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Honda VT750C2 Shadow Spirit, Service Manual

The Honda VT750C2 Shadow Spirit is a reliable cruiser motorcycle that offers a comfortable and smooth ride. To ensure proper maintenance and care, download the free Service Manual from manualshive.com to access comprehensive instructions and information on servicing your bike. Get your manual today and keep your ride in top condition.

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Summary of Contents for VT750C2 Shadow Spirit

Page 1: ......

Page 2: ...ing Your safely and the safely of others is very important To help you make informed decisions we have provided safely messages and other information throughout this manual Of course it is not practic...

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

Page 4: ...SPECIFICATIONS 1 9 CRANKSHAFT TRANSMISSION SPECiFiCATIONS 1 10 FINAL DRIVE SPECIFICATIONS 1 10 FRONT WHEEL SUSPENSION STEERING SPECIFICATIONS 1 11 REAR WHEEUBRAKE SUSPENSION SPECIFICATIONS 1 11 HYDRA...

Page 5: ...diagonally in incremental steps unless a particular sequence is specified 6 Clean parts in cleaning solvent upon disassembly Lubricate any sliding surfaces before reassembly 7 After reassembly check a...

Page 6: ...ing head The engine serial number is stamped on the right side of the crankcase The carburetor identification number is stamped on the throttle position sensor side ofthe c arburetor body CARBURETOR I...

Page 7: ...tion Label 07 model is located on the r EM IS S I O N C O N T R O L rear fender and frame cross pipe as shown INFORMATION LABEL Canada type EMISSION CONTROL INFORMATION LABEL Except Canada type The Em...

Page 8: ...mm 3 5 in 90 90 21 M C 54S 160 80 15M C 74S EXEDRA G701 BRIDGESTONE D404F DUNLOP EXEDRA G702 BRIDGESTONE D404 DUNLOP Hydraulic single disc Internal expanding shoe 34 30 158 mm 6 2 in 14 liters 3 7 US...

Page 9: ...Multi plate wet Cable operating Constant mesh 5 speeds 1 763 67 38 0 891 33 37 1 058 18117 3 091 34111 2 400 36 15 1 550 31 20 1 174 27 23 0 960 24 25 0 852 23 27 Left foot operated return system 1 N...

Page 10: ...ICATIONS Carburetor identification number 49 states Canada type VE5EA California type VE5ES Main jet Standard 122 High altitude 120 Slow jet 50 Pilot screw Initial final opening See page 6 25 High alt...

Page 11: ...11 0 004 Valve guide projection IN 18 7 18 9 0 736 0 744 above cylinder head EX 17 2 17 4 0 68 0 69 Valve seat width IN EX 0 90 1 10 0 035 0 043 1 5 0 06 Valve spring Free length IN 42 14 1 659 40 58...

Page 12: ...980 0 8648 0 8654 21 95 0 864 Clutch outer guide to mainshaft clearance 0 011 0 049 0 0004 0 0019 0 08 0 003 Clutch outer I D 32 000 32 025 1 2598 1 2608 32 09 1 263 Clutch outer to outer guide cleara...

Page 13: ...C1 C4 0 025 0 075 0 0010 0 0030 0 11 0 004 Gear bushing 1 0 M3 25 000 25 021 0 9843 0 9851 25 04 0 986 I C2 20 000 20 021 0 7874 0 7882 20 04 0 789 Mainshaft 0 0 at M3 bushing 24 959 24 980 0 9826 0 9...

Page 14: ...T Minimum tire tread depth 200 kPa 2 00 kgf cm2 29 psi 2 0 0 08 Cold tire I Up to 90 kg 200 Ibs load pressure I Up to maximum weight capacity Axle runout Wheel rim I Radial runout I Axial 250 kPa 2 50...

Page 15: ...tage 0 7 V minimum Ignition timing F mark 13 BTDC at idle TP sensor I Resistance 20 C 68 F I Input voltage 4 6 kn 5V ELECTRIC STARTER SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE UMIT Starter motor...

Page 16: ...EM Q TY THREAD DlA mm TORQUE N m kgf m Ibf ft REMARKS Left crankcase rear cover socket bolt Exhaust pipe joint stud bolt 1 4 6 8 10 1 0 7 See page 3 11 MAINTENANCE ITEM Q TV THREAD DIA mm TORQUE N m k...

Page 17: ...chain tensioner bolt Camshaft holder bolt Camshaft holder nut Over head cover socket bolt 4 4 8 4 4 6 4 8 6 8 10 7 6 8 8 6 10 to 7 23 2 3 17 47 4 8 35 23 2 3 17 10 to 7 23 2 3 17 23 2 3 17 10 to 7 App...

Page 18: ...Apply engine oil to the threads and seating surface mounting socket bolt Output drive gear bearing lock nut 4 8 3 3 2 23 Apply engine oil to the threads and seating surface inner 1 30 73 7 4 54 Lock...

Page 19: ...m kgf m Ibf ft REMARKS Air cleaner chamber stay mounting screw Air cleaner chamber connecting tube band screw 1 1 5 4 1 1 0 1 0 8 0 7 0 1 0 5 COOLING SYSTEM ITEM Q TV THREAD DIA mm TORQUE N m kgf m Ib...

