You may damage the rim se llil1lQ surface or the rim Check tire pressure when the tires are cold Front Rear 1980 1981 110 90 1 9 62H 130 90 17 68H Tire Size 1982 120 90 18 65H M120 90 18 140 90 16 I 71 H M140 90 16 Cold...

Page 50: ...p was omitted from the next two I 1 I i I I I I TIMING INSPECTION CAP HIe 063068 PIN 07999 3710001 Start the With the F mark on index mark on the to the No 1 or No 2 100 the flVINheel should with the mark hole the F 2 mark to the No 3 or No 4 is If the refer to section 15 for innitinm NOTE No innitinln marks do not system component Inspel tic n With the should 3 29 ...

Page 51: ...ION CHART CYl cn 2 4 FRONT the remaining three Normal compression pressure is 171 If COI 11pres sic n pressure is below 10 142 or if there is 14 variation between cylmders there is at the valves piston rings or cvlincjer head gasket the test cylinders and record the results 171 PSI 167 PSI Oil Pressure Test Remove the rear oil gauge and install an oil pressure pressure while the temperature below ...

Page 52: ...s rRflanrlina gum and remover NOTE If evidence of coolant is found at the core remove the heads and the head If found around the core drain the coolant and remove the core the valve train area for dark gummy coolant into the oil If can tamination Is evident remove camshafts and valve train to the plugs and filter Nuts Bolts Fasteners hose n and cable stays cotter Check Check that all chassis nuts ...

Page 53: ... the desiccant is colorless disconnect the air hoses and remove the air drier Remove the drier and the desiccant coior in the window The desiccant should be biue the top compartment cover and off the drier cover DESICCANT Close the top compartment cover Remove the other pa Klllgs and retainer RETAINER PLATE CCANT PACKING P SPRING PACKING I I CAP J RETAINER PLATE i 4t SPRING SEAT t COVER SCREW 12 4...

Page 54: ...ooting Fuel Filter Fuel Pump III II III II III II IIIl ill III II II II lit Ca rburetors Air Chamber System Removal Carburetors Carburetors Air Chamber System Installation Pilot Screw Adjustment Fuel Tank 4 2 4 3 4 4 4 8 4 5 4 8 4 13 4 14 4 15 ...

Page 55: ...place used J I n lS and cotter pins with flew ones WARNING Gasoline is flammable and is explosive under certain conditions Work in a well ventilated area Do not smoke or allow flames or sparks in the work area pump bolt Fuel pump cover bolt Carburetor to air chamber screws plate screws Air chamber screws Throttle center bolt Throttle link ta carburetor nuts Rear master cylinder bolts Rear fender 4...

Page 56: ...blocked Fuel line kinked restricted Fuel blocked Carburetor fuel inlet filter screen clc gged Carburetor needle and seat stuck closed Float level too low Air intake lock Mixture Excessive Fuel Choke stuck closed Float level set too or float tit kinn Needle and seat or worn Carburetor air Air cleaner Clc ggied The Cylinders During Acceleration malfunction air cutoff valve or accelerator pump Backfi...

Page 57: ...na at 1100 rpm at 5000 rpm 0 17 1 2 0 16 kn I 2 0 141 1 Connect a with Start the output pressure Fuel Pump _ Install the fuel bracket on the filter and Route the fuel under fuel tank and connect it to the pump Position the filter bracket on the fuel tank and install the nut the hose at the fuel pump NOTE Install fuel filter with the arrow on the filter nnintinn toward the fuel pump Disconnect the ...

Page 58: ...for blc ckage for tears or deterioration The must be if the See page 7 6 for fuel pump removal Carburetors Air Chamber System Removal Remove the top compartment tool box and air cleaner cover Remove the air cleaner element Remove the two bolts and the cleaner case holder 4 5 ...

Page 59: ... Disconnect the caps from the unhook the leads from the carburetor stay side Remove the 1 and No 3 carburetor vacuum chamber covers and place a towel over them II Do not pry between the intake pipes and the head because this may the mounting surfaces II Do not vacuum chamber covers and vacuum between carburetors Move the carburetors and air chambers as an to the left side and disconnect the thrott...

Page 60: ...om the 3 and No 4 carburetors at No Disconnect the choke rernOlllnlQ the two cotter arm at the No 3 carburetor Remove the air chamber seal Remove the five screws the air chamber halves tO let ler Sel larate the air chamber CAUTION Do not pry the chamber halves apart or the 0 and surfaces may be damaged Remove the two screwS each carburetor to the air h rr hl r half Remove the wire screen from the ...

Page 61: ... loosen the throttle linkage adiustil1lQ screw Carburetors _ Remove the vacuum chamber cover Carefully lift out the vacuum with its needle and CAUTION Do not interchange vacuum chamber covers and vaCuum between carburetors Insert a center hole and needle Remove the stopper from the vacuum narrow screwdriver into the vacuum remove the screw that secures the Ins pect the vacuum and vacuum chamber co...

Page 62: ...seat from the carburetor Clean the strainer with clean solvent for grooves nicks or deposits Remove the float for damaQe the float valve Replace if necessary NOTE If the needle is difficult to remove c8r efl lv press it out from the cvlm 1p r side Remove the main and needle carburetor to remove the needle jet holder Tilt the 4 9 ...

Page 63: ...am lge to the screw seat will occur if the screw is tiQlntened agairlst the seat screw with the limiter cap Remove the Tilt the carburetorto remove the Remove cutoff valve cover and In rt the and valve for cracks and brittleness Remove accelerator pump cover and II J the for cracks and brittleness Be sure the accelerat r pump rod is bent 4 10 ...

Page 64: ...ure the float level with the float level gauge necessary by the float arm Check the float level and NOTES l1li Do the air cutoff valve or the accelerator pump dillpl1ralgnn II When the air cutoff valve flat surface is the carburetor l1li Do not the needle holder and float valve Float level 15 5 mm 0 61 it if necessary If screw turn it to its removal before im tallinig Inspect the pilot screw for w...

Page 65: ...e adjustment is cOinpleted If Install float chamber The sequence is the reverse of washers between the with oil and assemble 3 and No 2 NOTE Insert the throttle as shown install the stay and attach the carburetor to the air chamber halves Be sure to install the wire screens in the chamber halves Assemble the air chamber halves and install the five screws Install the air chamber seal and No 2 and N...

Page 66: ... the hose the the accelerator pump before the car buretors on the Measure the clearance between the arm and stopper on the carburetor Carburetors Air Chamber System Installation Instal the carburetor air chamber system on the the left side Reconnect the throttle cables while the is accessible before final is made the installation of the carburetor air chamber system in the reverse order of removal...

Page 67: ... Adjustment Idle Procedure NOTE iIII The screws are necessary unless the 4 1 l1li Use tachometer with of 50 rpm or smaller that wi indicate a 50 rpm vll Cll I I If you with the throttle stop screw with the throttle stop screw screw turn out from the increases 50 rpm or more turn screw out 2 turn at a time until 50 rpm or less the idle Idle 950 rpm NOTE Use a tachometer with yn UIJiHIUII of 50 rpm ...

Page 68: ...The lirl it r r the stops so can be turned clockwise This will prevent in the counterclockwise direction which enriches the fuel mixture NOTE Do caps e You must fuel Tank Remove the seat and the top compartment Remove the fuel tank cap and overflow tray side cover Remove the rear master bolts and rod clevis Do not disconnect any brake hoses or rear nipn C n air hoses 4 15 ...

Page 69: ...ve the rear wheel and shock absorbers Refer to section 14 CAUTION Be sure to support the so it does not and final drive gear case or brake hose Disconnect the tail and turn wires Remove the hand rail and both sections of the rear fender Remove the left side cover Remove the box Remove the left side mount remove the fuel valve 4 16 ...

Page 70: ...Disconnect the fuel gauge wires Remove the tank bolt and cross Move the fuel tank toward the rear of the mc torcvcle and out of the frame reinstall the fuel tank reverse the removal PrlJcE dlHe 4 17 ...

Page 71: ...Cooling System Service Information 5 2 Troubleshooting 5 3 Coolant Replacement 5 4 System Testing 5 6 Removal Inspection 5 7 Reinstallation 5 10 ...

Page 72: ...eze system A 50 50 mixture is recommended for maximum corrosion Add coolant at the reserve tank Do not remove the radiator cap except to refill or drain the system ReIJIIl e coolant every 24 000 miles I Q V kilonnet ersl or whenever there is evidence of lime scale or rust in the radiator 6 MM CAP NUTS 12 N m 9 ft lbl Torque Values Thermostat cover bolts 23 N m 17 Water pump body bolts 10 N m 7 ft ...

Page 73: ... water Incorrect Ignlltl n Thermostat stuck closed Insufficient coolant Radiator cap not pressure Fan not WClrl lno thermostatic switch fan motor Water pump not rotlHing Water pump lml lelilers damage1d Incorrect coolant water ratio Insufficient Coolant External leaks in fl lrlliAt lr hoses or water cap not 110111iI ll0 pressure Coolant into oil head coolant into CYlilnaers Air leak or kink in hos...

Page 74: ... radiator cap counterclockwise to release pressure press down and twist to remove the cap Remove the reserve tank filler cap and pull out the tube RESERVE TANK down coolant will NOTE If the tube is left over the After the coolant has been Y nl t l drained reinstall and the Put a undertoe and remove the coolant drain Remove the bolt at the bottom of the reserve tank and the tank from its and rinse ...

Page 75: ...n the radiator the oriininRI steps Fill the radiator with water Run the then drain it the OrlQmal steps Do this twice to ensure that all is rinsed out of the system Fill the radiator with a 50 50 mixture of water and eUlVlEme antifreeze Run the without the radiator cap until the coolant level stabilizes add more coolant as necessary Fill the reserve tank to the FULL line while the is I mlll at nor...

Page 76: ... seconds If it does not hold pressure or if relief pressure is too or too low the cap Relief Pressure 0 75 1 05 kn t1 1 1 2 14 9 psi surface and Remove the radiator cap wet its pressure test it as shown System Pressure EXicesisi e pressure can damage the radiator Do not let system pressure exceed 1 12 kg cm2 15 9 these tests Connect the tester to the radiator and pressurize the system to 1 05 14 9...

Page 77: ...s Radiator is good NOTE If the radiator hose swells ex esslvely during these tests it is weak and should be replaced Heplclce the radiator Needle Small leaks sel3palge as necessary Disconnect the fan motor wires and drain the radiator Disconnect the radiator hoses and the reserve tank hose Remove the radiator and shrouds fan and fan motor as an 3 1 Removal Inspection Racliatl r And Check the radia...

Page 78: ...PIPE THERMOSTAT _ p HOUSING THERMOSTAT COVER SUI P indthe thermostat in heated water and watch for valve SlIlU Be sure the thermostat does not touch the bottom or sides of the container the thermostat if the valve to temperatures other than those shown in illustration or if it stays open at room temperature START TO OPEN 80 84 C 116 190 F FULLY OPEN 95 C 1940 F HEAT APPLIED VALVE LIFT 8 MM 0 32 IN...

Page 79: ...he water pump cap Remove the front cover and the three water pump ret flinino bolts Note the location of all collars and dowel Remove the water pump cover then remove the pump Inspel tthe pump for worn loose shaft ordamaged Do not try to the water pump If it is worn or dalmage d 5 9 ...

Page 80: ...ires NOTE Use thread sealant on the thermostatic switch and temperature unit they were removed Reinstall the fan on the motor and secure the a sp rnhlv to the radiator Install the radiator in the frame Connect the upper and lower hoses Install the reserve tank Connect the fan wire coupler Reinstall the oil filter and filter cover Fill the crankcase with appn ximcltely 3 2 liters U S of the recomme...

Page 81: ...enle antifreeze Run the without the radiator cap until the coolant level stabilizes add more coolant as necessary the tank and install the tube is the FULL line while the tank radiator cap the top compartment tool tr ay and seat Reinstall Fill the 5 11 ...

Page 82: ...Engine Removal I nstallation Service Information 6 2 Removal 6 3 Installation 6 8 ...

Page 83: ...se prclcedures the carburetor ass emlbly is sel arateld and left in the frame to removal dean the oil PICK liP screen when the of the crankcase is removed Access to the screen is through the lower nal1t t1anld side 35 N m 26 ft lb l r 60 N m 44 ft lbl 22 N m 16 ft lb __ 35N m 26 ft Ib Values 6 mm bolts 8 mm bolts a mm bolts 6 2 Radiator drain Oil drain Oil filter center bolt 38 N m ftolb 38 N m 27...

Page 84: ...einstall the drain COOLANT DRAIN PLUG 38 N m 27 ft lb Reinstall the drain bolt Drain the cover oil 3 14 and remove the oil filter Oil DRAIN BOLT 38 N m Rflmove the left horn Disconnect the upper and lower radiator hoses and the fan motor connector Remove the radiator 6 3 ...

Page 85: ... and generator connectors 1983 CAUTION When the a section of the metal brake lines has to be moved to keep them from hit by the vacuum controller loosen the bracket where the metal and rubber brake lines joln 1983 Calrefliily prop the pressure control valve holder bracket on the frame cross member as shown and continue removal Be sure to reinstall the holder and reti ghten the rear bracket reinsta...

Page 86: ...nector pressure sensor sensor neutral These are on the back of the shroud Free the wire harness from the shroud and remove the shroud on back of the fan Remove the starter motor cable from the motor Check that the fuel valve is OFF and disconnect the fuel lines at the fuel pump Disconnect the vacuum advance hose at the No 3 car buretor 6 5 ...

Page 87: ...able from the Aspencade 1 cylinder head Remove the carburetor inlet cap bolts and loosen the Mark the for the proper and car efLJlly pull them off the carburetors Do not twist the sleeves Hook cords under the carburetor stays and up to the handlebars to hold the carburetors clear of the Remove the 6 6 brElkeligllt switch ...

