Honda Hawk GT NT650 1988 Service Manual Download

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Technische Daten

Honda NT650 HAWK GT

Gegenstand

Technische Daten

Abmessungen

Länge über alles

2.085 mm

Breite über alles

750 mm

Höhe über alles

1.075 mm

Radstand

1.430 mm

Sitzhöhe

778 mm

Fußrastenhöhe

355 mm

Bodenfreiheit

155 mm

Trockengewicht

168 kg

Leergewicht, fahrfertig

184 kg

Rahmen

Typ

Aluminium-Kastenprofilrahmen (Twin tube diamond)

Vorderradaufhängung

Teleskopgabel

Federweg

130 mm

Hinterradaufhängung

Schwingarm

Federweg

120 mm

Fahrzeuggesamtgewicht

291 kg

Maximale Zuladung

156 kg

Reifengröße vorne

110/80 - 17 57H, schlauchlos

Reifengröße hinten

150/70 - 17 69H, schlauchlos

Reifenluftdruck, (Reifen kalt)

bis 90 kg Zuladung:
vorne: 225 kPa / 2,25 bar
hinten: 225 kPa / 2,25 bar
bis zur maximale Zuladung:
vorne: 225 kPa / 2,25 bar
hinten: 250 kPa / 2,50 bar

Vorderradbremse

Hydraulische Einscheibenbremse

Bremsscheibenfläche

262 x 2 cm²

Hinterradbremse

Hydraulische Einscheibenbremse

Bremsscheibenfläche

200 x 2 cm²

Kapazität des Kraftstofftanks

12,0 Liter

Reservemenge des Kraftstofftanks

2,0 Liter

Nachlaufwinkel

27 °

Nachlauf

111 mm

Füllmenge Gabelöl

bis Baujahr 1988:

497 ccm

ab Baujahr 1988:

502 ccm

Füllstand Gabelöl:

bis Baujahr 1988:

133 mm

ab Baujahr 1988:

128 mm

Motor

Typ

wassergekühlter Zweizylinder, Viertaktmotor, SOHC

Zylinderanordnung

2 Zylinder, 52 ° V

Bohrung und Hub

79,0 x 66,0 mm

Hubraum

647 ccm

Verdichtungsverhältnis

9,4 : 1

Ventiltrieb

leiser Mehrglieder-Kettenantrieb mit obenliegender
Nockenwelle und Kipphebeln

Schmiersystem

Druckumlaufschmierung mit Ölsumpf

1/4

Summary of Contents for Hawk GT NT650 1988

Page 1: ...88 91 NT650 HAWKTMGT ...

Page 2: ...tailed procedures If you don t know the source of the trouble go to section 20 Troubleshooting All information illustrations directions and speci fications included in this publication are based on the latest product information available at the time of approval for printing HONDA MOTOR CO LTD reserves the right to make changes at any time without notice and without incurring any obligation whatev...

Page 3: ...1 18 Systems 1 16 Engine Removal Installation 6 1 Installation 6 5 Oil Change 2 3 Oil Level 2 3 Engine Removal Evaporative Emission Control System California model only Flywheel Installation Removal Fork Front Wheel Suspension Steering Brake Caliper Master Cylinder Wheel Fuel System Line Fuel Pump Relay Fuel Tank Gearshift Linkage General Information Safety Handlebar Switches Handlebars Headlight ...

Page 4: ...e Stand 3 1 6 Spark Plug 3 6 Specifications 1 3 Spindle 13 11 Sprocket 13 6 Starter Clutch 8 4 Motor 17 3 Relay Switch 17 6 Steering Head Bearings 3 18 Stem 12 20 Suspension 3 16 Swingarm 13 19 Switches Location 18 2 System Testing 5 2 Temperature Gauge 18 8 Sensor 18 7 Thermostat 5 3 Thermostatic Switch 18 7 Throttle Operation 3 4 Tools 1 7 Torque Values 1 5 Transmission 11 9 Assembly Installatio...

Page 5: ...ic acid Protect your eyes skin and clothing In case of contact flush thoroughly with water and call a doctor if electrolyte gets in your eyes Do not remove the radiator cap when the engine is hot The coolant is under pressure and severe scalding could result The engine must be cool before servicing the cooling system CAUTION Used engine oil may cause skin cancer ifrepeatedly left in con tact with ...

Page 6: ...cation numbers are on the carbure tor body intake side 1 2 Vi 1 VEHICLE IDENTIF ICATION NUMBER The vehicle identification number VIN is attached to the right side of the down tube The engine serial number is stamped on the right crank case below the rear cylinder The color label is attached to the rear fender under the seat When ordering a color coded part always specify its desig nated color code...

Page 7: ... 2 sq in Hydraulic single disc 200 x 2 em 31 0 x 2 sq in 12 0 lit 3 18 US gal 2 64 Imp gal 2 0 lit 2 10 US qt 1 76 Imp qt 27 111 mm 4 37 in 497 cc 16 8 US oz 17 4 Imp oz 502 cc 16 9 US oz 17 6 Imp oz 133 mm 5 2 in 128 mm 5 0 in Type ENGINE Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Oil capacity Coolant capacity Lubrication system Air filtration Cylinder compres...

Page 8: ...Ignition timing F mark 10 BTDC at idle Full advance 31 BTDC at 7 000 200 rpm Starting system Starter motor Alternator 240 W 5 OOO rpm Battery capacity 12 V 8 Ah MF Battery Spark plug NGK ND Standard DPR8EA 9 X24EPR U9 For cold climate DPR7EA 9 X22EPR U9 Below 5 C 41 F For extended high speed DPR9EA 9 X27EPR U9 riding Spark plug gap 0 80 0 90 mm 0 031 0 035 in Firing order Front 232 0 Rear 488 0 Fr...

Page 9: ... nut Right crankcase cover bolt 15 6 10 1 0 7 2 Left crankcase cover bolt 9 6 10 1 0 7 2 Oil filter cartridge 1 20 10 1 0 7 2 Apply clean engine oil to the O ring Oil drain bolt 1 14 35 3 5 25 Neutral switch 1 10 12 1 2 9 Oil pressure switch 1 12 1 2 9 NOTE 4 Primary drive gear bolt 1 12 90 9 0 65 UBS bolt NOTE 2 Flywheel bolt 1 12 130 13 0 94 Left hand threads NOTE 2 Starter one way clutch 6 8 30...

Page 10: ... 8 22 2 2 16 Brake torque rod bolt 2 10 35 3 5 25 Handlebar pinch bolt 2 8 27 2 7 20 Ignition switch mounting bolt 2 8 25 2 5 18 Fork pinch bolt upper 2 7 11 1 1 8 Fork pinch bolt lower 2 10 50 5 0 36 NOTE 2 Fork tube cap 2 23 2 3 17 Fork socket bolt 2 8 17 1 7 12 NOTE 1 Steering bearing adjustment nut 1 26 20 2 0 14 NOTE 2 Steering stem nut 1 24 105 10 5 76 Flange nut Front axle bolt 1 14 60 6 0 ...

Page 11: ...er 5 5 mm 07984 200000B IN 07984 2000001 U S A only 9 Valve guide reamer 6 6 mm 07984 ZE2000B EX 07984 ZE20001 9 Steering stem driver 07946 MBOOOOO 12 Lock nut wrench 07908 KE90000 12 Bearing remover set 07946 MJOOOOO 13 driver head 07946 MJ00200 driver shaft 07946 MJ001 00 Driver handle 07949 3710001 Spherical bearing driver 07946 KA30200 NOTE 2 13 Ball race remover set 07946 KM90001 L djUstable ...

Page 12: ...ot 25 mm 07746 0040600 11 Extension bar 07716 0020500 rNOTE 1 12 Lock nut wrench 30 x 32 mm 07716 0020400 12 Pilot 35 mm 07746 0040800 13 Pilot 40 mm 07746 0040900 13 Pilot 22 mm 07746 0041000 11 13 Bearing remover shaft 07746 0050100 13 Bearing remover head 20 mm 07746 0050600 12 Driver 07749 0010000 11 12 13 Valve spring compressor 07757 0010000 Valve spring 07957 3290001 9 compressor NOTE 1 Equ...

Page 13: ...oroughly before applying tape o Do not use a wire or harness with broken insulation Repair by wrapping them with protective tape or replace them Route wire harnesses to avoid sharp edges or corners Also avoid the projected ends of bolts and screws Keep wire harnesses away from the exhaust pipes and other hot parts Be sure grommets are seated in their grooves properly After clamping check each harn...

Page 14: ...GENERAL INFORMATION 1 SUB FUSE BOX CONNECTOR 9P 4 METER WIRE CONNECTOR 3 SUB FUSE BOX fL 1 CONNECTOR 3P 2 HEADLIGHT CONNECTOR 1 10 ...

Page 15: ...EATHER TUBE 5 FUEL TUBE INLET LINE 6 FUEL TANK DRAIN CUP 7 ALTERNATOR WIRE 2 FRONT IGNITION COIL 3 PULSE GENERATOR WIRE 11 4 1 CLUTCH CABLE 4 RIGHT HANDLEBAR SWITCH 9P RED CONNECTOR 5 TURN SIGNAL 6P WHITE CONNECTOR 6 PULSE GENERATOR 4P WHITE CONNECTOR 1 11 ...

Page 16: ... IGNITION COIL 12 FUEL TUBE 11 COOLANT RESERVE TANK OVERFLOW TUBE 10 AIR CLEANER CASE 8 SHOCK ABSORBER DRAIN TUBE PLUG DRAIN TUBE 9 FUEL TANK DRAIN TUBE 1 REAR IGNITION COIL CONNECTOR 2P 3 FUEL TUBE 2 FUEL PUMP RELAY 7 REGULATOR RECTIFIER 4P BLACK CONNECTOR 1 12 ...

Page 17: ...GENERAL INFORMATION 8 AIR CLEANER 7 FUEL PUMP CASE DRAIN TUBE 11 RESERVE TANK OVER FLOW TUBE 12 AIR CLEANER CASE DRAIN TUBE 13 FUEL TANK DRAIN TUBE 1 13 ...

Page 18: ...appear on the Vacuum Hose Routing Diagram Label page 1 19 4 TUBE 3 FUEL TUBE 2 J TUBE 6 TO CARBURETOR VIEWZ VIEWY 10 PURGE CONTROL VALVE PCV 11 AIR VENT CONTROL VALVE AVCV 17 AIR SUCTION VALVE ASV 8 TUBE 7 TUBE 14 AIR CLEANER CASE DRAIN TUBE 19 FUEL TANK DRAIN TUBE SECTION AA 20 CD TUBE 1 14 ...

Page 19: ...CALIFORNIA MODEL ONLY 12 FUEL TANK DRAIN TUBE TO FUEL TANK 11 CANISTER GENERAL INFORMATION 2 AIR VENT CONTROL VALVE AVCV 4 GROUND CABLE 1 15 ...

Page 20: ...ons Control of hydrocarbons is very important because under certain conditions they react to form photochemical smog when subjected to sunlight Carbon monoxide does not react in the same way but it is toxic Honda Motor Co Ltd utilizes lean carburetor settings as well as other systems to reduce carbon monoxide and hydro carbons EXHAUST EMISSION CONTROL SYSTEM Except for California The exhaust emiss...

Page 21: ...es with California Air Resources Board evaporative emission requirements Fuel vapor from the fuel tank and carburetor is directed into the charcoal canister where it is adsorbed and stored while the engine is stopped When the engine is running and the purge control diaphragm valve is open fuel vapor in the charcoal canis ter is drawn into the engine through the carburetor 3 FUEL TANK 7 AIR VENT CO...

Page 22: ...h conducts exhaust gases 2 Removal of or puncturing of any part of the intake system 3 Lack of proper maintenance 4 Replacing any moving parts of the vehicle or parts of the exhaust or intake system with parts other than those specified by the manufacturer EMISSION CONTROL INFORMATION LABELS An Emission Control Information Label is located on the rear fender as shown It contains basic tune up spec...

Page 23: ...nly The Vacuum Hose Routing Diagram Label is on the air cleaner case cover Route the vacuum hoses as shown on this label VACUUM HOSE ROUTING DIAGRAM ENGlhE FAMI Y JI I064742G9 TO AIRIC t EVAPORATIVE FAMlY 88ZD IJWCV CAUFORNIA VEHiClE 1 VACUUM HOSE ROUTING DIAGRAM LABEL 1 19 ...

Page 24: ...LUBRICATION 1 ROCKER ARM 13 CAMSHAFT 12 PISTON 2 0 ...

Page 25: ...e oil pump can be serviced after removing the engine from the frame SPECIFICATIONS Engine oil Oil capacity 2 8 lit 2 94 US qt 2 46 Imp qt after disassembly 2 3 lit 2 43 US qt 2 02 Imp qt at oil filter and oil change 2 2 lit 2 32 US qt 1 94 Imp qt after draining Oil recommendation HONDA 4 stroke oil or equivalent API service classification SE or SF VISCOSITY SAE 10W 40 Other viscosities shown in th...

Page 26: ...G Dirty air cleaner Loose spark plug Mixture too rich Carburetor flooded Choke valve stuck open Dirty air cleaner element Cylinder flooded Improper spark plug WEAK OR NO SPARK Refer to page 16 2 ONE CYLINDER LOW COMPRESSION Improper valve and seat contact Damaged cylinder head gasket Valve stuck open Worn cylinder and piston rings 4 Spark test both cylinders I NO PROBLEM 5 J 1 0 com o 09 compressi...

Page 27: ... With the engine stop switch OFF start the starter motor for few seconds to drain any oil which may be left in the engine NOTE Do not operate the motor for more than few seconds After the oil has drained check that the drain bolt sealing washer is in good condition and install the bolt TORQUE 35 N m 3 5 kg m 25 ft Ibl Fill the crankcase with the correct quantity of the recommend ed oil OIL CAPACIT...