Page 20: ...Spoke 52 BC4 4 2 0 4 3 1 Front axle bolt 1 14 59 6 0 44 Front axle pinch bolt 2 8 22 2 2 16 Fork center socket bolt 2 10 29 5 3 0 22 Apply locking agent to the threads Fork cap 2 38 22 1 2 3 16 Tire v...

Page 21: ...ith a new one BATTERY CHARGING SYSTEM ITEM Q TV THREAD DIA mm TORQUE N m kgf m Ibf ft REMARKS Battery case cover screw 1 6 1 0 1 0 7 LIGHTS METERS SWITCHES ITEM Q TV THREAD DIA mm TORQUE N m kgf m Ibf...

Page 22: ...ifter arm sliding surface and slit Clutch discs and plates Cylinder wall Cylinder stud bolt threads Valve adjusting screw lock nut threads and seating surface Shift fork shaft whole surface Crankpin b...

Page 23: ...ansmission bearing setting plate bolt threads Cam chain tensioner setting plate bolt threads Stator socket bolt threads Oil filter boss crankcase side threads Left crankcase cover bolt threads marked...

Page 24: ...plines Apply 1 g grease Final drive shaft oil seal lip Apply 0 5 g Final drive shaft splines universal joint side Apply 1 g Final drive pinion joint splines Apply 2 g Molybdenum disulfide Final driven...

Page 25: ...HANDLEBAR SWITCH WIRE FRONT BRAKE HOSE CLUTCH CABLE FRONT TURN SIGNAL LIGHT WIRES FOG LIGHT 3P LEFT HANDLEBAR SWITCH RIGHT HANDLEBAR SWITCH CONNECTOR Option 6P BLACK CONNECTOR 6P RED COI INECTOR LEFT...

Page 26: ...GENERAL INFORMATION RIGHT HANDLEBAR SWITCH WIRE Up t 1 ft side J 30 5 1 23 0 _ _...

Page 27: ...GENERAL INFORMATION CLUTCH CABLE 1 24...

Page 28: ...ORMATION FUEL TANK FUEL TANK BREATHER HOSE BREATHER HOSE Except California type FUEL TANK BREATHER HOSE Except California type WATER HOSE Except California type FUEL VALVE Revised May 2007 2007 2008 V...

Page 29: ...RE 2 GROUND CABLE 3 STARTER MOTOR CABLE 4 ALTERNATOR WIR E 5 NEUTRAUOIL PRESSURE SWITCH WIRE 6 VS SENSOR WIRE 7 IGNITION SWITCH WIRE IGNITION SWITCH WIRE 1 5 4 STARTER MOTOR CABLE 1 1 NEUTRAUOIL PRESS...

Page 30: ...GENERAL INFORMATION FUEL TANK BREATHER California type EVAP CANISTER HOSE to fuel tank CARBURETOR AIR VENT RADIATOR RESERVE TANK BREATHER HOSE SIPHON HOSE HOSE Except California type 1 27 _...

Page 31: ...GENERAL INFORMATION SUB AIR CLEANERS STARTER MOTOR CABLE GROUND CABLE 1 28...

Page 32: ...MOTOR 2P NATURAL CONNECTOR REAR BRAKE LIGHT SWITCH 3P LIGHT GRAY CONNECTOR PAIR COI JTROL VALVE VACUUM HOSE MAIN WIRE HARNESS THROTTLE CABLES FUEL TANK BREATHER California type EVAP CANISTER HOSE Left...

Page 33: ...GENERAL INFORMATION PAIR CONTROL VALVE VACUUM HOSE t Up 450 1 _ Left side i Revised May 2007 2007 2008 VT750C2 1 30...

Page 34: ...GENERAL INFORMATION PAIR CONTROL VALVE PAIR CONTROL VALVE VACUUM HOSES SUB AIR CLEANERS 1 31...

Page 35: ...fornia type EVAP CANISTER HOSE LEFT REAR SPARK PLUG WIRE BRAKEITAIULICENSE LIGHT WIRE RIGHT REAR SPARK PLUG WIRE REAR TURN SIGNAL REGULATOR RECTIFIER LIGHT WIRES TURN SIGNAL RELAY STARTER RELAY SWITCH...

Page 36: ...IGNAL LIGHT 2P ORANGE CONNECTOR rCM 22P CONNECTOR BRAKEfTAIULICENSE LIGHT 3P ATURAL CONNECTOR INSIDE BOOT CONNECTORS ICM IGNITION SWITCH 2P BLACK AND 1P NATURAL CONNECTOR SIDESTAND SWITCH 2P GREEN CON...

Page 37: ...GEI lERAL INFO RMATION LEFT REAR TUR SIGNAL LIGHT IRE BRAKEfT LIGHT AIULICENSE WIRE 1 34...

Page 38: ...OID MAIN WIRE HARNESS VALVE VACUUM HOSE SECONDARYAIR SUPPLY HOSE EVAP CAV CONTROL EAVAPPURGECONTROL VALVE HOSE to fuel VALVE HOSE to canister SIPHON HOSE cut off solenoid valve EVAP PURGE CONTROL VALV...