Page 88: ...NT MOUNT BOLT HANGER BRACKET 1 __ 1 BOLTS support under the bolts and brackets the and left rear mount bolts Remove the and left front mount bolt and the Remove the left and the other nuts holdine the sub frame then remove the sub frame the move the forward or frame rearward to rll Ar n ltlP the output shaft from the CAUTION Be very careful not to the vacuum advance controller removal If the shaft...

Page 89: ...areful not to the vacuum advance controller installation If the shaft is bent the will not advance and the pulse generator aSlserl1biry Will have to be The has to be out of the frame to the output shaft splines into the frame while w lclnn and engage the output shaft and the the vacuum advance controller often to be sure it isn t of the frame 983 CAUTION Do not darn8i ile the metal brake lines for...

Page 90: ...5 N m 3 60 N m 4 60 N m 5 22 N m 16 6 35 N m and torque the Left side Left side only bolts in the hI n cords Check the rubber sleeves to are not twisted then secure the to the the 1 1 11 Remove the make sure cyll ndl9r head the notch in the rubber sleeves with the on the carburetors bnd reinstall the inlet on the carburetors Run the temperature sensor neutral switch and oil pressure sensor wire ha...

Page 91: ... the starter motor cable clutch cable tachometer cable fuel lines crankcase breather hose vac uu m controller hose caps Connect the drain tube to the crankcase breather storage tank and the tank coolant reserve overflow tubes and on the centerstand and bracket COOLANT OVERFLOW TUBE 10 _ _ 8IH ATlriER TUBE ...

Page 92: ... and radiator hoses Install the left horn Install the exhaust Fill the radiator partment and seat 5 11 then install the top com the sp cified type and quan tity of the clutch free oiL cover 3 23 and throttle cable filter play Install the 6 11 ...

Page 93: ...oting 7 3 Timing Belt Removal 7 4 Camshaft Rocker Arm Removal 7 6 Cylinder Head Removal 7 8 Valve And Guide Inspection 7 10 Valve Guide Replacement 7 11 Valve Seat Inspection Refacing 7 12 Cylinder Head Reassembly 7 13 Cylinder Head Installation 7 14 ...

Page 94: ...ices are not and that the 0 and dowel are in before installing the cylin jer heads Care should be taken to prevent the camshaft drive belts from contaminated with oil which will cause the rubber to swell and affect the camshaft Do not twist the belts or bend to a radius of less than 25 mm to avoid possible fracture of the materia TOfaUle Values belt drive belt driven I I I I 14 N m 11 ft Ibl 75 N ...

Page 95: ...en valve II Head or rl H rl W rn 11 or cracked nvllnri r II Camshaft Worn or darna ed Loose Worn or rh nafl ri II lower end pro blelms Compression High Over 14 kg cm2 199 psi II Excessive carbon OU1110 UD on head or combustion chamber EXlceSiSI re Noise Incorrect valve clearance II valve or broken valve II rocker arm or camshaft Loose or dalna ed camshaft drive belt II Loose or drive beit tensione...

Page 96: ...mark its direction of IdAnti fv each belt as left or rotation Mark the crankshaft indicate T D C No 1 with tape or pen to CAUTION To prevent belt damage do not use sharp tools such as a screwdriver to pry off belts Do not tum the camshaft after the belts have been removed since it is to bend the valves Loosen the tensioner bolts then belts in that order NOTE The belts can remain off the right and ...

Page 97: ...ect for jacket separation the belt tensioners for free movement and smoothness of in rollers CAUTION Do not lubricate the belt tensioners since oil will damage the belts To protect the sealed tensionsr bearings do not use solvents or other cleaning agents inside the front timing cover Spin rollers check for smooth rotation 7 5 ...

Page 98: ... hOUSlnQ from the Cyllindl r head Loosen the valve aOlus ter screws to relieve valve pressure Remove the six rocker arm holder bolts then remove the rocker arm and camshaft Mark each holder to IO imITV what side it was on NOTE To prevent the rocker arm unscrew the rocker arm holder bolts in a crisscross pattern two turns at a time CAUTION Do not let the camshaft fall out of the cyllim ler head 7 6...

Page 99: ...ders the NOTE If any rocker arms camshaft lobes for vir Shaft Hole Service limit 14 05 mm in Rocker Shaft Service Limit 13 94 mm 0 548 in Rocker Arm Service limit 14 05 mm in Inspe1ct the cam surfaces for or daimaae caused insufficient lubrication Check that the oil passages are clear Bolt the camshaft holder in Measure and record the LD of and torque the bolts 7 7 ...

Page 100: ...vllin jer is the clearance The clearance may also be checked BEARING JOURNALS Check each cam lobe s with a micrometer Rel lac e the cam if the is less than the service limit EXHAUST LOBE SERVICE l IMIT INTAKE LOBE SERVICE LIMIT 1 36 6 mm 1 44 in CAUTION Before rerno ving the cy i ndt tr heads drain the coolant See 5 nuts and wires and bolts and remove the Remove the muffler rear rn r t r exhaust s...

Page 101: ...dowels and oil orifice Cylinder Head Disassembly a valve compressor compress the and remove its ke Of rs Remove retainers and valves NOTE Gaskets will come off easier if soaked in solvent or sprayed with remover NOTE Clean valves and related parts in order material from the cylimjer head 7 9 ...

Page 102: ... 0 10 mm 0 004 in Check the head for warpage with a stn igllt and feeler gauges Measure and record the O D of each valve stem Valve And Guide Inspection Intake Valve 6 58 6 69 mm 0 2591 0 2595 Exhaust Valve 6 55 mm 0 2583 in Clean valves and H l ji Jt t l Measure and record the I D of each valve Valve Guide Service limit 6 64 mm in Run the proper reamer thn lUI lh the Valve Guide Reamers 072489 01...

Page 103: ...e head CAUTION Do not use a torch to heat the cylinder it may cause Support the cylinder head and driVEl the guide out from the valve port VALVE GUIDE DRIVER 6 6 mm H C 072490 PIN 07942 6570100 or H C 048721 PIN 07942 6110000 when handling the To avoid burns wear heavy heated head Heat the cylln ler head to 100 C NOTE head heat should still be at 100 C for installation of the new Drive in new head...

Page 104: ... carbon del JO I ts co ltil1lg of valve lappinlg cl JmpOtmd to each each valve and seat a rubber hose or harld laooirlo tool CAUTION 00 not allow lapping to enter the valve After wash out the compound cOlmp letely and coat the valve face and seat with oil CAUTION The valves cannot be ground If the valve face is worn or contacts the seat improperly the valve must be reflilac ed Remove the valve and...

Page 105: ...sing pressure After laj piing wash any cvllneter head and valve Check valve seat area for complete contact 1 72 in 1 67 1 58 in 1 54 of th I inner and outer vaIve pl III J Measure the free lon er Standard 40 2 mm Service limit 39 0 mm Outer Standard 43 8 mm Selrvic e Limit 42 5 mm Cylinder Head Reassembly InsUlI springs with tightly wound lIInd toward hlllad the new valve seals on the valve instal...

Page 106: ...ct side INTAKE A INTAKE B EXHAUST A EXHAUST B NOTE This will reduce the pm si ilil y of hp nrlinn the valves when the p fl Cylinder Head Installation 7 then rotate the mark on No 1 cylincJerTDIC Mark the crankshaft crankshaft 90 clockwise Check that the Install the oil orifice with new J l U Clean the head gasket residue from the that all oil and water passages are clear block and check graphite c...

Page 107: ...e the camshaft and lobes and install the camshaft into the cviim Jer head NOTE The camshaft has the tachometer drive gear some sealer to the cam holder surfaces then install and in a crisscross pattern Excessive sealant may clean away excess sealant oil passages Install the tachometer fuel pump drive l prnhlv on the right c llin head CAUTION To prevent the pump turn the drive as sernbly until the ...

Page 108: ...the cam belt cover hole before the heat shield bolts NOTE If the bolt is properly t rQIJed and one or both of the is loose disassemble and for Check that both wear belt drive are bolts to the Do not turn the camshaft while you may the valves NOTE The should be installed so that its boss is outward and the left with its boss inward Install the camshaft pUIIt y 27 N m 18 ...

Page 109: ...is centered Loosen the VALVE TIMING MARKS 11 IDENTIFIES RIGHT PULLEY TENSIONER BOLTS VALVE TIMING MARKS pressure counterclockwise on the camshaft pressure with the bolts loosened the tensioner bolts and recheck the valve Adjust the valves 3 1 so the belt will be slack at the tensioner The tensioner is positioned 7 17 ...

Page 110: ... 9 Piston Piston Ring and Rod Inspection 8 10 Cylinder Inspection 8 12 Crankshaft Removal and Inspection 8 13 Bearing Inspection and Selection 8 14 Crankshaft Installation 8 17 Piston and Rod Installation 8 19 Engine Case Reassembly 8 21 Oil Pumps Removal and Inspection 8 24 Oil Pumps Assembly and Installation 8 25 ...

Page 111: ...t be the side lcylln jer No 1 and it is not necessary to remove the head However refer to Section 10 for di as sem ly Certain steps are to prevent valve damclge seipal atilng the cases without first rp n lir n head It Whenever the crankcase is disassembled remove all gasket material from oil passages and water jackets ...

Page 112: ... l3iston or cylinc er Worn or hole Worn rod small end low Compression or Uneven Compression Worn or EXlce si e Smoke Worn cylinc ar Overheating Excessive carbon on head Blocked or restricted flow of coolant thermostat Knocking or Abnormal Noise Worn and cylind4 rs Excessive carbon build up on head 8 3 ...

Page 113: ...alues Engine case bolts 10 mm 8 mm 35 N m C 6 mm 27 N m connecting rod nuts 12 N m I 9 ft Ib N n er mdain bearing cap bolts 3 70 2 N m 23 ft Ib an 3 main N m 51 Vacuum advanc cap bolts 50 N m e b I ots 10 N m 7 ...

Page 114: ...efer to Section 6 Remove the vacuum advance mechanism Remove the mechanical advancer and from the advancer base VACUUM ADVANCE MECHANISM MECHANICAL ADVANCER Remove the rear cover Remove the mechanical advancer drive shaft Remove the scavenge pump bolt and sprocket 8 4 ...

Page 115: ... on the with the index mark on the of the inspel ticln hole Check that the No 1 is at TOC on the stroke If it is not on cOim lression rotate the crankshaft one turn and the T 1 mark with the index mark Mark each belt with an arrow to indicate direction of rotation and a letter to indicate or left side Mark the crankshaft to indicate TDC on the No 1 8 5 ...

Page 116: ...0 not let oil get on the belts Oil con tamination will cause and deterioration Rotate the crankshaft 900 in either direction from your TDC mark on the This will all four pistorls mlidvvay their and allow you to rotate the camshafts without a valve into a Remove the front Remove the left and Remove the left and 8 6 cover camshaft lJUIIl 1Y cyl inr er head heat shields ...

Page 117: ...en the valve adjuster screws on all rocker arms to relieve valve pressure from the camshafts Remove the six camshaft holder bolts on each cylio1deif h 3ad Remove the camshaft holders rocker arms and shafts as a unit NOTE Mark each holder to its 005ition Remove the vlinf lAY head bolts and the Iiin l r heads 8 7 ...

Page 118: ...m o o Remove the three bolts from the case mm Pull the shift arm away from the shift drum separate the case halves and install the case supports Place towels under the to prevent them from onto the transmission when the left case is removed Uft off the left case Rotate the up stand adaptor so the left case is 8 8 ...

Page 119: ...2 and 4 and on the NOTE The left side rod hA rir n inserts are drilled and with the rod oil holes to lubrication to the cylin ler walls Remove the side rods and Mark them to indicate the correct No 1 and 3 and on the cralnkp lns CAUTION On with high mileage inspect the cylindiers for a ridge above the highest point of ring travel Any ridge must be removed with an automotive type ridge reamer befor...

Page 120: ...mage Piston Rod Interference Standard 0 018 0 042 mm 0 0007 0 0017 Measure the bore in the connl ctinQ rod and the pin 0 0 KHIDI H the rod or if necessary Piston Piston Rings and Rod Inspection the driver to the second reference mark pilot into the collar then over pin and press the free of the piston Piston Pin To Piston Clearance Service Limit 0 050 mm in Measure the piston for clearance 10 ...

Page 121: ...e these areas Remove the InS Deict the lands for abnormal wear and piston thrust faces for scratches U __ T __ i__ land Clearance Standard 0 02 0 05 mm 0 001 0 002 in Service limit 0 12 mm 0 005 Check end gap 8 placel1 1ent is recluil ed Piston 0 0 Standard 74 950 74 980 mm 2 9508 2 9520 in Service Limit 74 850 2 94GB in Measure the diameter at the skirt 90 to the If show wear the service limit re...

Page 122: ... the driver pilot to the second reference mark 8 1 the into the place into the pin bore then press into the piston and rod If the cylmders do not Measure Pls to n to l ylincler clearance Standard 0 020 0 065 mm 0 0008 0 0026 in Service limit 0 15 mm To install the insert the collar inside the and Ol n u tiinn rod Place the and rod on the tool base so that the offset on the tool base tabs is toward...

Page 123: ... each cap toward the top of the The No 1 cap is at the front of the and the No 3 cap is at the rear The center cap takes the two bolts Remove the crankshaft main crankshaft from the case caps and lift the Set crankshaft a stand or vee blocks Set a dial indicator on the center mam hp uirlo Rotate the crankshaft and determine the amount of runout Crankshaft Runout Service limit 0 050 mm 0 0019 8 13 ...

Page 124: ...rankshaft cannot be if the Journals or are burnt cracked or out of tolerance jf the runout is limits Bearing Inspection and Selection With the case be arirlo inserts in place install the crankshaft Put a of across each main NOTE Do not the plasti iagre over oil holes Install the main be 3rirlg caps with inserts on the correct and them evenly to the spe cified torque NOTE Do not rotate the cranksha...

Page 125: ...od on its the nuts to the torque plzlstlgage over oil hoies rods to move NOTE II Do not Do not allow crankshaft Place Remove the cOlnm ctilnQ rod caps and measure the width of the compressed on each r nknin 1f the clearance is h nr ri the correct rel llac en1erlt b earmClS Bearino Clearance Standard 0 044 mm V 1VI JIO 0 0017 in Service limit 0 08 mm 0 0031 in cont d a D code hp Jnr ti the service ...

