Honda Shadow VT700C Manual Download Page 7

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Summary of Contents for Shadow VT700C

Page 1: ...s MANUAL VT7DDC VT75DC...

Page 2: ...some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe Please understand that those warn...

Page 3: ...ocedures If you are not familiar with this motorcycle read the Technical Features in section 23 If you don t know the source of the trouble go to section 24 Troubleshooting All information illustratio...

Page 4: ...e highly explosive Do not smoke or allow flames or spark near Ihe battery especially while charging il 1 Use genuine HONDA or HONDA recommended parts and lubricants or their equivalents Parts that do...

Page 5: ...ial number is stamped on the eering head right side The engine serial number is stamped on the lower left crankcase 1 2 o o The color label is attached to the rear fender under the seat The vehicle id...

Page 6: ...in 860 mm 33 8 in 1 2oomm 47 2 in 1 525 mm SO O in 760 mm 29 9 in 330 mm 13 0 in 150 mm 5 90 in 211 kg 465 Ib 225 kg 496 Ib Double cradle Telescopic fork 145 mm 5 7 in Swingarm Shock absorber 103 mm 4...

Page 7: ...perated return system 1 N 2 3 4 S 0D 170 cc 5 8 oz after disassembly 130 cc 4 4 oz after draining 1S0 cc S 1 oz after disassembly 130 cc 4 4 oz after draining Full transistor ignition SO BTDC at idle...

Page 8: ...14 1 0 1 4 7 10 Apply 3 BOND No 1211 or its equivalent Primary gear bolt 1 to the bolt threads 12 80 100 8 0 10 0 58 72 Clutch center lock nut 1 22 45 55 4 5 5 5 33 40 Clutch cover bolts 7 6 8 12 0 8...

Page 9: ...6 0 7 0 43 51 UBS Gear case cover bolts 2 10 35 45 3 5 4 5 25 33 6 8 23 28 2 3 2 8 17 20 Exhaust pipe joint nuts 4 6 8 14 0 8 1 4 6 10 Exhaust pipe clamp bolts 4 8 18 28 1 8 2 8 13 20 Sub frame bolts...

Page 10: ...der 07924 MC70001 Modify 07924 4150000 7 10 or 07924 MC700oo Torx bit Equivalent commercially 8 availble in U S A Fork tube holder attachment 07930 KA50100 10 Valve guide driver attachment IN 07943 65...

Page 11: ...ver 07742 0010200 Valve guide driver 07942 6570100 10 Valve spring compressor 07757 0010000 Valve spring compressor 07957 3290001 10 Remover weight 07741 0010201 Remover weight 07936 3710200 13 17 Att...

Page 12: ...a sharp edge or corner Clean the attaching surface thoroughly before applying tape Do not use wires or harnesses with a broken insulator Repair by wrapping them with a pro tective tape or replace the...

Page 13: ...GENERAL INFORMATION BRAKE BRAKE LIGHT TAIL LIGHT SENSOR CABLE FRONT HOSE 1 10 UNIT II CLAMP FRONT BRAKE HOSE...

Page 14: ...GEN ERAL INFORMATION After 84 HOKE CABLE CLUTCH HOSE SPEEDOMETER CABLE 1 11...

Page 15: ...GENERAL INFORMATION STARTER RELAY SWITCH REGULATOR RECTI FIER FRAME GROUND CONNECTION 1 12 BRAKE TAIL L GHT SENSOR FUE PUMP FUEL SENSOR...

Page 16: ...on process produces carbon monoxide and hydrocarbons Control of hydrocarbons is very important because under certain conditions they react to form photochemical smog when subjected to sunlight Carbon...

Page 17: ...thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the...

Page 18: ...abel is located on the rear down tube behind the right side cover as shown If gives basic tune up specifications VACUUM HOSE ROUTING LABE L After 83 California model The Vacuum Hose Routing Label is a...

Page 19: ...LUBRICATION CRAHK _ iti SHAFT 2 0 OIL PE DEFOAMI G CHAMBER ROCKER ARM SHAFT ____ HYDR UL CTAPPET MAIN SHAFT PUMP I FORK SHAFT SHAFT DRIVE SHAFT...

Page 20: ...sification SE or SF Viscosity SAE 10W 40 Other viscosities shown in the chart may be used when the average temperature in your riding area is within the indicated range OIL VISCOSITIES o 20 40 60 80 1...

Page 21: ...m 7 10 ft Ib Apply 3 BOND No 1211 or its equivalent to the bolt threads 8 12 N m 0 8 1 2 kg m 6 9 ft Ib 8 12 N m 0 8 1 2 kg m 6 9 ft Ib 07506 3000000 II 1 bl 07510 4220100 1 or commercia y aval a e 07...

Page 22: ...on the drain plug is in good condition and inst all it TORQUE 30 40 N m 3 0 4 0 kg m 22 29 ft lb Apply oil to the new oil filter O ring and install the new oil filter Torque the oil filter with a fi...

Page 23: ...Apply 3 BOND sealant or equivalent to the pres sure switch threads and install TORQUE 10 14 N m 1 0 1 4 kg m 7 10 ft lb Connect the oil pressure switch wire and start the engine Check that the oil pr...

Page 24: ...d washer gear shift linkage page 9 2 Pull the oil strainer downward out of the oil pump Remove the oil pump by removing the mounting bolts and remove the oil strainer Remove the O ring and dowel pin O...

Page 25: ...ve snap ring and disassemble the relief valve Check the spring and piston for wear or damage Check the valve for clogging or damage Assemble the parts in the reverse order of disassem bly Be sure to u...

Page 26: ...ure the pump body clearance STANDARD 0 15 0 22 mm 0 006 0 009 in SERVICE LIMIT 0 35 mm 0 014 in Remove the spacer and drive pin from the rotor shaft Remove the rotor shaft and measure ttJe pump end cl...

Page 27: ...ft Insert the drive pin into the rotor shaft Align the slots in the inner rotor with the drive pin Place the spacer into the inner rotor groove Install the dowel pin and oil pump body cover Make sure...

Page 28: ...the oil strainer into the crankcase and then install the oil pump Tighten the botts TORQUE 8 12 N m 0 8 12 kg m 6 9 ft Ib Install the oil strainer Place the oil pump driven sprocket into the drive cha...

Page 29: ...assembly pages 7 17 and 94 Install the dowel pins and a new gasket Install the following parts right side cover right sub frame front cylinder exhaust pipe right foot peg with the rear brake pedal Fi...

Page 30: ...lt to drain all oil from the final gear case Install the drain bolt securelv Fill the gear case with the recommended oil up to the correct level above Oil CAPACITY 130 cc 4 4 ozJ RECOMM ENDED Oil 83 H...

Page 31: ...METER DR IVE GEAR 2 12 FRC NT FDRK A T F l BRAKE PEDAL PIVOT GEARSHIFT PEDAL PIVOT 0 ICABLE LUBR ICANt CHOKE CABLE FOOT peG PIVOT _ SWINGARM PIVOT I I I I I SIDE AND CENTE R STAND PIVOT GR IP _m DRIVE...

Page 32: ...PECIFICATIONS ENGINE Spark plugs 3 10 3 10 3 11 3 11 See page 2 3 See page 2 3 See page 2 11 3 MAINTENANCE CYLINDER COMPRESSION 3 11 EVAPORATIVE EMISSION CONTROL SYSTEM 3 12 CHASSIS BATTERY 3 13 BRAKE...

Page 33: ...S Special Vacuum gauge set 3 2 5 BTDC 10 0 BTDC 26 BTDC at 3 500 rpm 26 BTDC at 4 000 rpm 900 100 rpm Both carburetor within 40 mm 1 6 in Hg of each other 12 2 kg cm2 171 28 psi 2 6 mm 1 8 1 4 in 20 3...

Page 34: ...RATIVE EMISSION I 3 12 NOTE 3 I I CONTROL SYSTEM FINAL DRIVE OIL I I R 2 11 BATTERY MONTH I I I I I I I 3 13 MONTH I R R BRAKE FLUID FRONT 2 YEARS R I I I I I 3 13 w t BRAKE SHOE PAD WEAR I I I I I I...

Page 35: ...ine between the fuel filter and fuel pump shut Disconnect the fuel tines from the filter Replace the fuel fi lter with a new one when indi cated by the maintenance schedule See page 3 31 Gasoline is f...

Page 36: ...if throttle operation is not smooth Measure throttle grip free play at the throttle grip flange FREE PLAY 2 6 mm 1 8 1 4 in Throttle grip free play can be adjusted at either end of the throttle cable...

Page 37: ...n the carburetors Remove the choke valve from the carburetor Push the choke lever on the handlebar all the way down to fully closed and make sure the distance between the nut s th raads and valve is 1...

Page 38: ...Soak the elements in gear oil SAE 80 90 and squeeze out the excess Install the removed parts in the reverse order of diassemblv CRANKCASE BREATHER Remolle the plug from the drain tube to empty any dep...

Page 39: ...attached thread each spark plug in by hand to prevent crossthreading Tighten the spark plugs another 1 2 turn with a spark plug wrench to compress the plug washer Connect the spark plug caps IGNITION...

Page 40: ...e the tool box at the back of the rear seat with the key Remove the rear and front seats Move the fuel tank back about 25 50 mm 1 2 in removing the fuel tank mounting bolts Let it rest on the frame Re...

Page 41: ...t idle speed after all other engine adjustments are within specifica tions The engine must be warm for accurate adjustment Ten minutes of stop and go riding is sufficient Warm up the engine shift to N...