Page 39: ...GENERAL INFORMATION RADIATOR RESERVE TANK BREATHER HOSE EVAP CANISTER HOSE to fuel tank Revised May 2007 2007 2008 VT750C2 1 36...

Page 40: ...FUEL CUT OFF SOLENOID VALVE VACUUM HOSE to rear PAIR check valve EVAPPURGECONTROL VALVE HOSE to throttle bore EVAP CAN ISTER HOSE EVAPCAVCONTROL VALVE HOSE to sub air cleaner EVAP CAV CONTROL VALVE H...

Page 41: ...HOSE to fuel cut off solenoid valve FUEL CUT OFF SOLENOID VALVE VACUUM HOSE EVAP CAV CONTROL VALVE HOSE to sub air cleaner EVAP CAV CONTROL VALVE HOSE to canister EVAPPURGECONTROL VALVE VACUUM HOSE E...

Page 42: ...of be Dil tributor s Limited Warranty for Honda Motorcycle Emission Control Systems is necessary in order to keep the emissions system warranty in effect SOURCE OF EMIS SIONS The combustion process p...

Page 43: ...the supply of fresh air during engine decel ration thereby preventing afterburn in the exhaust system No adjustments to the secondary air supply system should be made although periodic inspection of...

Page 44: ...eral law prohibits or Canadian provincial law may prohibit the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair...

Page 45: ...MEMO...

Page 46: ...2 TECHNICAL FEATURE OXIDATION CATALYTIC CONVERTER PROTECTION FROM UNBURNED GASOLINE California type only 2 2 2 1...

Page 47: ...changed according to above described conditions The fuel cut off solenoid valve consists of a coil and valve and 3 passages 1 Connection to sub air cleaner atmosphere 2 Connection to throttle bore 3 C...

Page 48: ...is running The engine stop switch is turned to suddenly while the engine is running and the throttle is snapped open addi tional fuel is discharged from the accelerator pump The heat tube is installe...

Page 49: ...MEMO...

Page 50: ...ANELS EXHAUST SYSTEM SERVICE INFORMATION 3 2 TROUBLESHOOTING 3 2 SEAT 3 3 SIDE COVER 3 3 FUEL TANK 3 4 STEERING SIDE COVER 3 5 LEFT CRANKCASE REAR COVER 3 5 FRONT FENDER 3 6 REAR FENDER 3 6 EXHAUST SY...

Page 51: ...s inspect the exhaust system for leaks after installation TORQUE VALUES Seat mounting socket 8 mm bolt 26 N m 2 7 kgf m 19 lbf ft Grab rail mounting bolt 64 N m 6 5 kgf m 47 Ibf ft Fuel tank mounting...

Page 52: ...frame Install the washer 6 mm bolt and tighten the 6 mm bolt securely Install and tighten the 8 mm socket bolts to the specified torque TORQUE 26 N m 2 7 kgf m 19 Ibf ft SIDE COVER REMOVALIINSTALLATIO...

Page 53: ...the washer facing rearward Install and tighten the mounting bolt to the specified torque TORQUE 27 N m 2 8 kgf m 20 Ibf ft Route the hoses Install the removed parts in the reverse order of properly r...

Page 54: ...ers by releasing the damage the boss left cover boss from the right cover slot and slot Installation is in the reverse order of removal NOTE After installation check that the wire harness and cables d...

Page 55: ...g GROMMETS COLLARS Nuts Collars Front fender brace Front fender Grommets Bolts Installation is in the reverse order of removal BRACE REAR FENDER REAR FENDER ASSEMBLY REMOVAL Remove the seat page 3 3 D...

Page 56: ...removal properly page 1 22 TORQUE Grab rail mounting bolt 64 N m 6 5 kgf m 47 Ibf ft REAR FENDER ASSEMBLY REAR FRAME REAR FENDER A REMOVAL Remove the rear fender assembly page 3 6 Release the rear fr...

Page 57: ...the mounting bolt collars grommets and rear fender A Remove the nut and reflector Assembly is in the reverse order of disassembly INSTALLATION Route the wires Installation is in the reverse order of...

Page 58: ...aust pipe protector using a plastic PLASTIC HAMMER hammer and break the lock tab reverse side of the protector and remove it NOTE The rear exhaust pipe protector can be removed wit loutremovingthe exh...

Page 59: ...ont muffler joint pipe Assemble the front muffler and rear muffler Install the muffler stay mounting bolts and tighten the mounting bolts to the specified torque TORQUE 27 N m 2 8 kgf m 20 Ibf ft Tigh...

Page 60: ...SSEMBLY If the exhaust pipejoint stud bolts are loose tighten them Be s ure tb verify the distance from the top of 40 0 40 2 mm the stud to the cylinder head as shown 1 57 1 58 in Install the flanges...

Page 61: ...insert the front exhaust pipe to the front exhaust port Temporarily install the all fasteners Tighten the exhaust pipe joint nuts to the specified torque TORQUE 25 N m 2 5 kgf m 18 Ibf ft Tighten the...

