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Honda REBEL 250, Service Manual

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Honda REBEL 250 Service Manual Download Page 188

Summary of Contents for REBEL 250

Page 1: ...ves If you have not received shop safety training or do not feel confident about your knowledge of safe servicing practice we recommended that you do not attempt to perform the procedures described in...

Page 2: ...other information throughout this manual Of course it is not practical or possible to warn you about all the hazards associated with servicing this vehicle You must use your own good judgment You will...

Page 3: ...ER HEAD VALVES CYLINDER PISTON CLUTCH GEARSHIFT LINKAGE ALTERNATOR STARTER CLUTCH CRANKSHAFT TRANSMISSION FRONT WHEEL SUSPENSION STEERING REAR WHEEL BRAKE SUSPENSION HYDRAULIC BRAKE BATTERY CHARGING S...

Page 4: ...lybdenum disulfide grease containing more than 3 molybdenum disulfide NLGI 02 or equivalent Example Molykote BR 2 plu9 manufactured by Dow Corning U S A Multi purpose M 2 manufactured by Mitsubishi Oi...

Page 5: ...OMPONENTS Awaruwj Engine and exhaust system parts become very hot and remain hot for some lime after the engine is run Wear insu lated gloves or wail until the engine and exhaust system have cooled be...

Page 6: ...recommended parts and lubricants or their equivalents Parts that don t meet HONDA s design specifications may cause damage to the motorcycle 2 Uso the special tools designed for this product to avoid...

Page 7: ...entification number VIN is attached on the left side of the down tube as shown 151 COLOR LABEL 14 CARBURETOR IDENTIFICATION NU 4 The carburetor identification numbers are stamped on the left side of t...

Page 8: ...ail length Fuel tank capacity Fuel tank reserve capacity Semi double cradle Telescopic fork 116 mm 4 6 in Swingarm 74 mm 2 9 In 3 00 18 47P 13Q90 15M C 66P Front L303A Rear G508 Front FI 1 Rear K627 H...

Page 9: ...ant mesh 5 speed Primary reduction 3 631 69 19 Final reduction 2 357 33 14 Gear ratio 1st 2 846 37 13 2nd 1 777 32 18 3rd 1 333 28 21 4th 1 083 26 24 j 5th 0 913 21 23 Gearshift pattern Left foot oper...

Page 10: ...08 0 25 0 010 End clearance 0 05 0 13 0 002 0 005 0 14 0 006 LUBRICATION SYSTEM Engine oil capacity STANDARD 1 5 liter 1 6 US qt 1 3 Imp qt 1 8 liter 1 9 US qt 1 6 Imp qt Unit mm in SERVICE LIMIT Oil...

Page 11: ...1 46 Rocker arm Rocker arm I D IN EX 10 000 10 015 0 3937 0 3943 10 10 0 398 Rocker arm shaft O D IN EX 9 972 9 987 0 3926 0 3932 9 91 0 390 Rocker arm to shaft clearance 0 013 0 043 0 0005 0 0017 0 0...

Page 12: ...Runout At both ends At bearing holder Unit mm in SERVICE LIMIT 0 60 0 024 0 05 0 002 0 03 0 001 0 05 0 002 Transmission Gear I D M5 20 020 20 041 0 7882 0 7890 20 08 0 791 Cl 20 020 20 041 0 7882 0 7...

Page 13: ...9 3 37 lbs STANOARD 200 kPa 2 00 kgf cm 29 psi 200 kPa 2 00 kgf cm 29 psi 21 6 1 0 85 t 0 04 20 30 3 4 1 1 4 HYDRAULIC BRAKE Specified brake fluid STANDARD DOT 3 or 4 Unit mm fin SERVICE UMIT 1 5 0 06...

Page 14: ...6 15 6 V 5 000 rpm mMiTtnai cvctcm ITEM SPECIFICATION Spark plug NGK DENSO Standard For cold climate below 5 0 C 41 F CR8HSA CR5HSA U20FSR U U16FSR U For extended high speed riding CR7HSA U22FSR U Spa...

Page 15: ...GENERAL INFORMATION Sub fuse...

Page 16: ...ump mounting scrow 3 6 10 1 0 71 Cylinder Head Valves Spark plug 2 10 12 1 2 9 Valve adjuster lock nut 4 5 10 1 0 7 Cylinder head camshaft holder nut 8 8 23 2 3 17 Cylinder head bolt 3 6 12 1 2 9 Cam...

Page 17: ...t upper 2 8 lower 2 10 Swingarm pivot nut 1 14 Drive chain slider mounting self tapping screw 3 5 Drive chain adjuster lock nut 2 6 Hydraulic brake Caliper pin boh 1 8 Caliper pin boh A 1 8 Caliper bl...

Page 18: ...040500 11 Pilot 25 mm 07746 0040600 11 Pilot 22 mm 07746 0041000 11 Bearing remover head 15 mm 07746 0050400 12 13 Bearing remover shaft 07746 0050100 12 13 Oil soal driver 07747 0010100 12 Oil seal d...

Page 19: ...iston base 07958 3000000 8 Valve guide reamer 5 485 mm 07984 0980001 NOTE 3 7 Clutch center holder 07GMB KT70101 07984 098000D U S A only 9 Peak voltage adapter 07HGJ 0020100 NOTE 3 16 Drive chain too...

Page 20: ...ft big end Shift fork claw and pivot inner surface Shift drum grooves Clutch disc Engine oil Valve stem valve guide sliding surface Valve guide valve stem sliding surface Camshaft bushing inner surfac...

Page 21: ...ipe inner surface Side stand pivot Gearshift pedal pivot Clutch lever pivot bolt Steering lock mounting screw threads Drive chain case mounting bolt threads Helmet holder mounting bolt threads Fork oi...

Page 22: ...ROUTING 7 LEFT HANDLEBAR SWITCH WIRE 18 CLUTCH CABLE 6 RIGHT HANDLEBAR SWITCH WIRE 16 WIRE BANDS 9 CHOKE CABLE THROTTLE CABLES RIGHT TURN SIGNAL WIRE 2 BRAKE HOSE 10 LEFT TURN SIGNAL WIRE 11 SPEEDOMET...

Page 23: ...4 SPEEDOMETER WIRE 21 INDICATOR PANEL WIRE 8 MAIN WIRE HARNESS 1 19...

Page 24: ......

Page 25: ...1 21...

Page 26: ...3 REGULATOR RECTIFIER CONNECTORS 1 CLUTCH CABLE 12 CHOKE CABLE 4 FUEL TANK BREATHER TUBE 5 CARBURETOR AIR VENT TUBE 6 CRANKCASE BREATHER TUBE 7 ALTERNATOR IGNITION PULSE 18 SIDE STAND SWITCH WIRE 1 22...

Page 27: ...R BRAKE SWITCH WIRE 51 CARBURETOR OVERFLOW TUBE 6 CRANKCASE BREATHER SEPARATOR TUBE 7 AIR CLEANER HOUSING DRAIN TUBE 91 FUEL TANK BREATHER TUBE 1101 AIR CLEANER TUBE 3 CARBURETOR AIR VENT TUBE 11 CRAN...