Page 28: ...80 o C 176 F Stop the engine If the engine must be running to do some work make sure the area is well ventilated Never run the engine in an enclosed area The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death Remove the oil pressure switch and connect an oil pressure gauge attachment and gauge to the pressure switch hole Check the oil level TOOLS ...

Page 29: ...ef valve TOOL Snap ring pliers 07914 3230001 1 SNAP RING INSPECTION Check the spring O ring and valve for fatigue wear or dam age Check the body for clogging or damage Clean all the parts and assemble them in the reverse order of disassembly Replace the relief valve if necessary as an assembly OIL PUMP REMOVALIDISASSEMBLY Remove the oil pump by removing two mounting bolts Remove the dowel pins and...

Page 30: ...strainer and oil pipe with non flammable or high flash point solvent 1 OIL SEAL Remove the three cover bolts Disassemble the parts and clean them with non flammable or high flash point solvent INSPECTION Install the outer and inner rotors to the pump body Measure the outer rotor to pump body clearance SERVICE LIMIT 0 35 mm 0 014 in 2 6 1 COVER SaLTS ...

Page 31: ...nce SERVICE LIMIT 0 10 mm 0 004 in Temporarily install the shaft in the pump body Measure the inner rotor tip clearance SERVICE LIMIT 0 20 mm 0 008 in Replace the oil pump if necessary as an assembly ASSEMBLY 1 PUMP BODY 2 OUTER ROTOR LUBRICATION 10 O RING 11 OIL STRAINER 2 7 ...

Page 32: ...tor groove Install the dowel pin and a new gasket on the pump body then install the cover Tighten the cover bolts securely 1 OUTER ROTOR 2 PUNCH MARK 6 INNER ROTOR 1 OIL PUMP BODY 2 OIL PUMP COVER 1 COVER BOLTS Install the O rings oil seal oil strainer and oil pipe on the oil pump CAUTION Install the O rings on the oil pipe with the tapered side facing out as shown or the engine will be damaged 2 ...

Page 33: ...s and new a rings Install the oil pump as an assembly Assemble the pressure relief valve and install it in the oil pump Install the pressure relief valve cover with the bolt Assemble the crankcase Section 11 LUBRICATION 2 DOWEL PIN 2 9 ...

Page 34: ...en not otherwise specified here Apply oil or grease to the other sliding surfaces and cables not shown here 5 DRIVE CHAIN GEAR OIL SAE 80 90 4 FOOT PEG PIVOTS AND SEAT LOCK STRIKER LATCH 6 SIDE STAND MAIN STAND PIVOT 3 SWINGARM PIVOT BALL AND NEEDLE BEARINGS 2 THROTTLE PIPE J I J J I I I J J J J J J J I I I _ 7 BRAKE PEDAL PIVOT 8 BRAKE CALIPER PIVOTS SILICON GREASE 9 SPEEDOMETER DRIVE GEAR 1 CLUT...

Page 35: ...rea is well ventilated Never run the engine in an enclosed area The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death Gasoline is extremely flammable and is explosive under certain conditions Work in a well ventilated area with the engine stopped Do not smoke or allow flames or sparks in the work area or where gasoline is stored GENERAL Engine oi...

Page 36: ...36 Tire brand Bridgestone G547G G548 Dunlop K505G K505 Wheel balance weight 60g Maximum 60g Maximum TORQUE VALUES Eccentric bearing carrier pinch bolt Valve adjusting screw lock nut Timing hole cap Crankshaft hole cap Spark plug TOOLS Special Valve adjusting wrench Vacuum gauge 3 2 75 Nom 7 5 kg m 54 ft Ib 23 Nom 2 3 kg m 17 ft Ib 10 Nom 1 0 kg m 7 2 ft lb TApply molybdenum disulfide grease to the...

Page 37: ...9 f t t 1f j RADIATOR COOLANT NOTE 5 R 3 9 wl j t j t t t t t j COOLING SYSTEM 3 10 SECONDARY AIR SUPPLY SYSTEM NOTE 5 3 11 EVAPORATIVE EMISSION CONTROL SYSTEM NOTE 4 3 11 DRIVE CHAIN BRAKE FLUID BRAKE PAD WEAR I j o BRAKE SYSTEM w BRAKE LIGHT SWITCH uJ HEADLIGHT AIM 0 1 _ Z CLUTCH SYSTEM a f___t_ Ui SIDE STAND 1__ SUSPENSION w Z NUTS BOLTS FASTENERS a Z WHEELS TIRES STEERING HEAD BEARINGS 3 12 3 ...

Page 38: ...maged Lubricate the throttle cables if throttle operation is not smooth Measure the free play at the throttle grip flange FREE PLAY 2 6 mm 1 16 1 4 in _ i vI 1 2 6 mm 1 16 1 14 in 2 FUEL FILTER Throttle grip free play can be adjusted at either end of the throttle cable Minor adjustments are made with the upper ad juster Major adjustments are made with the lower adjuster Adjust the free play by loo...

Page 39: ...e the choke valve from the carburetor Push the choke lever on the handlebar all the way up to fully closed and measure the distance between the ends of the choke valve and nut It should be 10 11 mm 0 39 0 43 in Adjust the distance to within specifications by loosening the lock nut and turning the cable s elbow at the left handlebar switch housing Tighten the lock nut securely and recheck the dista...

Page 40: ...e the spark plugs RECOMMENDED SPARK PLUG NGK ND Standard DPR8EA 9 X24EPR U9 For cold climate DPR7EA 9 X22EPR U9 below 5 C 41 F For extended high speed DPR9EA 9 X27EPR U9 riding Measure the new spark plug gap with a wire type feeler gauge SPARK PLUG GAP 0 8 0 9 mm 10 031 0 035 inl Adjust the gap if necessary by bending the side electrode carefully With the plug washer attached thread each spark plu...

Page 41: ...with the index notch on the left crankcase cover Make sure the piston is at TDC Top Dead Center on the compression stroke and the cam lobes are all facing down as shown 2 FT MARK Inspect the clearance of all three valves by inserting a feeler gauge between the adjusting screw and the valve VALVE CLEARANCES COLD Intake 0 15 0 02 mm 0 006 0 0008 in Exhaust 0 20 0 02 mm 0 008 0 0008 in Apply oil to t...

Page 42: ... Connect the vacuum gauge tube and vacuum gauge FRONT CYLINDER Remove the plug from the front cylinder intake port and install the vacuum gauge adaptor TORQUE Timing hole cap 10 N m 1 0 kg m 7 2 ft Ibl Crankshaft hole cap 15 N m 1 5 kg m 11 ft Ibl Perform this maintenance with the engine at normal operat ing temperature the transmission in neutral and the motor cycle on its center stand REAR CYLIN...

Page 43: ... sure the area is well ventilated Never run the engine in an enclosed area The exhaust contains poisonous carbon monoxide gas that may cause loss oj consciousness and lead to death Turn the throttle stop screw as required to obtain the specified idle speed IDLE SPEED 1 200 100 rpm RADIATOR COOLANT Check the coolant level of the reserve tank with the engine running at normal operating temperature I...

Page 44: ...s that may cause loss of consciousness and lead to death Stop the engine disconnect both spark plug caps and remove one spark plug NOTE To measure the cylinder compression of each individual cyl inder and remove only one plug at a time Turn the engine stop switch OFF Insert the compression gauge Open the throttle all the way and crank the engine with the starter motor Crank the engine until the ga...

Page 45: ...n the fuel tank canister purge control valve PCV air vent control valve AVCVl and carburetor for deterioration damage or loose connections 2 PURGE CONTROL VALVE 1 CARBURETORS ro JE ill l 4 DRAIN 5 CHARCOAL CANISTER U 1 6 AIR VENT I CONTROL VALVE 7 AIR VENT CONTROL 8 TO OPEN VALVE AIR ENGINE STOP FRESH AIR FUEL VAPOR 3 FUEL TANK Also check the tubes for bending or twisting and straighten if necessa...

Page 46: ... slack gauge is using the UP mark facing the swingarm without fail Make sure the upper edge of the chain is between lines A and B on the gauge A B Good Above A Too tight Below C Too loose CHAIN ADJUSTMENT Loosen the eccentric bearing carrier pinch bolt Turn the eccentric bearing carrier clockwise or counter clockwise by the bearing carrier wrench to obtain the drive chain slack as necessary Tighte...

Page 47: ...ugh the sight glass If the level is visible check pad wear first replace the pads if necessary Then remove the cover set plate and diaphragm Fill the reser voir to the upper level with DOT 4 fluid from a sealed contain er Check the system for leaks CAUTION Do not remove the reservoir cover until the handlebar has been turned so that the reservoir is level Do not mix different types offluid as they...

Page 48: ...REAR BRAKE PEDAL Check the rear brake pedal height To adjust the brake pedal height loosen the lock nut and turn the master cylinder push rod Tighten the lock nut NOTE Adjust the brake light switch after adjusting the brake pedal height BRAKE LIGHT SWITCH NOTE Perform the rear brake light switch adjustment after adjust ing the brake height The front brake light switch does not require adjustment A...

Page 49: ...lay at the lever end FREE PLAY 10 20 mm 3 8 3 4 in Minor adjustments are made with the upper adjuster Pull the lever cover back loosen the lock nut and turn the ad juster to obtain the specified free play Tighten the lock nut and install the cover Check clutch operation Major adjustments are made with the lower adjuster Loosen the lock nut and turn the adjusting nut to obtain the specified free pl...

Page 50: ...emove the return spring at the retracted position Remove the pivot bolt and side stand Check the following parts inside of the pivot and pivot collar for wear or damage pivot dust seal for damage Lubricate the pivot area with clean grease and reassemble the side stand TORQUE Side stand pivot bolt 38 N m 3 8 kg m 27 ft Ibl CAUTION Install the dust seal lip spring is facing out Make sure that the du...

Page 51: ...ts and bolts NUTS BOLTS FASTENERS Tighten the bolts nuts and fasteners at the intervals shown in the Maintenance Schedule page 3 3 Check that all chassis nuts and bolts are tightened to their cor rect torque values page 1 5 and 6 Check all cotter pins and safety clips WHEELS TIRES TIRE PRESSURE NOTE Tire pressure should be checked when the tires are COLD MAINTENANCE Front Rear Tire size Tubeless 1...

Page 52: ...s if the tread depth reaches the following limit MINIMUM TREAD DEPTH Front 1 5 mm 0 06 in Rear 2 0 mm 0 08 in STEERING HEAD BEARINGS NOTE Check that the control cables do not interfere with handle bar rotation Raise the front wheel off the ground Check that the fork pivots freely from side to side If the fork pivots unevenly binds or has vertical movement inspect the steering head bearings Section...

Page 53: ...FUEL SYSTEM 88 Shown 4 0 k m 9 ft Ibl 12 N m 1 2 g 16 ft Ibl 2 kg m 22 N m ...

Page 54: ...n disassembling fuel system parts note the locations of the a rings replace them with new ones on reassembly The carburetor float chambers have drain screws that can be loosened to drain residual gasoline For fuel pump inspection refer to section 18 All hoses used in the evaporative emission control system are numbered for identification When connecting one of these hoses compare the hose number w...

Page 55: ...rect idle speed Incorrect valve clearance Section 3 Incorrect carburetor synchronization Faulty carburetor Fuel contaminated Faulty air cut off valve California model only Faulty purge control valve Faulty air vent control valve Worn damaged emission system hoses Afterburning during deceleration Faulty ignition system Faulty air cut off valve Lean mixture California model only Worn damaged emissio...

Page 56: ...t may damage the front mounting collar Check that fuel flows out of the fuel valve freely If flow is restricted clean the fuel startiner After 88 Remove the rear fuel tank mounting bolt first then the front bolt Screw the rear mounting bolt in the front mounting collar Remove the rear mounting bolt and the collar as a set California model only Disconnect the No 1 fuel breather tube to canister fro...

Page 57: ...oses carburetors to sub air cleaner cov er Remove the sub air cleaner mounting bolt and cover and remove the element SUB AIR CLEANER ELEMENT Remove the following seat page 13 25 and fuel tank page 4 3 air cleaner case Wash the element in non flammable or high flash point sol vent squeeze out the solvent thoroughly and allow the ele ment to dry Soak the element in gear oil SAE 80 90 and squeeze out...

Page 58: ...retor NOTE Turn the choke lever fully in to avoid losing the choke valves Remove the choke valves from the carburetor and loosen the carburetor insulator bands California model only Disconnect the purge control valve No 5 tubes and air vent control valve No 6 and 11 tubes from the carburetor Pull the carburetors upward and away from the engine CARBURETOR DISASSEMBLY NOTE The carburetors can be dis...

Page 59: ...eedle holder in and turn it in 90 degrees counter clockwise Then remove the needle holder spring jet needle and from the piston Inspect the needle for excessive wear at the tip bending or other damge Inspect the diaphragm for damage fatigue or pin holes Inspect the vacuum piston for wear or damage 1 DIAPHRAGM PISTON FLOAT CHAMBER FLOAT AND JETS Remove the four screws and float chamber 4 6 ...

Page 60: ...lash point solvent Inspect the float valve seat and filter for grooves nicks or de posits Clean the filter with low pressure compressed air o 5 FILTER 4 VALVE SEAT 2 MAIN JET 3 SLOW JET PILOT SCREW REMOVAL NOTE The pilot screws are factory pre set and should not be re moved unless the carburetors are overhauled The pilot screw plugs are factory installed to prevent pilot screw misadjustment Do not...

Page 61: ...rotates with the screw Pull on the screw head with pliers to remove the plug Use compressed air to clean the pilot screw area and remove metal shavings 1 SELF TAPPING SCREW 7 NG o 4 WASHER 3 PILOT SCREW Remove the pilot screws and inspect them Replace them if they are worn or damaged CAUTION Turn each pilot screw in and carefully count the number of turns until it seats lightly Make a note of this...