Page 62: ...4 12 ENGINE OIL FILTER 4 13 ENGINE IDLE SPEED 4 15 RADIATOR COOLANT 4 15 COOLING SySTEM 4 15 SECONDARY AIR SUPPLY SYSTEM 4 16 EVAPCONTROLSYSTEM California type only 4 17 FINAL DRIVE OIL 4 18 BRAKE FLU...

Page 63: ...her JASO T 903 standard MA Viscosity SAE 10W 30 Engine oil At draining 2 5 liters 2 6 US qt 2 2 Imp qt capacity At oil filter change 2 6 liters 2 7 US qt 2 3 Imp qt At disassembly 3 2 liters 3 4 US qt...

Page 64: ...7 kgf m 19 Ibf ft 29 N m 3 0 kgf m 21 Ibf ft 12 N m 1 2 kgf m 9 Ibf ft 12 N m 1 2 kgf m 9 Ibf ft 1 5 N m 0 2 kgf m 1 1 Ibf ft 1 5 N m 0 2 kgf m 1 1 Ibf ft 15 N m 1 5 kgf m 11 Ibf ft 10 N m 1 0 kgf m...

Page 65: ...TER R R R R 4 13 til en ENGINE IDLE SPEED I I I I I I I 4 15 RADIATOR COOLANT NOTE 4 I I R 4 15 LU COOLING SYSTEM I 4 15 I I SECONDARY AIR SUPPLY SYSTEM I 4 16 I I EVAP CONTROL SYSTEM NOTE 5 I 4 17 I...

Page 66: ...cables and overhaul and lubricate the throttle grip housing If the throttle grip still does not return properly replace the throttle cables With the engine idling turn the handlebar all the way to the...

Page 67: ...n or damage to the SE valve cable If the operation is lot smooth lubricate the SE valve cable and SE valve knob sliding surface with a com mercially available cable lubricant or a light weight oil To...

Page 68: ...dust adhesive If the motorcycle is used in usually wet or dusty areas more frequent inspections are required Remove the socket bolts and air cleaner cover Remove the air cleaner element from the air...

Page 69: ...arrow mark fac ing down PAIR control valve side and connect the air suction hoses Install the left side cover page 3 3 ARROW MARK CRANKCASE BREATH ER NOTE Service more freqllently when ridden in rain...

Page 70: ...PECTION Check the insulator for cracks or damage and the electrodes for wear fouling or discoloration Replace each spark pj g if necessary RECOMMENDEDSPAFlKPLUG Standard DPR6EA 9 r lgl EPR U9 DENSO Fo...

Page 71: ...he cylinder head cover page 9 6 Remove the socket bolts and alternator cover Remove the timing and crankshaft hole caps FRONT Rotate the crankshaft counterclockwise and align the FT mark on the flywhe...

Page 72: ...is a slight drag on the feeler gauge TOOL Valve adjusting wrench 07908 KE90000 or 07908 KE90100 U S A only with 10 mm offset box wrench Hold the valve adjusting screw and tighten the valve aqjusting s...

Page 73: ...into the timing and crankshaft hole cap grooves Apply grease to the timing and crankshaft hole cap threads Install the timing hole cap and tighten it to the spec ified torque TORQUE 10 N m 1 0 kgf m 7...

Page 74: ...within the indicated range if necessary Coat the O ring with engine oil and install it Reinstall the oil filler cap dipstick For engine oil change page 4 13 ENGINE OIL FILTER NOTE Change the oil with...

Page 75: ...rque TOOL Oil filter wrench 07HAA PJ70101 or 07HAA PJ70100 U S A only or 07HAA PLCA100 U S A only TORQUE 26 N m 2 7 kgf m 191bHt Install the oil drain bolt with a new sealing washer and tighten it to...

Page 76: ...he reserve tank The level should be between the UPPER and LOWER level lines with the motorcycle in an upright position If the level is low remove the reserve tank cap and fill the tank to the UPPER le...

Page 77: ...necessary Check that all water hose bands are tight page 7 10 SECONDARY AIR SUPPLY SYSTEM This model is equipped with a built in secondary air supply system The pulse secondary air sup ply system is l...

Page 78: ...hoses are not kinked pinched or cracked California type shown EVAP CONTROL SYSTEMlCalifornia type only Check the EVAP canister for cracks or damage Remove the following Steering side covers page 3 5...

Page 79: ...the oil filler cap Install and tighten the oil filler cap to the specified torque TORQUE 12 N m 1 2 kgf m 9Ibf ft OIL CHANGE Support the motor cycle securely and raise the rear wheel off th grollnd Re...

Page 80: ...and the caliper pistons are pushed out this accounts for a low reservoir level If the brake pads are not worn and the fluid level is low check the entire system for leaks page 4 20 Turn the handlebar...

Page 81: ...4 If the brake drum 1 0 is within the service limit replace the brake shoes page 16 15 NOTE If no adjustment remains before the wear indicator limit is reached this indicates excessive wear and the br...