Page 28: ...GENERAL INFORMATION 12 RIGHT TURN SIGNAL WIRE II SUB HARNESS 3 LEFT TURN SIGNAL WIRE 1 24...

Page 29: ......

Page 30: ...n effect SOURCE OF EMISSIONS The combustion process produces carbon monoxide and hydrocarbons Control of hydrocarbons is very important because under certain conditions they react to form photochemica...

Page 31: ...IS PROHIBITED federal law prohibits the following acts or the caus ing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any...

Page 32: ...label on the right side of the down tube as shown Instructions for obtaining the update label are given in Service Loner 132 When readjusting the carburetor back to the low altitude specifications be...

Page 33: ...MEMO...

Page 34: ...FRAME BODY PANELS EXHAUST SYSTEM BODY PANEL LOCATIONS 2...

Page 35: ...ire or explosion This section covers removal and installation of the body panols fuel tank and exhaust system Always replace the exhaust pipe gaskets after removing the exhaust pipe from the engine Wh...

Page 36: ...ommets from the air cleaner housing tabs then removo the side cover Install the side cover m the reverse order of removel SEAT REMOVAL Remove the rear seat mounting bolts Slide the rear seat backward...

Page 37: ...the wire harness while installing the rearseat FUEL TANK REMOVAL INSTALLATION JA WARNING Gasoline is extremely flammable and explosive under certain conditions KEEP OUTOF REACH OF CHHJ RF N Remove the...

Page 38: ...ront fender mounting bolts front fender end brake hose guide Installation Is in the reverse order of removal REAR FENDER REMOVAL Remove the seat page 2 2 Remove the bolt and connector cover Disconnect...

Page 39: ...everse order of removal 21 CONNECTOR COVER EXHAUST SYSTEM REMOVAL Do not service the exhaust system while it is hot The left or right muffler can be removed individually Remove the exhaust pipe joint...

Page 40: ...INSTALLATION H N m 1 4 kgf m 10 Ibf ft Loosen he exhaust pipe joint band bolt Remove the following Passenger footpeg mounting bolt Footpeg end collar Muffler bracket mounting bolts and collars Exhaust...

Page 41: ...gasket with new ones When installing the exhaust pipe first install all the fasten ers loosely Next tighten the oxhaust pipe Oint nuts Then tighten the exhaust pipe joint bolt and mounting fasteners...

Page 42: ...le and is explosive under certain conditions Work in a well ventilated area Smoking or allowing James or sparks in the work area or where the gasoline is stored can cause a fire or explosion If the en...

Page 43: ...cm 29 psi pressure Rear 200 kPa 2 00 kg cm 29 psi Up to maximum weight capacity Front 200 kPa 2 00 kg cm 29 psi Rear 200 kPa 2 00 kg cm 29 psi Minimum tire tread depth Front 1 5 mm 0 06 in Rear 2 0 m...

Page 44: ...ED LU 1 1 1 1 mtam 3 11 1 EVAPORATIVE EMISSION CONTROL SYSTEM a yma 1 3 11 DRIVE CHAIN i 3 12 BRAKE FLUID NOTE 6 tor HI835 mexta 3 15 L BRAKE SHOE PAD WEAR uHImm m 3 16 BRAKE SYSTEM mmm m 3 16 BRAKE L...

Page 45: ...ot smooth Measure the free play at the throttle grip flange FREE PLAY 2 6 mm 1 12 1 4 in Throttle grip free play can be adjusted at either end of the throttle cable Minor adjustment are made with the...

Page 46: ...d allow moisture to enter Replace the cable If necessary AIR CLEANER Remove the left side cover page 2 2 Romove the screws and air cleaner housing cover Disconnect the breather tube from the air clean...

Page 47: ...escribed in the maintenance schedule INSPECTION i Check the following and replace if necessary recommended spark plug page 3 1 Insulator for damage Electrodes for wear Burning condition coloration dar...

Page 48: ...auge see above CAUTION Do not overtighten the spark plug Install and hand tighten the new spark plug then tighten it about 1 2 of e turn after the sealing washer contacts the seat of the plug hole VAL...

Page 49: ...10 mm 0 002 0 004 in Adjust if necessary by loosening the lock nut and turning the adjusting screw until there is a slight drag on the feeler gauge Hold the adjusting screw and tighten the lock nut TO...

Page 50: ...order of removal ENGINE OIL OIL LEVEL INSPECTION Place the motorcycle on level ground Check the oil level using the oil filler cap dipstlck by placing it into the filler hole without screwing it in If...

Page 51: ...er handling used oil Drain the oil completely Check that the sealing washer on tho drain bolt is In good condition and replace if necessary Install and tighton the drain bolt TORQUE 25 N m 12 6 kgf m...

Page 52: ...cifications The engine must be warm for accurate idle speed inspec tion and adjustment Warm up the engine for about ten minutes Turn the throttle stop screw os requirod to obtain the speci fied idle s...

Page 53: ...slots in the swingarm Tighten both lock nuts Tighten the rear axle nut to the specified torque TORQUE 88 N m 9 0 kgf m 65 Ibff ft Rocheck the drive chain slack and free wheel rotation Lubricate the dr...

Page 54: ...on worn sprockets Both chain and sprockets must be In good condition or the new replacement chain will wear rapidly Check the attaching bolts and nuts on the drive and driven sprockets If any are loos...

Page 55: ...9 CAUTION Never reuse the oil drive chain master link master link plate and O rtngs Install tho now drive chain Assemble the new master link O rings and plate CAUTION Insert the master link from the i...

Page 56: ...le with each other Do not ulla foreign material to enter the system when filling the reservoir A t onl spilling fluid on painted plasm or rubber sorts Place a rag user these ports whenever the system...

Page 57: ...pedal Is applied Refer to page 13 9 for brake shoe replacement BRAKE SYSTEM FRONT BRAKE Firmly apply the brake lever and check that no air has entered the system If the lever feels soft or spongy when...

Page 58: ...come on when the brake pedal is depressed 20 mm 3 4 in and brake engagement begins Hold the switch body and turn the adjusting nut Do not tum the switch body HEADLIGHT AIM Ah improperly adjusted headl...

Page 59: ...the adjusting nut to adjust free play Hold the adjusting nut securely while tightening the lock nut If proper free play cannot be obtained or the clutch slips during the test ride disassemble and insp...

Page 60: ...k service REAR Support the motorcycle securely and raiso the rear wheel off the ground Check for worn swingarm bushings by grabbing the rear wheel and attempting to move the wheel side to side Replace...

Page 61: ...13 Measure the tread depth at the center of the tires Replace the tires when the tread depth reaches the follow ing limits MINIMUM TREAD DEPTH FRONT 1 5 mm 0 06 in REAR 2 0 mm 0 08 in Tighten any loo...

Page 62: ...LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM 1 CAMSHAFT 8 CRANKSHAFT 7 MAINSHAFT 12 OIL PUMP DRIVE GEAR 13 OIL THROUGH 61 COUNTERSHAFT JNER SCREEN...