Page 62: ...or clogging a ring for damage Replace the air cut off valve as an assembly if necessary CARBURETOR CLEANING Separate the carburetors page 4 12 Remove the float valve all jets and the pilot screws Blow open all carburetor body openings with compressed air CARBURETOR ASSEMBLY FUEL SYSTEM 3 DIAPHRAGM I 4 SPRING 1 CARBURETOR BODY 16 NEEDLE JET 13 FLOAT CHAMBER 11 SLOW JET 12 MAIN JET 6 VACUUM CHAMBER ...

Page 63: ... pilot screw holes until after adjustment has been made If you replace the pilot screw in one carburetor you must replace the pilot screw in the other carburetor for proper pilot screw adjustment FLOAT CHAMBER FLOAT AND JETS Install the pilot screw and turn it in until it seats lightly Turn the pilot screw out the number of turns recorded during removal CAUTION Damage to the pilot screw seat will ...

Page 64: ...er groove Install the float chamber and tighten the screws securely NOTE Install the fuel tube clamps VACUUM CHAMBER Install the washer jet needle spring and jet needle holder in the vacuum piston Push the jet needle holder in and turn it in 90 degrees cloc kwise Hold the vacuum piston up to almost full open to avoid pinch ing the diaphragm with the chamber cover FUEL SYSTEM 1 JET NEEDLE HOLDER 4 ...

Page 65: ... with at least two screws before releasing the vacuum piston Install the fuel tubes as shown CARBURETOR SEPARATION ASSEMBLY SEPARATION Loosen the synchronization adjusting screw NOTE When separating the carburetors be careful not to lose the thrust spring and synchronization adjusting spring Separate the carburetors by removing the two attaching screws Remove the synchronization spring 4 12 1 CHAM...

Page 66: ...scribed below Open the throttle slightly by rotating the throttle valve then release the throttle Make sure that there is no drag when opening and closing the throttle Turn the throttle stop screw to align the rear cylinder carbure tor throttle valve with the edge of the by pass hole Align the front cylinder carburetor throttle valve with the by pass hole edge by turning the synchronization adjust...

Page 67: ...crews are replaced Use a tachometer with graduations of 50 rpm or smaller that will accurately indicate a 50 rpm change 1 Turn each pilot screw clockwise until it seats lightly and back it out to the specification given This is an initial setting prior to the final pilot screw adjust ment INITIAL OPENING 49 st model Carifornia model 88 2 1 8 turns out 2 1 2 turns out After Front 1 1 2 1 3 8 turns ...

Page 68: ...temperature Stop and go riding for 10 minutes is sufficient Turn each pilot screw clockwise 1 2 turn Adjust the idle speed to specification with the throttle stop screw IDLE SPEED 1 200 100 rpm NOTE This adjustment must be made at high altitude to ensure proper high altitude operation Drive new pilot screw plugs into the pilot screw bores page 4 7 Attach a Vehicle Emission Control Information Upda...

Page 69: ...e pump to the 8 mm 0 31 in 1 0 hose No 4 that goes to the charcoal canister While applying the speci fied vacuum to the PCV hose that goes to the 3 way joint pump air through the canister hose Air shoud flow through the PCV and out of the hose that goes to the 3 way joint Replace the PCV if air does not flow out Remove the vacuum pump and connect it to the vacuum hose No 11 that goes to the left c...

Page 70: ...uum leaks TOOL Vacuum Pressure pump Vacuum pump FUEL SYSTEM 2 TO OPEN AIR 3 AIR VENT CONTROL I VALVE 4 TO CHARCOAL CANISTER 1 5 TO CYLINDER INTAKE PORT 6 VACUUM PUMP 1 VACUUM PUMP Connect the vacuum pump to the No 1 0 hose that goes to the right carburetor body Connect the pressure pump to the air vent port of the AVCV While applying the vacuum to the AVCV No 10 hose that goes to the right carbure...

Page 71: ... to keep air from entering Connect the vacuum pump to the ASV TOOL Vacuum Pressure pump Vacuum pump A937X 041 XXXXX or ST AH 260 MC7 U S A only Start the engine and open the throttle slightly to be certain that air is sucked in through the intake hose If air is not drawn in check the air supply hoses and vacuum tube for clogging With the engine running gradually apply vacuum to the ASV Check that ...

Page 72: ...eplace if nec essary Install a new reed valve if the seat rubber is cracked or dam aged or if there is clearance between the reed valve and seat CAUTION Do not disassemble the reed valve assembly or bend the reed stopper If the stopper reed or seat is faulty replace the valve as an as sembly Assemble and install the ASV in the reverse order of disassem blylremoval NOTE After installing make sure t...

Page 73: ...h a cooling system tester For temperature sensor and thermostatic switch inspection refer to section 18 SPECIFICATIONS ITEM SPECIFICATIONS Radiator cap relief pressure 88 127 kPa 0 9 1 3 kg cm2 13 18 psi Freezing point Hydrometer test 55 Distilled water 45 ethylene glycol 32 C 25 F 50 Distilled water 50 ethylene glycol 37 C 34 F 45 Distilled water 55 ethylene glycol 44 5 C 48 F Coolant capacity Co...

Page 74: ...ply pressure Replace the radiator cap if it does not hold pressure or if it s relief pressure is too high or too low It must hold specified pressure for at least six seconds RADIATOR CAP RELIEF PRESSURE 88 127 kPa 0 9 1 3 kg em 13 18 psi SYSTEM PRESSURE TEST Remove the fuel tank and radiator cap Attach the tester to the radiator and apply enough pressure to test the radiator engine and hoses check...

Page 75: ...ing system Support the motorcycle on its center stand and shift the transmission into neutral Start the engine and snap the throttle grip 3 4 times at 4 000 5 000 rpm Then add coolant up to the radiator filler neck Reinstall the radiator cap Check the level of coolant in the reserve tank and fill to the correct level if the level is low THERMOSTAT REMOVAL Remove the following fuel tank page 4 3 ai...

Page 76: ...ft 8 mm 0 3 in minimum when heated to 95 C 203 F for five minutes INSTALLATION Install the following the thermostat into the housing case the new O ring into the case groove the cover onto the case with the bolts Assemble the case and filler neck with the new O ring Tighten the bolts Install the thermostat housing case and filler neck onto the frame Connect the removed hoses and tube securely Inst...

Page 77: ...nnector Disconnect the lower radiator hose at the radiator Remove the radiator side covers by removing mounting screws Remove the radiator lower mounting bolts Disconnect the upper radiator hose at the radiator Remove the radiator upper pivot bolt and radiator from the frame COOLING SYSTEM 5 5 ...

Page 78: ...ling fan motor RADIATOR INSPECTION NOTE See section 18 for thermostatic switch inspection Inspect the radiator soldered joints and seams for leaks Slow dirt out from between core fins with compressed air If insects etc are clogging the radiator wash them off with low pressure water Carefully straighten any bent fins 2 MOUNTING SOLTS 3 GROUND TERMINAL SOLT 1 COOLING FAN MOTOR 3 PIVOT SOLT 1 RADIATO...

Page 79: ...order of removal WATER PUMP MECHANICAL SEAL INSPECTION Inspect the telltale hole for signs of mechanical seal coolant leakage Replace the water pump as an assembly if the mechanical seal is leaking REMOVAL Drain the engine oil page 2 3 Remove the water pump cover mounting bolts and cover Remove the O ring and dowel pins from the water pump as sembly and disconnect the water hose Remove the water p...

Page 80: ...a ring and install it in the water pump shaft housing groove Align the water pump shaft groove with the oil pump shaft and insert the water pump into the crankcase Apply a coat of engine oil to a new a ring and install it around the impeller housing Install the two dowel pins Install the water pump cover and tighten the cover mounting bolts Fill the system with coolant page 5 3 Fill the engine wit...

Page 81: ...6 ENGINE REMOVAL INSTALLATION SERVICE INFORMATION ENGINE REMOVAL 6 2 ENGINE INSTALLATION 6 3 65 N m 6 5 kg m 47 ft Ibl 6 5 40 N m 4 0 kg m 29 ft Ibl 10 N m 1 0 kg m 7 2 ft Ibl 6 1 ...

Page 82: ...ght Oil capacity Coolant capacity TORQUE VALUES Muffler mounting bolt Exhaust pipe joint nut Gearshift arm bolt Drive sprocket bolt Swingarm pivot nut Swingarm pivot lock nut Swingarm pivot adjusting bolt Front engine bracket bolt Front engine mouning bolt Rear upper engine mouning bolt mounting bolt lock nut mounting bolt adjusting bolt Fuel tank mounting bolt Front Rear TOOL Special Lock nut wre...

Page 83: ...cover page 8 2 then remove the sprocket from the drive chain by removing two sprocket bolts and the plate Disconnect the following electrical connections oil pressure switch wire neutral switch wire pulse generator wire alternator wire starter moter cable and ground cable Disconnect the following cooling system connections water hoses to thermostat housing at the engine siphon tube at the filler n...

Page 84: ...t lock nut Remove the front engine lower mounting bolt Loosen the rear engine upper mounting bolt lock nut and remove the rear engine upper mounting and adjusting bolts TOOL Lock Nut wrench 07908 ME90000 Turn the pivot bolt with the adjusting bolt counterclockwise to release the engine mounting frame Pull the swingarm pivot bolt out to clear the engine mounting hole but do not remove it Remove the...

Page 85: ...bolt while aligning the serrations of the pivot bolt and adjusting bolt ENGINE REMOVAL INSTALLATION 2 ADJUSTING BOLT Turn the pivot bolt with the adjusting bolt clockwise fully to seat the swingarm left pivot collar Tighten the bolt to the specified torque TORQUE 15 N m 1 5 kg m 11 ft Ibl 1 PIVOTIADJUSTING BOLT TORQUE Actual 65 N m 6 5 kg m 47 ft Ib Indicated 59 N m 15 9 kg m 43 ft Ibl Install the...

Page 86: ...bl Install the lock nut onto the adjusting bolt TORQUE 55 N m 5 5 kg m 40 ft Ibl Install the rear engine upper mounting bolt and tighten it to the specified torque TORQUE 40 N m 4 0 kg m 29 ft Ibl Tighten all the fasteners to the torques given on page 6 1 and 2 NOTE Route the wires and cables properly Section 1 Fill the crankcase to the proper level with the recommended oil page 2 1 Fill the cooli...

Page 87: ...CLUTCH GEARSHIFT LINKAGE SS Shown 15 N m 1 5 kg m 11 ft Ibl 7 0 ...

Page 88: ...hickness Disc A 2 92 3 08 0 115 0 121 2 60 0 102 Disc B 2 62 2 78 0 103 0 109 2 30 0 091 Plate warpage 0 30 0 012 Outer guide 1 0 21 991 22 016 0 8658 0 8668 22 09 0 870 0 0 1 959 31 975 1 2582 1 2589 31 92 1 257 Outer 1 0 32 000 32 025 1 2598 1 2608 32 10 1 264 Oil pump drive sprocket 1 0 32 000 32 025 1 2598 1 2608 32 10 1 264 Mainshaft 0 0 at clutch outer guide 21 967 21 980 0 8648 0 8654 21 92...

Page 89: ...n accelerating No free play Discs worn Springs weak Clutch will not disengage Too much free play Plates warped Motorcycle creeps with clutch disengaged Too much free play Plates warped Excessive lever pressure Clutch cable kinked damaged or dirty Lifter mechanism damaged Clutch operation feels rough Clutch outer slots rough Dirty clutch cable 7 2 ...

Page 90: ...e the right crankcase cover bolts and cover NOTE R crankcase cover can be serviced with rear exhaust pipe removal only Remove the dowel pins and gasket Remove the oil orifice CLUTCH LIFTER Remove the clutch lifter piece and remove the snap ring and return spring from the right crankcase cover Remove the clutch lifter shaft Check the clutch lifter piece and shaft for damage or excessive scratching ...

Page 91: ...ring and return spring Hook the spring end in the cover tab securely and turn the shaft Install the clutch lifter piece aligning the piece end with the groove in the clutch lifter shaft CLUTCH REMOVAL Remove the following clutch bolts clutch lifter plate springs NOTE Remove the bolts in a crisscross pattern in 2 or 3 steps Be careful not to damage the shah threads Unstake the clutch lock nut with ...

Page 92: ... Clutch center holder Lock nut wrench 17 x 27 mm NOTE 07923 KE10000 or 07HGB 001000A U S A only 07716 0020300 Equiva lent commercially available in U S A CLUTCH GEARSHIFT LINKAGE Remove the following washer clutch center judder spring and spring seat discs and plates pressure plate Remove the thrust washer and clutch outer Remove the oil pump driven sprocket mounting bolt driven sprocket and oil p...

Page 93: ...bearing outer race fits tightly in the clutch lifter plate Replace the bearing if necessary Measure the spring free length SERVICE LIMIT 42 8 mm 1 69 in Replace the clutch discs if they show signs of scoring or dis coloration Measure the thickness of discs A and B SERVICE LIMITS Disc A 2 60 mm 0 102 in Disc B 2 30 mm 0 091 in NOTE Replace the discs and plates as a set if anyone is beyond the servi...

Page 94: ...k the clutch center for nicks or indentations made by the clutch plates Check the spring seat and judder spring for distortion wear or damage Replace them if necessary Check the slots in the clutch outer for nicks or indentations made by the clutch discs Measure the 1 0 of the clutch outer SERVICE LIMIT Clutch outer 1 0 32 10 mm 1 264 in CLUTCH GEARSHIFT LINKAGE 1 JUOOER SPRING 7 7 ...