Page 126: ... Codes 0 0791 v u ou 0 07871 2 010 2 014 2 006 2 010 2 002 2 006 1 998 2 002 1 994 1 998 After selecting new recheck clear ance with Incorrect clearance can cause major Cross reference the nA rmln support and journal codes to determine the correct color Blue Black Brown Green Yellow colnn cfmn rod clearance is be orld the service limit use follo l IinlQ procedure to select re la ernelnt bearmas Re...

Page 127: ...hen lay the crankshaft and chain in the right side case CAUTION After selecting new bearings recheck clearance with Incorrect clearance can cause major damage sure the connecting rod oil holes align with the oil holes in the No 2 and 4 cylinder connecting rods case Install main h r r halves in Install the main caps and halves in their correct locations the arrow on the bearing cap should point to ...

Page 128: ... Install the transmission mainshaft with the driven gear and clutch the primary chain 8e sure the set case fit in the h nr C outer races and the mamshaft end cap in its i in 1 p OSl1lon with the tab in the case recess Install the m n chain oiler 8 18 ...

Page 129: ...k cylllnd Olr bore diameter and the If gap is too selection n n t the end gap Oil Side Rail End Standard 0 2 0 9 mm O OOS 0 035 in Service limit 1 1 mm 0 04 in NOTE AI should be installed with the toward the top of the After installation they should be free to rotate in the grooves l areTiUIl install the onto the Stagg Olr the oil end gaps as shown LL i 20 mm OR MORE 20 mm OR MORE __ 8 19 ...

Page 130: ... so that the IN mark on the top is towards the top of the 6m me Install the 3 in their side rod assemblies into No 1 and po iti ns as marked before removal the rod caps Install the nuts and torque them to Install the left side rod assemblies for cylinders No 2 and 4 their as marked CAUTION Be sure the rod oil holes face towards the top of the and the rod insert holes with the holes or the left sid...

Page 131: ...wo crankcase supports OPIPOl ite each other on the crankcase surface end gaps are 1200 apart NOTE Be sure the the tops of the left side bases with the concave Lubricate the walls with oil and lower the left case until it rests on the supports Fnl l lCIP the shift arm with the shift drum 8 21 ...

Page 132: ...es case surfaces and seat Coat all 10 mm case bolts with mCllvt de l1um disulfide grease the case bolts to the spE cified torque Use a crisscross pattern sequence when tiaihtAnin n the 10 mm bolts 10 mOl 801m I 0101 35 N 01 25 27 N m 20 12 N m 9 lEfT ENGINE CASE 10 X 6 X 110 8 22 RIGHT ENGINE CASE S X 70 6 X35 ...

Page 133: ...all the vacuum advance mechanism and torque the mount ina bolts to the sp ci1ficGltio n CAUTION the vacuum advance mech anism mounting bolts may distort the case and cause Insert the 10 nti 00 advanc r Be sure the 0 028 in the shaft and install the mechanical air gap is within 050 0 70 mm Be sure the and knock pins are in their correct locations then install the front cover NOTE If the cover does ...

Page 134: ...moval and Inspection Pump Remove the rear cover clutch scavenge pump drive chain and Spifockel as described in Section 9 Remove the Pump as described in Section 6 Remove the three scavenge pump bolts Remove the scavenge pump Remove the pump covers Clearance Between Inner and Outer Rotor Inspect the pumps for damaloe and wear clearance Measure pump Standard 0 15 mm 0 006 Service limit 0 35 mm 8 24 ...

Page 135: ...te the pumps CAUTION Be sure that the pressure relief valve in the main oil pump moves the pump washer drive outer rotor inner rotor over the pump shaft and reassemble MAIN Oil PUMP PRESSURE RELIEF SPRING PRESSURE RELIEF VALVE INNER ROTOR PIN new 0 and ga skEltS CAUTION The rotor s must be the pump covers marks on the main oil pump outer out when the rotors are installed in SCAVENGE PUMP OIL PUMP ...

Page 136: ...Clutch Service Information 9 2 Troubleshooting 9 3 Clutch Cover and lifter 9 4 lifter Plate 9 5 Clutch Center 9 6 Clutch Plates and Discs 9 6 Clutch Outer Drum 9 7 Engine Flushing Procedure 9 9 ...

Page 137: ...All clutch Section 6 for pf c idures except clutch outer drum can be done with the engine in the frame Refer to removal if the outer drum must be repdaced LOCK WASHER DAMPER PLATE Value Vacuum advance mounting bolts 10 N m 7 9 2 ...

Page 138: ...No free Discs worn weak Will Not Disengage Too much free Plates warped Motorcycle Creeps With V HAl 1 Too much free Plates warped Pressure Clutch cable kinked or Lifter mechanism darnaQled ChJtch Operation Feels Rough Outer drum slots Disengaged 9 3 ...

Page 139: ...ifter cam for wear or rl m grease to the contact of the arm lifter cam and lifter shaft before installing them into the clutch cover Install a new cotter in the lifter shaft Refer to Section 3 clutch free 1980 1981 Remove the cotter and pull the lifter shaft out of the cover Remove the adjus tinlg arm 1982 Remove the lifter Remove the then remove the clutch lever lnSPElI t the lifter for wear or d...

Page 140: ...j for rj rn If1 and measure free Standard 35 5 mm 1 40 Service Limit 34 2 mm 1 35 NOTE When the lifter insert the two dowel bolts thr ouah the two lifter holes marked with small cast in buttons Install the lifter the pressure the dowel bolts into the two pressure holes with recessed threads Then install the four standard bolts and all six bolts two or more steps a crisscross pattern STANDARD BOLT ...

Page 141: ... out the clutch center Ins pe ct it for cracks or excessive wear on the Remove the clutch nut lutch Plates and Discs Rel la e the clutch and discs if they show of ir or discoloration Remove the clutch plates discs and Inspect the pressure plate for rl un r1p pressure plate Measure disc thickness Standard 3 42 3 58 mm 0 135 0 141 in Service limit 3 20 mm 126 9 6 ...

Page 142: ... and indentations made the friction discs If the surfaces are not smooth orthere is evidence of other the outer drum NOTE The clutch outer drum cannot be removed with the engine in the frame Refer to Section 6 for removal Remove the vacuum advance mechanism Remove the mechanical advancer and from the shaft COVER SPARK ADVANCER COVER 9 7 ...

Page 143: ...chanical advancer drive shaft Remove the scavenge pump bolt and sprocket Remove the mainshaft washer and 40 mm located on the center of the outer drum Remove the clutch outer drum NOTE The scavenge pump chain and spl ocket are removed with the outer drum ...

Page 144: ...r nnAr ti r n 10 N m 1 tHb after assierrlbly air gap is 0 50 0 70 mm 0 020 clutch free Be sure to Check that the 0 028 2 Drain the oil 1 Clean the clutch outer drum with a lint free solvent soaked rag CAUTION If any of the clutch friction discs have dis int eOrat ed the must be cleaned and flushed of any debris by the This only aPIPIIE S when the is still in the muffler nuts Flushing Procedure 3 R...

Page 145: ...l not to the case NOTE loosen the left cannot be flexed enough mount bolts if the frame 8 Remove the oil screen 9 pour 1 quart of clean oil the oil filler to flush any clutch toward the oil screen 10 Reach into the oil screen pal1icles as the oil is 1 Reassemble and the clutch 2 Instal and the oil drain 13 Clean and install the oil screen 14 Install the oil screen cover the front oil screen cover ...

Page 146: ...17 Install the muffler 18 Fill the crankcase with the recommended oil 3 1 19 Run the for 5 minutes 20 steps 2 to 9 ex ludirlg step 11 NOTE The clutch does not have to be disassembled 9 11 ...

Page 147: ...10 2 Troubleshooting 10 3 Gear Shift Mechanism 10 4 Engine Case Separation 10 6 Shift Shaft 10 10 Shift Forks and Drum 10 11 M ainshaft 10 12 Countershaft 10 14 Primary Driven Gear 10 15 Output Shaft 10 15 Engine Case Reassembly 10 11 ...

Page 148: ... by rprnn inn the from the frame and sepal atinQ the cases The Crankcase bolts 10 mm 8 mm 6 mm case se anaticm procedure in this section is to get you into the transmission as and quickly as pOlssilJle Refer to the in Section 8 jf you intend to remove the pistons or crankcase for inspection T n ItA Values 35 N m 21 N m 12 N m Vacuum advance m uritillig bolts 10 N m 1 ...

Page 149: ...justlmelot Too much free Shift forks bent Shift shaft bent Shift claw bent Shift bolt loose Shift drum stopper bent Shift drum cam grooves darna led Transmission Jumps Out Of Gear Gear worn III Shift shaft bent Shift drum stopper broken Shift forks bent 10 3 ...

Page 150: ... loosen the radiator cap NOTE If the tube is left in over the coolant wi down Remove the coolant drain bolt from beneath the water pump and drain the coolant into a clean container The coolant can be reused Reinstall the coolant drain bolt Disconnect the fan wires and the radiator hoses Remove the radiator 10 4 ...

Page 151: ...n is reCIUHsa must be from the frame and the cases Refer to Section 6 for removal J2 _SHlFT DRUM STOPPER NEUTRAL STI PI ER TIV all shift mechanism components for wear and 1982 Remove the shift drum SHIFT DRUM JOINT DRUM SET PlATE if 1 p P l 1 DRUM STOPPER CAM PLATE ROLLER STOPPER PLATE 1982 and the drum stopper cam NOTE If more extensive transmission repair is the must be removed from the frame an...

Page 152: ...Place the in an stand Remove the vacuum advance mechanism Remove the mechanical advancer and locFltiriO shaft from the COVER Remove the rear cover Remove the mechanical advancer drive shaft Remove the scavenge pump bolt and sprocket 10 6 ...

Page 153: ...l the T mark on the with the index mark on the of the inspection hole Check that the No is at TDC Dead on the stroke If it is on rotate tile crankshaft one com llet e tum and the T mark with the index mark Mark each belt with an arrow to indicate direction of rotation and letter indicate or left side Mark the crankshaft to indicate TDC on the No 10 7 ...

Page 154: ...tamination will cause swelling and deterioration Rotate the crankshaft 90 in either direction from your TDC mark on the This will all four their and allow you to rotate either camshaft without a valve into a Remove the left camshaft drive Remove the left cylin ier head heat shield Loosen the valve screws to relieve valve pressure from the camshaft Remove the at the rear of the left cylm ler head 1...

Page 155: ...e camshaft hoider rocker arms and shafts as a unit Remove the camshaft holder bolts Remove the cyl im ler head bolts and the cylinder head Remove the 19 left engine case bolts 10 MM ALL OTHERS I MM Remove the three case bolts 8 x 70 6 x 110 ex 10 9 ...

Page 156: ...en left case is removed Lift off the left case Rotate the up Shift Shaft Remove the shift shaft from the left case BOLT PINS ARM TO SHAFT Bolt pins arm to shaft InSpElI t the shift shaft shift arm and for wear or d81113ge If there is excessive shift ever movement before the shaft starts to rotate the shift arm or fJ W Reinstall the shift shaft LOCK TAB ANDBOLT SHIFT SHAFT 1lI SPRING ENDS i EACH SI...

Page 157: ...move the shift drum set of the case and slide the shift fork shaft out ROLLER SHIFT DRUM STOPPER JOINT 1982 Check the forks for burned ends or other evidence of abnormal contact if the gears FORK END THICKNESS 6 4 6 5 mm 0 25 0 26 in SERVICE LIMIT 6 1 mm 0 24 in n n FORK 1 0 13 02 mm 0 5118 0 5126 in SERVICE LIMIT 13 04 mm in SHAFT 0 0 12 979 12 98 mm 0 610 0 611 inl SERVICE LIMIT 12 90 mm 0 508 i...

Page 158: ...il as it drains into the sump and directs it into the center of the mainshaft Be sure to reinstall the cap in its or transmission lubrication will be iml air ed Remove the 1n1TI l rv chain oiler 10 12 DRUM MAJOR 0 0 35 96 35 98 mm 1 416 1 417 in SERVICE LIMIT 35 92 mm 1 414 in GROOVE WIDTH 7 05 1 15 mm 0 278 0 282 DRUM MINOR 0 0 11 97 11 98 mm 0 411 0 472 in SERVICE LIMIT 11 95 mm 0 470 in ...

Page 159: ... lassemt lv Refer to Section 1 for tool information Check the gears forfreedom of movement or rotation on the shaft Examine the gear for evidence of abnormal wear Note the of the and shaft oil holes Check the baH h rir n for smooth rotation da maae and wear re fsserrlblinQ the mainshaft measure the assembled to ensure proper with the case set 10 13 ...

Page 160: ...l 1 cap of the case Disassemble the countershaft Refer to Section 1 for tool information Check the gears for freedom of movement or rotation on the Examine the gear and slots for evidence of abnormal wear Note the of the and shaft oil r I Check the wear 10 14 smooth rotation dalmage and I 0 1 ...

Page 161: ... and dall1age Output Shaft NOTE To remove the output shaft and gear you must remove the from the frame 6 and remove the rear cover 1 It is not necessary to separate the case halves Refer to Section for tool information Remove the fuel pump and access plate Remove the gear thr ouigh the access hole confd Hold the output shaft gear and the shaft out of the case 10 15 ...

Page 162: ...tters NOTE The spring compressor attachment can be used without a press eSI 8C lally if the spE cified Check the case Install the and it II If U lf on the gear engage the Install the output shaft gear in the output shaft from the rear the gear Make sure the in the damper lifter Reassemble the shaft Measure the free Standard 110 9 mm Service limit 100 mm 10 16 ...

Page 163: ...rum and neutral switch Install the switch wire the Install the two countershaft shift forks and the mainshaft shift fork Insert the shift fork shaft into the case Align the hole the shaft with the hole in the case and insert the Install the mainshaft it til l OUiO h the chain Frl1 I the shift fork with the gearset and the be uirlgs with the set in the case 10 17 ...