Page 42: ...R COMPRESSION Warm up the engine to normal operating tempera ture Stop the engine disconnect both spark plug caps and remove one spark plug from each cylinder Insert the compression gauge Open the thr...

Page 43: ...bend twist or kink the tubes when installing Slide the end of each tube onto its fitting fully and secure with a tube band Seeme with the tube ctamps whenever specified Replace the tube1 with new one...

Page 44: ...tect your eyes ski and c othing If electrolyte gets in your eyes flush them thoroughly with wa er and gel prompt medi ca attention BRAKE FLUID Chec the front brake fluid reservoir level If the level n...

Page 45: ...ure ellen disc pressure BRAKE SHOE INSPECTI ON Replace the brake shoes if the arrow on the brake arm aligns with the reference mark 1 on full application of the rear brake pedal BRAKE SYSTEM Inspect t...

Page 46: ...ear brake light switch and brake pedal free play and adjust if necessary BRAKE PEDAL FREE PLAY NOTE Perform brake pedal free play adjustment after adjusting brake pedal height Check the brake pedal fr...

Page 47: ...crew clockwise to direct the beam toward the right side of the rider NOTE Adjust the headlight beam as specified by local taws and regulations An improperly adjusled headlihgl may blind oncoming drive...

Page 48: ...ling the side stand lower end with a spring scale SUSPENSION Do not ride Q vehicle with faulty suspension Loo worn or domoged suspension parts impair ehide stability and control FRONT Check the action...

Page 49: ...for cuts imbedded nails or other sharp objects RECOMMENDED TIRES AND PRESSURES FrOM Rear Tire lin 110190 1962H 140190 1570H Up to 90 kg 32 32 Cold 1200 11 1225 2 25 1225 2 25 lire prenure 90 kg psi 12...

Page 50: ...bar moves unevenly binds or has vertical movement adjust the steering head bearing by turning the steering head adjusting nut page 15 3 11 NUTS BOLTS FASTENERS Check that all chassis nuts and bolts ar...

Page 51: ...FUEL SYSTEM R C4 After 84 4 0...

Page 52: ...the work Q The engine uses down draft carburetors When disassembling fuel system parts note the locations of the Q rings Replace them with new ones on reassembly The float bowls have drain screws tha...

Page 53: ...3 Incorrect carburetor synchronization 4 Carburetor faulty 5 Fuel contaminated Misfiring during acceleration 1 Ignition system faulty Misfiring during acceleration Ignition system faulty Backfiring 1...

Page 54: ...s Remove the screws attaching the throttle cable stay and the throttle link cover and stav Disconnect the throttle cables from the throttle drum Remove the choke cables from the carburetors Remove the...

Page 55: ...CUUM CHAMBER REMOVA L Remove the four vacuum chamber cover screws and cover Remove the compression spring diaphragm and vacuum piston Inspect the vacuum piston for wear nick s scratches or other damag...

Page 56: ...washer from the piston Inspect the needle for excessive wear at the tip and for bending or other damage Check the diaphragm for deterioration and tears INSTA LLATI ON Installation is essentially the r...

Page 57: ...T LEVEL Measure the float level with the carburetor inclined 15 _45 from vertical and the float tang just con tacing the float valve SPECIFICATIONS 7 5 mm 0 30 in Adjust the float level by carefully b...

Page 58: ...Remove the main jet needle jet holder and slow jet Remove the float valve seat and filter Inspect the float valve seat and filter for grooves nicks or deposits ASSEMBLY Assemble the float chamber comp...

Page 59: ...ill pOint Drill through the plug with a 4 mm 5 32 in drill bit Attacn a drill stop to the bit 3 mm 1 8 in from the end to prevent drilling into the pilot screw CAUTION Be careful not 1 0 drill into th...

Page 60: ...urn them to their original position as noted during removal Perform pilot screw adjustment if new pilot screws are installed page 4 12 NOTE Do not install new plugs on new pilot screw holes until afte...

Page 61: ...ly Coat new O rings with oil and install them on the air joint pipe Put the No 1 and No 2 carburetors together with the air joint pipe thrust collar and spring Loosen the synchronization adjusting scr...

Page 62: ...age Then release the throttle Make sure that it returns smoothly Make sure that there is no drag when opening and closing the throttle CARBURETOR INSTALLATION Installation is essentially the reverse o...

Page 63: ...seat 2 Warm up the engine to operating temperature Stop and go driving for 10 minutes is sufficient 3 Attach a tachometer according to the manufac turer s instructions 4 Adjust the idle speed with th...

Page 64: ...OFF and disconnect the fuel line at the fuel filter Turn the fuel valve ON and drain the fuel into a clean container Disconnect the fuel lines at the auxiliary fuel tank and remove the fuel tank mount...

Page 65: ...page 16 3 Remove rear fenders A and B Detach the auxiliary fuel tank hose from the fuel pump Remove the auxiliary fuel tank mounting bolt and tank Install the auxiliary fuel tank in the reverse order...

Page 66: ...clockwise 1 turn Adjust the idle speed to specification page 4 with the throttle stop screw Drive new pilot screw plugs into the pilot screw bores page 4 12 NOT E This adjustment must be made at high...

Page 67: ...stoll When the vehicle is 10 be operoledcontinuous Iy below 1 500 m 5 000 feet turn each pi at screw counterclockwise I turn to its original position after mo ing each pi at screw plug and adjust Ihe...

Page 68: ...e the PCV if vacuum is not maintained Remove the vacuum pump and connect it to the vacuum hose that goes to the left carburetor body Apply the specified vacuum to the PCV SPECIFIED VACUUM 250 mm 9 8 i...

Page 69: ...ENGINE REMOVAL INSTALLATION 5 0 35 45 N M 3 5 4 5 kg m 25 33 60 70 N m 6 0 7 0 kg m 43 51 ft lb 8 14 0 8 1 4 kg m 6 10 ft Ib o z J 45 60 N m 4 5 6 0 kg m 33 43 ft Ib N m 6 0 8 0 kg m 43 58 ft Ib...

Page 70: ...pump and oil filter SPECIFICATIONS Engine dry eight Oil capacity TORQUE VA LUES Engine hanger bolts 8mmbolt 10mm bolt 12mmbolt Sub frame bolts Exhaust pipe joint nut Exhaust pipe clamp bolt Upper Lowe...

Page 71: ...e seat and fuel tank Remove the left and right frame side covers Drain the engine oil page 2 3 and the coolant page 3 Remove the carburetOf s page 4 3 Disconnect the spark plug caps and the crankcase...

Page 72: ...with the fuel lines connected Disconnect the starter motor cable at the starter motor Loosen the right exhaust pipe clamp bolts Remove the right exhaust pipe joint nuts and re move the right exhaust...

Page 73: ...coil Remove the left foot peg and gearshift pedal l oosen the left exhaust pipe clamp bolts Remove the exhaust pipe joint nuts and remove the left exhaust pipe Remove the bolt attaching the clutch sla...

Page 74: ...e alternator wire coupler Disconnect the pulse generator wire coupler Place a floor jack or other adjustable support under the engine NOTE The jack height must be continuously adjust ed so that the mo...

Page 75: ...mm 20 30 N m f2 0 J a kg m 14 22 ft tb SUS FRANE SOLTS Upper 70 80 N m 7 0 8 0 kg m 51 58 ft lb lower 35 45 N m 3 5 4 5 kg m 25 33 ft Ib NOTE Route the wires and cables properly page 1 9 Fill the cran...

Page 76: ...COOLING SYSTEM 6 0...

Page 77: ...spections SPECIF ICATIONS Radiator cap relief pressure 0 75 1 05 kglcm1 10 7 14 9 psi 55 Distilled water 45 ethylene glycol _ 32 C _25 F Freezing point Hydrometer test 50 Distilled water 50 ethylene g...

Page 78: ...too high or too low It must hold specified pres sure for at least six seconds NOTE Before installing the cap on the tester apply water to sealing surfaces RADIATOR CAP RELIEF PRESSURE 0 9 0 15 kg em...

Page 79: ...ump and drain the system coolant Replace the drain bolt Fill the system with a 50 50 mixture of distilled water and ethylene glycol Bleed air from the radiator Start the engine and run until there are...

Page 80: ...ain the coolant page 6 3 Remove the radiator cover Disconnect the radiator upper hose at the radiator Disconnect the wire connector from the tempera ture sensor Remove the bolt attaching the thermosta...

Page 81: ...8 mm minimum 10 31 in Valve lift when heated to 95 C 203 F for five minutes INSTALLATION Install a new O ring on the thermostat housing and insert the thermostat into the housing Install the thermosta...

Page 82: ...move the drain bolt and drain the coolant page 6 31 Remove the radiator cover Disconnect the fan motor and thermostatic switch couplers f rom the wire harness Loosen the upper and lower hose bands 6 6...

Page 83: ...the radiator while pulling the upper and 1000wr hoses off DISASSEMB LY Remove the fan shroud with tile fan by removing tile four bolts Remove the fan attaching nut and pull the fan off the fan motor F...

Page 84: ...d joints and seams for leaks Blow dirt out from between core fins with com pressed air If insects etc are clogging the radiator wash them off with low pressure water Carefully straighten any bent fins...

Page 85: ...d to the radiator with the four bolts INSTALLATION Install the radiator onto the frame and tighten the mounting bolts Connect the upper and lower hoses to the radiator arid tighten the hose bands Conn...

Page 86: ...a ter pump as an assembly if the mechanical seal is leaking REMOVA L Remove the engine from the frame Section 5 Remove the water pipes and hoses from the engine Disconnect the oil pressure switch wire...