Page 95: ...re the mainshaft 0 0 at the clutch outer guide SERVICE LIMIT 21 92 mm 0 863 in GEARSHIFT LINKAGE REMOVAL Remove the following drive sprocket cover page 8 2 gearshift pedal arm from the gearshift spindle right crankcase cover page 7 3 clutch assembly page 7 4 oil pump drive chain page 7 5 Loosen the two oil pipe stay mounting bolts and remove the oil pipe mounting bolt Pull the oil pipe out of the ...

Page 96: ...RTER CLUTCH ALTERNATOR STA SS Shown 3 0 kg m 30 N m 22 ft Ibl 8 0 ...

Page 97: ...s Refer to section 15 for troubleshooting and inspection of the alternator SPECIFICATIONS mm in ITEM STANDARD SERVICE LIMIT Starter driven gear 0 0 57 749 57 768 2 2736 2 2743 57 60 2 268 TORQUE VALUES Flywheel bolt Starter clutch torx bolts TOOLS Common Rotor puller Flywheel holder Torx bit 130 N m 13 0 kg m 94 ft Ibl Left hand thread 30 N m 3 0 kg m 22 ft Ib Apply locking agent to the threads 07...

Page 98: ...r the left crankcase cover to catch the engine oil Remove the eleven left crankcase cover bolts and the cover Remove the dowel pins and gasket STATOR REPLACEMENT Remove the wire clamp bolts and the clamps Remove the stator mounting bolts and stator Position the new stator and the grommets in the cover Apply a locking agent to the threads of the stator mounting bolts Tighten the stator mounting bol...

Page 99: ...wheel with the flywheel holder and remove the fly wheel bolt and washer TOOL Flywheel holder NOTE 07725 0040000 Equivalent commercially available in U S A Remove the flywheel with the rotor puller TOOL Rotor puller 07733 0020001 or 07933 3290001 Remove the needle bearing from the crankshaft then remove the woodruff key NOTE Do not lose the woodruff key 8 3 ...

Page 100: ...the starter clutch 111 STcER DRI N GEAR Remove the starter clutch outer and oneway clutch Hold the flywheel with the flywheel holder and remove the torx bolts using a torx bit TOOLS Flywheel holder Torx bit 07725 0040000 07703_0010100 EqUivalent commercially available in U S A INSPECTION Measure the 0 0 of the starter driven gear SERVICE LIMIT 57 60 mm 2 268 in Inspect the oneway clutch for wear o...

Page 101: ...alen t commercially available in U S A FLYWHEEL INSTALLATION Clean the crankshaft and install the woodruff key Install the needle bearing onto the crankshaft The flywheel bolt has left hand threads TORQUE 130 N m 13 0 kg m 94 ft Ib Install the driven gear and flywheel aligning the woodruff key on the crankshaft with the flywheel keyway 07725 0040000 Equivalent commercially available in U S A Hold ...

Page 102: ... and tighten the cover bolts with the neutral and oil pressure switch wire harness clamps as shown Route the alternator wire and connect the alternator 3P con nector Install the drive sprocket cover Install the gearshift arm onto the spindle by aligning the punch mark on the arm with the punch mark on the spindle Tighten the gearshift arm pinch bolt TORQUE 12 N m 1 2 kg m 9 ft Ib Install the drive...

Page 103: ...CYLINDER HEADIVALVES SS Shown m 17 ft Ib 23 N m 2 3 kg 7 2 ft Ib 1 0 kg m 10 N m m 17 ft Ibl 23 N m 2 3 kg m 17 ft Ibl 23 N m 2 3 kg 7 2 ft Ibl 10 N m 1 0 kg m 72ft lbl N 10 kg m 10 m 9 0 ...

Page 104: ...6 kPa 13 5 2 0 kg cm2 192 28 psi Camshaft Cam lobe height IN 38 189 1 5035 38 17 1 503 EX 38 213 1 5044 38 19 1 504 Journal 0 0 21 959 21 980 0 8645 0 8654 21 95 0 864 Runout 0 030 0 0012 0 05 0 002 Oil clearance 0 040 0 093 0 0015 0 0037 0 11 0 004 Rocker arm Rocker arm I D IN EX 12 000 12 018 0 4724 0 4731 12 03 0 474 Rocker arm shaft IN EX 11 966 11 984 0 4711 0 4718 11 96 0 471 0 0 Valve and V...

Page 105: ...Ibl 10 N m 1 0 kg m 7 2 ft Ibl 23 N m 2 3 kg m 17 ft Ib 07984 2000001 or 07984 200000B J U S A only 07984 ZE20001 or 07984 ZE2000B 07943 MF50100 07943 MF50200 07742 0010100 07742 0010200 or 07942 6570100 U S A only 07757 0010000 or 07957 3290001 07781 0010101 07781 0010201 07780 0012100 07780 0012300 07780 0014000 07780 0014100 07780 0010200 07780 0010400 Engine top end problems are usually perfor...

Page 106: ...emove Remove the radiator mounting bolts and release the radiator from the frame grommets Suspend the radiator with a piece of rope or something suitable refer to 9 8 page REAR Disconnect the spark plug caps Remove the cylinder head cover bolts and cover CAMSHAFT REMOVAL Remove the cylinder head covers and carburetors page 4 4 Remove the timing hole cap and crankshaft hole cap from the left crankc...

Page 107: ... while holding wedge B down Secure wedge A with a 2 mm pin as shown Remove the camshaft holder on the cam sprocket side by re moving the two mounting bolts Remove the cam sprocket bolt rotate the crankshaft counter clockwise one turn 360 and remove the other cam sprocket bolt NOTE Be careful not to let the cam sprocket bolts fall into the crankcase Remove the three camshaft holder mounting bolts a...

Page 108: ...d cylinder head journal surfaces for scoring or evidence of insufficient lubrication Camshaft runout Support both ends of the camshaft with V blocks and check the camshaft runout with a dial indicator SERVICE LIMIT 0 05 mm 0 002 in Using a micrometer measure the height of each cam lobe SERVICE LIMIT IN 38 17 mm 1 503 in EX 38 19 mm 1 504 in Check the camshaft journals for wear or damage Measure th...

Page 109: ...t 12 N m 1 2 kg m 9 ft Ibl 8 mm flange bolt 23 N m 2 3 kg m 17 ft Ibl 8 mm flange nut 23 N m 2 3 kg m 17 ft Ibl Remove the camshaft holder and measure the width of each plastigauge The widest thickness determines the oil clear ance SERVICE LIMIT 0 11 mm 0 004 in When the service limit is exceeded replace the camshaft and recheck the oil clearance Replace the cylinder head and camshaft holder if th...

Page 110: ...3 mm 0 474 in CYLINDER HEAD REMOVAL NOTE The cylinder head can be removed with the engine installed Drain the coolant page 5 3 and remove the following camshaft page 9 3 exhaust pipes California model only Remove the ASV pipes from the cylinder head Disconnect the clutch cable from the clutch lifter arm by re moving the clutch cable holder bolt Remove the oil pipe from the engine NOTE Do not bend ...

Page 111: ...emove the radiator mounting bolts Release the radiator from the frame grommets and suspend it with a piece of rope or something suitable Remove the upper exhaust port stud to allow frame clearance for cylinder head removal Lock two 8 mm nuts together on the stud to aid in removal Remove the front cylinder head REAR Remove the rear cylinder head Remove the gasket dowel pins and cam chain guide from...

Page 112: ...nd valves using a Valve Spring Compressor 07757 0010000 or 07957 3290001 To prevent loss of tension do not compress the valve springs more than necessary to remove the collers TOOL Valve spring compressor CAUTION Remove the valve stem seals and valve spring seats Remove carbon deposits from the combustion chamber 3 VALVE SPRINGS 4 VALVE r TIERS Valve springs Measure the free length of the inner an...

Page 113: ...obtain the stem to guide clearance SERVICE LIMITS IN 0 07 mm 0 003 in EX 0 11 mm 0 004 in If the stem to guide clearance exceeds the service limits de termine if a new guide with standard dimensions would bring the clearance within tolerance If so replace any guides as necessary and ream to fit TOOLS Valve guide reamer IN 07984 2000001 or 07984 200000B J U S A only EX 07984 ZE20001 or 07984 ZE2000...

Page 114: ...ing the cylinder head Make note of the valve guide projection specifications follow ing then drive in new guides from camshaft side of the cylin der head TOOLS Valve guide driver 5 5 mm IN 07742 0010100 6 6 mm EX 07742 0010200 Attachment 5 5 mm IN 07943 MF50100 6 6 mm EX 07943 MF50200 VALVE GUIDE PROJECTION HEIGHT IN 19 4 19 6 mm 0 76 0 77 in EX 17 9 18 1 mm 0 70 0 71 in Ream the new valve guides ...

Page 115: ... 1 mm 0 035 0 043 in SERVICE LIMIT 1 5 mm 0 06 in If the seat is too wide too narrow or has low spots the seat must be ground VALVE SEAT CUTTERS Honda Valve Seat Cutters grinder or equivalent valve seat refacing equipment are recommended to correct a worn valve seat NOTE Follow the refacer manufacturer s operating instructions IN 07780 0014000 30 EX 07780 0014100 37 5 C Zl 320 IN 07780 0012100 28 ...

Page 116: ...idth Make sure that all pitting and irregularities are removed Refinish if necessary Apply a thin coating of Prussian Blue to the valve seat Press the valve through the valve guide and onto the seat to make a clear pattern NOTE The location of the valve seat in relation to the valve face is very important for good sealing If the contact area is too high on the valve the seat must be lowered using ...

Page 117: ...cylinder head and valve NOTE Do not allow lapping compound to enter the guides CYLINDER HEAD ASSEMBLY Install the valve spring seats and new stem seals Lubricate each valve stem with MoSz paste grease and insert the valve into the valve guide Turn the valve slowly while in serting to avoid damaging the seals Move the valves up and down to check for smooth operation Install the valve springs with t...

Page 118: ...ly with a soft hammer to firmly seat the cotters NOTE Support the cylinder head above the work bench surface to prevent possible valve damage Apply locking agent to the threads of the sealing bolts and tighten them if removed CYLINDER HEAD INSTALLATION Install the cam chain guide into the cylinder Make sure that the cam chain guide bosses are in the grooves of cylinder Clean the cylinder head surf...

Page 119: ... m 35 ft Ibl 8 mm bolt 23 N m 2 3 kg m 17 ft Ibl 8 mm nut 23 N m 2 3 kg m 17 ft Ibl 6 mm bolt 10 N m 1 0 kg m 7 2 ft lbJ Install the following cam chain tensioner with washers and bolts water pipes TORQUE Cam chain tensioner bolt 10 N m 11 0 kg m 7 2 ft Ibl Check the oil pass pipe bolts and oil pass pipe for clogging or bending Install the oil pass pipe new sealing washers oil pass pipe bolts and ...

Page 120: ...n the cam sprocket bolt holes in the cam sprocket and camshaft install and tighten the cam sprocket bolt TORQUE 23 N m 2 3 kg m 17 ft Ibl Install the holder oil plate 8 mm bolts 8 mm nut and 6 mm bolts TORQUE 8 mm bolt 23 N m 2 3 kg m 17 ft Ibl 8 mm nut 23 N m 2 3 kg m 17 ft Ib 6 mm bolt 10 N m 1 0 kg m 7 2 ft Ib Turn the crankshaft counterclockwise 360 0 and install the other sprocket bolt Instal...

Page 121: ... the cam sprocket bolt holes in the cam sprocket and camshaft install and tighten the cam sprocket bolt TORQUE 23 N m 2 3 kg m 17 ft Ibl Install the holder oil plate 8 mm bolts 8 mm nut and 6 mm bolts TORQUE 8 mm bolt 23 N m 2 3 kg m 17 ft Ibl 8 mm nut 23 N m 2 3 kg m 17 ft Ibl 6 mm bolt 10 N m 1 0 kg m 7 2 ft Ibl Turn the crankshaft counterclockwise 360 0 and install the other sprocket bolt Insta...

Page 122: ...ace the camshaft into correct position with the cam lobes all facing down Install the cam sprocket and camshaft holders using the same procedure as for the front cylinder page 9 17 CYLINDER HEADIVALVES FRONT AND REAR CAMSHAFTS Turn the crankshaft counterclockwise and align the FT mark on the flywheel with the index mark on the timing hole Install the front camshaft with all the cam lobes facing DO...

Page 123: ...NSTALLATION Clean the gasket and apply contact cement to the gasket groove Install the cylinder head cover rubber washer washer cover and cylinder head cover bolts Tighten the cover bolts TORQUE 10 N m 1 0 kg m 7 2 ft Ibl Connect the water hose to the water pipe and install the spark plug caps Install the following parts carburetors page 4 191 air cleaner case page 4 4 fuel tank page 4 31 Fill the...

Page 124: ...CYLINDER PISTON 10 0 ...

Page 125: ...4 0 65 0 026 pin SECOND 0 35 0 50 0 014 0 020 0 65 0 026 OIL 0 20 0 80 0 008 0 031 0 95 0 037 Piston 0 0 78 970 78 990 3 1086 3 1098 78 92 3 107 Piston pin bore 20 002 20 008 0 7874 0 7877 20 018 0 7881 Connecting rod small end 1 0 20 016 20 034 0 7880 0 7887 20 04 0 789 Piston pin 0 0 19 994 20 000 0 7871 0 7874 19 984 0 7867 Piston to piston pin clearance 0 002 0 014 0 0001 0 0006 0 034 0 0013 C...

Page 126: ...ine the cyl inder wear SERVICE LIMIT 79 05 mm 3 112 in Calculate the piston to cylinder clearance Take the maximum reading to determine the clearance SERVICE LIMIT 0 13 mm 0 005 in Calculate the cylinder for taper at three levels in an X and Y axis Take the maximum reading to determine the taper SERVICE LIMIT 0 06 mm 0 002 in Calculate the cylinder for out of round at three levels in an X and Y ax...