Page 164: ...OTE The tops of the should r l be aligned because you rotated the crankshaft 90 after the belts 1 CAUTION Do not rotate the crankshaft further than is re luilred to the tops of the or the side pistonls may strike open valves the tops ohhe and install the the concave downward bases with Make sure the piston 10 1 end gaps are stalooerEld as shown 120 r _ I I J _ ...

Page 165: ...d crankcase supports and seat the cases sealant to where the crankcase sealant to the NOTE Be sure to supports were case surfaces Coat all case bolts and under with m lvbden um disulfide grease the case bolts to the speclified torque Use a crisscross pattern sequence when tigihtenirlg the 10 mm bolts 8X70 6 X 110 6X35 6 X 35 1 1 10 mm 35 N m 8 mm 27 N m 6 mm 12 N m RIGHT ENGINE CASE LEFT ENGINE CA...

Page 166: ...n in a 90 range between N1 and N2 If the needle of the ohmmeter moves the switch is in the proper position If the needle does not move rotate the pin 80 and re check for continuity 1982 CAUTION The neutral switch must be in the proper position before the front cover Check for cOlntirluilty between the switch wire and the front cover with an ohmmeter 1982 1983 Black wire green IRed wire Install the...

Page 167: ...shaft and install the mechanical advancer Install the vacuum advance mechanism and the bolts to the specified torque CAUTION the vacuum advance mechanism mCluf1ltil1lg bolts may distort the case and cause faulty vacuum controller op aratiolrl into the frame Refer to Section 6 air gap is 0 50 0 70 mm 0 020 0 028 Be sure the Install the 10 21 ...

Page 168: ...nal Drive Service Information 11 2 Troubleshooting 11 3 Final Gear Case Removal 11 4 Backlash Inspection 11 4 Oil Seal Removal Installation 11 5 Preload Adjustment 11 11 Final Gear Case Installation 11 14 ...

Page 169: ... seal and replacement RFH lI 1 al oil seals and U I IIIIJ whenever the final drive gear ass emlbly is disassembled Refer to Section 3 for final drive gear oil chlec Vr pl acelm mt Gear case cover bolts 8 mm 10 mm Rear axle nut Axle bolt Shock absorbers 11 26 N m 40 N m 90 N m 27 N m 35 N m ...

Page 170: ...ear brake dralggilng Rear axle bent Bent SW In 18rrn II II and wheel hub gear backlash Noise level Dal l18 jed driven Excessive D81 l1B jed drive Worn or darnB jed ring gear shaft and driven Worn pinion and gears Oil Oil level too 411 hub breather Seals dalmaoA rl 11 3 ...

Page 171: ...se Remove the final gear case from the A inrHlrl Yl Drain the final gear case oil if disias sernblling the gear case Backlash Inspection Set a horizontal type dial indicator on the gear throU lh the filler hole Install the preload inspe ticm tool then rotate the until slack is taken up Standard 0 08 0 18 mm Service limit 0 30 mm in gear 0 007 filler cap gear back and forth to read backlash Turn th...

Page 172: ...ear and measure backlash this prclcedUire once more the difference of the three measurements Oil Seal Removal Installation NOTE ail final gear case oil seals and whenever the case is disassembled Gear Bearing Retainer Remove the final gear case aSI ernblly from the mCltolrcvcle 11 Remove the distance collar lock washer tabs and remove Remove the wrench Remove the gear be nirlg retainer with the re...

Page 173: ...el ad retainer 11 1 careful not to fold NOTE After installing the do the f I J n Final gear as ernblv p rel sd check III Backlash 11 Install the or darnaCle Coat the new Remove the dis tar1ce collar lock washertabs and remove final gear case as ser l lbly from the m o rcvcle the dust Remove 11 lift gear case cover from the gear case loosen the gear be anrlg pirel ad retainer 5 notches with the ret...

Page 174: ... race Coat the new oil seal with gear oil Install the oil seal sqiuarely into the case darna le the bearing careful not to Remove the old sealant from the gear case and cover surfaces NOTE the gear case clean Be careful not to the gear case and cover surfaces Clean the gear case and cover surfaces with an oil stone 11 7 ...

Page 175: ...dust seals with mliltil mrpose NLGI No 2 grease Place the gear case cover onto the final gear case NOTE After installing the gear case cover do the follo l vinlg Final gear check 11 1 Backlash 11 Insert the gear case cover bolts the three bolts with the on the photo at the locations shown these bolts until the case cover touches the gear case Then all bolts in a crisscross pattern 8 mm bolts 10 mm...

Page 176: ... 041305 PIN 07924 3710000 shaft Remove the shaft nut and washer NOTE The nut can be removed without Orlof1lnn off the staked area Remove the retainer and retainer lock tab Remove the tool and Remove the wrench retainer with the gear retainer Remove the retainer oil seal and U IIIIUS Coat the new with lithium based NLGI No 2 grease and install them onto the retainer 11 9 ...

Page 177: ...ainer into with the retainer wrench until the oil seal is contacted CAUTION Be careful not to the O rings The retainer very fine threads so be careful not to cross thread it Remove the oil seal NOTE If the retainer is ovl rtightenled it will cause excessive Thread the retainer into the case by hand Tum the shaft the retainer when shaft resistance is felt Do not the retainer PINION GEAR RETAINER WR...

Page 178: ...n the normal direction of rotation Pinion Gear Preload 1 000 1 200 9 2 2 2 7 Ib 5 0 6 0 4 3 5 2 NOTE If measurements are not consistant rotate the gear 50 60 turns then check preload Force to movement may exceed prlEllolad If is ins ufficiEmt remove the Dre locld irlspection tool then install gear retainer wrench and retainer Recheck the gear prs load If is excessive remove the tool then install t...

Page 179: ...e Or ilOclCl irlspect ion tool onto the and Pinion Preload the wire around the tool groove and attach a scale Measure the force needed to turn the shaft in the normal direction of rotation NOTE Use this whenever the retainer is removed or iffinal gear ass errlbly preilosld checked NOTE Force to movement may exceed or loosen the the correct oreload Recheck gear prE load gear retainer as recluil ed ...

Page 180: ... nut Install the tool to hold the shaft and the nut 45 N m Stake the nut to a minimum of1 mm inl at the two locations CAUTION Be careful not to the shaft threads Install the distance collar Install the dust Bend ooe of the plate and bend the three lock tabs up retainer lock tabs as shown 11 13 ...

Page 181: ... gear case nuts until after the axle and axle nut have been installed and lithium based NLGI No 2 ad clitive grease to the final driven surface and and to the final driven gear Coat the rear axle with lithium based mLlltil UrpOlse grease and install the rear wheel 14 1 the rear axle nut to 90 N m the gear case nuts to 40 N m Torque the axle bolt Install the rear shock absorbers and install a new 1...

Page 182: ...veshaft joint grease Make sure the final drive drain bolt is Remove the oil filler cap Add the recommended lubricant until it reaches the filler neck threads Recommended lubricant Hypoid Gear Oil API GL 6 SAE 90 above SoC 41 SAE 80 below 5 C 140 160 cc 5 4 11 15 ...

Page 183: ...al Disassembly 12 8 Front Fork Assemblyl Installation 12 14 Handlebar Replacement 12 20 Steering Stem Removal 12 23 Steering Head Bearing Replacement 12 25 Steering Stem Installation 12 27 Rear Shock Absorber 12 29 Swingarm 12 34 Center Stand Inspectionl Replacement 12 39 On Board Air Compressor System 12 40 1 1 It ...

Page 184: ...light hOliJsino and he adligt1t brackets are included in the Muffler removal and installation is included in Center Stand and Replacelment If the motorcycle has been involved an accident the frame should be very carefully at the steering head and at the mounts as these are the areas that are most likely to suffer rl ITll lr lP Always a bent handlebar or bent forks str aightenirlQ them will weaken ...

Page 185: ...83 28 20 Front master cylinder holder bolt 6 10 7 Brake hose oil bolt 10 30 22 Brake hose jomt bolt 6 12 9 Rear wheel axle nut 18 90 65 Rear caliper torque link 8 22 16 Rear master cylinder attaching bolt 8 27 20 Brake reservoir bolt 6 12 9 Rear brake hose oil bolt 10 30 22 Metal brake line nuts 1983 9 6 Brake rod joint lock nut 8 18 13 Rear caliper bolt 8 18 13 Rear axle pinch bolt 8 27 20 Final ...

Page 186: ...oken rellr sprmQI sl Faulty rear shocks Insufficient air pressure Suspension Noise Incorrect fluid level in forks Broken parts in forks stem nut too loose Loose axle or rear rear shocks or 1 1 1 Sy in lann U U y Front Forks leaking fork seals Too much fluid in forks Incorrect fluid in forks Too much clearance between seals and fork Too much air pressure Hard Low tire pressure stem nut too tight st...

Page 187: ... SuspEmsion Does Not Operate ON at the pump fuse terminals switch turned to the 1982 983 No Voltage Check for voltage at the pump terminals with ignition switch at 1982 P and pump switch depressed 1983 ON with Front Rear selector button and pump switch del Jr8 ssed No Voltage OK cont d 12 5 ...

Page 188: ...coot d Needle Does Not Move 1982 NOTE Refer to page 18 1 7 for 1983 lCD Air Pressure Air Will Not Release troubleshooting Check the main valve Incorrect Correct drier air hose valve main valve to drier drier to relief hose three way joint ...

Page 189: ...e it from the cap NOTE Drain and refill one fork at a time Place a drain pan below the fork and remove the drain plug a block under Raise the front wheel off the the tllll jlllt Reinstall the drain Work the sw p msion up and down to cOimp letely drain the fork Remove the fork cap Refill the fork with the SPElcified amount of ATE NOTE Removinlg the top fork the fork ATF after draining 198 r 1981 22...

Page 190: ...N Be sure to release front fork air pressure before dis as1sernblyinig to prevent parts from becoming proljectile s Release front fork air pressure the air valve located on the fork cap on 1980 1982 models or on the left fork cap on 983 models On the button DelJrellS and hold the Air Pressure Decrease button until air pressure is released emoval Disassembly Front Fork Removal Remove the front whee...

Page 191: ...em from be orning proj Bct ile s Wear eye and face protection 1980 1982 NOTE Fork seal replacement does not require fork tube and slider PLUG Hie 095806 PIN M 2280 999 95806 I This procedure is for air assisted forks only 1983 Seal removal is accomplished Therefore refer to Fork on page 12 10 for further front fork All MODELS Release air pressure and remove valve stem and hose connec tor if Instal...

Page 192: ...er Pour out the fork fluid by the fork up and down several times Place the fork slider in a vise with soft jaws or a shop towel onto the brake bosses CAUTION Do not distort the slider in the vise Remove the socket bolt with a hex wrench and pump the rernainirlg ATF out through the socket bolt hole NOTE install the and fork cap is encountered in removing the bolt 1983 Remolle the dust cover foam wa...

Page 193: ...cK UD already removed from the fork tube if not FORK TUBE BUSHING ALL MODELS Remove the piston and rebound from the fork tube SPRING SEAT SPRING CIRCLIPS seat from and oilloek 1983 Remove the the Remove the oil lock from inside the slider 442 0 mm 17 40 in 462 8 mm 18 22 in 466 2 mm 18 35 in 412 2 mm 18 59 in if B the and SelVice limit 198 i982 1983 Standard 198 1982 1983 Spring A Check the fork f...

Page 194: ...95 38 98 mm 1 633 1 534 Service Limit 38 90 mm 1 532 in BUSHING f Set the fork tube in V blocks and read the runout Take Y2 oHotal indicated to determine the actual runout Runout Service limit 0 2 mm 0 01 in Inspect the fork tube slider and and replace if necessary for excessive wear BACK UP RING COPPER SURFACES BUSHING it if there is any distortion at the Check the ba k tllJ shown the slider and ...

Page 195: ... anti dive case Check the necessary and for wear or darnag e Replace if Check the orifice for c c gging by aplplying comr lrel seld air WARNING Wear appropriate eye protection when using complrelssiIl d air and stopper ball and orifice if necessary Remove the stopper ball screw Remove the orifice screw Also check the orifice for damsige and 12 13 ...

Page 196: ... Fork Assembly Installation Assembly 1980 1982 RIGHT FORK ASSV fORK SPRING A 4C O RING RElaOllNO SPRING LEfT fORK ASSV RIGHT FORK ASfl I M lY 12 14 FORK TUBE FORK PISTON FORK TUB H II FORK fUBE BUSHING LEFT FORK ASSEMBI Y VALVE ...

Page 197: ...he pivot bo t collar boot retainer as shown NOTE Apply ATF to the piston and piston O ring silicone grease to the pivot bolt collar o II thread lock agent to the threads of the screws and socket bolts the socket bolts to 6 9 N m 6 5 Check the operation of the collar and lcont d 12 16 ...

Page 198: ......

Page 199: ...tall the 1980 1982 Install the back up Remove the fork tube cap and pOlJrthe sp cified amount of ATF into the fork tube 1980 1981 240 cc 1982 290 cc Install the fork tube cap Hand the top pinch bolt then torque the fork tube cap Check that air fittings are still facing punch marks If not loosen upper pinch bolt and Installation Slide the front forks toward the the fork marks with the airfitting ho...

Page 200: ...ue Install the valve stem and connector bolts to the specifiE d grease to a new and install the air hose into the cap grease to a new and install the connector into the fork cap 1980 1982 Left fork cap 1983 fork cap Attach the air hose to the connector and spElcified torque 12 18 to the ...

Page 201: ...ept ASpe rlClldEI Recommended Pressure 1 0 1 5 21 CAUTION Use a hand air pump to fill the fork tubes Do not use compressed air o Maximum pressure is 300 kPe 3 43 Do not exceed this or fork tube component may occur With the front brake applied pump the front forks up and down several times Place the on its center stand Check the air pressure and if necessary 1 19 ...