Page 87: ...water pump as an assembly if necessary INSTALLAT ION Apply a coat of clean engine oil to a new a ring and install it in the water pump shaft housing groove Align the water pump shaft groove with the o...

Page 88: ...el pins Install the water pump cover Connect the radiator lower hose to the water pump cover and tighten the hose band Connect the oil pressure switch wire to the switch Install the water pipes and ho...

Page 89: ...CLUTCH 7 0 25 35 N m 2 5 3 5 kg m 18 25 ft lb 0 5 2 N m m 0 4 0 9 ft lb _____ 0 05 0 2 kg r 1O 14N m P 11 0 1 4 k m 9 7 10ft lb 5_7N m 4 5 ft Ib 0 5 0 7 kg m 25 35 N m 18 25 ft Ib 2 5 3 5 kg m...

Page 90: ...ING CLUTCH MASTER CYLINDER 45 55 N m 4 5 5 5 kg m ft Ib 7 2 7 3 7 4 7 5 CLUTCH SLAVE CYLINDER CLUTCH DISASSEMBLY CLUTCH ASSEMBLY PRIMARY GEAR 80 100 N m 8 0 10 0 kg m 58 72 ft lb 8 12N m 0 8 1 2 kg m...

Page 91: ...x 27 mm Driver Attachment 37 x 40 mm Pilot 35 mm 7 2 STANDARD 14 000 14 043 mm 0 5512 0 5524 in 13 957 13 984 mm 0 5495 0 5506 in 38 100 38 162 mm 1 5000 1 5024 in 38 036 38 075 mm 1 4975 1 4990 in 24...

Page 92: ...sticking Clutch lever too hard 5 Plates warped 1 Sticking piston s 2 Clogged hydraulic system Excessill B leyer pressure 1 Hydraulic system sticking Clutch slips 2 Ufter mechanism damaged 1 Hydraulic...

Page 93: ...Do not mix different types of fluid since they are not compatible Close the bleed valve fill the reservoir and install the diaphragm To prevent piston overtravel and clutch fluid see page keep a 20 m...

Page 94: ...e upper and the lower levels CLUTCH MASTER CYLINDER DISASSEMBLY Drain dutch fluid from the hydrauli c system Remove the rear view mirror and dutch lever Disconnect the clutch switch wires and remove t...

Page 95: ...ster cylinder 1 0 Check the master cylinder for scores scratches or nicks SERVICE LIMIT 14 06 mm 0 553 in MASTER PISTON 0 0 INSPECTION Measure the master piston 0 0 SERVICE LIMIT 13 94 mm 0 549 in Che...

Page 96: ...nd install the holder and the two mounting bolts Align the end of the holder with the handlebar punch mark Tighten the top bolt first then the bottom bolt Install the oil hose with the bolt and its tw...

Page 97: ...spilling clutch fluid on painted surfaces to prevent damage to the paint Remove the slave cylinder Remove the piston from the cylinder If piston removal is hard place a shop towel over the piston to c...

Page 98: ...s or damage PISTON 0 0 INSPECTION Check the piston for scoring or scratches Measure the outside diameter of the piston with a micrometer SERVICE LIMIT 38 02 mm 1 497 in CYLI NDER 1 0 INSPECTION Check...

Page 99: ...ne grease or brake fluid before assembly Be certain the piston seal is seated in tile pistOfl groove Place the piston in the cylinder with the oil seal end facing out Install the insulator and slave c...

Page 100: ...e snap ring clutch lifter plate bearing lifter guide and lifter rod Shift the transmission into high gear and apply the rear brake NOTE When the engine is not in the frame shift the transmission into...

Page 101: ...CLUTCH Remove the clutch pressure plate Remove the clutch plates and discs Remove clutch center B and the one way clutch as an assembly Remove clutch center A and washer 7 12...

Page 102: ...service limit CLUTCH DISC Replace the clutch discs if they shOw signs of scor ing or discoloration Measure the thickness of each disc SERVICE LIMIT 3 1 mm 0 12 in Replace any discs that are thinner th...

Page 103: ...nspect the one way clutch for smooth operation Check the rollers for excessive wear Measure the l D of clutch center B SERVICE LIMIT 74 50 mm 12 933 in Measure the 0 0 of the one way clutch inner SERV...

Page 104: ...xhaust pipe clamp bolts Remove the exhaust pipe joint nuts and remove the right exhaust pipe Place a jack or other adjustable support under the engine to support the engine Remove the fou r sub frame...

Page 105: ...H OUTER Check the slots in the clutch outer for nicks cuts or indentations made by the friction discs Check the clutch outer needle bearing for damage or excessive play If the needle bearing is diffic...

Page 106: ...CLUTCH ASSEMBLY Install the clutch outer guide over the mainshaft Install the needle bearing into the clutch outer A lign the holes in the clutch outer with the pins on the oil pump drive sprocket and...

Page 107: ...ft Ib lower 35 45 N m 3 5 4 5 kg m 25 33 ft lbl Install and torQue the engine mount 10 mm nut TORQUE 45 60 N m 4 5 6 0 kg m 33 43 ft lb Install t he right exhaust pipe and tighten the ex haust pipe j...

Page 108: ...into the one way clutch with its grooves facing down Turn it clockwise as you install it Install the one way clutch clutch center B assembly over the mainshaft NOTE Make sure the one way clutch assemb...

Page 109: ...ooves CAUTIO N Do not pull c ulh center B out after installing the discs and plates or plate will all between clutch centen A and B This will cause the clutch to nor this engage Install the clutch pre...

Page 110: ...n servicing the clutch with the engine out of the frame shift the transmi ssion into gear and hold the output shaft with the HOLDER 07923 6890101 TORQUE 45 55 N m 14 5 5 5 kg m 33 40 ft Ib Install the...

Page 111: ...ap ring Install a new gasket onto the clutch cover Install the clutch cover and tighten t he cover bolts TORQUE 8 12 N m 0 8 1 2 kg m 6 9 ft Ib Fill the crankcase with the recommended oil page 2 3 7 2...

Page 112: ...the primary gear Align the center of two pulse generator plate teeth with the flat of the crankshaft serrations and install the plate Measure the pulse coil air gap and adjust if nealS sary COIL AIR G...

Page 113: ...ALTERNATOR STARTER CLUTCH 8 0 18 25 N m 13 18 ft Ib 1 B 2 5 kg m n _ 40N_ m 13 0 14 0 kg m 94 101 ft Ib 8 12 N m 0 8 1 2 kg m 6 9 ft Ib...

Page 114: ...ter driven gear 0 0 57 710 57 840 mm 2 2720 2 2772 in Starter clutch outer I D 74 414 74 440 mm 2 9297 2 9307 in TORQUE VALUE 8 1 8 2 8 3 8 4 8 5 8 6 8 6 SERVICE LIMIT 57 60 mm 2 268 in 74 50 mm 2 933...

Page 115: ...DVAL Hold the flywheel with the flywheel holder and remove the f lywheel bolt NOTE The flywheel bolt has left hand threads Aemove the flywheel with the rotor puller ALTERNATOR STARTER CLUTCH FLYWHEE L...

Page 116: ...until it stops Then remove the needle bearing from the gear Remove the driven gear Remove the six torI bolts attaching the starter clutch to the flywheel and remove the starter clutch and clutch outer...

Page 117: ...bolts and tighten the bolts with a torx bit TORQUE 18 25 N m 11 8 2 5 kg m 13 18 ft lb Install the starter driven gear and needle bearing over the crankshaft Install the starter reduction gear drive...

Page 118: ...l to the flywheel bolt threads and molybdenum grease to the bolts flange seating surface Install the bolt hold the flywheel with the flywheel holder and torque the bolt TORQUE 130 140 N m 13 0 14 0 kg...

Page 119: ...rotector and tighten tile two bolts TORQUE 8 12 N m 0 8 1 2 kg m 6 9 ft lb Install the left foot peg and gear shift pedal Install the clutch slave cylinder page 7 10 Connect the alternator coupler Ins...

Page 120: ...GEARSHIFT LINKAGE a 7 1 tI OO 9 0...

Page 121: ...in the frame 9 1 9 2 9 3 9 4 If the shift forks drum and transmission require servicing remove the engine and separate the crankcase section 13 TROUBLESHOOTING Hard to shift 1 Improper clutch hydrauli...

Page 122: ...rankcase cover and clutch as semblv section 7 Remove the oil pipe Remove the oil pump driven sprocket bolt Remove the oil pump drive chain drive and driven sprockets Remove the snap ring spring and ge...

Page 123: ...cam plate Remove the dowel pin and the shift drum center Remove gear shift spindle B Remove the flywheel and starter clutch asse mbly section 8 Remove the shift spindle guide plug from the left crankc...

Page 124: ...lign the holes in the shift drum and drum center and install the drum center and dowel pin Align the teeth of gear shift spindle A and B as shown and install shift spindle B Install the shift spindle...

Page 125: ...en the cam plate bolt securely Install the drum stopper arm spring and bolt Tighten the bolt securely Install the shift spindle plate spring and snap ring oller shift spindle B Rotate the gearshift sp...

Page 126: ...n and tighten the driven sprocket bolt securely The driven sprocket IN mark must face the crankcase Install new a rings on the ends of the oil pipe Install the oil pipe Install the clu tch assembly an...

Page 127: ...CYLINDER HEADiVALVE _ 7 TORQUE 20 25 N m 2 0 2 5 kg m 14 18 ft lb TORQUE 10 15 N m S 1 0 1 5kg m 0o t2 7 11 ft Ib ro n 10 0 TORGUE 10 14 N m 1 0 1 4 kg m 6 9 ft lb...