Page 82: ...urely After adjusting the brake pedal height check the fol lowing Brake pedal freeplay page 4 21 Rear brake light switch operation page 4 22 BRAKEPEDALFREEPLAV NOTE Perform brake pedal freeplay adjust...

Page 83: ...ht switch so that the light comes on at the proper time Do not turn the Hold the rear brake light switch body and turn the switch body while adjusting nut as required turning the Recheck the rear brak...

Page 84: ...stment is complete tighten the lock nut while holding the adjusting nut Check the clutch operation If the freeplay cannot be obtained or the clutch slips during the test ride disassemble and inspect t...

Page 85: ...ntire shock absorber assembly for leaks damage or loose fasteners Replace damaged components which cannot be repaired Tighten all nuts and bolts For shock absorber service page 16 21 Support the motor...

Page 86: ...side ways with the force to see if the wheel bearings are worn For rear wheel service page 16 6 Inspect the spokes for looseness by tapping them with a screwdriver If a spoke does not sound clearly o...

Page 87: ...in Rear 2 0 mm 0 08 in STEERING HEAD BEARINGS Support the motorcycle securely and raise the front wheel off the ground Check t atthe handlebar moves freely from side to side Mcikesure the control cab...

Page 88: ...5 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM 5 2 OIL PRESSURE INSPECTION 5 5 SERVICE INFORMATION 5 3 OIL PUMP 5 6 TROUBLE SHOOTING 5 4 5 1...

Page 89: ...LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM CAMSHAFT MAINSHAFT COUNTERSHAFT OIL PUMP OIL FILTER PRESSURE RELIEF VALVE 5 2...

Page 90: ...page 4 12 For engine oil and filter change page 4 13 For oil pressure indicator inspection page 21 15 SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Engine oil capacity At draining 2 5 liters...

Page 91: ...valve guide Low oil pressure Oil level low Clogged oil strainer Faulty oil pump Internal oil leak Incorrect oil being used No oil pressure Oil level too low Oil pressure relief valve stuck open Broke...

Page 92: ...set MT37A and adaptor AT77AH Check the oil level and add the recommended engine oil if necessary page 4 12 Start the engine and check the oil pressure at 5 000 rpm OIL PRESSURE 530 kPa 5 4 kgf cm2 n...

Page 93: ...the crankcase page 13 9 Remove the bolts and oil pump assembly from the left crankcase RemoveJhe dowel pin collars and O rings DISASSEMBLY OIL PUMP BODY Remove the oil pipe oil pipe seal and O ring Re...

Page 94: ...inner and outer rotors PRESSURE REblEFVALVE C lcttJe operation of the pressure relief valve by SNAP RING pushing Qnthe piston The snapring is Remo thes ap ing l fasher spring and piston underspring f...

Page 95: ...n snap ring which could easily spin in the groove Check that the snap ring is seated in the groove INSPECTION NOTE Measure each clearance at several points and use the larg st reading to compare the s...

Page 96: ...ts in clean engine oil 13 N m 1 3 kgf m 10 IbHt DRIVE PIN OIL PUMP BODY SNAP RING 7 DOWEL PINS DRIVE SHAFT II JI JER ROTOR OIL PIPE WASHER PIPE SEAL OIL PUMP COVER Install the outer and inner rotors t...

Page 97: ...on the pump body Install and tighten the assembly bolts to the speci fied torque TORQUE 13 N m 1 3 kgf m 10 IbHt Clean the oil strainer Coat a new gasket with engine oil and install it to the pump bod...

Page 98: ...e oil pipe to the pump cover securely PIPE SEAL 71 INSTALLATION et 71 O RING OIL PIPE LUBRICATION SYSTEM Install the dowel pin and collars Coat new O rings with engine oil and install them Install the...

Page 99: ...MEMO...

Page 100: ...HOUSII lG 6 6 CARBURETOR REMOVAL 6 7 CARBURETOR DISASSEMBLYI INSPECTION 6 9 CARBURETOR ASSEMBLy 6 15 CARBURETOR INSTALLATION 6 21 INTAKE MANIFOLD 6 23 PILOT SCREW ADJUSTMENT 6 25 HIGH ALTITUDE ADJUST...

Page 101: ...FUEL SYSTEM COMPONENT LOCATION 27 N m 2 8 kgf m 20 IbHt 6 2...

Page 102: ...For TP sensor inspection page 19 10 SPECIFICATIONS ITEM SPECIFICATIONS Carburetor identifica tion number 49 states Canada type VE5EA California type VE5EB Main jet Standard 122 High altitude 120 Slow...

Page 103: ...mproper SE valve operation Improper throttle operation No spark at plug faulty ignition s stem page 19 5 lean mixture Clogged fuel jets Faulty float valve Float level too low Restricted fuel line Clog...

Page 104: ...ed hose of the EVAPcontrol system Faulty ignition system page 19 5 Afterburn when engine braking is used Lean mixture in stow circuit Faulty air cut off valve Faulty PAIR sy fem Faulty PAIRcontrol val...

Page 105: ...using mounting bolts and collars Disconnect the crankcase breather hose from the air cleaner housing Loosen the air cleaner housing connecting tube band screw Remove the air cleaner housing DISASSEMBL...