Page 202: ...ree screws from the left switch assembly and remove it Loosen the bolt in clutch lever holder Remove the two bolts from the master assembly and support it so it does the brake hose Remove the three screws from the switch aSl ennbly Remove the caps and socket bolts from each handlebar while the handlebar and remove the holders 12 20 ...

Page 203: ...ks of the holders handlebar s upper holders on the handlebar punch marks the holders forward Position the bracket between the forward ends of the left Loosely install the four socket bolts forward bolts to the torque first then rear bolts the same torque Install the four caps into the socket bolts H A NIIIIOD L E B A R U P P EIIIIR H O lD E BOLTS 22 N m 16 ft ibl 12 21 ...

Page 204: ...cl1led between the switch and the handlebar master on the handlebar with the punch mark down the two gap between the holder and master with mark the handlebar the top bolt to specified torque first then to the same torque Position the Position clutch lever holder so the gap with the rnark on the handlebar and the bolt seJ urelv contact cement to the left handlebar and the handlebar end caps wire h...

Page 205: ...Remove the two nuts and lift off the instruments and as an Disconnect the tachometer and spee dOm lter cables from the instruments Remove the two inr ition switch me r tir n bolts and remove the switch Release the front fork air pressure Disconnect the air hose from the left fork cap then remove it from the cap Remove the air hose connectorfrom the left fork cap 12 23 ...

Page 206: ...rubber cap stem nut and washer Use the lock nut wrench 26 x 30 mm with the extension bar to remove the nut loosen the tork tube bolts and the bolt Lift the fork off the stE erlf1c stem and fork tubes Remove the front wheel Remove the front brake calipers and front fender Interstate and ASlperlcade Remove the steerirlg weight Loosen the fork bolts and slide the fork tubes out of stF Arinn stem Set ...

Page 207: ...matched sets to ensure a precision fit Remove and install sets do not mix or races with parts BEARING DRIVER Hie 106553 PIN 07953 4250002 Remove the upper beluirlg head outer race from the Remove the lower h r n outer race from the stE sn ng head conrd BEARING RACE REMOVER DRIVER H C 064768 PIN 01946 3110600 BEARING RACE REMOVER H C 064166 PIN 07946 3110500 replaCE d due t l riinn head for cracks ...

Page 208: ...000 ATTACHMENT HIe 064761 PIN 07946 3110700 Instal the lower h irlrl outer race Remove the lower and dust seal from the tA nrlrl stem Place the dust seal on the stem and install the lower AITACHMENT HIe 064167 PIN 07946 3710700 DRIVER H C 093324 PIN 01749 001 0000 or H C 029824 PIN 07949 6110000 12 26 BEARING RACE REIIIIOVEI ORI ER Hie 064168 PIN BEARING ...

Page 209: ...sert the stem into the steering head Install the upper holder and u y grease to the nut threads Install and the nut to the speclltled torque sequence you before the stl p rina stem lock to lock five times to seat the the and stem sequence twice more NOTE After each and should be able to turn nut sp ecified torque a used lock washer with a new one grooves NOTE Install a new beiarirlg a djustnnellt ...

Page 210: ...n it over and reinstall Bend two lock washer tabs up into the top thread nut 8 grooves t r r1F1 stem Then nstall the front forks into the t pr rll1 stem and fork NOTE Be sure the holes the caps face towards the marks in the fork Install and the fork tube stem to the sp 9ciJ iec torque bolts in the t pr nn the stem nut to the spl cified torque Then install the rubber cap the fork tube SPl9cified to...

Page 211: ...e cap and release air pressure except Rear Shock Absorber Removal NOTE Place the on the center stand and remove one shock absorber at a time to facilitate removal and installation side cover On the Selector button DeprE1SS and hold the Air Pressure Decrease button until pressure is released Remove the seat and Disconnect the air pressure switch wire connector Remove the nut and remove the 12 29 ...

Page 212: ...sconnect the air hose Reinstall the shock boot Install a schrader valve into the air hose connector hole 8 and back uo Remove the Remove the boot Turn the shock upside down and drain the shock oiL Place the shock lower mount in a vise with soft towel around the seal area to prevent oil WARNING Do not hold the shock below the shock body The seal A and are removed with air pressure Wear eye and face...

Page 213: ... necessary AIR SPRING CLIP I AIR PRESSURE SWITCH the air hose hole in the top of the shock absorber Turn the shock absorber unSIOe IJO Nn Fill the shock absorber with the sp ecified amount of ATF 365 cc a new oil seal in ATF and install it into the shock absorber Install the busihirlg and 03C t llJ A 12 31 ...

Page 214: ...t side shock absorber onto the stud at the top and install the bolt at the bottom Install the cap nuts on the three mounting studs the nuts bolt to the spE cified Position the handrail onthe mClto rcycle and install the three mountmg bolts side shock absorber onto the two mounting Push the studs Route the air hoses thnClil h the fuel tank on the rearfender and 12 32 ...

Page 215: ...nter stand fill the shock on the bracket and install the nut NOTE Some pressure will be lost when the gauge from the valve Determine the amount of loss and compensate With the absorbers with air Recommended Pressure 1980 2 0 3 0 1980 1982 AIQ 1983 Aspencade 1983 STD Interstate Fit the Install the side cover and seat 12 33 ...

Page 216: ...ve the case 11 NOTE Do not the final drive case over on its side gear oil may flow out of the breather Disconnect the left shock absorber from the lIf n n rm hang by the brake hose CAUTION Do not the Remove the brake Remove the brake hose from the swm lanl1 and torque arm hose Loosen the lock nut on the left side with the lock nut wrench adaptor and remove the bolt Remove the and left caps Remove ...

Page 217: ...move the boot Remove the drive shaft and remove the Remove the drive shaft Remove the dust seals and tar ered roller hp nr1l1 and races for dam lge and remove the outer races the swingarrn NOTE wear 12 35 ...

Page 218: ...se to the races and dust seals Install the beiaril1QS and dust seals into the swinglarrn grease to the drive shaft and drive shaft and reinstall the swmo srrn Install the Install the boot grease to the tip of each bolt Position the swingarrr in the frame and bolts the pivot bolt to 100 N m install the Install the pivot lock nut to the left bolt the left bolt to the spl cij ied torque 12 36 ...

Page 219: ...ich will be NOTE lock nut wrench increases the torque wrench s leversiqe so the torque wrench will be less than the torque to the lock nut The torque is the actual torque to the lock nut not on the torque wrench when used with the lock nut wrench adap1tor the lock nut to 100 N m 90 N m on the wrench GIVES YOU THE SPECIFIED VALUE OF 100 N m 72 tt lbl HERE Install the caps Reinstall the left shock a...

Page 220: ...ear case and install nuts Install the right shock absorber onto the final drive gear case and the nut to the specified torque Install rear wheel 14 Torque final gear case nuts to 40 N m ft lbl Push the brake hose grommet back into the sw jn lllrm llnd torque the llrm hose clamps on the torque arm Reinstall the brake 12 38 ...

Page 221: ...uts and remove the left muffler Disconnect the return Drive out the shaft and remove the center stand Loosen the bolts and remove the cotter When the center stand be sure to grease the shaft 40 N m 22 N m 16 8 N m 13 22 N m 16 ft Ib Values Muffler mr tinn Crossover Exhaust nuts Center stand pinch bolt nut Installation is the reverse of removal Be sure to all fasteners to the torque 12 39 ...

Page 222: ...nd Suspension On Board Air ompressor System 1982 MAIN VALVE _ AIR PRESSURE SENSOR AND DRIER MAIN VALVE REARSHOCKABSORBER IGNITION SWITCH MAIN FUSE Ace 30A 15A 10A PUMP SWITCH PRESSURE GAUGE RELIEF VALVE 12 40 ...

Page 223: ...1982 10 N m 7 ft lb 14 N m pO ft Ib 6 N m 4 ft lb if t cont d 12 41 ...

Page 224: ...Frame and Suspension On Board Air Compressor System cont d Aspencade 198 lCO UN T 12 42 SELECTOR SWITCH REAR SHOCK ABSORBER I o PUMP SWITCH lOA RELIEF VALVE Tt _ I ...

Page 225: ...onnector Connect the hose to the drier and torque Install the pump in the reverse order of removal Install the pump filter hose Connect the air hose to the motor and specllfied torque Remove the drier CAUTION Do not turn the air hose more than one turn the top compartment cover and remove the motor ren oving the Disconnect the air hose from the gauge bolt Removal Disassembly Loosen the air hose at...

Page 226: ...wn necessary Check the color of the desiccant It should be blue If not bake the desiccant until it is blue or if necessary Check the J l lti n for dirt or moisture and 1 necessary if Clean the inside of the cornplresised air 12 44 and the cover openings with SPRING ONE WAY VALII A tf SPRING SEA COVER tf ...

Page 227: ... boit and put the 9 8 1 9 mm onto the drier Install the O ring on the air hose from the main and connect to the drier the drier until the hose is hand r _ _ the hoses and Drier AssemblyIInstallation Gauge Cluster Removal Disassembly NOTE The procedure pertains to the 1 Aspencade The 1983 air gauge is contained in the LCD instrument panel to page 18 27 for 1983 instrument panel Disconnect the front...

Page 228: ... the four screws and remove the gauge cluster Remove the gauge the cluster Remove the connectors bolts and disconnect the wire 0 PU hH1Q it out from the back side of Remove the thn3e tlliilV from the gauge CAUTION Turn the nut by holding the thr 8e I I IV turn the thr ee wEIV joint body THREE WAV JOINT 12 46 ...

Page 229: ...turn the nipple nut using two wrenches Remove the pump switch and relief valve screws Cluster Assembly renl1o i ina the 1982 Install the thl ee Wl3V on the gauge as shown to the SPl3cii ied torque Push the gauge into the cluster Connect the air hose to the relief valve and spE cified torque Install the relief valve and pump switch to the 12 47 ...

Page 230: ...the air hose from the drier and tighten the bolt to the torque Install the top compartment on the frame and connect the air hoses to the front and rear sus pension Main Valve DisassemblylAssembly Remove the valve and SOI n CIS the valve button off with a screwdriver dean ATF to the valves and U I mOIS VALVE BODY the screws and the valve button onto the holder Install the valve holder VALVE BUlTON ...

Page 231: ...h button is depressed Replace if necessary n 1982 SHOWN 1983 the pump Relay Inspection Remove the Remove the seat and top compartment and remove it from it s holder Connect a fully 12V battery and an ohmmeter to the pump relay terminals as shown The relay is normal iftnere is continuitywhen is applied OHMMETER confdl 12 49 ...

Page 232: ...EAR 0 D FRONT 0 D SELECTOR BUTTON Locate the 3 P black at the sensor which is mounted in front of the coolant reserve tank With the connected and the ON measure the between the Blue and Green wires It should be 0 at zero air pressure and it should increase smoothly to a maximum of 3 volts at 8 1 PHi Air Remove the Inspection seat and top compartment To remove the air pressure sensor bleed all air ...

Page 233: ...Information 13 2 Troubleshooting 13 4 Brake Fluid Replacement 13 5 Brake Bleeding 13 6 Metal Brake Lines Replacement 13 7 Brake Pad Replacement 13 9 Caliper 13 12 Front Master Cylinder 13 16 Rear Master Cylinder 13 19 ...

Page 234: ...sealed container when servicing the system The brake fluid re Ia en lerlt and bleeding prc cedures for the front and rear brakes are the same CAUTION Spilled brake fluid will severely damage instrument lenses and painted surfaces The 1983 Gl11 OO s are ElQIJipl sd with a unified brake system which provides simultaneous braking action of the right front and rear disc brakes of the foot operated bra...

Page 235: ......

Page 236: ...ystem stic king Incorrect of lever or pedal Frozen PlstO 1 S Brake lever Pedal Too Hard Frozen PIStOI1I S system Pads or worn ex esslvely Mr rtlu S Grab Or Pull To One Side Pads contaminated One side of front system Disc or wheel ml all Jne j Bn31kets C h l lIt tFU Or Squeal Pads contaminated Excessive runout on installed incomectllv Disc or wheel mi1saligm d 13 4 ...

Page 237: ...ve and put the other end in a container NOTE 1980 1981 model shown 1983 NOTE Loosen the bleeder valves on the rear and right front and then pump until no more fluid fluid flows out wa sne l then bleed the system Loosen the valve and squeeze the lever no more fluid flows out Close the valve Remove the reservoir caP and dil lphlra m the rear and fill the reservoir Reinstall the dil lphlral m 1 the p...

Page 238: ...e bleed valve dust cap Connect a bleed hose to the valve and put the other end in a clean container 1983 When the unified brake system bleed the Ii f i t and then the rear the same prc cedures described below 15 mm prevents overtravel during the bleeding procedure NOTE If air has gotten into the system the 1 Arln f l i will fee spongy instead of solid Close the valve before the lever or reaches th...

Page 239: ...e Replacement Remove the storage tank and the nuts sel uring the metal lines pressure control valve and disconnect the line at the rear master nut and disconnect the line connected to the rear brake hose 13 7 ...

Page 240: ... fuel tank page 4 1 Loosen the nut and disconnect the line connected to the front brake hose Remove the clamps new lines the nuts Be careful not to twist the metal lines when tightening Secure the lines with clamps as before Bleed the system 1 METAL BRAKE LINES CLAMPS ...

Page 241: ...are the same for both front and rear brakes 1980 1981 Remove the two remove both Install the new arrow on the shim with the shim on the outside The in the direotion of wheel rotation the deterioration and dust covers for seal and boot for deterioration reCllac e if install the If nn Press the back into the torque the bolts Inspect the necessary 13 9 ...

Page 242: ...ts lind lift off the bolt and caliper pivot bolt and lift off the 13 11 982 Front Brake Remove the two 1983 Remove the caliper Remove the retainer bOlt and the retainer Pull the out of the and remove the brake Position the in the as shown the brake pads the to allow installation of new 13 1 ...