Page 63: ...aining 1 5 liter 1 6 US qt 1 3 Impqt At disassembly 1 8 liter 1 9 US qt 1 6 Impqt Recommended engine oil Honda GN4 4 stroke oil or equivalent motor oil API service classification SF or SG Viscosity SA...

Page 64: ...eel counterclockwise until the holes in the oil pump gear aligns with the oil pump attaching screws Remove the three screws and oil pump assembly Remove the O ring DISASSEMBLY Remove the oil strainer...

Page 65: ...components Measure the pump body clearance SERVICE LIMIT 0 25 mm 0 010 in Measure the side clearance using a straight edge and feeler gauge SERVICE LIMIT 0 14 mm 0 006 In Measure the tip clearance SER...

Page 66: ...2 BOLTS 1 GEAR COVER...

Page 67: ...he screw Install the oil strainer screen to the oil pump body INSTALLATION Apply oil to the new O ring Install a new O rlng into the crankcase Install tho oil pump and tighten the throo screws to the...

Page 68: ......

Page 69: ...bind resulting in loss of vehicle control Worit In a well ventilated area Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion CAUTION Be su...

Page 70: ...a type VE35D Main jet 110 Slow Jet 35 Pilot screw Initial opening 2 3 4 turns out High altitude setting 2 1 4 turns out Float level 18 6 mm 0 73 in Idle speed 1 400 100 rpm Throttle grip free play 2 6...

Page 71: ...y Lean mixture Afterburn during acceleration Ignition system faulty Lean mixture Poor performance driveability and poor fuel economy Fuel system clogged Ignition system faulty Air cleaner clogged Afte...

Page 72: ...ist the throttle cable It will not tsperute smoothly and may stick if it is kinked or twisted Loosen the connecting tube band screw Remove the carburetor mounting nuts and carburetor Disconnect the ai...

Page 73: ...ston for wear nicks or other damage Make sure the piston moves up and down freely in the chamber Push the jet needle holder down and turn it counterclock wise 90 degrees with a screwdriver Then remove...

Page 74: ...operation of the valve Remove the following Main jet Needle jet holder Needle jet Slow jet Turn the pilot screw in and record the number of turns bofore it seats lightly Use this as a roferonce for r...

Page 75: ...FUEL SYSTEM e VK 8fcgl...

Page 76: ...pilot screw is installed page 5 121 5 PILOT SCREW Install the float and float valve in the carburetor body then install the float arm pin through the body and float FLOAT LEVEL INSPECTION With the fl...

Page 77: ...nstall the float chamber Install the four float chamber ecraws Install the accelerator link washor collar and link bolt Set the boot and install the accelerator pump shaft dia phragm NOTE Align the di...

Page 78: ...open so the dia phragm is not pinched by the chamber cover Install tho chamber cover with the spring aligning its tab with the hole in the carburetor and secure with at least two screws before releasi...

Page 79: ...and tighten the carburetor mounting nuts Tighton the insulator band scrow Connect the throttle cables to the throttle drum then install and tighten the throttle cable guido screws Install the startin...

Page 80: ...is tight ened against the seat INITIAL OPENING 2 3 4 turns out 2 Warm tho engine up to operating temperature Stop and go riding for 10 minutes is sufficient 3 Stop the engine and connect a tachometer...

Page 81: ...t that can be oasily removed from the vehicle CAUTION Sustained operation at an altitude lower than 5 000 feet 1 00 mi with the carburetor adjusted for high altitude lettings nun cause engine to idle...

Page 82: ...e 13 3 Battery page 15 4 Disconnect the rear brake light switch connector Remove the starter relay switch from the battery tray Remove the bolts and battery tray Disconnect the crankcase breather tube...

Page 83: ...FUEL SYSTEM 5 15...

Page 84: ...6...

Page 85: ...with engine installed In the frame Camshaft Section 7 Clutch Section 9 Gearshift linkage Section 91 Carburetor Section 5 Oil pump Section 4 SPECIFICATIONS ITEM SPECIFICATION Engine oil capacity At dr...

Page 86: ...e from the bracket and clutch arm Remove the nut and starter motor cablo from the starter motor Remove the bolt and engine ground wire Disconnect the crankcase breather separator tube from the crankca...

Page 87: ...nd left crankcase rear cover Remove the upper engine hanger nut and bolt Remove the nuts bolts and upper engine hanger bracket Remove the front engine hanger nuts and bolts Remove the nut bolt and fro...

Page 88: ...specified torque TORQUE 62 N m 6 3 kgf m 46 Ifaf ftl Tighten the upper ongine hanger plate nuts and hanger nut securely Install the drive sprocket and fixing plate to the counter shaft Install and ti...

Page 89: ...utral switch connector Alternator connector Connect the crankcaso breather tube to the engine Install the engine ground wire and tighten the bolt Connect the clutch cable to the clutch arm and bracket...

Page 90: ......

Page 91: ...d rocker arm holder Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Cylinder compression Cyli...

Page 92: ...ese problem can be diagnosed by a compression test or by tracing engine noises to the top end with a sounding rod stothoscope If the performance is poor at low speeds check for white smoke in the cran...

Page 93: ...tarter motor until the gauge reading stops rising COMPRESSION PRESSURE 1 100 kPa 11 2 kg cm 159 psi at 600 rpm Low compression can be caused by Blown cylinder head gasket Improper valve adjustment Val...

Page 94: ...e left crank case cover Loosen the camshaft holder nuts and cylinder head bolts In sequence shown in 2 3 steps Remove the nuts and camshaft holders and dowel pins Remove the rocker arms and rocker arm...

Page 95: ...urn the crankshaft counterclockwise one turn and remove the other cam sprocket bolt NOTE Be careful not to drop the cam sprocket bolts into the crank case Slide the cam sprocket off the camshaft flang...

Page 96: ...er arm SERVICE UMIT 10 10 mm 10 398 In Inspect the rocker arm shafts for wear or damage Measure the 0 0 of each rocker arm shaft SERVICE UMIT 9 91 mm 10 390 In Calculate the rockor arm to ahaft cleara...

Page 97: ...height of each cam lobe SERVICE UMrT IN 27J2 mm 1 07 ln EX 27 0 mm 1 06 in CYLINDER HEAD REMOVAL Remove the engine from the frame section 6 Remove the camshaft page 7 3 Remove the nuts and intake mani...

Page 98: ...ket CYLINDER HEAD DISASSEMBLY Remove the spark plugs from the cylinder head Remove the valve spring cotters retainers springs and valves using the special tools as shown TOOL Valve spring compressor 0...

Page 99: ...r warpage with a straight edge and feeler gauge SERVICE LIMIT 0 10 mm 0 004 in VALVE SPRING Measure the free length of the inner end outer valve springs SERVICE LIMITS Inner 29 0 mm 1 14 in Outer 37 0...

Page 100: ...ons would bring the clearance within tolerance If so replace any guides as necessary and ream to fit If the stem to guide clearance exceeds the service limits with new guides also replace the valves a...