Page 106: ...ll the fuel tank page 3 4 CARBURETOR REMOVAL Remove the following FueltaAk page 3 4 Air e1eanerhoiisIng page 6 6 Disconnect the PAIR control valve vacuum hose from the wayjgint Disconnectthe TP sensor...

Page 107: ...ables from the throttle drum and cable stays Disconnect the carburetor air vent California type fuel cut off solenoid valve hose from the carbure tor California type only Disconnect the EVAP purge con...

Page 108: ...uum hoses and VACUUM HOSES fuel hose from the carburetor SE VALVE Loosen the SE valve nut and remove the SE valve fromthe carburetor CARBURETOR FUEL STRAINER Remove the fuel strainer from the carburet...

Page 109: ...s Remove the air cut off valve cover spring and air cut off valve diaphragm from the carburetor body Check the diaphragm for pin holes deterioration or other damage Check the air cut off valve forwear...

Page 110: ...Check the orifice in the accelerator pump cover and carburetor body for clog or restriction Air will leak out of the vacuum chamber if the dia phragm is damaged in any way even with just a pin hole SP...

Page 111: ...while pressing it in and release the diaphragm holder flange from the vacuum piston Remove the jet needle holder spring and jet needle DIAPHRAGMNACUUM PISTON Check the jetneedle for stepped wear Check...

Page 112: ...p link Remove the screws float chamber and O ring Remove the float pin float and float valve Check the float for damage or fuel in the float Check the float valve and valve seat for scoring scratches...

Page 113: ...ber of turns until it seats lightly Make a note of this to use as a reference when reinstalling the pilot screw TOOL Pilot screw wrench 07KMA MS60102 or 07MMA MT3010B U S A only Remove the pilot scre...

Page 114: ...FUEL SYSTEM CARBURETOR ASSEMBLY JET NEEDLE HOLDER VACUUM CHAMBER COVER JET NEEDLE DIAPHRAGMNACUUM PISTON PLASTIC WASHER ACCELERATOR PUMP LINK COMPRESSION SPRING ACCELERATOR PUMP COVER 6 15...

Page 115: ...ot screw is installed page 6 25 Install the needle jet needle jet holder main jet and slow jet TORQUE Needle jet holder 2 3 N m 0 2 kgf m 1 7Ibf ft Main jet 2 1 N m 0 2 kgf m 1 5 Ibf ft Slow jet 1 8 N...

Page 116: ...asbers CoJlat Act etaj or pump link Plastic washer New cotter pin Tighten the accelerator pump link mounting bolt to the specified torque TOR9UE 3 4 N rri 0 3 kgf m 2 5 Ibf ft VACUUM CHAMBER Insenthe...

Page 117: ...of the cover with the grooves of the carbure tor body and secure the cover with at least two screws before releasing the vacuum piston Install and tighten the vacuum chamber cover screws to the specif...

Page 118: ...specified torque while holding the cover tORQUE 2 1 N m 0 2 kgf m 1 5 Ibf ft DIAPHRAGMIROD AIR CUT OFF VALVE Be careful not to Install the air cut off valve diaphragm spring and pinch the cover onto...

Page 119: ...68 F Measure the resistance B between the Yellow and Black wire terminal then adjust the TP sensor initial position so that the resistance B is within the stan dard value Resistance 8 Resistance AI x...

Page 120: ...TALLATION Connect the water hoses to the carburetor heater and relea e the clamps California type only Connect the EVAP purge control valve vacuum hose to the carburetor GonnElct the carPLJretorairven...

Page 121: ...lator band screw securely Except california Connect the air vent hose to the clamp type Connect the TP sensor 3P connector Connect the PAIR control valve vacuum hose to the 3 way joint Install the fol...

Page 122: ...insulator from the intake manifold Disconnect the water hose from the rear cylinder head Remove the bolts and choke cable stay Remove the bolts intake manifold and a rings Seal the intake ports of the...

Page 123: ...r heads I stall the choke Tighten the bolt cable stay and b I s securely 0 ts Install the c b msulato ar uretor sid with the CA e manifold e ahgnlng S gm m a k fadng the Ighten the insulato e With the...

Page 124: ...rm up the engine to operating temperature Ride the motorcycle for approximately 10 min utes 3 Stop the engine and connect a tachometer according to its manufacturer s instructions 4 Remove the fuel ta...

Page 125: ...ation STANDARD SETIING HIGH ALTITUDE SETIING Below 5 000 ft 1 500 m Above 6 500 ft 2 000 m Main jet 122 120 Pilot 49 states Canada Factory preset 3 4 turn in from factory preset screw type 2 turns out...

Page 126: ...l I NOTICE I Sustained operation at an altitude lower than 5 000 feet 1 500 m with the parts replaced and adjusted for high altitude settings may cause the engine to idle roughly and stall in traffic...

Page 127: ...throttle slightly to be certain that air is sucked in through the air suction hose If the air is not drawn in check the air suction hoses for clogs With the engine running gradually apply vacuum to th...