Page 243: ... the other pin pushing the pads the caliper to depress the pad retainer over the pad the in the retainer Then slide the retainer to secure the the pin retainer bolt NOTE Check brake fluid level in the brake master cylimrjer reservoir this causes the level to rise darna e the pads positiorled between bolts to the correct value dust on the rear brake TORQUE Bolts 1982 Bolt 1983 Pivot Bolt 1983 M l u...

Page 244: ...1 REAR CALIPER BRACKET BOOT 1 1 PAD SPRING CALIPER PIN SILICONE GREASE SPACER PAD SPRING SILICONE or BRAKE 00T 3 GREASE FLUID DISC COVER 18 N m 13 tt Ibl ...

Page 245: ...CAUTION Put a pan under the and remove the brake line bolt Discard the brake fluid that drains and lift off the caliper 1980 1981 boot boot and boots 1 pads caliper Remove the short spurts of compressed air to the inlet to get the out Place a shop rag to cushion the when it is ex elled in short spurts Remove and discard the the bore seal Be careful not to 1 13 ...

Page 246: ... 92 mm I 1 687 1 689 in 1 690 in 1982 Piston O D 30 148 30 198 mm 30 140 mm 1 187 1 189 in 1 866 in Bore I D 30 23 30 28 mm 30 29 mm 1 190 1 192 in 1 193 in bore 1 0 0 0 and the Measure Lubricate the and new seals with a medium temperature silicone grease bore groove and then install the is re la ed whenever the Seat the seal the seals must disassembled it hardened or for illustration of disassemb...

Page 247: ...the disc before 9 9 10 1 mm 0 40 in 9 0 mm 4 8 5 2 mm 0 20 4 0 mm 0 16 6 9 7 1 mm 0 28 6 0mm Service limit Service limit Standard Rear Front and Rear Standard Measure disc thickness renlountirlg the Standard and Interstate Front Standard Install the the mCluf1ltin 9 bracket and torque the bolta NOTE See page 13 1 for 983 caliper bolt torque speci fications Connect the brake line to the caliper fil...

Page 248: ...amination Secure the hose to the fork Remove the mirror brake lever and bolts Remove the brake switch connector and master cylinder Remove the boot from the cvllinc ler body Then remove the circlip Remove the washer cup cup and Remove the reservoir screws and pull off the reservoir NOTE It may be necessary to low pressure sir at the cylincler outlet to remove the piston and cup 1 16 ...

Page 249: ...ice limit Measure the master cvl in jer I D and Standard 0 0 Service limit Coat all parts with clean brake fluid and install the in the master Be careful the don t turn inside out when the cups are installed Make sure the is seated in its groove With the in cylinder baSEl reinstall the reservoir on the master DIAPHRAGM FRONT MASTER CYLINDER BODY 1 17 ...

Page 250: ...et above the mark on the handlebar the upper holder bolt first then the lower bolt Install and torque the brake line bolt with washers and pull on the dust cover Reinstall the brake lever and rear view mirror Connect the brake switch wires Fill the reservoir to the upper level with fresh DOT 3 brake fluid bleed the system then refill 1 18 ...

Page 251: ...olts a pan under the brake top of the master cylincler Remove the rod eye Remove the side cover and Disconnect the line from Disconnect the reservoir and its hose NOTE You may need apply a small amount of air pressure to the fluid outlet to get the piston and cup out Remove the rod eye boot piston cup and and pw hrod Remove the 13 19 ...

Page 252: ...he Coat parts with clean brake fluid and reassemble them in the cviincter body Be careful that the lips don t turn out when the are And make sure the circlip is firmly seated in its groove the nut and eye master cylinder in position and install the mCluntting rod eye pin and brake line Reinstall the reservoir and connect the hose to the master cylinejer and reservoir brake Fill the reservoir to th...

Page 253: ...ormation 14 2 F Wheel Removal isassembly 14 4 Rear Wheel Removal Disassembly 14 5 I 11 II lII III IIll II Ii iii II IfI 14 6 Front Wheel Assemblyl Installation 14 9 Rear Wheel Assemblyl Installation 14 12 Wheel Balancing 14 14 ...

Page 254: ... removed use new beari ng s wheels are not serviceable If either the spokes rim or hub is dalmaged the entire wheel must be Tubeless Caution removal and live 11I1 1 procedures are covered in the Tubeless Tire Manual H e 068216 will cause Check for Correct Wheel Tie Down Front Wheel 1 ...

Page 255: ... m 29 tt Ib 23 N m 17 90 N m 95 N m Front axle nut Front axle holder nut 1980 1982 1983 Front mount bolt 1980 1982 1983 Upper Lower Front bolt 980 1981 982 Front caliper pivot bolt 1983 Rear shock mount bolt Rear axle bolt Rear axle nut 1980 982 983 ...

Page 256: ...om the wheel aSllernblly NOTE Do not operate the brake lever after the removed has been and left front axle holders speedometer cable Remove the Disconnect Jack the until the fork remove front wheel lift free of the axle and RemClVe the axle speedometer gear bOl axle and collar RemClve the bolts discs and dust seal retainer Retainer wrench H C 091562 PIN 07710 0010200 Retainer wrench body H C 0907...

Page 257: ...t side the then remove the axle out the axle the rest of the way CAUTION If you do not s in ta m you may bend it when 1980 Remove the cotter axle nut and axle bolts Loosen the three nuts for the final drive as en1blv Reinstall the shock absorber lower mounts then raise the brake Pull the wheel to the final driven from the final drive case and remove the wheel 1980 1981 Interstate After the remove ...

Page 258: ...ls Inspect the rim the wheel if the rim is dalml ed or deformed Mount the wheel in an stand Use a dial indicator to measure axial and radial runout while the wheel If either front or rear runout exceeds 2 0 mm the wheel Ii 11 1 1 I I t RADIAL RUNOUT t If the tire is removed from the wheel for check the rim for or corrosion of the Clean the and smooth it with if necessary Rel la e the wheel if the ...

Page 259: ...r tear than 6 0 mm in in diameter Separated ply Separated tread Cracked carcass Broken cord If the tire is removed from the rim for repair check for these abnormalities Replace do not repair the tire if it has Rim bruise cord in the rim area caused a severe inner liner chafer BrOken bead wire or dallull ed bead TREAD INNER LINER BEAD SIDE WALL RIM VALVE If the tire can be re ail ed refer to the Ho...

Page 260: ...002 in exceeds 0 3 mm indicator needle disc Rear 6 0 mm 6 9 7 1 mm 0 28 in Front 4 0 mm 6 in 4 9 nI dtiure disc thickness at the middle of Service limit Standard Standard and Interstate Aspencl Ide Front Rear Standard Service Limit 9 9 9 0 rom 9 9 10 1 mm 0 39 0 40 in 9 0 rom in 1 ...

Page 261: ...n the new the closed end out Use tools Hetalfler wrench the retainer then peen the retalnerto the hub of the seal and the retainer and peen the Install th e sl eE dome tergear box retainer and dust seal and disc bolts the disc and disc nuts collar and axle Lubricate gear box with grease NLGI 2 No the gear box tangs with the n tch in the retainer then install and torque the axle nut to Check wheel ...

Page 262: ... then torque the On the side measure the clearance between the outside surface of the disc and the rear of the holder with a 0 7 mm feeler gauge If the gauge will not fit pull the fork outward until the gauge can be inserted and torque the forward nut Then torque the rear nut and remove the gauge If the gauge inserts torque the be ginOlrlg with the forward nut axle holder nuts clearance at the oth...

Page 263: ...een the brake disc and the on both the inside and outside surlaces of the left and discs If the guage fits the axle holder forward nuts to the spl cified torque first then the rear nuts to the same torque TORQUE 18 25 N m 1 8 2 5 kg m 13 18 ft lb If the gauge cannot be inserted pull the fork outward or push inward until the gauge can be inserted CAUTION After the wheel the brakes several times and...

Page 264: ...e bel rirlo retainer feC lac B it if the threads are Use tools Retainer wrench HIC 090735 07710 001 0401 Attachment 080970 PIN 07710 0010100 Install the retainer then peen the retainer to the hub Install the brake disc and nuts Check wheel balance 14 1 a lithium based mulltiplJrpl Se NLGI No 2 aoclitili e grease to the the final drive splines and inside the final driven Position the wheel in the f...

Page 265: ...k that it rotateS then hand the axle nut the gear case nuts to 40 N m the axle nut and install a new cotter pin 90 N m 66 ft lb 95 N m 69 Remove the from the bolt slot and screwdriver from the hole in the axle REAR AXLE NUT TORQUE 1980 1982 1983 Hold a screwdriver axle to it from Install and torque the bolt to 26 N m 19 Install and torque the shock absorber nut and bolt to 35 N m 14 13 ...

Page 266: ...the wheel tire and brake disc in an stand a stand is not available mount the wheel on its axle and clamp the axle in a vise wheel ailow it to stop and mark the lowest 1I l a l ie5 t1 part of the wheel with chalk Do this two or three the heaviest area If the wheel is balanced it consiistEmtly in the same n itinn To balance the wheel install wheel on the hinlhp t side of the rim the side the chalk m...

Page 267: ...Ignition Service Information 15 2 Troubleshooting 15 3 Component Testing 15 5 ...

Page 268: ...ooth When the rotor tooth passes the generator tooth the circuit is broken causing the primary coil flux field to and rises firing the spark Dwell time is just 0 2 0 4 milliseconds lit A mechanical advance and a vacuum advance dizlOhlra Jm move the adJ us ted for and load generators to control ignition Ignition IENl3INiE STOP SWITCH IGNITION COilS 7 IGNITION SWITCH I ENGINE STOP SWITCH RESISTOR SP...

Page 269: ...em No Problem in pnm llV circuit see next page coil for a short to Rel lac e coil Aenlslce cap Check each cable then coil for continuity Rel lsc e faulty parts Trace power from main fuse through igr11tion and stop switch as necessary No No No No No No between chassis Should be infinite caps for wear and 5K 10 Ohms me aSllIre vOltage Should meaSlJre Should be 9V or 16 3 ...

Page 270: ...L UIlU Should be infinite resistance No generator Check for wire Should be apr rOlcimately 12V unit B W No Trace power from ignition switch or parts as necessary unit splecified torque or rotor bolt to ret liac e rotor if necessary No If Faulty rotor bolt is Yes OK Check If to this point the prc bl em may be caused heat or vibration Substitute parts that have checked and recheck system If Still Ch...

Page 271: ...0 04 Ohms 22K 5K Ohms 16 7K 1 67K Ohms THIRD ELECTRODE Measure these resistances White and leads 1 2 cylind gfsl White blue and blue leads Service limit 530 50 Ohms at any convenient Disconnect the generator connector and the terminal 3 4 cviindensi intlHrrlittEmtly the igniticm switch on The unit is normal ifthe Jnllt r than 2V when the white blue terminal is gr ufided Attach the ne gative Attach...

Page 272: ...vancer tube from the carburetors Remove the rear wheel and swing arm iDl rK Advance 14 5 and 1 generator cover Remove the Attach a vacuum pump 058369 PIN A973X 041 XXXXX to the end of the vacuum advancer tube and check that the advancer operates vacuum 1980 1981 ODenltic n should atart at 40 mm Hg 1 6 Op sultio n should cease at 100 mm Hg Op anltio n should start at 40 ml ll ll Hla Op ar ltioln sh...

Page 273: ...rator 14 5 and 1 connector generator cover generator attachlrlg bolts and generator Remove the Remove the advancer cam is not Check that the mechanical Lubricate the surfaces and check the tel1310n and the advancer for wear for loss the rotor tooth with the advancer cutout when 15 ...

Page 274: ...onent Testing Assemble the adv8 flcer Ilnd of dis 3ssElmb y generator in the reverse order NOTE Do not to install the dowel spacer and pulse generator 1 between the PULSE GENERATOR ASSEMBLY SPARK ADVANCER DOWEL PIN ...

Page 275: ...Charging Service Information 1 Troubleshooting 16 3 Battery Removal Inspection 16 4 Charging Rate Inspection 16 5 Voltage Regulator Rectifier Inspection 16 6 Alternator 16 ...

Page 276: ...ng system slow may be tested on the mc torC lcI19 but to seNies the alternator the must be the motor cycle for chl roi n l If the must be char led on the mc torc lcI16 disconnect the CAUTION away from a char Jing hAttAN because batteries prC dLlce eXlplosiv e gases ALTERNATOR 1 2 ...

Page 277: ... 12 page 16 6 show 40 Ohms show 6000 Ohms more No Stator Test page 16 7 ohmrneter relldings measured between Yas output wire wire No Replace stator rate Reguliat r Test r lr tifier are OK but charge rate is still low check of JcE dtJre on page 16 6 If proper test equipment is not re lul BtO f recl ifiluand recheck rate 16 3 ...

Page 278: ...meta parts otherwise a short may occur On Instalilation rRc nnnA r l the plates add distilled AI t tr plates if darnafleej r rackE d or electnolyte level If the upper mark 1 280 20u C F Normal 1 260 20 C F Needs 1 200 20 F Normal Reiading Needs Charclin t1 12 volts 1 2 volts Below 1 volts 1 ...

Page 279: ... II The battery contains acid avoid contact with skin eyes or shield eyes when w rking with batteries Antidote Flush with water and get prompt medical attention Skin Flush with water Intemal Drink of water or milk Follow with milk of beaten egg or oil Call BATTERY CABLE 1 and check that minutes before for o 20V voltmeter and a 0 a amp ammeter to output of the system increase 1800 rpm DIE connect t...

Page 280: ...BK Ie shown the Normal Direction 5 40 Ohms 1 ...

Page 281: ...for v ul y with each to the frame before the described generator must be removed Remove the in 6 the 1 ...

Page 282: ...Charging Alternator 16 8 STARTER DRIVE SOCKET ROTOR WITH PERMANENT MAGNETS ROllER OVERRUNNING CLUTCH ...

Page 283: ... over rUlinina rotor is removed Clutch Remove the three rollers from the Ar1l1hh and them for flat spots See that move up and down their ramps Remove the and caps and InSpel t them for wear Reolclce if necessary NOTE Worn or corroded I us caps or rollers will often cause the starter to without the or will emit a loud noise as the is rotated Remove the sOI ocket tab and starter drive spl ocket from...