Page 101: ...Clean the cylinder head thoroughly to remove any metal particles Ref8ce the valve seat see below VALVE SEAT INSPECTION REFACING Clean the intake and exhaust valves thoroughly to remove carbon deposit...

Page 102: ...operating instruc tions Use a 45 degrees cutter to remove any roughness or irregu larities from the seat NOTE Reface the seat with a 45 degrees cutter whenever a valve guide is replaced Use a 32 degr...

Page 103: ...lve face is very important for good sealing If the contact area is too high on the valve the 968t mu6t be lowered using a 32 degrees flat cutter 1 CONTACT TOO HIGH If the contact area is too low on th...

Page 104: ...M SEAL 7 VALVE GUIDE 8 O RING Install the valvo spring seat and a new atom seal Lubricate the valve stems with molybdenum disulfide oil end insert the valve into the valve guide To avoid damage to the...

Page 105: ...CAUTION Support the cylinder head aho e the work bench surface to prevent possible vahe damage CYLINDER HEAD INSTALLATION Clean the gasket material off tho mating surface of the cylin der head Make s...

Page 106: ...plugs CAMSHAFT ROCKER ARM INSTALLATION ROCKER ARM HOLDER ASSEMBLY Lubricate the rocker arm and rocker arm shaft with clean engine oil Install the rocker arms and springs in tho camshaft holder and ins...

Page 107: ...ckwise and align the T mark on the flywheel with the index mark on the left crank case cover Install the cam sprocket with the timing marks index lines facing toward the left side NOTE Pass the camsha...

Page 108: ...ocket bolt holes in the sprocket and camshaft Apply a locking agent to the threads of the cam sprocket bolts Install and tighten the sprocket bolt Turn the crankshaft counterclockwise one full turn 36...

Page 109: ...washers and nuts Tighten the nuts and bolts in the sequence shown in 2 3 steps TORQUE Nut 23 N m 2 3 kgf m 17 IW ft Pour fresh oil into the oil pockets In the cylinder heed until the cams are submerg...

Page 110: ...s and connect the connectors Install the spark plug caps to the spark plugs Check that the O rings of the crankshaft and timing hole cap are in good condition replace if necessary Install and tighten...

Page 111: ......

Page 112: ...STANDARD SERVICE LIMIT Cylinder I D 53 000 53 010 12 0866 2 0870 63 10 2 091 Out of round 0 05 0 002 Taper 0 05 0 002 Warpage 0 05 0 002 PtotOM pis ton ring Piston mark direction IN mark facing towar...

Page 113: ...smoke Worn cylinder piston or piston rings Improper installation of piston rings Scored or scratched piston or cylinder wall Overheating Excessive cartoon build up on the piston head or com bustion c...

Page 114: ...nder gasket PISTON REMOVAL Remove a piston pin dip with pliers NOTE Do not let the dip fall into the crankcase Press the piston pin out of the piston and remove the pis ton CAUTION Always support the...

Page 115: ...ERVICE LIMIT Taper 0 06 mm 0 002 In Out of round 0 05 mm 0 002 in The cylinder must be rebored and an oversize piston fitted if the service limits are exceeded The following oversize pistons are avail...

Page 116: ...nd measure the ring end gap NOTE Push the rings into the cylinder with the top of the piston to be sure they are squarely in the cylinder SERVICE LIMIT Top 0 46 mm 0 018 in Second 0 60 mm 0 024 In Oil...

Page 117: ...lean the piston ring grooves thoroughly and install the pis ton rings NOTE _ Apply oil to the piston rings Avoid piston and piston ring damage during installation Install the piston rings with the mar...

Page 118: ...sing new piston pin clips Remove the rag NOTE Install the piston with its IN mark facing the Intake side Do not align the piston pin clip s end gap with the piston cut out Do not let the clip fall int...

Page 119: ...CYLINDER PISTON Install the cam chain tensioner lower bolt Install the cam chain tensioner guide Install the cylinder head page 7 15 8 8...

Page 120: ...9 0...

Page 121: ...th 37 8 1 49 Clutch disc thickness 2 92 3 08 0 115 0 121 Clutch plate warpage Clutch outer I D 26 000 26 021 1 0236 1 0244 26 04 1 025 20 05 0 789 Clutch outer guide l D 20 000 20 021 0 7874 0 7882 O...

Page 122: ...ity or additive used Check for oil additive Transmission jumps out of gear Worn shift drum stopper arm Wear or broken gearshift spindle return spring Bent shift fork shaft Damaged shift drum cam groov...

Page 123: ...il page 3 10 Remove Ihe bolts and right footpeg bracket CLUTCH GEARSHIFT LINKAGE 1 BOLTS Disconnect the clutch cable from the clutch arm Remove the bolts and right crankcsse cover CLUTCH LIFTER REMOVA...

Page 124: ...Apply grease to the oil seal lip and insen the clutch arm into the right crankcase cover Install the lifter spring Slightly turn the clutch arm clockwise and install the lifter rod Into the right cra...

Page 125: ...in USA Remove Ihe following Clutch center Spring seat Judder spring Clutch discs and plates Pressure plate Spline washer Clutch outer Outer guide Thrust washer INSPECTION Clutch lifter bearing Turn th...

Page 126: ...ch disc SERVICE LIMIT 2 6 mm 010 Ini Clutch pete Check each disc plate for warpage on a surface plate using a feeler gauge SERVICE LIMIT 0 20 mm 0 008 In Clutch outer ckrtch outer guide Check the slot...

Page 127: ...EARSHIFT LINKAGE INSTALLATION 4 PRESSURE PLATE 3 CLUTCH DISCS 21 LOCK NUT 74 N m 7 6 kgf m 54 lbf ft 5 CLUTCH OUTER 1 LIFTER PLATE 16 CLUTCH PLATES 7 JUDDER SPRING Note the direction of the spline was...

Page 128: ...ion of the judder spring Install the lock washer with its OUT SIDE mark facing out Attach the clutch center holder using the clutch lifter bolts Install a new lock nut then tighten It to the specified...

Page 129: ...3 Remove the oil pump page 4 2 Remove the oil through and spring from the crankshaft Attach the gear holder between the primary drive and dri ven gear as shown TOOL Gear holder 07724 0010200 Remove t...

Page 130: ...1 ll1 1 j 1 GEARSHIFT SPINDLE 9 10...

Page 131: ...e screwdriver and Install the shift drum stopper plate by aligning tho dowel pins with the holes in tho stopper plate Install and tighten the shift drum stopper plate bolt Install the gearshift spindl...

Page 132: ...tall the right crankcase cover and connect the clutch cable to the dutch arm Set the clutch cable guide and tighten the right crankcase cover bolts Install the right footpeg bracket and tighten the bo...

Page 133: ...10 0...

Page 134: ...pection SPECIFICATIONS Unit mm in ITEM STANDARD Starter driven sprokot 1 0 22 010 22 022 0 8665 0 8670 Boss 0 0 36 975 37 000 1 4557 1 4567 36 90 1 453 TORQUE VALUES Flywheel bolt Starter clutch mount...