Page 127: ...clips fall into the crankcase Push the piston pin out and remove the piston INSPECTION Clean the piston domes ring lands and skirts Measure the piston ring to groove clearance SERVICE LIMITS Top 0 11 mm 0 004 in Second 0 10 mm 0 004 in If clearance is excessive replace the piston ring Remove the piston rings and mark them to indicate the correct cylinder and piston position for reassembly NOTE Do ...

Page 128: ...nto the cylinder squarely and make the mea surement SERVICE LIMITS Top 0 65 mm 0 026 in Second 0 65 mm 0 026 in Oil 0 95 mm 0 037 in Measure each piston pin bore SERVICE LIMIT 20 018 mm 0 7881 in Measure each piston pin 0 0 SERVICE LIMIT 19 984 mm 0 7867 in Calculate the piston pin to piston clearance SERVICE LIMIT 0 034 mm 0 0013 in Measure the 1 0 of the connecting rod small end SERVICE LIMIT 20...

Page 129: ...ngs facing up NOTE NOTE NOTE To install the oil ring install the spacer first then install the side rails After installing the rings check that they rotate freely without sticking PISTON INSTALLATION Place a shop towel into the crankcase Coat the rod small end with molybdenum disulfide grease As semble the piston and connecting rod with the piston and piston pin clips as shown NOTE Install the pis...

Page 130: ...new a ring onto the cylinder joint and install the cylin der joint collar by sliding the collar toward either cylinder Install the clips securely Install a new a ring into the connector and install and tighten the connector mounting bolts if the connector was removed If only the water hose was removed connect the hose with the clamp Clean the cylinder gasket surface NOTE Avoid damaging the gasket ...

Page 131: ...CRANKSHAFT TRANSMISSION SS Shown 20 30 N m 2 0 3 0 kg m 14 22 ft Ibl 11 0 30 50 N m 3 0 5 0 kg m 22 36 ft Ib 20 30 N m 2 0 3 0 kg m 14 22 ft Ib ...

Page 132: ...8 0 3 0 012 connecting rod Crankpin oil clearance 0 028 0 052 0 0011 0 0020 0 08 0 003 Main journal oil clearance 0 025 0 041 0 0010 0 0016 0 05 0 002 Crankshaft runout 0 05 0 002 Transmission Gear 1 0 C1 24 000 24 021 0 9449 0 9457 24 03 0 946 M4 M5 C2 C3 28 000 28 021 1 1024 1 1032 28 03 1 103 Gear bushing 0 0 C1 23 959 23 980 0 9433 0 9441 24 95 0 982 M4 M5 C2 C3 27 959 27 980 1 1007 1 1016 27 ...

Page 133: ...ng Worn crankpin bearing Connecting rod Worn rod small end Worn crankpin bearing Hard to shift Shift fork bent Shift fork shaft bent Shift spindle claw bent Shift drum cam grooves damaged Shift fork guide pin damaged Transmission jumps out of gear Gear dogs worn Shift shaft bent Shift fork bent 11 2 34 N m 3 4 kg m 25 ft Ib 20 30 N m 2 0 3 0 kg m 14 22 ft Ibl 30 50 N m 3 0 5 0 kg m 22 36 ft Ibl 07...

Page 134: ...plate Remove the front cam chain from the crankshaft Remove the 8 mm bolts and 6 mm bolts from the left crank case NOTE Remove the bolts in a crisscross pattern in 2 or 3 steps Loosen the 6 mm bolts first then loosen the 8 mm bolts 88 Only Remove the countershaft set plate bolt and the plate After 88 Remove the countershaft set plate bolts 2 pcs and the plate 88 After 88 Remove the 8 mm bolts and ...

Page 135: ... connecting rod side clearance with feeler gauge SERVICE LIMIT 0 30 mm 10 012 inl If either side clearance exceeds the service limit replace the connecting rod and recheck If still beyond the limit replace the crankshaft Inspect the crankshaft for rough spots or damage CONNECTING ROD DISASSEMBLY Remove the connecting rod bearing caps noting their loca tions NOTE Tap the side of the cap lightly if ...

Page 136: ...ring inserts for damage or separation Clean all oil from the bearing inserts and crankpins 2 SEPARATION 1 DAMAGE OIL CLEARANCE INSPECTION Put a piece of plastigauge on each crankpin avoiding the oil hole Install the bearing caps and rods on the correct crankpins and tighten them evenly TORQUE 34 N m 3 4 kg m 25 ft Ibl NOTE Do not rotate the crankshaft during inspection Remove the caps and measure ...

Page 137: ...he crankpin and connecting rod codes to de termine the replacement bearing color 1 CRANKPIN 0 0 CODE A B 39 982 39 974 39 990 mm 39 983 mm CONNECTING 1 5741 1 5738 ROD 1 0 CODE 1 5744 in 1 5741 in 1 43 000 43 008 mm C B 1 6929 1 6932 in BROWN BLACK 2 43 008 43 016 mm B A 1 6932 1 6935 in BLACK BLUE BEARING INSERT THICKNESS A BLUE 1 495 1 499 mm 0 0589 0 0590 in B BLACK 1 491 1 495 mm 0 0587 0 0589...

Page 138: ...rank weight Determine the corresponding main bearing 1 0 code The code will be either a letter A or B on the crankcase 2 MAIN BEARING r 0 F th th d b t Choose rep acemen main eanngs In accor ance WI e table below MAIN JOURNAL 0 0 CODE on crank weightl 1 2 44 992 45 000 mm 44 984 44 992 mm 1 7713 1 7717 in 1 7710 1 7713 in MAIN 8EARING A 48 990 49 000 mm C 8 1 0 CODE 1 9287 1 9291 in BROWN BLACK on...

Page 139: ...and press the main bearing into the crankcase 2 MARKS CAUTION 3 GROOVE Be careful not to damage the bearings CONNECTING ROD SELECTION A letter stamped on the connecting rod is the code for the rod s weight When replacing the connectring rod select the new rod by cross matching the front and rear cylinder connecting rod weights using the selection table below 1 DRIVER 2 ATTACHMENT 07749 0010000 07H...

Page 140: ... that the rods move freely without binding TORQUE 34 N m 3 4 kg m 25 ft Ibl Install the crankshaft in the left crankcase Install the dowel pins and assemble the crankcase page 11 16 TRANSMISSION REMOVAL Remove the mainshaft countershaft shift fork shaft and shift drum as an assembly Separate the shift forks shaft mainshaft and countershaft as semblies from each other DISASSEMBLY INSPECTION Bend do...

Page 141: ...aft for scratches scoring or evidence of insufficient lubrication Measure the shift fork shaft 0 0 SERVICE LIMIT 12 96 mm 0 510 in Measure the 1 0 of each shift fork and the fork claw thickness SERVICE LIMITS 1 0 13 03 mm 0 513 in CLAW THICKNESS 5 83 mm 0 230 in Inspect the shift drum and shift fork shaft journals for exessive wear or damage Measure the 0 0 of mainshaft and countershaft SERVICE LI...

Page 142: ... 0 0 24 95 mm 10 982 in M4 C2 C3 bushing I D 25 03 mm 10 985 in C1 bushing 1 0 20 05 mm 10 789 in Calculate the bushing to shaft clearances and gear to bushing clearance SERVICE LIMITS bushing to shaft M4 C3 0 08 mm 0 003 in C2 0 07 mm 0 03 in gear to bushing M4 M5 C1 C2 C3 0 08 mm 0 003 in CRANKCASE BEARING REPLACEMENT Turn the inner race of each bearing with your finger The bear ings should turn...

Page 143: ...ly Install the new mainshaft bearing set plate on the left crank case NOTE Install the new bearings with the following tools Apply fresh engine oil to the new crankcase bearings before installation 07749 0010000 07746 0010300 07749 0010000 07746 0010400 07746 0040600 TOOLS Left mainshaft bearing Driver Attachment 42 x 47 mm Left countershaft bearing Driver Attachment 52 x 55 mm Pilot 25 mm Install...

Page 144: ...taching bolt Install the set plate aligning the edge of the set plate with the slot on the bearing outer and tighten the bolt securely INSPECTION 1 10 mm STUD BOLT HOLES Crankcase studs Check that the studs are tight If any are loose remove them clean their threads with contact cleaner then reinstall tn m using Honda Anaerobic Thread Lock or equivalent EM E oco I q I 00 CO CO co E E 0 001 oo 10 00...

Page 145: ...atique and damage Check the oil jet orifice for clogging TRANSMISSION ASSEMBLY INSTALLATION Apply MOS2 grease to the shift fork journals of M3 C4 and C5 gears Clean all parts in solvent and dip them in clean engine oil CAUTION Align the oil holes in the bushings and gears with the oil holes in the shaft Mainshaft 11 14 o0q OO 00 M5 M3 ...

Page 146: ...hings Install the shift forks onto the shaft as follows Left side MN8L mark facing R crankcase Center C mark facing L crankcase Right side MM9R mark facing R crankcase Tighten the bolt with the lock washer and bend up the tabs of the lock washer Assemble the mainshaft countershaft shift fork shaft and shift drum Install them into the left crankcase as an assembly 1 TRANSMISSION ASSEMBLY 11 15 ...

Page 147: ...and check for misaligned parts Apply oil to all crankcase bolts Install and tighten the right crankcase bolts in a crisscross pat tern in 2 or 3 steps NOTE Tighten the 8 mm bolts first then tighten the 6 mm bolts Install and tighten the left crankcase bolts in a crisscross pat tern in 2 or 3 steps NOTE Tighten the 8 mm bolts first then tighten the 6 mm bolts 88 Only Install the countershaft set pl...

Page 148: ...m chain over the drive sprocket Install the oil pipe stay and cam chain tensioner set plate Tighten the bolt sercurely Install the front cam chain over the front cam chain drive sprocket Install the cam chain tensioner set plate and tighten the bolt securely Install the remaining parts in the reverse order of removal page 11 3 CRANKSHAFT TRANSMISSION 11 17 ...

Page 149: ...FRONT WHEEl SUSPENSION STEERING 22 N m 2 2 kg m 16 ft Ib 12 0 105 N m 10 5 kg m 76 ft Ib 11 N m 1 1 kg m 8 ft Ibl ...

Page 150: ...unout Radial 2 0 0 08 Axial 2 0 0 08 Fork spring free length 336 4 13 2 Fork tube runout 0 2 0 01 Fork fluid capacity 88 497 cc 16 8 US OZ 17 4 Imp oz After 88 502 cc 16 9 US OZ 17 6 Imp OZ Fork fluid level 88 133 5 2 After 88 128 5 0 Steering bearing preload 1 0 1 5 kg 2 2 3 3Ib TORQUE VALUES m Master cylinder holder bolt Front axle bolt Front axle pinch bolt Fork top pinch bolt Fork bottom pinch...

Page 151: ...710100 07914 323000 Equivalent commercially available in U S A 07946 MBOOOOO 07716 0020400 Equivalent commercially available in U S A 07716 0020500 J 07749 0010000 07746 0010300 07746 0010400 07746 0040500 07947 KA50100 07947 KF00100 07746 0050100 T Equivalent commercially available in U S A 07746 0050600 Soft Suspension Weak fork springs Insufficient fluid in fork legs Hard Steering Steering bear...

Page 152: ...ube 6 PINCH BOLT Disconnect the clutch switch wires from the switch terminals Remove the following rear view mirror from the clutch lever holder clutch lever holder mounting bolts and holder left handlebar switch screws and switch Disconnect the choke cable and remove the left handlebar switch from the choke lever Remove the left handlebar retainer ring and loosen the left handlebar pinch bolt Rem...

Page 153: ...IGHT Install the new retainer onto the handlebar weight Install the grip end weight onto the handlebar weight aligning the boss with slot Clean and apply a locking agent to the mounting screw threads and tighten it securely Insert the handlebar weight assembly onto the handlebar 1 RETAINER 3 HANDLEBAR WEIGHT 3 HOOKING HOLE Hooking the retainer tab to the hooking hole securely Install the grip onto...

Page 154: ...bar Install the right grip end weight and tighten the screw 2 MASTER CYLINDER 6 PINCH BOLT Place the front brake master cylinder on the handlebar and in stall the master cylinder holder with the UP mark facing up FRONT WHEEL SUSPENSION STEERING Align the end of the holder with the punch mark on the handle bar Tighten the upper holder bolt first then tighten the lower bolt TORQUE 12 N m 1 2 kg m 9 ...

Page 155: ...crew first then tighten the rear screw Install the right rear view mirror in the holder Secure the wires with wire bands 1 LOCATING PIN Install the clutch lever and holder with the UP mark facing up Align the end of the holder with the punch mark on the handle bar and tighten the upper bolt first then tighten the lower bolt TORQUE 12 N m 1 2 kg m 9 ft Ibl Adjust the following throttle operation an...

Page 156: ...so that it does not hang on the brake hose Do not twist the brake hose NOTE If you squeeze the front brake lever after the caliper is re moved the caliper piston will move out and make assembly difficult Loosen the right and left front axle pinch bolts and remove the axle bolt Remove the axle and the front wheel Remove the side collar from the right side and remove the speedometer gear box from th...

Page 157: ...s the stability handling and over all safety of the motorcycle Always check balance when the tire has been removed from the rim NOTE For optimum balance the tire balance mark a paint dot on the side wall must be located next to the valve stem Remount the tire if necessary Mount the wheel tire and brake disc assembly in an inspection stand Spin the wheel allow it to stop and mark the lowest heavies...