Page 284: ...generator a press Comrlre s and necessary more SPRING COTTER 1 1 ...

Page 285: ...of the With a pressure tension at the 386 Tension at 20 mm Standard 55 175 Free l l Standard 26 mm 023 the pins in gears be HirlQ holder the holes the WIUuwt a HY U1cIUIIL to the while four the 1 11 ...

Page 286: ...etween the rotor and will allow space to install the spr ocket tab Install the sprocket tab and torque it s bolt to 12 N m 9 install the rear cover and the clutch cover Install the generator and check that the pulse air gap is 0 50 0 70 mm IU J l u V O cover it bottoms then torque the rotor onthe the stator coils in the rear Reinstall the Now nut 16 1 ...

Page 287: ...Starter Service Information 17 2 Troubleshooting 1 Starter Relay Removal Inspection 17 5 Starter Motor Disassembly Inspection 17 6 Ilr lE Il1 Motor Reassembly Installation 17 8 ...

Page 288: ... 8 Starter motor engagement is controlled an by pushing the starter switch This closes a contact to to the starter A starter clutch is used to prevent to the starter armature due to when the starts The starter remains until the starter button is released 6 mm case bolts 12 N m 9 6 mm washer head bolts for generator beluirlo holder 12 N m 9 1 ...

Page 289: ...IGNITION SWITCH RELAY WINDINGS COMMUTATOR AND BRUSHES STARTER MOTOR ElK FUSE 5A I WjR NEUTRAL LIGHT lG R NEUTRAL SWITCH NEUTRAL DIODE CLUTCH SWITCH ALTERNATOR SHAFT STARTER MOTOR 17 3 ...

Page 290: ...battery is in good condition before trouble h lotmg the starter system Yes Disconnect starter lead from Il l Connect DC Voltmeter SWltctles to L l terminal and to u u Press starter button Should be battery V No 1 ...

Page 291: ...rv NOTE the connector at the relay disconnect Re pl ce the if the rwinn coil has an open circuit or is shorted the case Also test for shorts from either nnm lead to the an ohmmeter test the resistance Sp ecifiEld Resistance 3 4 10 Ohms coil for correct case across the must be re ilaced test for rn rlti l1i cv the With the there is no rnn l secoind ary terminais 12 volt across the leads The should ...

Page 292: ...ws and the brush cover scale 0 511 tension with a Standard 560 680 grams Service limit 400 grams Measure brush Standard Service limit I n t the brushes and measure brush Remove the armature from the gear end of the motor case NOTE Check for spacers on the armature shaft ends On reaSS mIDly recliac e the spacers in the correct locations Spacers may be included 1 ...

Page 293: ... and segments above the insulation CAUTION Do not use emory or on the commutator since this will cause the brushes to wear INSULATION MINIMUM HEIGHT 2 mm Checkfor between of commutator bars and also between commutator bars and armature shaft the starter motor if armature coils afe open Of shorted the armature shaft Field Check for continuity from the cable terminal to the motor case and from the c...

Page 294: ...as been removed from the Install the armature in the case careful not to da maige brushes Install the commutator cover and the case Be sure the original assembly marks line up on the motor calle and ends cover rear Remove Rel lac e the Motor n8 8sselmt uv lnstallation the drive install the cover the starter motor into the into the the the Reconnect the battery cable at both ends With the stop swit...

Page 295: ...Lights Switches Instruments Wiring Service Information 18 2 Troubleshooting 18 4 Inspection 18 18 Headlight Taillight 18 35 Wiring Diagrams 18 37 ...

Page 296: ...tion and on the abbreviations B Blue BK Black SR Brown G Green GR LB Blue the followino thl OUQh the part A continuity check can rjl rlnrIAc tinln the wires and a It In order isolate an electrical failure check the I lntlnllltv be made without the part from the met ol cy cla cOlntifluitv tester volt ohmmeter to the terminals or connections cOlltiriui tv tester is useful when to find out whether or...

Page 297: ...RONT BRAKE SWITCH NEUTRAL SWITCH 1980 1981 RIGHT SIDE 1982 FRONT T oraLie Values Oil pressure switch Thermostatic fan switch TelT1pl rai ure sensor Self Cancelling Turn Signal System Components 1982 18 3 ...

Page 298: ...lights Switches Instruments Wiring Troubleshooting NOTE Before perfl rming any work 011 electrical components be sure is charged go on but are but or engine starts don t work 18 4 ...

Page 299: ...with iNI itiinn switch Yes Check for of main fuse volitRClP at cOlnponlmt sicle Yes No Check for at nn t rm switch No Yes iClnitirln switch on check for component side of switch No Check switch page 18 21 cont d 18 5 ...

Page 300: ...bout 5 seconds The speed of the motorcycle exceeds 10 mph 15 km hl with the suspension air pressure below the value for which the system is designed When the lamp remains on determine the cause and take necessary steps to correct See Trr ur II l nl1 otina on next page BATTERY lVAI NING LIGHT I BK BR I H o p G LB BK BR L B W i UNIT P PINK GREEN SR BROWN W WHITE BI BLACK B BLUE LB LIGHT BLUE 18 6 ...

Page 301: ...the system check shock absorber air pressure and if necessary If stays on go to page 18 9 If comes ON and goes out after 3 7 seconds but comes on after 3 go to page B 8 If comes ON but goes out within 3 seconds the control unit still remains OFF t Blown bulb Blown fuse Loose or connector circuit in wire harness bl tVl eem LU U and bulb and fuse and t Over 8 V_ IL liell JW 8 v cant d 18 7 ...

Page 302: ...h an ohmmeter Switch continuity Above 2 6 Below 2 0 kg emf No corltinluity Disconnect coupler from control unit and check for between terminal LB and sensor terminal There should be No CONTROL UNIT COUPLER Comes ON within 4 seconds Comes ON after 4 8 seconds Disconnect P wire connector at back of Disconnect air sensor LB terminal wire Ground LB terminal wire to frame Measure time reclulI ed after ...

Page 303: ...luster and disconnect p and G wire connectors from and check for between terminals Control unit coupler p terminal and meter harness P terminal It Control unit terminal and meter harness BKlBR terminal Control unit G terminal and meter harness G terminal No Open circuit in wire harness be tween and B W terminal confd 18 9 ...

Page 304: ...by follow lI1g the procedure on page 18 Turn Hamess Disconnect the coupler from the unit tum the switch to ON and test to see if the battery is more than 1av Normal Normal 1 10 No Abnormal Check the corltin uity of the solenoid wires by following the on page 18 31 Check the continuity of the sensor sub wire harness fnllmll l nn the prc ceaure on page 18 33 Abnormal Abnormal ...

Page 305: ...nit the on page 18 32 Normal Measure the resistance of the se 1S0 r b Y fo Io wiriO the on page 18 33 Normal Abnormal Abnormal Check the continuity of the speed sensor wires at the sp1eeejo meter by following the on page 18 31 Abnormal cont d 18 11 ...

Page 306: ...t the connector to the control unit following the on page 18 32 Normal Check the continuity of the sensor harness at the connector to the control unit the prclcedUl 1l on page 18 32 18 12 Abnormal Abnormal Abnormal Check the rrll ti i tv afthe sensor sub wire harness following the prclcedur e on page Abnormal ...

Page 307: ... check the switch in both RIGHT and LEFT locks Check the switch in both RIGHT and LEFT with the nlln f disconne cted from the control unit locks Does Not lock Does Not lock Does Not lock Turn switch to OFF and check resistance between RIi RI k and Brown White contacts in main connector to control unit 00 normal o Resistance confd 18 13 ...

Page 308: ...t panel has displa vs for the speedometer tachometer gear position indicator trip meter fuel level and coolant tenlpSiratiure fsuspEmsion air pressure The odometer is electrically driven and the display is mechanical COOLANT TEMPERATURE SUSPENSION AlA PRESSURE GAUGE DIGITAL TRIPMETEI l KEYBOARD 18 14 ...

Page 309: ...re the couplers are secure and locked Disconnect white 3 P behind switch ON between G B and BI Br wire sockets should be about 1OV Abnormal Check continuity of G S BI V and wires between white 3 P sockets and brown 10 P coupler inside instrument paneL See NOTE A Odometer Failure Continuity unit coupler IS Normal Instal known good odometer to see if problem is solved Normal Abnormal Abnormal Clean ...

Page 310: ...connect white 4 P Check and chassis V Bu to Ground V G to Ground Voltage normlll Check continuity cf V Bu and V G wires from white 4 P coupler to brown 1o p coupler at instrument 1 Nrt10 itY llli R e p ai r o p e n c ir c u it J See NOTE A I Fuel Failure NOTE The fuel gauge may not work if there is less than 7 liters of fuel in the tank Fill the tank before troubleslloclting fuel gauge sensor resi...

Page 311: ... NOTE B Air Pressure Gauge Failure Short or open circuit wire Normal wire Short or Check lb wire for short or open circuit from black 3 P 1 10 1 socket at sensor green 6 P coupler behind open circuit l J to brown 5 P coupler at instrument See NOTE A Wire ok Replace LCD unit See NOTE B Ke b lrd Switch Failure Gear Indicator Failure Inspect gear switch see page 16 1 9 Normal I _A_b_n_o_r_m_8_1 j Reo...

Page 312: ... REAR FRONT stop switch for rn tir1llillv with rear brake brake stop switch for c u w IUlly with front brake necessary Bmke AOIDlied Brake Not A p jed 1980 1981 Check switch for between switch terminal and ground with transmission in neutral and with transmission in any gear In Neutral In Gear No COlntilnuity replace the switch remove the YOHIM H screen cover lower bolt retainer bolt Flex the fram...

Page 313: ...etween the switch wires and with the transmission in neutral and all other gear pOl iti ms To the neutral switch follow the same procedures described to the 1982 switch 1983 Aspencade Change Switch The rotary gear change switch is inside the front cover To inspect the disconnect the e p black coupler the down tube Check for between each pin and chassis in the proper gear Continuit y Check Position...

Page 314: ...W to B to W BR W to B W to W Left 2 TURN SIGNAL SWITCH STARTER SWITCH l TlI PFl Pl o I3RIW lBIW O W Left W R GR to 0 BR W to lB W 1 1 N Off BR W to O W to LB W I 1 COLOR GR I B GR to LB BR W to O W 2 Start button BK to BK R with button released BK to V R with button del lreSSE d IG ST Hll H1 2 FREE 0 to PUSH 10t O COLOR 13K VIR iRK R B W ENGINE STOP SWITCH switch Run SK BR to BK W Off KBj KW OFF R...

Page 315: ...emove the cluster disconnect the and the switch switch remove the instrument remove the bolts Check contlnulity of terminals on switch in each Switch Position No nTllnlmV No R to BK Park Lock Off On Insert to in the IQllltlion switch and turn the Push the with a screwdriver 1 1 ...

Page 316: ...ard remove the instrument and remove the screws on both sides of the keyboard SCREW Color Code Y W Y SI Y G G SI R G RN Lg Y Bu BI Button TRIP 100 0 TRIP 10 TRIP 1 0 O SET l 0 TRIP 0 0 DIG TACH I MPH Km h 0 0 1983 ASlpencadle Remove the and and locate the 3 P white coupler from the sensor With the cou pier connected and the switch ON measure the between the Black Brown and Green Black wires should...

Page 317: ...e if necessary CLUTCH APPLIED CONTINUITY CLUTCH RELEASED NO CONTINUITY Switch Check continuity of clutch lever released and applied switch with clutch CLUTCH SWITCH Unplug the wires Remove the clutch lever and cable Pry the switch out NOTE The switch case has a small protrusion that must toward clutch cable when installed 18 23 ...

Page 318: ...tio n Resistance Should Be 104 0 Ohms 43 9 Ohms 20 3 Ohms 16 1 Ohms 60 C i 40 F 85 C 185 F 110 C F 1200 C F shown to the gauge to be tested CAUTION The temperature gauge operates on 7 volts Do not the aWI ilialry v lta e rfllQuliatclf 12 volts difl ctlly to the gauge apply the 01t81 18 to sensor a pan of as in the test above Do let the sensor or thermometer touch the pan false readirlgs will resul...

Page 319: ...eded to remove the sensor from the tank LEVEL SENSOR FULL the fuel gauge with a tested sensor and aU i1I HV volt CIA rE gulaH r as shown CAUTION The fuel gauge operates on 7 volts Do not 12 volts to the gauge the to the au c iliarv v llta e re guliatolr Float at bottom of travel gauge should read empty Float at top of travel gauge should read full 12 V rr 18 25 ...

Page 320: ...2070 F Switch Closed Cl mt intlit l 98 1020 C 215 F TO TEMPERATURE GAUGE AND SENSOR FUEL GAUGE AUXII IARY VOI TAGE nC UL J 1 telllperclture gauge circuit Includes an auxiliary reduces from 12V to 7 be used as the heated to check operation C 212 the thermometer or switch touch the pan as it a false reading Test 1l i IUI Hur from the rear of the and voltmeter as shown Vnlltacle Should 8e 7 Volts 18 ...

Page 321: ... bulb remove the cable and the meter set screws Pull the meter out and pry out the rubber bulb sockets and remove the bulbs 1983 Aspencade Remove the Remove the four cover mcam tino screws and the cover Pull the rubber bulb sockets out of the instrument housing Reol lce any burned out bulbs m t lIin 1 a new bulb test it If the bulb does not for an open or short circuit Removal 1983 ASIJencadie Rem...

Page 322: ...Lights Switches Instruments Wiring I disconnect the instrument panel to remove the bulb Instrument DisaSS4 mblY BRACKET CAUTION Do not OhIIAI1 the lens mo untting screws 1983 Aspencade ...

Page 323: ...ter and the tachometer and connect the tachometer cable to the speedometer is equivalElnt to and allow it to idle Idle Start the 1 km h Push the switch to the RIGHT lock position and turn front wheel to the Hold the wheel in this position for 5 seconds then return to center The should cancel in 1 second Check the left signal in the same way If either cancels before the front wheel is returned to c...