Page 135: ...footpag bracket Remove the bolt and gearshift pedal link Remove the fuel tank page 2 31 Disconnect the alternator exciter coil and ignition pulse generator wire connectors Remove the alternator wire...

Page 136: ...07733 0020001 STATOR REMOVAL Remove the following Sockot bolts and ignition pulse generator Socket bolts and wire clomp Socket bolts and stator 1 ROTOR PULLER STARTER CLUTCH REMOVAL Remove the bolt a...

Page 137: ...n clock wise DISASSEMBLY Remove the rollers spring caps and springs from the clutch outer Remove the clutch outer mounting screws using an impact driver Remove the starter clutch outer side plate and...

Page 138: ...R CLUTCH OUTER Measure the starter driven sprocket I O and O D SERVICE LIMITS I D 22 08 mm 0 869 in O D 36 90 mm 1 463 in Check the rollers spring caps and spring for wear damage or deformation Check...

Page 139: ...g agent to the starter clutch outer mounting screw threads Tighten the screws to the specified torque TORQUE 9 N m 0 9 kgf m 6 5 Ibf ft Stake the screws into the groove of the starter clutch outer Ins...

Page 140: ...NATOR STARTER CLUTCH Install the ignition pulso generator wire grommet into the left crankcase cover groove securely ALTERNATOR INSTALLATION Install the dowel pins new side plate gasket and side plate...

Page 141: ...in the flywheel with the dowel pin on the crankshaft Install the washer and flywheel bolt Hold the flywheel using the special tool then tighten the bolt to the specified torque TOOL Flywheel holder 0...

Page 142: ...he bolts Install the gearshift pedal by aligning the punch marks then tighten the bolt Install the left footpeg bracket and tighten the bolts Connect the alternator exciter coil and ignition pulse gen...

Page 143: ...11 0...

Page 144: ...7890 20 08 0 791 Cl 20 020 20 041 0 7882 0 7890 20 08 0 791 C4 20 020 20 041 0 7882 0 7890 20 08 0 791 Gear bushing O O Cl 19 979 20 000 0 7866 0 7874 19 93 0 785 Gear bushing I D Cl 16 516 16 534 0 6...

Page 145: ...1000 07746 0040600 TROUBLESHOOTING Crankshaft noisy Worn connecting rod big end bearing Bent connecting rod Worn crankshaft main journal bearing Transmission jumps out of gear Worn gear dogs or slots...

Page 146: ...e 11 1 for the parts which must be removed before separating the crankcase Remove the bolt neutral switch set plate and neutral switch Remove the two left crankcase bolts Place the left crankcase faci...

Page 147: ...s and shift drum Remove the mainshaft end countershaft as an assembly from the left crankcase Disassemble the transmission INSPECTION Check the shift fork and fork shaft for wear or damage Measuro the...

Page 148: ...m 0 791 in Measure the I D and O D of Cl gear bushing SERVICE LIMIT O D 19 93 mm 0 785 in ID 16 58 mm 0 653 in Calculate the gear to gear bushing clearance SERVICE LIMIT 0 10 mm 0 004 in Check the shi...

Page 149: ...11 6...

Page 150: ...ION install the mainshaft end countershaft as an aseemble Into the left crankcase Install the shift drum into the crankcase Align the neutral switch rotor tab with tne neutral switch hole in the left...

Page 151: ...move the crankshaft Remove the B clips plain washer and cam chain tansioner Position the crank balancer weight as shown Pass the cam chain between the guide insertion part and crank balancer weight th...

Page 152: ...e crankshaft runout at both ends SERVICE UMIT 0 03 mm 0 001 In Measure the crankshaft runout at the center Bearing holder SERVICE LIMIT 0 06 mm 0 002 in Check the cam chain guide and slipper for exces...

Page 153: ...olts and nut to the speci fied torque TORQUE Bolts 23 N m 2 3 kgt m 17 Ibf ftl Nut 12 N m 1 2 kgf m 9 Ibf ftl Install the transmission page 11 7 Assemble the crankcase page 1 1 13 CRANK CASE BEARING R...

Page 154: ...tools TOOLS Crankshaft bearing Driver Attachment 62 x 68 mm Pilot 25 mm Mainshaft bearing Driver Attachment 52 x 68 mm Pilot 20 mm 07749 0010000 07746 0010500 07746 0040600 07749 0010000 07746 001060...

Page 155: ...haft bearing Driver Attachment 62 x 68 mm Pilot 26 mm Mainshaft bearing Driver Attachment 32 x 35 mm Countershaft bearing Driver Attachment 42 x 47 mm Pilot 22 mm 07749 0010000 07746 0010500 07746 004...

Page 156: ...nstall the now crankshaft and countershaft oil seals HAFT OIL SEAL CAUTION Do not drive the countershaft oil seal below the end cf the crank ease as this will Nock the otl passafte in the shaft 1 DOWE...

Page 157: ...In 2 3 steps Install the neutral switch and neutral switch set plato and tighten the bolt Install the removed parts in the reverse order of removal Assemble the crankcase halves together Install and t...

Page 158: ...12 0...

Page 159: ...PECIFICATIONS Unit mm in TORQUE VALUES Steering stem nut Steering stem bearing adjusting nut Fork top pinch bolt Fork bottom pinch bott Front axle bolt Brake caliper bracket mounting bolt Brake disc m...

Page 160: ...ng nut too tight Faulty steering head bearing Insufficient tire pressure Faulty tire Steers to one side or doas not track straight Bent fork Bent front axle Wheel installed Incorrectly Faulty steering...

Page 161: ...rip end by holding the grip end and removing the screw Disconnect the clutch switch wires from the switch Remove the clutch lever holder bolts holder and clutch lever bracket assembly CLUTCH SWITCH WI...

Page 162: ...ve the left handlebar switch 2 CHOKE LEVER Disconnect the front brake switch wires from the switch Remove the master cylinder holder bolts holder and master cylinder assembly Disconnect the throttle c...

Page 163: ...andlebar Remove the bolts and speedometer indicator panel assem bly Remove the nuts lower holders cushion washers and cush ion rubbers INSTALLATION Install the cushion rubbers washers and lower holder...

Page 164: ...s first then tighten the rear bolts If the handlebar grips were removed apply Honda Bond A or Honda Hand Grip Cement U S A only to the inside of the grip and to the clean surfaces of the right and lef...

Page 165: ...ith the UP mark facing up Tighten the upper bolt first then the lower bolt TORQUE 12 N m 1 2 kgff m 9 Ibfftl Connect the brake switch wires Connect the choke cable to the choke lever Install the left...

Page 166: ...er bracket holder with the UP mark facing up Tighten the upper bolt first then the lower bolt TORQUE 12 N m 1 2 kgf m 9 IbMt Connect the clutch switch wires Install the wire bands Install the rearview...

Page 167: ...1 2 the total Indicator reading SERVICE LIMIT 0 20 mm 10 008 in METER GEARBOX Turn the tnner race of each bearing with your finger The bearings should turn smoothly and quietly Also check that the be...