Page 128: ...s in the head covers with fresh engine oil as described in this section To service the cylinder heads the engine must be removed from the frame See Section 5 for removal and installation of the engine...

Page 129: ...with a sounding rod or stethoscope Low Compression 1 Valves hydraulic tappet locked Engine will not start Depress hydraulic tappet Chatter noise insufficient air bleeding noise will stop after about 1...

Page 130: ...Carefully remove the rocker arm covers to keep the hydraulic tappet assist springs from falling into the cylinder head Remove the cylinder head coven and cam sprocket covers NOTE The hydraulic tappet...

Page 131: ...e crankcase cover Cylinder Rotor timing mark Front F T Rear R T Measure the amount of the cam chain tensioner pro jects as shown Replace the cam chain with a new one if the projection exceeds 9 0 mm 0...

Page 132: ...ge with the cam chain Rotate the crankshaft clockwise half a turn 180 and remove the cam chain from the sprocket Hang the cam chain on the camshaft behind the camshaft flange and remove the cam sprock...

Page 133: ...in CAM LOBE HEIGHT Using a micrometer measure the height of each cam lobe SERVICE LIMITS IN EX 36 38 mm 1 4282 in Wipe any oil from the journals Lay a strip of plast i gauge lengthwise on top of each...

Page 134: ...dth of each plastigauge The widest thickness determines the oil clearance SERVICE LIMITS CENTER 0 07 mm 0 0027 in BOTH ENOS 0 07 mm 0 0027 in When the service limits are exceeded replace the camshaft...

Page 135: ...rom the rocker arm shaft hole Thread 6 mm bolts into the plugs on the cam chain side Then pull on the bolts with pliers to remove the plugs Remove the rocker arm shafts and rocker arms 10 8 IN ROCKER...

Page 136: ...pet as follows Attach the Hydraulic Tappet Bleeder to the hydrau lic tappet and compress and extend the hydraulic tappet slowly in a jar filled with kerosene NOTE Hold the hydraulic tappet upright whi...

Page 137: ...ASSEMBLY Remove the valve spring cotters retainers springs and valves with the Valve Spring Compressor CAUTION To prevent loss of tension do not com press the valve springs more than necessary to remo...

Page 138: ...head gasket surfaces NOTE Avoid damaging the gasket surfaces Gaskets will come off easier if soaked in solvent INSPECTION CYLINDER HEAD Check the spark plug hole and valve areas for cracks Check the c...

Page 139: ...in NOTE Ream the guides to remove any carbon de posits before checking clearances Measure and record each valve guide 1 0 SERVICE LIMIT 6 66 mm 0 2622 in Subtract each valve stem 0 0 from the correspo...

Page 140: ...ombustion chamber side of the cylinder head NOTE I Avoid damaging the cylinder head Drive new guides in from the rocker arm side of the cylinder head VALVE GUIDE PROJECTION ABOVE CYLINDER HEAD IN 14 S...

Page 141: ...aust valves thoroughly to remove carbon deposits Apply a light coating of Prussian Blue to each valve seat Lap each valve and seat using a rubber hose or other hand lapping tooL Remove and inspect eac...

Page 142: ...e a 45 degree cutter to remove any roughness or irregularit ies from the seat NOTE Reface the seat with a 45 degree cutter when a valve guide is replaced Use a 32 degree cutter to remove the top 1 4 o...

Page 143: ...hrough 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 seal ing If the contact area is too high o...

Page 144: ...the valve spring seat and a new stem seal l ubricate each valve stem with molybdenum disul fide grease and insert the valve into the valve guide To avoid damage to the stem seal turn the valve slowly...

Page 145: ...o the comprenor will not touch the cylinder head Tap the valve stems gently with a soft hammer to firmly seat the cotters NOTE Support the cvlinder head above the work bench surface to prevent possibl...

Page 146: ...washer CAMSHAFT INSTALLATION l ubricate the camshaft journal surface of the cylinder head with molybdenum disulfide grease Run the camshaft through the cam chain and install the cam sprocket on the s...

Page 147: ...that the timing marks on the cam sprocket align with the top of the cylinder head CAUTI ON Afrer inJlalling the front cylinder turn rhe cranksho r clockwise 225 rum and rhen install rhe rear cylinder...

Page 148: ...t slots are facing up Rotate each rocker shaft so that the arms are moved in toward the center of the cover NOTE Put your finger on the rocker arms as you rotate the shaft to be sure which way the are...

Page 149: ...ft clockwise and align the timing mark F T with the index mark Install the gear holder on the cylinder head cover using the 6 mm bolt and place the dial indicator on the assist shaft Measure the assis...

Page 150: ...Install the hydraulic tappets into the cylinder head CAUTI ON Do not tilt the hydraulic tappets keep them as upright as possible Install the dowel pins and grommets NOTE Apply a liquid sealant to the...

Page 151: ...eat the preceeding step and recheck NOTE Both intake rocker arm shafts should fall within the same limits Torque the cylinder head cover bolts and cap nuts NOTE Tighten the bolts and cap nuts in a cri...

Page 152: ...nd align the timing mark T D C on the rotor with the index mark on the right crankcase Make sure the rocker arm can be slided side way_ Install the cam sprocket cover with a new gasket Torque the 8 mm...

Page 153: ...ghten to the specified torque TORQUE 10 14 N m 1 0 1 4 kg m 6 9 ft ib Coat new water pipe Q rings with oil and place them on the water pipe Connect the water pipe and t ighten to the specified torque...

Page 154: ...CYLINDER PISTON 11 0...

Page 155: ...0118 3 0124 76 66 3 018 Out af round 0 05 0 002 Taper 0 05 0 002 Warpage 0 10 0 004 Pistons piston rings Piston skirt 0 0 83 79 470 79 490 3 1287 3 1295 79 35 3 124 and piston pins Piston skirt 0 0 Af...

Page 156: ...sket 3 Incorrect valve timing Excessive smoke 1 Worn cylinder and piston rings 2 Improperly installed piston rings 3 Damaged piston or cylinder Overheating 1 Excessive carbon deposits on piston or com...

Page 157: ...dowel pins and the cam chain guides Remove the cam chain tensioner bolt and sealing washer Remove the union bolts and remolle the right and left water pipes from the cylinders by pulling them out by h...

Page 158: ...gasket will come off easier if it is soaked in olvent CY LI NDER INSPECTION Inspect the cylinder bores for wear or damage Measure the cylinder 1 0 at three levels in X and Y axis SERVICE LI MIT 83 79...

Page 159: ...ions shown SERVICE LIMIT 0 10 mm 0 004 in PISTON REMOVAL Place a shop towel into the crankcase and remove the piston pin clips NOTE I Do not tet the clips fall into the crankcase Push the piston pin o...

Page 160: ...excessive wear or carbon build p NOTE Do not damage the piston rings when remoy ing them Measure the top and second piston ring end gaps using a piston push the ring into the cylinder squarely and ma...

Page 161: ...the piston pin to piston clearance SERVICE LIMIT 0 25 mm 0 010 in PISTON RING INSTALLATION Clean the piston domes ring lands and skirts NOTE Insert the outside surface of the ring into the proper ring...

Page 162: ...and piston rings during assembly Stagger the ring end gaps 180 0 apart from each other as shown NOTE To install the oi ring install the spacer first then install the side rails After installing the ri...

Page 163: ...piston and connecting rod with the piston and piston pin clips as shown NOTE Install the pistons with the marking IN facing towards the inlet side After installing the piston pin clips make sure that...

Page 164: ...ly is returned to its original position as noted during removal NOTE Be careful not to damage the piston rings during assembly Apply oil to new water pipe Q rings and place them on the water pipes Con...

Page 165: ...rs while pulling up on the tensioners Install the dowel pins Install new gaskets Clean the cvlinder contacting faces of the cylinder heads of gasket material and carbon deposits Install the cylinder h...

Page 166: ...CRANKCASE BmmBOLTS r 20 25 N m 2 0 2 5 kg m 14 18 ft lbJ 6mm SCREW 7 11 N m 0 7 1 1 kg m 5 8 ft lb 12 0 8mm BOLT 20 25 N m 2 0 2 5 kg m 14 18 ft lbl mm SOCKET BOLT 20 25 N m 2 0 2 5 kg m 14 18 ft Ibl...

Page 167: ...he crankcase must be separated TORQUE VA LUES 8 mm bolt 8 mm socket head bolt 20 25 N m 2 0 2 5 kg m 14 18 ft lbl 20 25 N m 2 0 2 5 kg m 14 18 ft lbl 12 1 12 2 12 4 6 mm bearing set plate screw 10 mm...

Page 168: ...er motor Aefer to section 9 Refer to section 10 Refer to section 11 Refer to section 20 Remove the cam chain tensioners cam chains and primary drive gear Remove the mainshaft countershaft and shift dr...

Page 169: ...crankcase 8 mm and 6 mm bolts NOTE To prevent a distorted crankcase loosen the bolts in a crisscross pattern in 2 3 steps Remove the left crankcase 8 mm and 6 mn bolts Remove the 8 mm socket head bol...

Page 170: ...ion 13 Section 13 Sect ion 13 Section 13 Refer to section 13 for crankcase bearing inspection and replacement CRANKCASE ASSEMBLY Remove all traces of gasket mating surfaces from the crankcase halves A...

Page 171: ...the 6 mrn bolt to the standard torque Tighten the right crankcase 8 mm bol ts in the sequence shown in 2 3 steps to the specified torque TORQUE 20 25 N m 2 0 2 5 kg m 14 18 ft Ibl NOTE The bolts 1 thr...