Page 158: ...g outer race fits tightly in the hub Remove and discard the bearings if the races do not turn smoothly quietly or if they fit loosely in the hub NOTE Replace hub bearings in pairs BEARING REPLACEMENT Remove the brake disc mounting bolts and discs Remove the dust seal from both sides Remove the speedometer gear retainer NOTE If the bearings are removed they must be replaced with new ones Install th...

Page 159: ... the wheel until it is fully seated Do not allow the bearings to tilt while driving them in Never install an old bearing once a bearing is removed it must be replaced with a new one 07749 0010000 07746 0010300 07746 0040500 NOTE TOOLS Driver Attachment 42 x 47 mm Pilot 20 mm ASSEMBLY NOTE The front wheel has no rim band Do not get grease on the brake disc or stopping power will be reduced 4 SPEED ...

Page 160: ... power will be reduced Coat the speedometer gear retainer with clean grease and in stall the retainer into the wheel hub aligning the tangs with the slots in the hub Apply clean grease to the dust seal lip and install the dust seal over the gear retainer Fill the speedometer gear box with clean grease and install the drive gear Install the speedometer gear box into the wheel hub Apply clean grease...

Page 161: ...ghten the axle bolt TORQUE 60 N m 6 0 kg m 43 ft Ibl Tighten the axle pinch bolts TORQUE 22 N m 2 2 kg m 16 ft Ibl Install the brake caliper with the caliper bracket Install the caliper mounting bolts and tighten the bolts TORQUE 27 N m 2 7 kg m 20 ft Ibl Connect the speedomater cable with the set screw FORK REMOVAL Remove the following handlebars page 12 3 front wheel page 12 7 brake caliper page...

Page 162: ...m the fork top bridge and steering stem DISASSEMBLY Remove the fork tube cap and the spring The cap is under spring pressure Use care when removing it and wear eye and face protection Drain the oil by pumping the tube up and down several times Hold the fork slider in a vise with soft jaws or use a shop towel Remove the socket bolt with a hex wrench NOTE Temporarily reinstall the spring and cap if ...

Page 163: ...be separates from the slider The slider bushing will be forced out by the fork tube bushing Remove the oil lock piece from the piston Remove the piston and rebound spring from the fork tube Remove the oil seal back up ring and slider bushing from the fork tube NOTE Do not remove the fork tube bushing unless it is necessary to replace it with a new one See bushing inspection page 12 15 12 14 2 STOP...

Page 164: ... spring for fatigue or damage 4 REBOUND SPRING 7 PISTON RING Set the fork tube in V blocks and read the runout Use 1 2 the total indicator reading to determine the actual run out SERVICE LIMIT 0 20 mm 0 008 in 1 FORK TUBE 1 BUSHING Bushings Visually inspect the slider and fork tube bushings Replace the bushings if there is excessive scoring or scratch ing or if the teflon is worn so that the coppe...

Page 165: ...assembly into the fork tube Place the oil lock piece on the end of the piston and insert the fork tube assembly into the slider 2 FORK TUBE CAP I 2 OIL LOCK PIECE Place the fork slider in a vise with soft jaws or use a shop towel to avoid damaging the slider Clean and apply a locking agent to the socket bolt threads and screw the bolt into the piston Temporarily install the fork spring and cap to ...

Page 166: ...scratch the fork tube sliding surface Install the new dust seal onto the fork slider Compress the fork tube and pour in the recommended fork oil to the specified level RECOMMENDED FORK OIL ATF or EQUIVALENT SPECIFIED LEVEL 88 133 mm 5 2 in After 88 128 mm 5 0 in CAPACITY 88 497 cc 16 8 US OZ 17 4 Imp oz After 88 502 cc 16 9 US OZ 17 6 Imp ozl Gently install the fork spring in the fork tube then in...

Page 167: ...REAR WHEEL SUSPENSION 13 0 15 N m 1 5 kg m 11 ft Ibl w Tiro 120 N m 12 0 kg m 87 ft Ibl Revised June 1991 1991 American Honda Motor Co Inc All Rights Reserved MSV 5511 9106 88 91 NT650 ...

Page 168: ...e Do not allow fire or heat near the shock absorber Before disposal of the shock absorber release the nitrogen see page 13 16 IIIE I l SPECI FICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Rear wheel rim runout Radial 2 0 0 08 Axial 2 0 0 08 Shock absorber spring free length 148 3 5 84 Shock absorber spring preload adjuster position 3 Compression force at 10 mm 004 in compressed 15 20 kg 33 1 44 ...

Page 169: ...roperly Swingarm pivot bearing worn Bent frame or swingarm Damaged drive pin and pin hole Soft suspension Weak spring Improper shock absorber spring preload Leaking damper Hard suspension Improper shock absorber spring preload Bent shock absorber rod Swingarm pivot bearings damaged Bent frame or swingarm Suspension noise Faulty rear damper Loose fasteners 13 2 07914 323000 Equivalent commercially ...

Page 170: ...procket and place it on the outside of the sprocket Rotate the eccentric bearing carrier to its rearward most maxi mum chain slack position Remove the wheel nut shim and axle center collar Tap the axle with soft hammer and push the axle in until it clears the wheel Attach tape to the wheel rim edge of the spindle and brake caliper to avoid damaging the wheel Remove the wheel from the drive pins th...

Page 171: ...ide wall must be located next to the valve stem Remount the tire if necessary Remove the dust seal from the wheel Mount the wheel and tire assembly in an inspection stand Spin the wheel allow it to stop and mark the lowest heaviest part of the wheel with chalk Do this two or three times to verify the heaviest area If the wheel is balanced it will not stop consistently in the same po sition To bala...

Page 172: ... aligned Tap the axle with soft hammer to seat the axle securely Turn the eccentric bearing carrier counterclockwise until it stops Install the drive chain onto the rear sprocket Clean and apply clean grease to the axle threads CAUTION Make sure that the axle threads are applied clean grease to obtain the specified torque Install the axle center collar shim and wheel nut Tighten the wheel nut to t...

Page 173: ...et by using the bolts and nuts TORQUE 43 N m 4 3 kg m 31 ft Ibl Reinstall the drive chain and adjust the slack page 3 12 ECCENTRIC BEARING CARRIER REMOVAL Remove the rear wheel page 13 3 Loosen the eccentric bearing carrier pinch bolt and turn the carrier to loosen the drive chain 1 REAR WHEEL 1 SPROCKET Tap the axle with a soft hammer until the splines clear the driven flange cover Remove the axl...

Page 174: ...iper from the brake disc while holding it with a piece of wire or something suitable Remove the spindle Remove the final driven flange assembly and remove the drive chaine from the sprocket Remove the snap ring and brake disc guard plate Remove the eccentric bearing carrier from the swingarm REAR WHEEl SUSPENSION 2 FINAL DRIVEN FLANGE p iBAKE DISC GUARD PLATE 13 7 ...

Page 175: ... signs of wear Remove and discard the ball bearings if they do not turn smoothly quietly or if they fit loosely in the eccentric bearing carrier page 13 9 NOTE Replace the bearings in pairs Replace the needle bearing if it is damaged 5 ECCENTRIC BEARING CARRIER Damper Separate the driven flange cover with the sprocket from the flange Check the driven flange damper for damage Replace the dampers if...

Page 176: ...00 2 ECCENTRIC BEARING CARRIER _ 1 DRIVER Press the needle bearing out of the carrier with the special tools TOOLS Driver Attachment 52 x 55 mm 07749 0010000 07746 0010400 2 ECCENTRIC BEARING CARRIER NOTE Install the bearing with marks facing out Install the inner dust seal in the carrier Carefully press the new needle bearing into the carrier first with the special tools 3 ECCENTRIC BEARING CARRI...

Page 177: ...y press the new ball bearings in with the special tools 3 ATTACHMENT PILOT 2 ECCENTRIC BEARING CARRIER 07749 0010000 07746 0010500 TOOLS Driver Attachment 62 x 68 mm Apply clean grease to the dust seal lip Install the bearing stop ring and dust seal securely Driven flange Separate the cover and the flange Remove the dampers and the a ring 8i 3 DAMPER 4 O RING 2 FLANGE 13 10 ...

Page 178: ... of the spindle splines for damage drive pins for damage lock nut threads for damage If necessary remove the brake disc retaining bolts and nuts and lock nut and separate the brake disc from the spindle Apply a locking agent to the drive pin bolt threads and tighten the drive pin bolts to the drive pin if replaced them TORQUE 15 N m 1 5 kg m 11 ft Ibl Install the brake disc to the spindle and tigh...

Page 179: ...SC RETAINING BOLT 8 BRAKE DISC 35 N m 3 5 kg m 25 ft Ibl Install the eccentric bearing carrier onto the swingarm Loosely install the eccentric bearing carrier pinch bolt Install the brake disc guard plate onto the eccentric bearing carrier by using the snap ring 13 12 2 LOCK NUT 3 LOCK WASHER 6 SNAP RING 27 N m 2 7 kg m 20 ft Ib 2 PINCH BOLT 1 ECCENTRIC BEARING CARRIER ...

Page 180: ...e making sure the splines are correctly mated CAUTION Use care not to damage the pads when installing the caliper Install over the brake caliper onto the brake disc Install and tighten the mounting bolts TORQUE 27 N m 2 7 kg m 20 ft Ibl 1 CALIPER MOUNTING BOLT Install the rear axle from the left side Install the side collar onto the driven flange Install the lock washer onto the spindle as shown N...

Page 181: ... the shock absorber set the spring adjuster to the softest position at this time REMOVAL Raise the rear wheel off the ground by placing the motorcycle on its center stand Remove the seat page 13 25 Remove the shock absorber lower mounting bolt while sup porting the wheel Remove the following sub frame upper mounting bolts shock absorber upper mounting bolt and nut fuel filter base mounting bolt an...

Page 182: ...absorber 1 SHOCK ABSORBER COMPRESSOR ATTACHMENT 10 UPPER SPRING SEAT jlLOWER JOINT 3 SPRING GUIDE 2 SPRING 1 LOWER SPRING SEAT 11 STOP RING 12 DAMPER __ Remove the following upper spring seat spring lower spring seat spring adjuster dust seal lock nut and lower joint stop rubber seat INSPECTION Inspect the following parts damper unit for oil leaks damper rod for bends or damage stop rubber for wea...

Page 183: ...ure the tab of the seat is aligned with the groove of the spring guide NOTE Make sure the spring adjuster is set to the softest position Set the shock absorber in the hydraulic press with the special tool TOOL Shock absorber compressor attachment 07967 KE10000 Compress the spring until the stop ring can be installed and in stall the stop ring REAR WHEEL SUSPENSION 2 SPRING GUIDE 6 LOWER JOINT 1 SE...

Page 184: ... 26 mm Pilot 17 mm 07946 KA30200 Not available in U S A 07749 0010000 07746 0010700 07746 0040400 1 DRIVER INSTALLATION Install the lower mounting collar into the mount Install the shock absorber in the frame with the drain tube facing forward Tighten the shock absorber upper mounting bolt TORQUE 65 N m 6 5 kg m 47 ft Ibl Install the fuel filter base and mounting bolt TORQUE 22 N m 2 2 kg m 16 ft ...

Page 185: ...r wheel page 13 3 and eccentric bearing car rier page 13 6 Remove the shock absorber lower mounting bolt Remove the swingarm pivot nut Unhook the rear brake hose and remove the rear brake caliper page 14 15 REAR WHEEL SUSPENSION Loosen the lock nut and remove it Do not pull the swingarm pivot bolt out at this time TOOL lock nut wrench 07908 ME90000 Using a hex wrench turn the pivot bolt and adjust...

Page 186: ...move the following components drive chain slider driven sprocket guard plate brake disc guard plate brake torque rod shock absorber drain tube clamp brake hose clamp 6 BRAKE HOSE CLAMP 2 DRIVEN SPROCKET 3 BRAKE DISC GUARD PLATE GUARD PLATE PIVOT BEARING REPLACEMENT 1 SNAP RING Remove the dust seals from the swingarm Remove the snap ring from the right side 2 SWINGARM 13 20 ...

Page 187: ...is flush with the surface Apply clean grease to the pivot needle bearing Press the left needle pivot bearing into the swingarm until it is flush with the surface TOOL Driver shaft Driver handle TOOL Driver shaft set TOOLS Driver Attachment 32 x 35 mm Pilot 15 mm TOOLS Driver Attachment 32 x 35 mm Pilot 22 mm 07746 MJ00100 or 07949 3710001 07746 MJOOOOO 07749 0010000 07746 0010100 07746 0040300 077...

Page 188: ...m 13 5 kg m 25 ft Ibl Install the brake torque rod with a new cotter pin Install the following components drive chain slider driven sprocket guard plate brake disc guard plate shock absorber drain tube clamp brake hose clamp 6 DRIVEN SPROCKET GUARD PLATE 5 BRAKE DISC GUARD PLATE INSTALLATION Install the pivot collars and bushing in the swingarm Loosely install the pivot adjusting bolt then install...

Page 189: ...ndicated 59 N m 5 9 kg m 43 ft Ib Loosely install the lock nut Tighten the lock nut while holding the adjusting bolt and pivot bolt TOOL Lock nut wrench 07908 ME90000 Install the pivot nut and tighten to the specified torque TORQUE 65 N m 6 5 kg m 47 ft Ib Install the following eccentric bearing carrier page 13 12 rear brake caliper page 14 17 shock absorber lower mounting bolt page 13 19 rear whe...

Page 190: ...and exhaust pipes INSTALLATION Installation is the reverse order of removal Install the exhaust pipe and muffler as an assembly TORQUE Exhaust pipe joint nut 27 N m 2 7 kg m 20 ft Ibl Muffler mounting bolt 27 N m 2 7 kg m 20 ft Ibl Muffler band bolt 27 N m 2 7 kg m 20 ft Ibl CAUTION Be sure the new exhaust pipe gaskets are correctly seated on the pipe flange before installing the pipes 13 24 1 I E...