Page 168: ...he total Indicator reading SERVICE LIMIT Radial 2 0 mm 0 08 in Axial 2 0 mm 0 08 in Install the bearing remover head into the bearing From the opposite side install the bearing remover shaft and drive...

Page 169: ...en the new mounting bolts to the specified torque TORQUE 39 N m 4 0 kgf m 29 Ibf ft Do not get grease on the brake disc or stopping power will be reduced Drive in a new left bearing squarely with its...

Page 170: ...Install tho speedometer gear retainer into the left wheel hub aligning its tangs with the slots in the hub Apply grease to the dust seal lips and install it into the left wheel hub Fill the speedomete...

Page 171: ...page 12 8 Brake caliper page 14 10 WARNING Do not allow the brake caliper to hang from Ike brake hoie Remove the bolts end front fender Loosen the front turn signal brackot bolt nut Loosen the fork to...

Page 172: ...ft jaws or a shop towel Remove the fork socket bolt with a hex wrench NOTE If the fork piston turns with the socket bolt temporarily install the fork spring and fork cap 1 DUST SEAL Remove the dust se...

Page 173: ...rk tube out until resistance from the slider bush ing is felt Then move it in and out tapping the bushing lightly until the fort tube separates from the fork slider The slider bushing will be forced o...

Page 174: ...s neces sary to replace it with a new one 1 OIL SEAL 3 SLIDER BUSHING 12 BACK UP RING INSPECTION Fork spring Measure the fork spring free length SERVICE LIMIT 535 1 mm 21 07 In Fork tube slider piston...

Page 175: ...ngs if there is excessive scoring or scratch ing or if the teflon is worn so that the copper surface appears on more than 3 4 of the entire surface Check the back up ring replace it if there is any di...

Page 176: ...hing has been removed Install the sliding bushing back up ring and a new oil seal NOTE Install the oil seel with its lip facing down Install the rebound spring and fork piston into the fork tube Insta...

Page 177: ...Ibf ft Drive the oil seal in using the special tools TOOLS Oil seal driver body 07747 0010100 Oil seal driver attachment 07747 001 0501 Install the stopper ring into the fork slider groove securely ST...

Page 178: ...2 Imp oz Pump the fork tube several times to remove trapped air from the lower portion of the fork tube Compress the fork leg fully and measure the oil level from the top of the fork tube FORK OIL LE...

Page 179: ...TORQUE 34 N m 3 5 kgf m 25 Ibf ft Tighten the fork cap to the specified torque if it was removed TORQUE 22 P4m 123 kgf m 16 Ibf ft Tighten the top fork pinch bolt to the specified torque TORQUE 11 N m...

Page 180: ...e 18 6 Remove the bolts and connector bo Remove the front brake hose clamp bolts hose clamp and front cover Remove the nut and headlight bracket Loosen the steering stem nut Remove the fork legs page...

Page 181: ...ring stem nut onto the stem to prevent the threads from being damaged when removing the lower bearing inner race from the stem Remove the lower bearing inner race with a chisel or equiv alent tool bei...

Page 182: ...PER BEARING STEEL BALL 21 4 UPPER INNER RACE 1 STEERING STEM 5 UPPER OUTER RACE 6 LOWER OUTER RACE 10 LOWER BEARING STEEL BALL 21 7 LOWER INNER RACE 9 WASHER Apply grease to upper and lower bearing ra...

Page 183: ...ing Install the top bridge Install the fork legs page 12 21 Install the washer and stem nut Tighten the steering stem nut to the specified torque TORQUE 74 N m 7 5 kgf m 54 lbf ft STEERING HEAD BEARIN...

Page 184: ...cket and tighten the nut Install the brake hose clamp and tighten the bolts Install the connector box and tighten the bolts Install the following Ignition switch page 18 6 Speedometer page 18 4 Headli...

Page 185: ...REAR WHEEL BRAKE SUSPENSION 13 0...

Page 186: ...p to maximum weight capacity 200 kPa 2 00 kgf cm 29 psi Axle runout 0 20 0 008 Wheel rim runout Radial 1 Axial 2 0 0 08 Wheel hub to rim distance 21 6 1 0 85 0 04 Brako pedal froe play 20 30 3 4 1 1 4...

Page 187: ...001 07936 3710100 07936 3710600 07741 0010201 or 07936 3710200 07936 KA50000 TROUBLESHOOTING Suspension noise Weak shock absorber spring Oil leakage from damper unit Incorrect suspension adjustment Lo...

Page 188: ...orward Derail the drive chain Remove the axle from the left side and remove the rear wheel Remove the drive chain adjusters INSPECTION Axle Place the axle in V blocks and measure the runout Actual run...

Page 189: ...ven sprocket teeth Roplace the sprocket if worn or damaged NOTE If the final driven sprocket roqulres replacement inspect the drive chain and drive sprocket Never install a now drive chain on a worn s...

Page 190: ...n flange collar Drive out the driven flange bearing Wheel bearing removal Install the bearing romover head into the bearing From the opposite side install the bearing remover shaft and drive the beari...

Page 191: ...ed the hearing must he replaced with a new me Drive in a new left bearing squarely with its sealed side fac ing out Install the distance collar then drive in the right side bear ing with its sealed si...

Page 192: ...nce from the hub right end surface to the side of rim is 21 6 1 mm 0 85 0 04 in as shown Apply grease to the dust seal lips than Install it into the dri ven flange Place the rim on the work bench Plac...

Page 193: ...was removed install the driven sprocket and tighten the nuts TORQUE 64 N m 6 5 kgfm 47 Ibf ft Install the left side collar INSTALLATION Install both drive chain adjusters into the swingarm Piace the r...

Page 194: ...t piece to the brake arm and connect the brake rod with the spring Install the adjusting nut Adjust the drive chain slack page 3 12 Tighten the axle nut to the specified torque TORQUE 88 N m 9 0 kgf m...

Page 195: ...J 2 FELT SEAL REAR WHEEL BRAKE SUSPENSION Measure the brake lining thickness SERVICE LIMIT 2 0 mm 0 08 in DISASSEMBLY Remove the brake shoes and springs Remove the nut boll and brake srm Remove the in...

Page 196: ...HOE SPRINGS 61 BRAKE PANEL Apply grease to the anchor pin and bcako cam Install the brake cam into the brake panel Apply oil to the felt seal and install it onto the brake panel Install the wear indic...

Page 197: ...ge 13 81 SHOCK ABSORBER REMOVAL Support the motorcycle securely using a hoist or equiva lent Remove the upper and lower mounting bolts and shock absorber INSPECTION Visually inspect the shock absorber...

Page 198: ...Lower mounting bolt 42 N m 14 3 kgf m 31 Ibf ftl SWINGARM REMOVAL Remove the rear wheel page 13 3 Disconnect the rear brake pedal return spring Remove the bolts and drive chain cover Remove the rear...

Page 199: ...ACEMENT Remove the outside pivot bushings using the special tools TOOLS Bearing remover set 07936 731 0001 Bearing remover hand 07936 3710100 Bearing remover set 07936 37 1 0600 Remover weight 07741 0...