Page 172: ...the 6 mm screws Install the primary drive gear on the crankshaft with the flat on the drive gear aligned with the flat on the crankshaft splines Install the cam chain over the drive gear Install the l...

Page 173: ...CRANKSHAFT TRANSMISSION 13 0 35 45 N m 25 33 ft Ib 3 5 4 5 kgr tJ 16 20 N m 12 14 ft Ibl 11 6 2 0 m 41 45N m 3033ft lb 4 1 4 5 kg m...

Page 174: ...5 21 25 N m 2 1 2 5 kg m 15 18 ft Ibl 35 45 N m 3 5 4 5 kg m 25 33 ft Ib 90 110N m 9 0 11 0 kg m 65 80 ft lb TRANSMISSION REMOVAL OUTPUT GEAR SHIFT FORK SHIFT DRUM CRANKCASE BEARINGS REPLACEMENT 13 1...

Page 175: ...CATI ONS Unit mm in ITEM STANDARD SERVICE LIMIT Crankshaftl Connecting rod big end side clearance 0 10 0 25 0 0039 0 010 0 40 0 0157 connecting rod Connecting rod small end 1 0 20 020 20 041 0 7882 0...

Page 176: ...kg m 25 33 ft lb 35 45 N m 3 5 4 5 kg m 25 33 ft lbl 21 25 N m 2 1 2 5 kg m 15 18 ft lbl 21 25 N m 2 1 2 5 kg m 15 18 ft lb 30 40 N m 3 0 4 0 kg m 22 29 ft lb 70 80 N m 7 0 8 0 kg m 51 58 ft lb 90 1 1...

Page 177: ...ing holder O ring replace ment page 13 26 Tooth contact adjustment page 13 30 Oilorifice and O ring inspection and replace ment Aemove the 8 mm cap nuts and sealing washers Remove the output gear case...

Page 178: ...dowel pins Remove the crankshaft CONNECTI NG ROO REMOVAL Check the connecting rod side clearance SERVICE LIMIT 0 40 mm 0 0157 in Remove the connecting rod bearing caps and note their locations NOTE T...

Page 179: ...eassembly Measure the connecting rod small end 1 0 SERVICE LIMIT 20 09 mm 0 7909 in CRANKSHAFT INSPECTION Place the crankshaft on a stand or Vee blocks Set a dial indicator on the main journals Rotate...

Page 180: ...avoiding the oil hole Install the bearing caps and rods on the correct crankpins and tighten them evenly TORQUE 41 45 N m 4 1 4 5 kg m 30 33 ft lb NOTE Do not rotate the crankshaft during inspec tion...

Page 181: ...arance between the main journal and the main bearing SERVICE LIMIT 0 06 mm 0 0024 in BEAR ING SELECTION If oil clearance is beyond tolerance select repalce ment bearings as follows CONNECTING ROD BEAR...

Page 182: ...08 46 ooBmm 46 o16mm CRANK A 42 982 F Pinkl Yellowl PINO D 42 990mm COO S 42 974 IY lIowl 0 Greenl 42 982mm BEAR ING INSERT THICKNESS o Green 1 495 1 499 mm 0 0589 0 0590 in E Yellow 1 491 1 495 mm 0...

Page 183: ...R ING INSERT THICKNESS BROWN 1 989 1 999 mm 0 0783 0 0787 in BLACK 1 994 2 004 mm 0 0785 0 7798 in BLUE 1 999 2 009 mm 0 0787 0 0791 in MAIN JOURN AL BEARI NG REMOVAL Pres lhe main bearing out of the...

Page 184: ...s and caps NOTE Align the boss on the bearing with the groolle in the rod or cap Apply molybdenum disulfide grease to the bearings Install the rods and caps on the crankshaft Be sure each part is inst...

Page 185: ...crankcase page 12 2 lay the left crankcase down on it s outer surface Remove the crankshaft page 13 5 Remove the shift drum shaft and shift drum from the left crankcase Remove the final gear Remove t...

Page 186: ...Hicient lubri cation Measure the 1 0 of each gear SERVICE LIMIT MS M6 gears Cl C2 C3 gears C4 gear 28 04 mm 1 104 in 28 04 mm 1 104 in 29 04 mm 1 143 in Measure the 1 0 and 0 0 of each gear bushing SE...

Page 187: ...MS 6 gear to MS 6 bushing 0 10 mm 0 004 in 0 06 mm 0 002 in 0 10 mm 0 004 in 0 10 mm 0 004 in 0 10 mm 0 004 in 0 10 mm 0 004 in 0 10 mm 0 004 in M5 bushing to M5 shaft C1 gear to Cl bushing Cl bushing...

Page 188: ...MS r 9 Align the ho e I h ft when instal 10 the mams a hole In ft f movement or Countenha for freedom 0 k the gears Chec he shaft rotation on t d in the grooves rings are seate Check that the snap FR...

Page 189: ...g the C5 gear Install the C4 gear recess facing the crankcase bearing not the C6 gear Align the lock washer tab into the thrust washer groove between the C5 and Cl gears and the C2 and C3 gears 13 16...

Page 190: ...Je the nuts and the set plate Pull the output gear assembly off the crankcase Remove the gasket and dowel pin OUTPUT DRI VE GEAR DAMPER ASS Y REMOVAL Separate the output drive shaft and bearing holder...

Page 191: ...ck nut INSTA LLATI ON Install the damper spring and damper cam on to the output drive shaft NOTE Seat the damper spring on the bearing lock nut Attach the spring compressor in the output drive shaft t...

Page 192: ...eat this pro cedure once more Compare the difference of the three measurements DIFFERENCE OF MEASUREMENTS SERVll e LIMIT 0 10 mm 0 004 in If the difference in measurements exceeds the limit it indicat...

Page 193: ...he shah Unstake the inner bearing race lock nut with a drill or grinder Be careful that metal particles do not enter the bearing and the threads on the shaft are not damaged Remove the inner bearing r...

Page 194: ...he bearing holder OUTPUT DRIVE SHAFT BEARING REPLACEMENT NOTE The d rive shaft must be removed before replacing the bearing Place the bearing holder in a vise wi th soft jaws or a shop towel NOTE Do n...

Page 195: ...ock nut to the specified torque value TORQUE 90 110 N m 9 0 11 0 kg m 65 80 ft Ib Torque wrench scale reading 80 100 N m 18 0 10 0 kg m 58 72ft lbl Then stake the new nut 13 22 ATTACHMENT 52 x 55 mm 0...

Page 196: ...ve shaft into the bearing Support the inner bearing race using the special tool NOTE Place the pilot s threaded end into the final drive shaft Install the stud bolts into the beari ng holder Place the...

Page 197: ...take the inner and outer lock nuts After 83 Install the O ring Place the output drive shaft bearing holder and correct shim into the output gear case Install the cap nuts and sealing washers Tighten t...

Page 198: ...e the output driven gear case into a vise Unstake and remove the output driven gear bearing inner race lock nut Remove the driven gear bearing holder mounting bolts and remove the shim gear and holder...

Page 199: ...utput driven gear oil seal from the output gear case Place the output driven gear bearing holder into a vise with soft jaws Unstake and remove the output driven gear bearing outer race lock nut from t...

Page 200: ...llation Place the bearing holder into a vise with soft jaws Install and tighten a new bearing outer race lock nut to the specified torque value TORQUE 90 110 N m 9 0 11 0 kg m 65 80 ft lb Torque wrenc...

Page 201: ...port the inner bearing race using the special tools Insta ll the O ring and correct shim Attach the bearing holder onto the gear case with the four hex bolts Tighten the bolts in a crisscross pattern...

Page 202: ...T Head the output gear case around the driven shaft bearing to 80 C 176 F CAUTION Always wear gloves when hOl dling Q heated gear case Remove the bearing with the bearing remover CRANKSHAFT TRANSMISSI...

Page 203: ...standard shims Rotate the drive gear several times in the normal direction of rotation Check the gear tooth contact pattern after removing the drive gear Contact is normal if Prussian Blue is transfer...

Page 204: ...ess of the shim is changed by 0 10 mm 0 04 in OUTPUT DRIVEN GEAR ADJUSTMENT SHIM A 0 40 mm 0 016 inl B 0 45 rnm 0 018 in C 0 50 mm 0 020 inl STANDARD 0 0 55 mm 0 022 in E 0 60 mm 0 024 inl Check the b...

Page 205: ...up SHIFT FORK SHIFT DRUM SHIFT FORK DISASSEMB LY Remove the outer shift forks from the shaft Bend the lock washer tab down and remove the center fork mounting bolt and fork GEAR SHIFT DRU M AND SHIFT...

Page 206: ...rication Measure the shift fork shaft 0 0 at the right and left shift fork surfaces SERVICE LIMIT 13 90 mm 0 547 in Measure the right and left shift fork LD and the shift fork claw thickness SERVICE L...

Page 207: ...ard the left CRANKCASE BEARINGS REPLACEMENT LEFT CRANKCASE BEARINGS Heat the left crankcase around the mainshaft and counter shaft bearings to saoe 176 F CAUTION Always wear gloves when Iwndling a het...

Page 208: ...kcase with the following tools Main shaft Attachment 62 x 68 mm 07746 0010500 Pilot 25 mm 07746 0040600 Driver 07749 0010000 Counter shaft Output drive shaft Driver 07749 0010000 Attachment 07946 3710...

Page 209: ...cal and secure it Install the shift fork mainshaft and countershaft together as an assembly Install the shift drum aligning the grooves with the boss of each shift fork Install the shift drum shaft wi...