Page 324: ... left and check the sensor for wear or looseness Turn Switch the CHECK fOR __ 0 LOOSENESS ANGLE SENSOR CHECK fOR LOOSENESS WEAR Check the switch in the RIGHT position in the same way Connect the I I and Brown White terminals in the connector with a wire Remove the seat and the upper compartment Disconnect main connector from the control unit 8R W 8113K the directional returns to neutral Ica nc els...

Page 325: ...e cables from the and tachometer connect the tachometer cable to the W BK G speedometer I Connect an ohmmeter between the White Black and Green terminals in the control unit coupler Start the and allow it to idle ohmmeter needle should fluctuate rapidly in the middle of scale Sensor Wire Harness Measured Resistance A JVhitA Bla k and a I l Iih f O I k and Green B Green and Green Green and Wihitlel...

Page 326: ...nal switch in each po sltion Position A M L B uel vv He v 1 1 I I NEUTRAL Minimuml0V Minimum 10V RIGHT OV Minimum 10V LEFT Minimum OV OV Sensor Harness and Measure the resistance of the Black Yellow White and Green White wires of the sensor harness located inside the he adlam p h inn ISt nf1 r rll or in the hotlSin o behind the B A Black Yellowl B Grelln White C White To Ground IJ 1 Blk Yet o Ohms...

Page 327: ...ite sensor 10 19K Ohms White and r r JVhi t Resistance should increase stt aclily when front wheel is turned slowly from leftto should not Sensor Sub Wire H amass Sp ecifiE d Resistance Be mfeEII I same colors 0 Ohms Between different colors c o Disconnect the main harness Check the contirlui11 y sensor sub wire harness from the end to end of each wire BK Y h It w conrd 18 33 ...

Page 328: ...e the new fuse is the same as the old one Always make sure the cause of a burned out fuse has been corrected before the fuse replaced Terminals are provided to power 12V D C accessories not exceeding 60 watts 5 current demands may blow the fuse or di chiar e It electrical problems persist after components or switches have been found or have been test the to the switch or component for wire or conn...

Page 329: ...nbly from the heiadligt1t case and remove the Unfasten bulb retClininCJ and remove the bulb Reassemble in reverse order of dlsas ernbly NOTE Do not fin oernrints on the headlight bulb they may create hot spots on the bulb ADJUSTING SCREW MOUNTING RING RETAINER CONNECTOR HOLDER LAMP ASSEMBLY MOUNTING SCREW REFLECTOR 18 35 ...

Page 330: ...Lights Switches Instruments Wiring light Taillight cant d To bulb or any part of the t illinht remove the lens and then remove the part CAUTION Do not ove rtigllten the lens mmJOtillg screws LENS 18 36 ...

Page 331: ...o STARTER SWITCH I wl W I BAT IG Ace TLI TLl P IGNITION SWITCH OFF ce ON LOCK P COUll II SWITCH CONTINUITY o I TURN SIGNAL RELAY Q nor SILICON LG R RECTIFIER G IGMITION COIL LJ n 1 w m I REGULATO IRCE1IFI R o t _ 1 p rlS O _ G_ rrNG C 5 IlkIBr SA J t __ I HEAD10A O O I rUSE ACCESSO h BQ Bk R Brlw er IGNITION SWITCH rO t 8lo cc J OiW IL W t f8 G Gllbe CJ fJ J1F POSITION LIGHT rMep IW INDICATOR LIGH...

Page 332: ...ink REAR SToP LIGHT 5Wl1CI1 o IGNITION SWITCH SToP SWITCH STARTER SWITe AT ce Tli TI 2 0 ST 11 11 2 LOCI n n 1M 51 ACC l I n COUll 0 VIR BIl R 81 f COUll e 811 I COUll I Lli BIl B y o a a y 0 SILICONRECTIF IER rLGf f IE JTRAl SWITCH JSE ACC BOX B TERM CE i i O G E C I f A I I 8k 8 AILL GHT A __ t 8 8 HEADl C HT DA 810 i 80 I II g 0 1 CLUTCH SIfI ITCH I HIll Jj1jL Iini r iiliiiili ruRN SIGNAL DIMME...

Page 333: ...0 R Red 0 Orange G Green P Pink ON 10 Kl o f p K ACe Io f CllOI R a LG a adW adO I e v e w a VB oe w MINO 4Ft WINKER REL AY Iml v _ G jD PlCK uP ILICONRr C T ER lG LG REGuLATOWR CTIFIER I LGUI nIl nmm vvv G_ 1 l IR Ge_ I I l UTR l S ITC OIL PflESSeJRf SW CH I IP G SA LG IGNITION SWITCH th PARKING SA ruSE BO ACe BOx INTERMI HENCE G ISA NGINl BkBr S TAIL e l lA HEAO 1 10 lfiltffH HEADLIGHT 12V1OW 55...

Page 334: ... ITC BAT IG ACe TLI TLl P AB LOCJ OF OFF I Ace OFF ON 0 0 1 Cll OIl BIoI P Cll OIl II LGI B I V B VB B MINIJ 4P REGUlATOR RECTlF IER IGNITION COIL Bt 11 U II 432 sp lIT 11tt YiZ I _ G lGIR B U O CC llGI8k IA P r 1 IA INTERMITTENCE Il 5 0 I 1 0 8118 I I HEAD _ _ 1 1 10 r F USE BOx CC SOx I I Br J I I 0 dO n j t L c T PO LIGHT 12 1 1 INDICATOR LIGHT CLUSTER 1 SPEEDOMETER LIGHT 12V 3 4W 2 2 TEMP FUEL...

Page 335: ...TARTER SWITCH SWITCH CONTINUITY M IMT IG ACe TLI TL2 P KB KW Iii Sf Hli Hl 2 I Ace 0 _ f O OfF COlOR B VIA SIR L I OH Iofo ca oc PA PLuG MINI 0 1 111 1 I 1 ITlON SWITCH i 1iP mJ ABrW c G 10 L PARlC i I INTEIlMITTENCE I G FU5E 8OK Ace BOX E I M o IG A CRJCRJ rLllt rl 3 I HfG G J I CI J J TEMP METEA FUEL WETER K o 0 INDICATOR LIGHT CLUSTER 1 R TURN SIGNAL INDICATOR 12V 3 4W 2 L TURN SIGNAL INDICATOR...

Page 336: ... COl 00SILICON r E CT E 17 U1R l 5wl1 r cee o_ __ r o t I 1 Il L __ TERMITTENCE ljA W I G E i j _ 81 _ fA t HE _D t L _ L t FuSE BOX Ace 801 L CLuTCH ITCH II lJlln L L ll IJIJt ifl I 1 11TIt1tf I b f 1 r l I L 5 _O MO ___ J I I klJl lr STOP LJ JHI SWrTCIo1 1 TuRN SIGNAL DIMMER HORN SWITCH STARTER Ef lGIf jE SToP SWI ITCH L UIlN IGNAL IMl ll l FRONT POSITION LIGHT IM D II TEMP fUR FUEL METER L fc J...

Page 337: ... 8 8r MAIN UJ 30A 0 OFF e TTERY 1 12V lOA ruRH SIGNAL RELAY SIL CONE RECTIFIER I j J II I 1If IGNITION COIL 1 5O 1CDNlE MCT RER IDA 0 lOfT W G 1 1 _ J o _ Br l_ D FUSlIOX HOMSWfTCH DNt 1t SWITCH TURN 5 GNAl SWITCH HD HI ID HI W ou n fA ID A 0 I IfW W u 0 fW REGULATOR 7 1 I ANTENNA I I TEMP ETERfUEl METER TE fUELMETEItLIGHT12V3 _ snEO St I lSOft I AIR PRESSURE wMNtHG lAIR MESSUMJ L J LIGHT 12V J 4W...

Page 338: ...y y I I 0 I CC rvSE 90x t1 _0 I C IOA PARI ING lAo IINT RMJTT TLY 0_ E A 8 TAILlOA 8 11kl i AO IDA O I COlOR Go L b 0 Btl L iI Of iF c J Bll IGNITION SWITCH GHHi OVHIDRI I f ICAT 11 0 1 1 fl G m I BJ U W o t I OI l l g l j I l 1 RTIJRN SIGNAL toOCArOR 1M 1 111 2 l T SIGNAL fOC T 1m n 3 OIL pqESSUR LI T 1M 4 111 4 f fI BEAM INlCATOR 12V3 HI 5 EVTRAl INDICJ TOR 12V3 HI 1 rr 0 III n R TURN SIGNAL 12V...

Page 339: ...0 10 1 0 l TLI r I G l O CO Ol PARl lNGiA Ace F1JSr BOX 1 I 4ll0 o INTERMITTENTLY W I G I ENGlE SA 8r19r I n 10A 1 Btlb HEAD lOA I BI Ft 0 CQ OR c Lb 0 llrfwlIIl O Rl Co 101 0 Rl 10k IG ST i fL1 HLZ COLOR Bl y R 811Ft Bo RTlMll SIGNAL Iroc TOR 1M 4 LTlIlN SIGNAL fOCATM 1M 4 all PJf SSURE LIGHT llV3 HIGH BEAM Iff lCoIiTOR 1M 4 N UTRAL IroC T ltv IW 1 2 3 4 5 IGNITION ENGI SHIP IG ce Tel Te Loe 10 c...

Page 340: ...OlI o U UGHT LLE G GAWt LIGHT GREEN 10 WHITE M VIOLET BATTERY 12V7DAi l I L2 ERI l WA l J y G Ikd IREGULATOflIR CTlflE III G G FI R y y _ GGr I II l l 11 ttt 1 I i iii y iii IIlIN I _USE lnl MliNi J n RTING MorOA M rl SWITCfj CONTffJlTV IGNITION SWITCH ENGINE STOP SWITCH STARTER SWITCH HClIIfII SWITCH OlMM A SWITCH II FAOiIT 1UIN SlGNAll POSITION I T l vn Je lSlfwj DU 1UU ...

Page 341: ......

Page 342: ...enance and service procedures are the same for both models refer to the section Cable Hamess Routing 19 2 1 harness 2 Ground terminal 3 connector 4 Fuse cases 5 Air duct 6 Counterweight 7 Main wire harness 8 Horn wire 9 Throttle cables 10 Wire band 11 Right side switch 12 Instrument wire harness 13 Ignition switch wire 14 Turn signal buzzer wire 15 Left side switch 16 Taillight wire 17 Rear turn s...

Page 343: ... _ IUFAiRING HARNESS 19 3 ...

Page 344: ...e care not to touch the new bulb with your the fingerprints may cause hot spots on the bulb off the and remove collars panels and Bracket Removal nut lockwasher and flat washer and reverse order of removal Remove the three screws the left lower Remove Disconnect the wire harness from the main harness connector on the left side of the 19 4 ...

Page 345: ...emove the ret aiilin o bolts and remove the horns from the bracket Remove the and left inner coverscrews and remove the covers from the main bracket Remove two 6 x 14 bolts from the brackets and remove the brackets and left Remove the Remove the 8 x 80 mm bolt and four 6 mm nuts and d tmy work the bracket out of the frame 19 5 ...

Page 346: ...Accessories Engine Guard Index 19 6 ...

Page 347: ...Saddlebags Travel Trunk and Bumper Index RIGHT BUMPER TRAVEL TRUNK _ 1_ __ 8 X 45 mm fiJ 25 N m 1 18 ft lb _ LUGGAGERACK 10 X 20 mm 40 N m 29 ft Ib 19 7 ...

Page 348: ...Accessories and Bracket Installation Reinstall shown and Instal the main bracket the inner covers and the left and all screws and connect the wires cowl brackets the 8 mm bolt and the 6 mm nuts as 19 8 ...

Page 349: ... then torque the bolts bolts bracket and insert the cowl bracket and holes Place and left innercOVB Fit and left lowers over the inner cover hooks Install the collars and the screws harness to the main harness and the 19 9 ...

Page 350: ...either the screws in the reverse order WARNING An headlight may blind onlcofnil1lg drivers or it may fail to light the road for II safe local laws NOTE the he ldlight beam as SPE cltled and regjulaltions distance Vertical can be made with the beam adjusting knob Horizontal are made adjius tmlElllt screw located 011 the side of the heiadlighlt 19 10 ...

Page 351: ...RADIO SWI1 CH NOTE 1982 radio shown LEFT SPEAKER RADIO INDICATOR I 19 11 ...

Page 352: ...t radio tuner radio tuner harness Blown fuse indicator No Sound Blown fuse harness radio tuner antenna cable antenna cable connector antenna radio tuner Poor Sensiiti ity Auto Seek Switch Does Not Work connector or poor connection auto seek switch radio tuner Distortion radio tuner antenna Low Sound ill antenna III radio tuner III mute switch 19 12 ...

Page 353: ...RED GR GRAY 0 ORANGE V VIOLET A A RIGHT SPEAKER GR J RADIO INDICATOR LEFT SPEAKER 7 crT W r W BL 9 0 POWER AMPLifiER Bl V I 1 rn Til Bl RADIO TUNER Bt Bt CONTROL BASE Bl PANEL G G R Bt J i0 5 2 IGNITION SWITCH 1 j ACC BAT 5A V 1A m 2A I f F R BATTERY G B J B Y 19 13 ...

Page 354: ...s Pull the radio control base out from the Disconnect the speaker wire connectors Remove the four nuts and pull the out Remove the screws and left turn by rernO llno the Disconnect the wire connectors and remove the base 19 14 from the rArnovirm the four screws nut from the back of the indicator base Remove the left Remove the indicator base Remove the ...

Page 355: ...out from the base panel Remove the right fairing Disconnect the wire connector remove the screws and pull the radio tuner out of the I Remove the cap nuts and pull the power amplifier out far UUII to disconnect the wire connectors conrd 19 15 ...

Page 356: ...wer from the Remove the lower left cover Remove the wire bands and disconnect the antenna cable Remove the top compartment seat and antenna cable Remove the antenna from the antenna bracket Installation is the reverse order of removal NOTE 1982 radio shown 19 16 ...

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