Page 200: ...3 Icgfrm 2 2 3 PIVOT BUSHING 2 DUST SEAL CAP 1 PIVOT COLLAR 7 DRIVE CHAIN SUDER ASSEMBLY Install the rear brake stoooer arm bolt spring washer plain washer and nut Tighten the nut securely Install a n...

Page 201: ...ock absorber lowor mounting bolts and tighten them to the specified torque TORQUE 42 N m 4 3 kgf rn 31 lbf ft Install the drive chain cover and tighten the bolts Install the rear brake pedal return sp...

Page 202: ...ake pedal pivot pinch bolt and brake pedal Remove the brake pedal pivot shaft and brake rod as an assembly Remove the cotter pin and joint pin and separate the brake rod from the pivot shaft 2 JOINT P...

Page 203: ...HYDRAULIC BRAKE...

Page 204: ...le SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Specified brake fluid DOT 3 or 4 Brake disc thickness Brake disc runout 4 0 0 16 3 5 0 14 0 30 0 012 Master cylinder Cylinder I D 12 700 12 743...

Page 205: ...icking wom master cylinder piston Contaminated master cylinder Bent brake lever Brake lever hard Clogged restricted brake system Sticking wom caliper piston Caliper not sliding properly Clogged restri...

Page 206: ...UTION Do not mix different types offluid There are not compatible Connect a commercially available brake bleodor to the bleed valve Pump the brake bleeder and loosen tho bleod valve adding fluid when...

Page 207: ...losed 2 Release the brake lever after the bleed valve has been closed Repeat steps 1 and 2 until bubbles cease to appear in the fluid coming out of the bleed valve Tighten the bleed valve TORQUE 6 Nm...

Page 208: ...pads against the pad spring then install the pad pins Push the caliper pistons all the way In to allow installation of new brake pad NOTE Check the brake fluid level in the brake master cylinder rese...

Page 209: ...Tighten the pad pins TORQUE 18 N m 1 8 kgfrn 13 tbfftl install and tighten the pad pin plugs TORQUE 2 N m 0 2 kgf m 1 4 lb ft BRAKE DISC INSPECTION Measure the brake disc thickness with a micrometor S...

Page 210: ...e master cylinder DISASSEMBLY Remove the boot Remove the snap ring from the master cylinder body using the special tool as shown TOOL Snap ring pliers 07914 3230001 Remove the master piston and spring...

Page 211: ...the piston cups spring snap ring and boot as a set do not substitute individual parti Coat all parts with clean brake fluid before assembly Dip the piston in brake fluid Install the spring to the pis...

Page 212: ...H MARK Install the brake hose eyelet with the oil bolt and new seal ing washers Push the brake hose against the stopper then tighten the oil boh to the specified torque TORQUE 34 N m 3 5 kgf m 25 Ibf...

Page 213: ...ke system page 14 31 Remove the oil bolt sealing washers and brake hose eyelet joint Remove the caliper mounting bolts and the brake pads page 14 4 CAUTION jre to the fluid inlet to remove the 1 1 Do...

Page 214: ...for scoring or other damage Measure the caliper cylinder I D SERVICE LIMIT 25 450 mm 1 0020 Ini Check the caliper pistons for scratches scoring or other dam age Measure the caliper piston O D SERVICE...

Page 215: ...all the bracket pin boot into the caliper body Install the caliper pin boot into the bracket Apply silicone grease to the caliper and bracket pins and install the caliper bracket over the caliper body...

Page 216: ...BATTERY CHARGING SYSTEM SYSTEM DIAGRAM 15 0...

Page 217: ...life CAUTION The battery caps should not be removed Attempting to remove the sealing caps from the cells may damage the battery The battery car be damaged if overcharged or undercharged or if left to...

Page 218: ...y Tester and Christie Battery Charger for detailed battery charging steps The Christie Battery Charger MC 1012 21 is a constant current amperage type designed to produce current at a con stant rate fo...

Page 219: ...rogulator rectifier Inspect the regulated voltage page 15 7 _tp_ 1 Regulated Low voltage same as battery voltage rouny uniicry Abnormal Check the voltage of the regulator rectifier battery charging li...

Page 220: ...battery voltage using a digital multimeter VOLTAGE Fully charged 13 0 13 2 V Under charged Below 12 3 V TOOL Digital multimeter Commercially available BATTERY TESTING NOTE Always clear the work area...

Page 221: ...t allowing at least a 30 minu e cool down period NOTE The result of a tost on the meter scale is relative to the amp hour rating of the battery Any BATTERY READING IN THE GREEN ZONE IS OK Batteries sh...

Page 222: ...d by the Honda Battery Tester RED 3 RED 2 or YELLOW 1 If you are charging a new battery set the switch to the NEW BATT position 4 Attach the clamps to the battery terminals RED to Positive BLACK to Ne...

Page 223: ...y neg ative cable from the battery Connect the tester between the negative cable and the neg ative terminal The voltage should indicate less than 1 mA with the Ignition switch off LEAKAGE AMPERE 1 mA...

Page 224: ...for stator removal REGULATOR RECTIFIER SYSTEM INSPECTION Remove the fuel tank page 2 3 Disconnect the regulator rectifier connectors and check them for loose contact or corroded terminals If the regu...

Page 225: ...BATTERY CHARGING SYSTEM...

Page 226: ...4 NEUTRAL DIODE 7 CLUTCH SIDE STAND OIODE 6 BATTERY 112 IGNITION COIL 11 SPARK PLUG 1101 IGNITION PULSE GENERATOR 81 NEUTRAL SWITCH 9 SIDE STAND SWITCH SYSTEM DIAGRAM 2 IGNITION SWITCH 1 1 CLUTCH SWIT...

Page 227: ...ule ICM is factory preset The Ignition Control Module ICM may be damaged if dropped Also if tho connector is disconnected when current is flowing the excessive voltage may damage the module Always tur...

Page 228: ...m 1 2 kgf m 9 Ignition pulse generator socket bolt 10 N m 1 0 kgf m 7 lbf ft TOOLS Imrie diagnostic tester model 625 or Peak voltage adapter 07HGJ 0020100 with Commercially available digital multimet...

Page 229: ...r engine stop switch 4 Loose or poor connected ICM connectors 6 Open circuit or poor connection In ground wire of the ICM 6 Faulty ode stand switch circuit 7 Faulty peak voltage adapter or Imrie teste...

Page 230: ...tion If the sys tem is disconnected incorrect peak voltage might be mea sured Check cylinder compression and check that the spark plugs are installed correctly Shift the transmission into neutral disc...

Page 231: ...PEAK VOLTAGE 100 V minimum A void touching the spark plugs and tetter probes to prevent elec tric shock If the peak voltage measured at ICM connector is abnormal disconnect the exciter Black Red conn...

Page 232: ...voltage PEAK VOLTAGE 0 7 V minimum MUVARWUG A void touching the spark plugs and tester probes to prevent elec tric shock If the peak voltage measured at the ICM connector is abnor mal disconnect the i...