Page 210: ...DRIVE TRAIN 8 mm 23 28 N m 2 3 2 8 kg m 17 20 ft b 10 mm 45 50 N m 14 0 4 5 5 0 33 36 ft lb 100 120 N m 10 12 kg m 72 87 I 100 120 N m 10 12 kg m 72 87 ft lb _ 60 70 N m 6 0 7 0 kg m 43 51 ft lb...

Page 211: ...ill be less than the torque actually applied to the lock nut The specification given is the actual torque applied to the lock nut not the reading on the torque wrench when used with the lock nut wrenc...

Page 212: ...793 1 4630200 and 07931 MBOOOOO or 07935 MBOOOOO 07924 ME90000 07931 4630300 or 07947 3710101 and 07746 0010200 07973 4630200 07936 3710400 07749 0010000 07746 0010300 07746 0010400 07746 0010100 0774...

Page 213: ...case attaching nuts and remove the gear case from the swingarrn DRIVE SHAFT REMOVAL Separate the drive shaft from the gear case by gently revolving the shaft in a circular motion while tugging slight...

Page 214: ...op ring UNIVERSAL JOINT REMOVAL INSTALLATION Remove the swingarm page 16 13 Remove the universal joint from the engine output shaft Inspect the universal joint bearings for excessive play or damage Ap...

Page 215: ...If the ring gear stays in the cOlier do the following Place the cover in a press with the ring gear down Make sure the cover is secrelv supported Press the ring gear out of the cover with driver 0774...

Page 216: ...cover and press in a new oil seal PINION GEAR REMOVAL Install the pinion joint holder onto the pinion joint and remove the pinion shaft nut Remove the tool and pinion jOint 14 6 ATTACHMENT 32 x 35 mm...

Page 217: ...pinion retainer wi th the pinion retainer wrench Pull the pinion assembly off with the pinion puller DRIVE TRAIN LOCK NUT WRENCH PINION PULLER ATTACHMENT KIT PINION PULLER 07931 4630200 and 07931 MBO...

Page 218: ...the same tool Remove the pinion adjustment spacer PINION RETAINER 01 L SEAL REPLACEMENT Remove the O ring and oil seal from the pinion retainer Drive a new oil seal into the retainer Coat a new O ring...

Page 219: ...ndling the gear it has been healed Use bearing remover 35 mm 07936 37 10400 to re move ring gear case bearing Remove the ring gear shaft oil seat Drive a new oil seal into the case using the special t...

Page 220: ...R ASSEMBLY Install the original pinion gear spacer NOTE When the gear set pinion bearing and or gear case has been replaced use a 2 0 mrn thick spacer Press the bearing onto the pinion gear shaft with...

Page 221: ...spacer onto the ring gear NOTE If the gear set pinion bearing ring gear bear ing and or gear case is replaced install a 2 0 mm thick spacer Place the ring gear bearing over the ring gear shaft Place a...

Page 222: ...0 60 mm 0 012 0 024 in Remove the ring gear If the clearance exceeds the service limit heat the gear case cover to approxi mately SO C 17SoF and remove the stop pin by tapping the cover Abwys wear lol...

Page 223: ...n gear teeth for a gear tooth contact pattern check Place the wave washer and ring gear into the gear case Apply gear oil to the lip of the oil seal on the gear case cover and install the gear case co...

Page 224: ...place the pinion spacer Replace the pinion spacer with a thicker one if the contacts are too high toward the face Replace the pinion spacer with a thinner one if the contacts are too low to the flank...

Page 225: ...re once more Compare the difference of the three measurements DIFFERENCE OF MEASUREMENT SERVICE LIMIT 0 10 mm 0 004 in If the difference in measurements exceeds the limit it indicates that the bearing...

Page 226: ...e oil seal lip contact surface of the pinion jOint and install the pinion jOint Install the pinion joint holder tool and tighten the pinion nut TOROUE 100 120 N m 10 12 kg m 72 87 ft lb Remove the pin...

Page 227: ...grooves NOTE Make sure that the stop ring is seated properly by pulling on the drive shaft lightly Be careful not to damage the drive shaft oil seal Insert the drive shaft assembly into the swingarm...

Page 228: ...bl T ighten the axle pinch bol t TORQUE 20 30 N m 2 0 3 0 kg m 14 22 ft Ib Install the left shock absorber page 16 12 Place the motorcycle on its center stand Make sure that the drain bolt is tightene...

Page 229: ...13 20 ft Ib g m 18 28 N m 11 8 2 8 k m _____ 13 20 ft Ib 55 65 N m 5 5 6 5 kg m 40 47 ft Ib 15 0 o M _N o 9 13 N m IfI 0 9 1 3 kg m 7 9 ft lb 45 55 N m 4 5 5 5 kg m 33 40 ft lb 15 30N m 1 5 3 0 kg m f...

Page 230: ...p Steering stem nut Brake disc Front fork top pinch bolt Front fork bottom pinch bolt Front fork brace socket bolt Radial Axial STANDARD 0 3 mm 0 01 in max 0 3 mm fO Ol in max 465 6 mm 18 33 in 467 5...

Page 231: ...2 Worn front wheel bearings 3 Faulty tire 4 Axle nut tightened properly Soft suspension 1 Weak for springs 2 Insufficient fluid in front forks 3 Front fork air pressure incorrect Hard suspension 1 In...

Page 232: ...ead light CASE REMOVAL INSTALLATION Disconnect the wire connectors in the headlight Remove the headlight case mounts and headlight Install the headlight case in the reverse order of re moval Align the...

Page 233: ...aled beam unit from the rim Assemble the headlight in the reverse order of dis assembly After installation adjust the headlight aim page 3 1S IGNITION SWITCH REMOVA l INSTA LLATION Remove the headligh...

Page 234: ...nsert the ignition key and turn it to between the ON and OFF detent positions Push in the lugs in the slots and pull the contact base from the switch Assemble the ignition switch in the reverse order...

Page 235: ...spect the wiring for an open or short circuit or check for loose connec tions REMOVAL Remove the headlight and case page 15 31 Disconnect the speedometer cable from the instru ments Remove the two scr...

Page 236: ...side o the lens Remove the screvvs attaching the indicator panel and panel Remove the screws attaching the fuse holder and fuse holder from the instruments Remove the socket bolts attaching the instru...

Page 237: ...b does not light check the wiring for a short or open circuit or check for loose connections ASSEMBLY INSTA LLATI ON lubricate the speedometer cable with light oil be fore reconnecting Assemble and in...

Page 238: ...MOVA L Disoonnect the clutch switch wires and remove the clutch master cylinder Disconnect the choke cable from the choke lever Remove the left handlebar switch assembly FRONT WHEE L SUSPENSION CHC KE...

Page 239: ...FRONT WHEEL SUSPENSION Remove the right handlebar switch assemblv and disconnect the front brake switch wires Remove the brake master cylinder Remove the handlebar upper holder and handlebars 15 10...

Page 240: ...ver the handlebar Place the handlebar on to the lower holder aligning the punch mark with the upper face of the lower holder Install the upper holder tighten the forward bolts first then tighten the r...

Page 241: ...bolt Install the right handlebar switch assembly and con nect the brake light switch wires Connect the choke cable to the choke lever and instali the clutch master cylinder Align the end of the holder...

Page 242: ...dometer cable Remove the left brake caliper mounting bolts and remove the caliper from the fork leg NOTE Do not operate the front brake leller after removing the caliper To do so will cause difficulty...

Page 243: ...FRONT WHEEL SUSPENSION DISASSEMBLY Remove the brake disc mounting bolts and discs Remove the side collar and right seal Remove the left seal and speedometer gear retainer 15 14...

Page 244: ...ay SERVICE LIMIT 0 03 rnm 0 001 in WHEEL INSPECTION Check the rim runout by placing the wheel in a truing stand Spin the wheel slowly and read the runout using a dial indicator SERVICE LIMITS RADIAL R...

Page 245: ...unout is 1 2 of the total indicator reading SERVICE LIMIT 0 2 mm 0 01 in ASSEMBLY NOTE The cast wheel has no rim band The front wheel uses a tubeless tire For tubeless tire repair refer to the Honda T...

Page 246: ...g squarely making sure that it is fully seated ahd that the sealed side is facing out Install the speedometer gear retainer into the wheel hub aligning the tangs with the slots Install the left seal I...

Page 247: ...the slots Clean the brake discs with a high quality degreasing agent INSTALLATI ON Fit the calipers over the discs taking care not to damage the brake pads Install the caliper mounting bolts TORQUE 3...

Page 248: ...le pinch bolt to the specified torque TORQUE 18 28 N m 1 8 2 8 kg m 13 20 ft lb Install the speedometer cable into the speedometer gearbox and tighten tile set screw FRONT WHEEL SUSPENSION SPEED DMIET...

Page 249: ...SUSPENSION FRONT FORKS REMOVAL Remove the following parts front wheel brake calipers front fender Remove tile fork brace Loosen the fork upper and lower pinch bolts and remove the front fork tube 15 2...

Page 250: ...ork tube cap CAUTION Be care ul not to damage the fork tube s sliding surface Remove the fork spring spacer and washer Pour out the fork fluid by pumping the fork up and down several times Hold the fo...

Page 251: ...ates from the slider The slider bushing will be forced out by the fork tube bushing Remolle the oil lock piece from inside the slider Remove the oil seal back up ring and slider bushing from the fork...