Page 191: ...me Installation is the reverse order of removal NOTE Apply clean grease to the seat lock striker and latch 2 HOLDER HOOK REAR WHEEL SUSPENSION REAR COWLING REMOVAL INSTALLATION Remove the seat Disconnect the tail brake and turn signal light wire harnesses connectors Remove the four rear cowling mounting bolts and the cowling Installation is the reverse order of removal 13 25 ...

Page 192: ...HYDRAULIC BRAKE 14 0 1 5 N m 0 15 kg m 1 4 ft Ibl I 12 N m 1 2 kg m 9 ft Ib J 27 N m 2 7 kg m 20 ft Ibl ...

Page 193: ...c and rubber parts by covering them with a shop towel If fluid does get on these parts wipe it off immediately with a clean cloth Always check brake operation before riding the motorcycle Inhaled asbestos fibers have been found to cause respiratory disease and cancer Never use an air hose or dry brush to clean brake assemblies Use an OSHA approved vacuum cleaner or alternate method approved by OSH...

Page 194: ...hydraulic system Pads glazed or worn excessively Brake drag Hydraulic system sticking Sticking piston s Clogged hydraulic system Incorrect pedal adjustment Caliper slide pins sticking Disc or wheel misaligned 14 2 12 N m 1 2 kg m 9 ft Ibl 12 N m 1 2 kg m 9 ft Ibl 30 N m 3 0 kg m 22 ft Ibl 1 5 N m 0 15 kg m 1 4 ft Ibl 6 N m 0 6 kg m 4 3 ft Ibl 27 N m 2 7 kg m 20 ft Ibl 28 N m 2 8 kg m 20 ft Ib 27 N...

Page 195: ...NING Connect a bleed hose to the bleed valve Loosen the caliper bleed valve and pump the brake lever Stop operating the lever when fluid stops flowing out of the bleed valve BRAKE FLUID FILLING NOTE Check the fluid level often while bleeding the brakes to pre vent air from being pumped into the system When using the Brake Bleeder follow the manufacturer s instructions Do not mix brake fluid types ...

Page 196: ...lt AIR BLEEDING Bleed the system as follows 1 Connect a bleed hose to the bleed valve 2 Squeeze the brake lever lor depress the brake pedal then open Ithe bleed valve 1 4 turn and close the valve NOTE Do not release the brake lever or pedal until the bleed valve has been closed 3 Release the brake lever or pedal slowly and wait several seconds after it reaches the end of its travel Repeat steps 2 ...

Page 197: ...en disc pressure 88 Only Remove the cotter pin 88 and After 88 Remove the pad pin plug and loosen the pad pin Push the pistons all the way in to allow installation of new brake pads NOTE Check the brake fluid level in the reservoir as this operation causes the level to rise Pull the pad pin out of the caliper and remove the brake pads Insert the new brake pads Install the pad pin by pushing the pa...

Page 198: ...aliper pistons against the pads REAR BRAKE PAD REPLACEMENT NOTE Always replace the brake pads in pairs to assure even disc p ressure Remove the pad pin plug Loosen the pad pin Remove the caliper pivot bolt Swing the brake caliper from the brake disc Pull the pad pin out of the caliper Remove the brake pads 14 6 ...

Page 199: ...ushing the pads against the caliper to depress the pad spring Install the caliper onto the brake disc so the disc is positioned between the pads being careful not to damage the pads Install the caliper pivot bolt and tighten it TORQUE 22 N m 2 2 kg m 16 ft Ibl Tighten the pad pin TORQUE 17 N m 1 7 kg m 12 ft Ibl Install the pad pin plug TORQUE 2 5 N m 0 25 kg m 1 8 ft Ibl Operate the brake pedal t...

Page 200: ...irror from the master cylinder and dis connect the brake light switch wires Disconnect the brake hose by removing the oil bolt and sealing washers CAUTION A void spilling brake fluid on painted surfaces Place a rag over the fuel tank whenever the brake system is serviced NOTE When removing the oil hose bolt cover the end of the hose to prevent contamination Secure the hose to prevent fluid from le...

Page 201: ...or nicks Measure the master piston 0 0 at the location shown SERVICE LIMIT 12 65 mm 0 498 in Check the primary and secondary cups for damage before as sembly ASSEMBLY CAUTION Handle the master cylinder piston cylinder and spring as a set Coat all parts with clean brake fluid before assembly Install the spring in the master cylinder with its large diameter facing inside Install the piston CAUTION W...

Page 202: ...lder UP mark facing up Temporarily install the holder bolts Align the slit of the master cylinder with the punch mark on the handlebar Tighten the upper bolt first then the lower bolt Connect the brake light switch wires to the switch terminals Install the rear view mirror Connect the brake hose with the oil bolt and two sealing wash ers and tighten the oil bolt TORQUE 30 N m 3 0 kg m 22 ft Ibl Fi...

Page 203: ...Place a shop rag under the caliper to cush ion the pistons when they are expelled Use the air in short spurts Do not use high pressure air or bring the nozzle too close to the inlet Push the dust seals and piston seals in lift them out and dis card them NOTE The seals must be replaced whenever they are removed Clean the seal grooves with clean brake fluid CAUTION Be careful not to damage the pisto...

Page 204: ... and pad pins in the caliper Install the caliper assembly over the brake disc so that the disc is positioned between the pads CAUTION Be careful nol 1o damage rhe pads Install and tighten the caliper mounting bolts TORQUE 27 N m 2 7 kg m 20 ft Ibl Tighten the pad pins and install and tighten the pad pin plug page 14 5 Connect the brake hose to the caliper with the oil bolt and two new sealing wash...

Page 205: ...d disconnect the reservoir hose from the master cylinder 2 MASTER CYLINDER Remove the cotter pin and joint pin and disconnect the brake actuating arm from the master cylinder push rod Remove the rear master cylinder from the foot peg bracket DISASSEMBLY CAUTION Remove the rubber boot The push rod will pop out when the snap ring is removed 07914 3230001 Equivalent commercially available in U S A Re...

Page 206: ...master cylinder with compressed air Dip the piston cups in clean brake fluid before assembly Install the spring and master piston together NOTE The master cylinder piston cups and spring must be in stalled as a set CAUTION 2 SNAP RING When installing the cups do not allow the lips to turn inside out and be certain the snap ring is seated firmly in the groove Install the push rod into the master cy...

Page 207: ...et Tighten the mounting bolts TORQUE 22 N m 2 2 kg m 16 ft Ibl Install the muffler mounting bolt and nut TORQUE 27 N m 2 7 kg m 20 ft Ibl Connect the rear brake hose with the oil bolt and two new sealing washers TORQUE 30 N m 3 0 kg m 22 ft Ibl Fill and bleed the rear brake system page 14 3 Check the brake light switch operation Operate the brake pedal to seat the caliper piston against the pads R...

Page 208: ...e high pressure air or bring the nozzle too close to the inlet Push the dust and piston seals in and lift them out Wash the caliper cylinder seal gooves and caliper piston with clean brake fluid CAUTION Be careful not to damage the piston sliding surface INSPECTION Check the caliper piston for scratches scoring or other dam age Measure the caliper cylinder I D SERVICE LIMIT 38 24 mm 1 505 in Measu...

Page 209: ...ton and dust seals with clean brake fluid and install them with the small diameter facing in Lubricate the caliper cylinder and piston with clean brake fluid and install the piston into the caliper cylinder with the piston dished end facing toward the pads The piston and dust seals must be replaced whenever they are removed Install the brake hose with the oil bolt and the new sealing washers Tight...

Page 210: ...g brake light switch spring snap ring brake pedal Apply clean grease to the brake pedal pivot and install the pedal into the bracket with the snap ring Installation is the reverse order of removal Install the right foot peg bracket Tighten the mounting bolts TORQUE 22 N m 2 2 kg m 16 ft Ibl Install the muffler mounting bolt and nut TORQUE 27 N m 2 7 kg m 20 ft Ibl 14 18 ...

Page 211: ...BATTERY CHARGING SYSTEM 1 IGNITION SWITCH 4 MAIN FUSE 6 R Red 7 W White 8 G Green 9 Y Yellow L y _ _ ilnl1l1 l1f 1 y 1 y _ 5 ALTERNATOR 15 0 G G 11 1 IGNITION SWITCH 2 BATTERY j12VBAh ...

Page 212: ...rrent at a constant rate for the duration of the charge even if the voltage varies The Honda Battery Tester BM 21 0 puts a load on the battery so that the actual battery condition at the time of the load can be measured This provides an accurate determination of the battery condition good green fair yellow or poor red Quick charge a battery only in an emergency Slow charging is preferred Remove th...

Page 213: ...tor rectifier Type Three phase full wave Regulated voltage Amperage 13 5 15 5 V 0 5 A 3 000 rpm Alternator Charging coil resistance at 20 C 68 F 0 1 1 0 n Output 0 24 kw 5 OOO rpm Charging start rpm 1 200 100 rpm TOOLS MULT1TESTER 07411 0020000 KS AHM 32 003 07308 0020001 TH 5H KOWA Digital type KOWA Digital type U S A only SANWA Analogue type KOWA Analogue type Christie battery charger MC 101 2 2...

Page 214: ...REGULATED Fault batter Measure the voltage between the R W and G with terminals of the regulator rectifier 4P Black connector wire harness side page 15 8 NO VOLTAGE Open or short circuit in wire harness Loose connector BATTERY VOLTAGE COMES STANDARD Loose 3P connector I ABNORMAL l l Faulty stator coil Disconnect the 3P connector of the regulator rectifier check the alternator stator coil resitance...

Page 215: ... battery out of the battery holder INSTALLATION Install the battery in the reverse order of the removal After installing the battery coat the terminals with clean grease 1 COVER BOLTS 4 POSITIVE TERMINAL 5 BATTERY VOLTAGE INSPECTION VOLTAGE Fully charged 13 0 13 2 V Under charged Below 12 3 V TESTING WITH HONDA BATTERY TESTER NOTE Remove the seat Remove the battery case cover Measure the battery v...

Page 216: ...tery is OK if the meter reading registers in the GREEN zone If the metter reading registers in the YELLOW or RED zone charge the battery and re test and judge it in accordance with the chart below First check Green OK Yellow Red Charge Second check First check Yellow Green OK Yellow Replace First check Red Green OK Yellow Recharge Red Replace Third check Green OK Yellow Replace CHARGING NOTE Refer...

Page 217: ...ce the battery below the charger gases from the battery may corrode and damage the charger Do not place the battery on top of the charger Be sure the air vents are not blocked During operation the charger will grenerate heat To avoid causing afire always clear the work area offlammable materi als such as gasoline brake fluid electrolyte or cloth towels Turn the Power Switch to the OFF position Set...

Page 218: ...have the correct range LEAKAGE INSPECTION BATTERY CHARGING SYSTEM CAUTION When measuring small capacity circuits keep the ignition switch off If the switch is suddenly turned on during a test the tester fuse may blow Check the battery ampere leakage before making the regulated ampere inspection Turn the ignition switch off and disconnect the battery nega tive cable from the battery Connect the tes...

Page 219: ...INSPECTION Remove the seat and rear cowling Disconnect the 3P WHITE and 4P BLACK regulatorlrectifier connectors Check the connectors for loose or corroded terminals If the regulated voltage reading was out of specification check the circuits between the connector terminals wire har ness side and alternator side following the chart on next page NOTE The regulator rectifier is semiconductorized unit...

Page 220: ...testers Using other equipment may not allow you to obtain the correct results This is due to the characteristic of semiconductors which have different resistance values depending on the applied voltage SPECIFIC MULTITESTER 07411 0020000 KOWA Digital type KS AHM 32 003 KOWA Digital type U S A only 07308 0020001 SANWA Analogue type TH 5H KOWA Analogue type Select the following range SANWA kO KOWA X1...

Page 221: ...Disconnect the alternator 3P WHITE connector Measure the resistance between the yellow wire terminals and check for no continuity between each terminal and ground STANDARD 0 1 1 0 n 20 C 68 F Replace the stator if the resistance is out of specification or if there is continuity between any yellow wire terminal and ground 15 10 1 ALTERNATOR 3P WHITE CONNECTOR ...

Page 222: ...8 PULSE GENERATORS 6 MAIN FUSE 5 BATTERY I 1 7 SPARK UNIT BIIW tt it 8JAR IGNITION COIL 9 FRONT IGNITION COIL ITo fuel pump relay To tachometer 1 ENGINE STOP 2 3 IGNITION 4 SWITCH FUSE 10 A SWITCH MAIN FUSE 30 A I 10 W White 11 G Green 12 Y Yellow 13 Bu Blue 14 BI Black 16 0 ...

Page 223: ...ation see section 7 When inspecting the ignition system check the system components and lines step by step according to the troubleshoot ing on next page Each pair of spark plugs Front and Rear has its own ignition circuit To test the neutral switch refer to section 18 SPECIFICATIONS Spark plug Spark plug For cold climate NGK DPR7EA 9 Saprk plug gap Below 5 C 41 F ND X22EPR U9 Standard NGK DPR8EA ...

Page 224: ...re harness NORMAL 3 1 Check the pulse generator resistances at ABNORMAL I 3 2 Check the pulse generator page 16 4 the spark unit 4P connector page 16 4 NORMAL l ABNORMAL No spark at either spark group Front or Rear CHECK WRONG SPARK GROUP 1 1 Check the ignition secondary coil resistance f r _A_B_N_O_R_M_A_L __ Faulty ignition coil page 16 3 I Faulty spark plug wire NORMAL ABNORMAL Faulty ignition ...