Page 233: ...ness and may lead to death NOTH Read the manufacturer s instructions for timing light oper ation Warm up the engine Stop the engine and remove the timing hole cap Connect a timing light to the No 1 sp...

Page 234: ...IGNITION SWITCH 3 STARTER SWITCH ID CLUTCH SWITCH yf 7 CLUTCH SIDE STAND DIODE 4 NEUTRAL DIODE I 5 STARTER RELAY SWITCH l6J BATTERY _ 110 STARTER MOTOR 8 NEUTRAL SWITCH 9 SIDE STAND SWITCH fTIClUTCM S...

Page 235: ...FORMATION 17 1 STARTER RELAY SWITCH 17 10 TROUBLESHOOTING 17 2 DIODE 17 11 SERVICE INFORMATION GENERAL The starter motor can be removed with the engine In the frame For the starter drive and driven sp...

Page 236: ...ELECTRIC STARTER 17 2 Faulty starter relay switch...

Page 237: ...side stand switch Abnormal Faulty side stand switch Normal Open circuit in wire harness Loose or poor contact connector Starter motor turns engine slowly Low battery voltage Poorly connected battery...

Page 238: ...kets chain and side spacer page 10 3 Disconnect the starter cable from the starter motor Remove the four mounting bolts and the starter motor DISASSEMBLY Record the location and number of shims Remove...

Page 239: ...d be continuity Check for continuity between the rear cover and the brush wire the indigo cover wire or the insulated brush holder Thoro should be no continuity Remove the following Nut Washer Insulat...

Page 240: ...r cover for wear or damage Inspect the commutator bars for discoloration Bars discolored in pairs indicate grounded armature coils in which case the starter motor must be replaced NOTE Do not use emer...

Page 241: ...uity between individual commutator bars and the armature shaft there should be no continuity ASSEMBLY 2 REAR COVER 3 BRUSH I4 BRUSH HOLDER 5 SHIMS 11 INSULATORS 16 RING GEAR ID ARMATURE 10 SHIMS 9 MOT...

Page 242: ...ECTRIC STARTER 2 ARMATURE 5 REAR COVER 2 REAR COVER 1 MOTOR CASE 3 INDEX MARK Install the shims properly as noted during removal OTE Assemble the motor case and rear cover aligning the index marks 17...

Page 243: ...its groove with the projection in the motor case If the front cover ring gear is removed install the ring gear onto the pinion gears aligning its groove wrth the projection in the front cover Install...

Page 244: ...rd Inspect the relay switch using the procedure below GROUND LINE INSPECTION Disconnect the relay connector Check for continuity between the Green Red wire and ground If there is continuity when the t...

Page 245: ...hould be continuity while 12 V battery is connected to the starter relay switch connector terminals and should be no continuity when the battery is disconnected DIODE REMOVAL Remove the seat and fuel...

Page 246: ...UGHTS METER SWITCHES 3 IGNITION SWITCH 111 CLUTCH SWITCH 41 TURN SIGNAL RELAY 7 HORN 5 NEUTRAL SWITCH 16 SIDE STAND SWITCH 2i SPEEDOMETER 18 0...

Page 247: ...this section Bu Blue G Green Ig Light Green R Red Bl Black Gr Gray O Orange W White Br Brown Lb Light Blue P Pink Y Yellow SPECIFICATIONS ITEM SPECIFICATION Bulbs Headlight 96 2000 12 V 36 5 35 W High...

Page 248: ...emove the headlight unit NOTE If the headlight bulb is worn replace the headlight unit as an assembly Install the headlight unit in the reverse order of removal TAIL BRAKE UGHT Remove the two screws a...

Page 249: ...le pushing In turn tho bulb counterclockwise to remove it Replace it with a new one Install the tail brake light Ions in the reverse order of removal TURN SIGNAL Remove the three screws and turn signa...

Page 250: ...IDE STAND INDICATOR BULB AND INSTRU MENT BULB Disconnect the speedometer cable Remove the nuts and speedometer rear cover Pull the side stand indicator bulb and instrument bulb socket out of the speed...

Page 251: ...move the bolts and speedometer indicator panel as an assembly Remove the nuts washers and speedometer rear cover Disconnect the side stand indicator bulb socket and meter light socket Remove the screw...

Page 252: ...witch wire connectors Check for continuity between the wire terminals of the igni tion switch connector in each switch position Continuity should exist between the color coded wires as follows IGNITIO...

Page 253: ...sconnect the handlebar switch connectors Check for continuity between the wire terminals of the han dlebar switch connectors Continuity should exist between the color coded wire termi nals as follows...

Page 254: ...applied and there should be no continuity when the brake pedal is released CLUTCH SWITCH Disconnect the clutch switch connectors There should be continuity with the clutch lever applied and there shou...

Page 255: ...ws SIDE STAND SWITCH 96 2000 Green White 1 Yellow Black 1 Green Side stand up Side stand O o down After 2000 GreervWhite Green Side stand up 0 Side stand down REMOVAL Disconnect the side stand switch...

Page 256: ...urn signal switch function Loose connectors If above items all normal check the following Disconnect the turn signal connectors from the relay 1 Short the black and gray terminals of the turn signal r...

Page 257: ...s sssss t ss sss...

Page 258: ...ted spark plug wire Broken or shorted ignition coil Faulty ignition switch Faulty ignition pulse generator Faulty exciter coil Faulty engine stop switch Loose or disconnected ignition system wires 3 T...

Page 259: ...Or Discolored Not fouled Or Discolored l 9 Check oil level and condition Incorrect Correct l 10 Remove cylinder head cover and Valve Train Not Lubricated inspect lubrication Properly Faulty tire valve...

Page 260: ...POOR PERFORMANCE AT LOW AND IDLE SPEED 1 Check ignition timing Incorrect Correct t 2 Check carburetor pilot screw Incorrect adjustment Correct I 3 Check for leaking intake pipe Leaking No Leak 4 Perfo...

Page 261: ...ignition pulse generator Clogged fuel line Clogged fuel tank breather Clogged fuel strainer screen Clean Cam sprocket not installed properly Faulty spring POOR HANDLING 1 If steering is heavy Possibl...

Page 262: ...SYSTEM CALIFORNIA TYPE ONLY 3 1 1 EXHAUST SYSTEM 2 5 FORK 12 13 FRONT FENDER 2 4 FRONT WHEEL 12 8 FUEL UNE 3 4 FUEL TANK 2 3 GEARSHIFT LINKAGE 9 10 GENERAL SAFETY 1 1 HANDLEBAR 12 3 HANDLEBAR SWITCHES...

Page 263: ...PISTON 6 2 ELECTRIC STARTER 17 2 ENGINE DOES NOT START OR IS HARD TO START 20 1 ENGINE LACKS POWER 20 2 FRAME BODY PANELS EXHAUST SYSTEM 2 1 FRONT WHEEUSUSPENSION STEERING 12 2 FUEL SYSTEM 5 3 HYDRAU...

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