Page 128: ...Remove the fuel tank page 3 4 Remove the bolts and PAIR check valve cover Remove the PAIR check valve from the cylinder head coveF Check the reed for damage or fatigue Replace if necessary Replace the...

Page 129: ...emove the fuel tank page 3 4 Disconnect the EVAP purge control valve hoses and EVAP purge control valve vacuum hose page 1 35 Remove the EVAP purge control valve Route the hoses Installation is in the...

Page 130: ...pump to the EVAP canister port While applying the specified vacuum to the vacuum port pump air through the EVAP canister port SPECIFIED VACUUM 25 mm Hg 1 0 in Hg Air should flow through the EVAP purg...

Page 131: ...should hold steady Replace the EVAP CAV control valve if vacuum leaks VACUUM PUMP Remove the vacuum pump and reconnect it to the vacuum port Connect a pressure pump to the sub air cleaner port Damage...

Page 132: ...PECTION Remove the fuel cut off solenoid valve page 6 33 Damage to the fuel Connect a vacuum pump to the vacuum port Apply cut off solenoid the specified vacuum to the fuel cut off solenoid valve may...

Page 133: ...ump to the EVAP CAV control valve port Apply the specified vacuum to the fuel cut off pJenoid valve SPECIFIED VACUUM 250 mm Hg The specified vacuum should be maintained Replace the fuel cut off soleno...

Page 134: ...TEM FLOW PATTERN 7 2 SERVICE INFORMATION 7 3 TROUBLESHOOTING 7 4 SYSTEM TESTING 7 5 COOLANT REPLACEMENT 7 6 THERMOSTAT 7 8 _ THERMOSTAT HOUSiNG 7 9 RADIATOR COOLING FAN 7 11 WATER PUMP 7 16 RADIATOR R...

Page 135: ...COOLING SYSTEM SYSTEM FLOW PATTERN CARBURETOR THERMOSTAT RESERVE TANK 7 2...

Page 136: ...ch inspection page 21 14 SPECIFICATIONS ITEM SPECIFICATIONS Coolant capacity Radiator and engine 1 58 liters 1 67 US qt 1 39 Imp qt Reserve tank 0 38 liter 0 40 US qt 0 33 Imp qt Radiator cap relief p...

Page 137: ...blocked in radiator hoses or water jacket Air in system Faulty fan motor Faulty fan motor switch Faulty water pump Engine temperature too low Thermostat stuck open Faulty fan motor switch Coolant lea...

Page 138: ...1 028 1 027 1 026 1 025 1 024 1 022 1 020 1 018 1 016 1 014 1 012 20 1 036 1 035 1 034 1 033 1 031 1 029 1 027 1 025 1 023 1 021 1 019 25 1 045 1 044 1 043 1 042 1 040 1 038 1 036 1 034 1 031 1 028 1...

Page 139: ...t exceed 137 kPa 1 4 kgf crrr 20 psi Repair or replace components if the system will not hold the specified pressure for at least 6 seconds Remove the tester and install the radiator cap Install the f...

Page 140: ...the siphon hose from the reserve tank and drain the coolant Empty the coolant by removing the reserve tank page 7 17 and rins the inside of the reserve tank with water Install the following Reserve ta...

Page 141: ...T INSPECTION Visually inspect the thermostat for damage Replace the thermostat if the valve stays open at room temperature Wear insulated Heat a container of water with an electric heating gloves and...

Page 142: ...10 N m 1 0 kgf m 7Ibf ft Connect the ECT sensor switch connector Fill and bleed the cooling system page 7 7 Install the steering side covers page 3 5 THERMOSTAT HOUSING REMOVAL INSTALLATION Drain the...

Page 143: ...RING Thermostat housing page 7 9 TherJTIostat page 7 8 ECT sensor switch page 21 13 Remove the bolts and a ring I I __ 1 I I I BOLTS ASSEMBLY Install a new a ring to the radiator filler RADIATOR FILLE...

Page 144: ...move the steering side covers page 3 5 fins while servicing Remove the wire band and disconnect the fan the radiator and fan motor switch 2P Natural connector motor Loosen the water hose band screw an...

Page 145: ...diator FAN MOTOR WIRE BRAKE L1GHTSWITCH PULSE GENERATOR WIRES DISASSEMBLY For fan motor Release the fan motor wires from the radiator grill RADIATOR GRILL switch inspection Remove the radiator mountin...

Page 146: ...OOLING SYSTEM Remove the nut and cooling fan Remove the bolts and fan motor from the shroud ASSEMBLY RADIATOR GRILL RADIATOR FAN MOTOR SHROUD 8 4 N m 0 9 kgf m 6 2 IbHt 7 O RING MOUNTING RUBBER 7 13 j...

Page 147: ...Install the cooling fan onto the motor shaft aligning the flat surfaces Clean and apply locking agent to the nut threads Tighten the nut to the specified torque TORQUE 2 7 N m 0 3 kgf m 2 0 Ibf tt In...

Page 148: ...ires through the radiator grill page 1 22 Connect the fan motor switch wire to the clamp Install the collar bolt and tighten the bolt Connect the radiator upper and lower water hoses page 1 22 Tighten...