Page 252: ...d piston for score marks scratches or excessive or abnormal wear Replace any components which are worn or damaged Check the fork piston ring for wear or damage Check the rebound spring for fatigue or...

Page 253: ...the back up ring replace it if there is any distortion at the points shown ASSEMBLY Before assembly wash all parts with a high flash point or non flammable solvent and wipe them off completely BUSH IN...

Page 254: ...2 5 kg m 11 18 ft lb Place the slider bushing over the fork tube and rest it on the slider Put the back up ring and an old bushing or equivalent tool on top Drive the bushing into place with the seal...

Page 255: ...PACITY 467 5 472 5 cc 15 82 15 99 ozs Install the fork spring spring seat and spacer into the fork tube NOTE Note the spring direction the narrow pitches should face toward the top Install and torque...

Page 256: ...calipers front wheel Tighten the front fork brace to the specified torque TORQUE 18 28 N m 1 8 2 8 kg m 13 20 ft Ib Install the bolt caps Fill the fork tubes with air to 0 40 kPa 0 4 0 kg em 0 6 psi C...

Page 257: ...15 6 handlebar 15 9 front wheel 15 131 horns brake hose three way joint steering stem nut front forks page 15 201 fork top bridge Remove the bearing adjustment nut Remove the steering stem top cone r...

Page 258: ...nd dust seal and drive a new bottom cone race into place BALL RACE REPLACEMENT Inspect the top and bottom ball races and replace if worn or damaged Remove the upper ball race with the special tool NOT...

Page 259: ...Drive the upper ball race into the head pipe with the special tools Drive the lower ball race into the head pipe with the special tool INSTALLATION Apply grease to the top ball race and install 18 bal...

Page 260: ...em rotates freely Install the fork top bridge and stem nut Temporarhly install the front forks and tighten the stem nut TOROUE 80 120 N m 8 0 12 0 kg m 58 87 fHb Install the removed parts in the rever...

Page 261: ...RAKE 15 25 N m 1 5 2 5 kg m 11 18 ft Ibl 100 130 N m 00 0 13 0 kg m 72 94 ft Ib 7 10 ft lbl 100 130 N m 10 0 13 0 kg m 72 94 ft lb 16 0 30 40 N m 3 0 4 0 kg m 20 30 N m 2 0 2 0 kg m 14 22 SO 80 N m 6...

Page 262: ...r Slide hammer handle Common Driver Attachment 42 x 47 mm Pilot 17 mm Attachment 32 x 35 mm Shock absorber compressor Wheel bearing remover collet 17 mm Wheel bearing remover expander Remover weight S...

Page 263: ...ion 1 Bent rim 2 Loose wheel bearings 3 Faulty tire 4 Loose axle 5 TIre pressure incOrrect 6 Swingarm bearings worn 7 Worn tires Soft wspension Weak spring s Hard IUspen on Bent shock absorber Suspens...

Page 264: ...ake torque link bolt and disconnect the torque link Remove the brake adjusting nut and the brake rod l oosen the axle pinch bolt and remove the rear axle Move the wheel to the right to separate it fro...

Page 265: ...and distance collar with the special tool INSPECTION AXLE Set the axle in V blocks and read the axle runout with a dial indicator The actual axle runout is 1 2 of the total indicator reading SERVICE...

Page 266: ...L RIM RUNOUT Check the rim for runout by placing the wheel in a truing stand Spin the wheel slowly and read the runout using a dial indicator SERVICE LIMITS RADIAL RUNOUT 2 0 mm 10 08 in AXIAL RUNOUT...

Page 267: ...ng out making sure they are fully seated 16 6 NOTE Use lithium based Multipurpose grease with MoS2 additive as fol lows MOLYKOTE BR2 S manufactured by Dow Corning U S A MULT1PUAPQSE M 2 manufactured b...

Page 268: ...t splil es loosen the final gear case attaching nuts to ease axle installation and to assure proper driven flange alignment Engage the rear wheel with the final drive case making sure the splines are...

Page 269: ...3 18 REAR BRAKE PANEL LINING THICKNESS INSPECTION Measure the rear brake lining thickness SERVICE LIMIT 2 0 mm 0 08 in Replace the brake shoes if thinner than the service limit DISASSEMBLY Remove the...

Page 270: ...all the felt seal return spring and wear indicator Install the brake arm aligning the punch marks and tighten the brake arm bolt TORQUE 24 30 N m 2 4 3 0 kg m 17 22 ft Ib REAR WHEEL SUSPENSION BRAKE 1...

Page 271: ...move the shock absorber DISASSEMBLY Replace base and guide of shock compressor PIN 07959 3290001 with attachments 07959 MB10000 Place the collar PIN 52486 463 0000 or equiva lent in the shock s bottom...

Page 272: ...irection shown and remove the compressor SPR ING FREE LENGTH Measure the rear shock absorber spring free length SERVICE LIMIT 211 mm 8 3 in ASSEMB LY Place the spring adjuster the spring lower seat sp...

Page 273: ...locking agent to the damper rod threads and screw the upper joint on Hold the upper ioint in a vise and tighten t he lock nut securely NOTE Check that the lock nut is seated against the rod s bottom t...

Page 274: ...garm pivot caps and loosen the right pivot bolt lock nut Remove the right pivot bolt using the 10 rnm socket bit Remove the left pivot bolt and remove the swing arm Remove the boot from the swingarm P...

Page 275: ...uter races as a set Replace the grease retainer plate when ever it is removed Install new grease retainer plates and drive new bearing outer races into the swingarm pivot INSTALLATION Apply grease to...

Page 276: ...m 7 10 ft lb Move the swingarm up and down several times Retighten the right pivot boh to the specified torque Tighten the lock nut while holding the right pivot bolt TORQUE 100 130 N m 110 0 13 0 kg...

Page 277: ...Ib V 10 05 0 2 kg m 10 14N m 7 10 ft Ibl I l t 25 35 N m 2 5 35 kg m 18 25 ft Ib 17 0 l 25 35 N m J S1z 2 5 3 5 kg m 18 25 ft Ib 130 4 0 kg m 30 40 N m 22 29 ft Ib 30 36 N m 3 0 3 6 kg m 22 26 ft lbl...

Page 278: ...g the motorcycle SPECIF ICATIONS Front disc thickness Front disc runout Front master cylinder 1 0 Front master piston 0 0 Front caliper piston 0 0 Front caliper cylinder 1 0 TORQUE VALUES 8rake hose b...

Page 279: ...ty 3 Hydraulic system leaking 3 Oisc or wheel misaligned Brake lever too hard Brake chatter or squeal 1 Sticking piston s 1 Pads contaminated 2 Clogged hydraulic system 2 Excessive disc runout 3 Pads...

Page 280: ...op operating the lever when fluid stops flowing out of the bleed valve A contaminated brake disc or pod reduces slopping power Discard conlaminaled pads and ckan a contaminated disc with a high BRAKE...

Page 281: ...ut during brake bleeding because this will impair the efficiency of the brake system 1 Squeeze the brake lever oepn the bleed valve 1 2 turn and then close the valve NOTE Do not release the brake leve...

Page 282: ...re even disc pressure Remove the caliper bolt Pillot the caliper up out of the way Remove the pad pin retainer and pull the pad pins out of the caliper Remove the brake pads Position the pad spring in...

Page 283: ...er to depress the pad spring Place the pad pin retainer over the pad pins Push the retainer down to secure the pins Install the pad pin retainer bolt Pivot the caliper down S0 the brake disc is positi...

Page 284: ...ke fluid from the hydraulic system Remove the brake lever and rear view mirror from the master cylinder Disconnect the brake hose CAUTION Avoid spilling brake fluid 011 painted surfaces Place a rag ov...

Page 285: ...g Remove the brake light switch from the master cylinder body jf necessary Clean the inside of the master cylinder and reservoir wi t h brake fluid INSPECTION Measure the master cylinder 1 0 SERVICE L...

Page 286: ...piston cup in brake fluid before assembly CAUTION Wilen installing the cups do not allow the lips to turn imide out Be certain the circlip is seated innly n the groolle Install the pistOf l clip and...

Page 287: ...SASSEMBLY Remove the following pads and pad spring caliper pivot collar and boots pistons from the caliper If necessary apply compressed air to the caliper fluid inlet to get the piston out Place a sh...

Page 288: ...when removing the seals PI STON INSPECTION Check the pistons for scoring scratches or other fau lts Measure the piston diameter with a micro meter SERVICE LIMIT 30 14 mm 1 187 in CY LI NDER INSPECTI...

Page 289: ...and caliper grooves properly Install the pad spring and pads Install the pivot boot INSTALLATION Install the caliper pivot bolt if it was removed TORQUE 30 36 N m 3 0 3 6 kg m 22 26 ft Ib Apply silico...

Page 290: ...TTERY CHARGING SYSTEM 1 __ IGN ITION SWITCH ALTERNATOR GREEN BATTER Y CHARG ING SYSTEM 18 0 RECTIFIER AED WHITE VOLTAGE r SENSOR 1 Ie REGULATOR RECTIFIER B 1 RED l a w FUSE 30A VI GN T ONI 1 SWITCH LA...

Page 291: ...ging If the battery must be charged on the motorcycle disconnect the battery cables keep flames away trom a charging battery The gas produced by a battery will explode If flames or sparks ore near All...

Page 292: ...failure 2 loose battery connection Low power engine running 1 Battery undercharged low fluid level One or more dead cells 2 Charging system failure 18 2 Intermittent power 1 loose battery connection...

Page 293: ...ry must be recharged if the spe cific gravity is below 1 230 The specific gravity varie1 with the tempe rature as shown in the accompanying table Replace the battery if sulfation is evident or if the...