Page 225: ...itch ON and engine stop switch RUN 4P CONNECTOR ITEM TERMINALS STANDARD 20 C 68 F Pulse generator coil W Y and Y Front W Bu and Bu Rear 450 550 fl Each terminal and body ground NO CONTINUITY IGNITION COIL INSPECTION Remove the seat and fuel tank page 13 25 Measure the primary coil resistance of the front and rear igni tion coils NOTE The rear ignition coil is behind the swingarm pivot nut PRIMARY ...

Page 226: ...r spark plug wire if you see that the ignition timing is incorrect and you might be able to see the timing is correct Warm up the engine to operating temperature If the engine must be running to do some work make sure the area is well ventilated Never run the engine in an enclosed area The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death Remove ...

Page 227: ...ITCH 4 STARTER RELAY SWITCH 3 CLUTCH DIODE 1 STARTER RELAY SWITCH 2 STARTER MOTOR 6 STARTER SWITCH 7 SUB FUSE 15 A 3 G D EUTRALTCH L G R 5 LUTCH SWITCH I G G Y R J 9 R W TO REGULATOR RECTIFIER R I C1 O O 1 8 IGNITION SWITCH 10 MAIN FUSE 30 A 17 0 ...

Page 228: ...arged battery Starter motor does not turn 1 1 Check the starter relay switch operation CLICK You should hear the relay CLICK when I lEARD I 1 2 Apply battery voltage to the starter motor I the starter switch button is depressed I directly and check the operation page 17 6 TURNS DOES NOT TURN Loose cables Faulty starter motor CLICK NOT HEARD Faulty starter relay page 17 3 switch page 17 6 ABNORMAL ...

Page 229: ...ive resistance in circuit Binding in starter motor Starter motor turns but engine does not turn Faulty starter clutch Faulty starter motor gears Starter motor and engine turns but engine does not start Faulty ignition system Engine problems Low compression Fouled spark plugs 17 2 ...

Page 230: ...the following components motor case screws front and rear covers armature NOTE Record the location and number of shims ELECTRIC STARTER 2 CASE INSPECTION Measure each brush length SERVICE LIMIT 6 5 mm 0 26 in Check for continuity from the cable terminal to the motor case and from the cable terminal to the brush wire black CABLE TERMINAL MOTOR CASE NO CONTINUITY NORMAL CABLE TERMINAL BRUSH BLACK WI...

Page 231: ...te grounded armature coils Check for continuity between pairs of commutator bars There should be continuity Check for continuity between individual commutator bars and the armature shaft There should be no continuity Check the front cover oil seal for wear or fatigue 17 4 1 COMMUTATOR 1 OIL SEAL ...

Page 232: ...VER Set the brushes on the brush holder Align the starter motor case notch with the brush holder tab Install the armature in the case Set the brush springs Install the rear shims in the same location and number as before disassembly Install the a ring on the case Install the rear cover aligning its slot with the brush holder pin 17 5 ...

Page 233: ...the motor mounting bolts securely NOTE Install the ground cable with one mounting bolt as shown Connect the motor cable to the motor terminal and install the rubber cap over the terminal Connect the battery negative cable STARTER RELAY SWITCH OPERATION INSPECTION Depress the starter switch button with the ignition switch ON The coil is normal if the starter relay switch clicks VOLTAGE INSPECTION I...

Page 234: ... the battery is discon nected CLUTCH DIODE REMOVAL Remove the rear cowling page 13 25 Remove the clutch diode from the wire harness INSPECTION Check for continuity with an ohmmeter Connect the positive probe to the terminal and the negative probe to the terminal of the diode There should be continuity then reverse the probes there should be no continuity NOTE The test results shown above are for a...

Page 235: ... an electrical failure check the continuity of the electrical path through the part A continuity check can usually be made without removing the part from the motorcycle Simply disconnect the wires and connect a continuity tester or volt ohmmeter to the terminals or connections A continuity tester is useful when checking to find out whether or not there is an electrical connection between the two p...

Page 236: ...ulty switch Wiring to that component has open circuit Fuse blown Wiring loose broken or at fault Battery dead or disconnected SWITCHES LOCATION All Lights Come On but Dimly when Ignition Switch Is Turned ON Battery voltage low Faulty bulb Headlight Beam Does Not Shift When HI LO Switch Is Op erated Faulty dimmer switch Wiring loose broken or at fault 1 METERS 2 IGNITION SWITCH 8 OIL PRESSURE SWITC...

Page 237: ... Do not put finger prints on the headlight bulb they may create hot spots on the hulb Ifyou touch the bulb with your bare hands clean it with a cloth moistened with alcohol to prevent its early failure Do not try to replace the bulb or clean the headlight with the light ON After replacing the bulb instal the rubber boot tightly against the unit 1 RETAINE NOTE Install the rubber protector with the ...

Page 238: ... Disconnect the speedometer cable from the meter cover Remove the headlight Disconnect the meter harness connectors and ignition switch connectors in the headlight case Remove the mounting bolts and meters 3 SPEEDO METER HARNESS 2 6P BLACK J CONNECTOR 1 SPEEDOMETER CABLE S8 Only Remove the mounting bolts and ignition switch After S8 Remove the torx mounting bolts using the special tool and the ign...

Page 239: ...d parts in the reverse order of disassem bly INSTALLATION 88 only Install the meters and ignition switch in the reverse order of re moval After 88 Install the meters in the reverse order of removal Install the ignition switch and tighten the torx bolts using the special tool TORQUE Ignition switch mounting bolt 25 N m 2 5 kg m 18 ft lbJ After 88 2 IGNITION SWITCH 07703 0010100 or equivalent commer...

Page 240: ...itch HL2 Hi Lo Lo N Hi Color code Bu W Bu W Turn Signal Switch W R L TL2 PR PL RIGHT N LEFT Color code Gr Lb 0 Br B Lb W O W Horn Button 1 LEFT HANDLEBAR SWITCH 1 RIGHT HANDLEBAR SWITCH I HOl H02 Released Depressed Color code WIG Lg RIGHT HANDLEBAR SWITCH Disconnect the right handlebar switch connector 9P Red and check for continuity between the terminals Continuity should exist between the color ...

Page 241: ...es Make sure that there is no continuity at room temperature and then gradually raise the coolant temperature The switch should show continuity close at 93 97 C 199 207 F NOTE Keep the temperature constant for 3 minutes to confirm continuity A sudden change of temperature will cause error tempera ture reading between the thermometer and switch Do not let the switch or thermometer touch the pan as ...

Page 242: ...e gauge needle should move all the way to H CAUTION Do not leave the temperature sensor wire grounded for longer than aJew seconds or the temperature gauge will be damaged FUEL PUMP RELAY Gasoline is extremely flammable and is explosive under certain conditions Work in a well ventilated area Do not smoke or allow flames or sparks in the your work area or where gasoline is stored 1 JUMPER WIRE Insp...

Page 243: ... does not come on inspect as follows Remove the drive sprocket cover Disconnect the oil pressure switch wire from the switch by re moving the terminal screw Short it to ground using a jumper wire Turn the ignition switch ON The oil pressure warning light should come on If the light does not come on check the bulb sub fuse 10 A and wires for a loose connection or an open circuit Start the engine an...

Page 244: ... the turn signal circuit for proper connections before making this test Connect each terminal as indicated below White Green D C 12 V Positive Green D C 12 V Negative Gray Turn signal wire of one side connect the other side to ground frame Check the left and right turn signal operation If the turn signal relay fails this test replace it 18 10 ...

Page 245: ...1 __ l fl i s OJ TAn lICHTIM f A lIG nlQ lI R A llfV o t TURN SoGNAI t OllOl 1 2 CD L I U F1lOHJ SKAo lll 1ll O ll l l ItGofI F1lOHJ fUl IflSlGlw 1 k l1l s II II II 2 5 I G 1 __1 J L l L tACHOMfTEFI M f AUOt 1 SPEEDOMETEA MtT IlLlGI T TDIP 1ol 1tlllJ il T uon U Nrr 0030Z MN8 6700 I IIoS TO D iK51Ol UrTo STUTOI Sollo HOI I rlEE FlU m i K 10f0IC lIIo OIt NEuTAAl 5 oOOt J ll 1110 1 7 FIJlIlQI lIl n l...

Page 246: ...fuel filter to carburetor strainer I Clogged fuel tank breather hole REACHING CARBURETOR Loose or disconnected fuel pump and relay wire Faulty fuel pump relay Faulty fuel pump Sticking float valve Faulty float Clogged carburetor body 2 Check spark plug I NO PROBLEM I 3 Perform the spark test I GOOD SPARK 4 Pour 1 2 cc 0 03 0 06 US OZ 0 04 0 07 Imp OZ fuel into cylinders through the spark plug hole...

Page 247: ...G Dirty air cleaner Loose spark plug Mixture too rich Carburetor flooded Choke valve stuck open Dirty air cleaner element Cylinder flooded Improper spark plug WEAK OR NO SPARK Refer to page 16 2 ONE CYLINDER LOW COMPRESSION i Improper valve and seat contact Damaged cylinder head gasket Valve stuck open Worn cylinder and piston rings 4 Spark test both cylinders I NO PROBLEM 5 J Ii d omp o compressi...

Page 248: ... Check exhaust smoke at half throttle I NO PROBLEM 2 c1 0 9 09 09 1 00 I NO PROBLEM 3 chLk spark plug condition I NORMAL 4 Check the specified fuel flow capacity I NO PLOBLEM 5 Telt cylinder compression using compression gauge I COMPRESSION NORMAL cJntinued on following page BLUE Engine oil leaking refer to sections OIL IN FUEL 9 10 GRAY Rich mixture EXCESSIVE CARBON Worn piston rings Incorrect ig...

Page 249: ...e spring ABNORMAL _ Improper ignition timing Faulty pulse rotor or generator with ferrous burrs Continued 6 Ch Ik ec Ignition timing uSing timing light 7 ChJk valve train I NO PROBLEM 8 Cle n the carburetors air passages and ets DOES NOT IMPROVE 1 1 _ Seized cylinder and piston Seized connecting rod bearing Damaged main bearing 20 4 ...

Page 250: ...mproper valve and seat contact Valve stuck open Improper valve timing Damaged cylinder head gasket Worn cylinder and piston rings BETTER CONDITION Intake pipe leaking Improper carburetor adjustment Clogged carburetor slow jet Improper float level BETTER CONDITION Dirty air cleaner element Improper carburetor adjustment Clogged carburetor air passages Improper float level 1 Check engine condition w...

Page 251: ... compression uSing compression gauge I COMPRESSION NORMAL 7 Ch k ec Ignition timing uSing timing light with full advanced I NORMAL Icottinued on following page 20 6 WET PLUG Rich mixture Dirty air cleaner element Improper heat range DISCOLOURED Improper heat range Light gray White Lean mixture Improper float level Intake pipe leaking BLUE Engine oil leaking refer to sections 9 10 GRAY Rich mixture...

Page 252: ...ft 9 Ch Ck for clutch slippage CLUTCH SLlPS Improper clutch lever free play I Faulty clutch lifter system NO PROBLEM Worn or warped clutch disc plate I Weak clutch spring 10 Clean the carburetors air passages BETTER l_ Clogged air passages and jets Clogged jets I DOES NOT IMPROVE 1 Seized cylinder and piston Seized connecting rod bearing Damaged main bearing 20 7 ...

Page 253: ...e 225 kPa 2 25 bar hinten 225 kPa 2 25 bar bis zur maximale Zuladung vorne 225 kPa 2 25 bar hinten 250 kPa 2 50 bar Vorderradbremse Hydraulische Einscheibenbremse Bremsscheibenfläche 262 x 2 cm Hinterradbremse Hydraulische Einscheibenbremse Bremsscheibenfläche 200 x 2 cm Kapazität des Kraftstofftanks 12 0 Liter Reservemenge des Kraftstofftanks 2 0 Liter Nachlaufwinkel 27 Nachlauf 111 mm Füllmenge ...

Page 254: ...zung 4 Gang 1 174 23 27 Getriebübersetzung 5 Gang 0 965 29 28 Schaltschema Fußschaltung links mit Rückführsystem 1 N 2 3 4 5 Eektrik Zündung Digitale Transistorzündung Zündzeitpunktmarkierung F 10 vor OT im Leerlauf Frühzündung voll 31 vor OT bei 7 000 U min 200 U min Anlaßsystem Elektrischer Anlasser Wechselstromlichtmaschine 240 W 5 000 U min Batteriekapazität 12 V 8 Ah MF Batterie Zündkerzen St...

Page 255: ...seschraube 14 8 27 2 7 Kurbelgehäuseschraube 6 6 12 1 2 Schraube der Schaltwalzen Anschlagplatte 1 6 26 2 6 Zündzeitpunkt Prüflochkappe 1 14 10 1 0 Kurbelwellenabdeckappe 1 30 15 1 5 Schraube des Ölpumpen Antriebsrads 1 6 15 1 5 Sicherungsmutter Einstellschraube Ventile 6 7 23 2 3 Zylinderstehbolze 8 mm 2 8 20 30 2 0 3 0 Zylinderstehbolzen 10 mm 8 10 30 50 3 0 5 0 Halteschraube der vorderen Motora...

Page 256: ... 2 7 11 1 1 Klemmschraube der unteren Gabelbrücke 2 10 50 5 0 Gabelstopfen 2 23 2 3 Befestigungsschraube Dämpfer Standrohr 2 8 17 1 7 Einstellmutter des Lenkkopflagers 1 26 20 2 0 Lenkschaftmutter 1 24 105 10 5 Schraube der Vorderradachse 1 14 60 6 0 Vordere Achsklemmschraube 4 8 22 2 2 Hinterrad Schwinge Hintere Radmutter 1 18 120 12 0 Sicherungsmutter des Lagerkäfigs Hinterrad 1 35 165 16 5 Ober...

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Honda Hawk GT NT650 1988, Service Manual

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Summary of Contents for Hawk GT NT650 1988

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