Page 294: ...pre e ed Route the breather tube as shown on the battery caution label After installing the battery coat the terminals with clean grease CHARGING SYSTEM CURRENT TEST NOTE Be sure the battery is in goo...

Page 295: ...T Remove the left side cOlier Disconnect the regulator rectifier couplers Check for continuity between the leads with an ohmmeter NOTE The test results shown are for a positive ground ohmmeter and the...

Page 296: ...GE REGULATOR PERFORMANCE TEST Connect a voltmeter across the battery Ched regulator performance with the engine running The regulator must divert current to ground when battery voltage reaches 14 0 15...

Page 297: ...SYSTEM IGNITION SWITCH 2 2 SPARK PLUGS 19 0 NGINE STOP SWITCH IGNITION COILS SPARK PLUGS PULSE GENERATOR IGNITION COILS 2 2 TO TACHOMETER SPARK UNITS SPAR UNITS IGNITION SWITCH ON OFF PULSE GENERATOR...

Page 298: ...nts can be made SPECIFICATIONS ND NGK Spark plug Standard X24EPR U9 DPR8EA 9 For cold climate below SoC 41 F X22EPR U9 DPR7EA 9 For extended high speed driving X27EPA U9 DPR9EA 9 Spark plug gap 0 8 0...

Page 299: ...oorly connected broken or shorted wires Between ignition switch and engine stop switch Between spark unit and engine stop switch Between spark unit and ignit ion coil Between ignition coil and plug Be...

Page 300: ...the ignition coil wire leads Remove the coils bV removing the attaching bolts CONTINUITY TEST Measure the primary coil resistance RESISTANCE 2 0 ohms Measure the secondary coil resistance with the sp...

Page 301: ...d measure the coil resistance RESISTANCE 480 ohms 10 Between white and yellow leads 1 cyliner Between white and blue leads 2 cylinder PULSE GENERATOR REPLAC EMENT Remove the right crankcase cover and...

Page 302: ...UN IT If the pulse generators ignition coils and wiring are good and the ignition timing is not within specification replace the spark units with new ones and recheck the ignition timing IGNITION SYST...

Page 303: ...C STARTER CLUTCH SWITCH 20 0 STARTER MOTOR NEUTRAL SWITCH STARTER BUTTON 8 ffi BATTERY STARTER RELAY SWITCH IGNITION SWITCH GREEN RED DIODE I NEUTRAL INDICATOR GREEN c u I 3 en CLUTCH J SWITCH a l w z...

Page 304: ...ulty neutral switch 5 Faulty starter relay switch 6 Loose or disconnected wire or cable 7 Clutch diode open Starter motor turns engine slowly 1 Low specific gravity 2 EKcessive resistance in circuit 3...

Page 305: ...St rI ic ng Remove the alternator cover flywheel and starter drive gear section 8 Disconnect the starter motor cable at the motor Remove the starter motor mounting bolts and starter motor o REAR CO E...

Page 306: ...mber of thrust washers Inspect the commutator bars for discoloration Bars discolored in pairs indicate grounded armature coils NOTE Do not use emery or sand paper on the com mutator Check for continui...

Page 307: ...it is shorted to the motor case ASSEMBLY INSTALLATION Assemble the starter motor Align the case notch with the brush holder pin Install the rear cover aligning its slot with the brush holder pin Inst...

Page 308: ...arter relay switch clicks Connect an ohmmeter to the starter relay switch term inals Connect a 12 V battery to the switch cable termi nals The switch is normal if there is continuity CLUTCH DIDDE REMO...

Page 309: ...ELECTRIC STARTER INSPECTION Check for continuity w ith an ohmmeter 20 6 NORMAL DIRECTION CONTINUITY REVERSE DIRECTION NO CONTINUITY...

Page 310: ...des used are indicated throughout this section and on the wiring diagram B Blue Bk Black Sr Brown G Green Gr Grey lB light Blue lG light Gr n o Orange P Pink R Red W White Y Yellow To isolate an elect...

Page 311: ...switch in the crankcase and leave two threads from the bottom Then tighten it to the specif ied torque TORQU E 15 20 N m 11 5 2 0 kg m 11 14 ft Ib NOTE 00 not overtighten the switch to prevent the cra...

Page 312: ...2 Disconnect the wire from the switch and remove the switch Install the neutral and DO switches in the reverse order of removal TORQUE 10 14 N m 11 0 1 4 kg m 1 10 ft Ibl CLUTCH SWITCH Check continui...

Page 313: ...in each chart HEADLIGHT HI LOW SWITCH Headlight Hi Low Switch HI MIDDLE IN 8 W to B BlWtoWto B B W to W LO TURN SIGNAL SWITCH LEFT OFF RIGHT Gr to D 8rtw toLB W 8r W to LB W and om Gr to LB artw to O...

Page 314: ...SWITCH IG Bk W BATs HL Ok R B W Remolle the headlight headlight case and instru ment lower cOlier and disconnect the ignition switch coupler Check cont inuity of terminals on the ignit ion switch coop...

Page 315: ...ht when the ignition switch is turned ON when the amount of fuel in the fuel tank is more than 6 5 liters 1 72 US gal If the warning light goes on check for a short circuit in the wire harness or coup...

Page 316: ...ack and green leads from the thermostatic switch and short them together with a jumper wire as shown Turn the ignition switch on The cooling fan motor should start running If it starts repalce the fan...

Page 317: ...lant Run the engine and measure the change in resistance of the sensor with the engine at the operating temperatures in the chart Temperature 60 0 e 8S D C 140 D F 18SoF Resistance 104 0 43 9 Ohms Rep...

Page 318: ...mperature gauge will be damaged TACHOMETER f the tachometer does not indicate properly check and repair the NO 1 cylinder ignition system If the problem still appears check continuity between the yell...

Page 319: ......

Page 320: ...j CH L J CLUTCH SWITCH ENGINE STOP OIL PRESSURE FAN MOTOR FUSE THERMO FAN MOTOR FUSE BOX IGNITION COIL I IGNITION COIL DRIVE SWITCH SWITCH u LAMP CHECKER RESERVE SENSOR MOTOR MAGNETIC SWITCH FUSE lOA...

Page 321: ...lnCtll HEAOLIGIH SIGNAL STOP LIGHTol1OANJ S W IT01 CONTlMArv IGHTION SWITCH E tCilJ IE STOP SWITCH START II SWITCH TURN SIGNAL SWITCH OIMIolER SIITOI ioC AI I SWITCH Ie otc1 010 FREE HOI MOZ I HLl II...

Page 322: ...23 TECHNICAL FEATURES THE HONDA V TWIN ENGINE OFF SET DUAL PIN CRANKSHAFT HYDRAULIC VALVE ADJUSTER SYSTEM 3 VALVE 2 SPARK PLUGS ONE WAY CLUTCH SYSTEM 23 2 23 3 23 4 23 7 23 7 23 1...

Page 323: ...e clearance i adjustment AUlomatK eam djult r The automatic cam eh in tensioner autom t c lIv compensate for eam chain wear elimlnat ing periodic adjultment and mai te ance services Off wt dual pi c r...

Page 324: ...e they would not contribute to the goal of compactness and light weight So the engineers decided to try off setting the crankshaft pins They sucessfully developed a mathmatical formu la to determine t...

Page 325: ...crankshaft flywheels are precisely weighted in the opposite direction The primary inertia produced by vector F and that of the flywheels oppose each other and cancel out overall primary vibration HYD...

Page 326: ...ic tappet f its in a notch in the bottom of the shaft Togethl f they make the eccentric rocker arm shaft revolve to help maintain zero vallie clearance HYDR AUIUIC TAPPET The tappets are continuously...

Page 327: ...8gainst the tappet plunger This causes a very small amount of oil to leak out of the high pressure chamber bet ween the plunger and body This allows the plunger to absorb the shock from the effects o...

Page 328: ...k plug ONE WAYCLUTCH SYSTEM TECHNICAL FEATURES First time on a production motorcycle this system has been proven on the race circuits of Europe in Hondas Gran Prix road racers Rear wheel lock up cause...

Page 329: ...lock up the one way clutch A will slip just enough to prevent the wheel from locking without losing the benefit of maximum engine compression braking POWER FLOW DIAGRAM CLUTCH DUTE R r FRICTION DISC...

Page 330: ...1 131 141 151 161 m 181 11 121 131 141 151 1 1 21 31 41 SI _ 11 2 131 4 24 1 24 2 24 3 24 3 24 3 24 4 POSSIBLE CAUSE Fuel lenk empty Clogg fu 1 tuM or fu 1 filt Sticking flNt wolve Flul1y fu 1 pump Pl...

Page 331: ...l holes 121 Worn val SUt CORRECT 131 Dammaged tappet t 7 TMt cvlind r eotnprtulon TOO lOW 11 V lva stuck open 121 Worn cylind r nd piston rings NORMAL III lukin hMe gasket 141 Improper v lva liming S...

Page 332: ...OWS FREELY 3 1 Remove carburetor and check for clogged jets NO tLOGGED JETS 4 Check valva timing CORRECT t 6 Check valve spring tension NOT WEAKENED INCORRECT 1 Faulty spark unit 2 Faulty pulse genera...

Page 333: ...CKS POWER 1 Turn the engine for a few seconds ENGINE STARTS with the starter ENGINE DOES NOT START 2 Check oil pressure TOO LOW CORRECT 3 Remove tappet and check INCORRECT 24 4 344 1 Contaminated oil...

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Honda Shadow VT700C, Manual

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