Page 149: ...Drain the coolant from the system page 7 7 Loosen the water hose band screw and disconnect the water hose Remove the bolts sealing washer and water pump cover Disconnect the water hose Remove the O ri...

Page 150: ...he bolts to the specified torque in a criss cross pattern in several steps TORQUE 13 N m 1 3 kgf m 10 Ibf ft Connect the water hose page 1 22 and tighten the water hose band screw to the specified ran...

Page 151: ...MEMO...

Page 152: ...8 ENGINE REMOVAL INSTALLATION 8 4 SERVICE INFORMATION 8 3 ENGINE INSTALLATION 8 7 COMPONENT LOCATION 8 2 ENGINE REMOVAL 8 1...

Page 153: ...N COMPONENT LOCATION 26 N m 2 7 kgf m 19 IbHt 10 N m 1 0 kgf m 7lbHt 12 N m 1 2 kgf m 91bHt 1 9 N m 0 2 kgf m 1 4IbHt 39 N m 4 0 kgf m 29 IbHt 26 N m 2 7 kgf m 19 IbHt 54 N m 5 5 kgf m 40 Ibf ftj 54 N...

Page 154: ...nder head page 9 14 Cylinder piston page 10 4 Crankshaft page 13 10 Transmission Including gearshift drum shift fork page 13 20 Output gear case page 13 28 Oil pump page 5 6 The following components c...

Page 155: ...rear cover page 3 5 Exhaust system page 3 8 Carburetor page 6 7 Radiator page7 11 Over head covers page 9 6 Clutch cover page 11 5 Alternator cover page 4 10 NOTE Wrap the intake manifold port with a...

Page 156: ...connector Disconnect the EOP switch wire by removing the terminal screw Remove the pinch bolt and gearshift arm Disconnect the secondary air supply hoses from the PAIR check valvecovers RElmove the c...

Page 157: ...main footpeg and brake pedal brackets from the frame FOOTPEG BRACKET BOLTS NUT The jack height Place a floor jack or other adjustable support under must be continually the engine adjusted to relieve R...

Page 158: ...ot tot he frame to the right damage the frame and engine ENGINE INSTAL LAtJON NOTE Notet ie oiiegtiJ iDEl hanger bolts Alftbet pgjn gbolts and nuts loosely instalh the tbebolts and nuts to the sp gifi...

Page 159: ...all engine hanger plates mounting fasteners and collar Tighten the front lower then front upper engine mounting nuts to the specified torque TORQUE 54 N m 5 5 kgf m 40 Ibf ft Tighten the rear lower th...

Page 160: ...he specified torque TORQUE 26 N m 2 7 kgf m 19Ibf ft Tighten the right rear upper engine hanger plate bolts to the specified torque TORQUE 26N I n 2 1kgf m 19 Ibf ft FBRAK E PEDAL B AC Inst 1 the righ...

Page 161: ...ose the terminal cover securely Connect the clutch cable end to the clutch lifter arm Install the clutch cable holder and bolt Tighten the bolt securely Connect the secondary air supply hoses to the P...

Page 162: ...n switch 2P Black and 1P Natural VS sensor 3P Natural Alternator 3P Natural Install the jollowing Radiator page 7 15 Carburetor page 6 21 Exhaust system page 3 11 Left crankcase rear cover page 3 5 Sp...

Page 163: ...MEMO...

Page 164: ...9 6 CYLINDER HEAD COVER REMOVAL 9 6 CAMSHAFT REMOVAL 9 8 CYLINDER HEAD REMOVAL 9 14 CYLINDER HEAD DiSASSEMBLy 9 15 VALVE GUIDE REPLACEMENT 9 18 _ VALVE SEAT INSPECTION REFACING 9 19 CYLINDER HEAD ASSE...

Page 165: ...ONENT LOCATION 10 N m 1 0 kgf m 7 IbHt 10 N m 1 0 kgf m 7 IbHt 23 N m 2 3 kgf m 17 IbHt 23 N m 2 3 kgf m 17Ibf ft 47 N m 4 8 kgf m 35 Ibf ft 0 23 N m 2 3 kgf m 17 Ibf ft 10 N m 11 0 kgl m 71bHt 23 N m...

Page 166: ...ance IN EX 0 020 0 141 0 0008 0 0056 0 16 0 006 Rocker arm Rocker arm shaft O D IN EX 11 966 11 984 0 4711 0 4718 11 83 0 466 rocker arm Rocker arm I D IN EX 12 000 12 018 0 4724 0 4731 12 05 0 474 sh...

Page 167: ...cially avail able in U S A Flat cutter 28 mm 320 IN 07780 0012100 or equivalent commercially avail able in U S A Flat cutter 35 mm 320 EX 07780 0012300 or equivalent commercially avail able in U S A I...

Page 168: ...der head gasket Warped or cracked cylinder head Loose sparkphig Cylinder piston problem page 10 3 Compr lfsion too high Excessive carb n build up on piston head or combustion chamber Exce sivesmOke Wo...

Page 169: ...the transmission into neutral Install a compression gauge into the spark plug hole Open the throttle all the way and crank the engine with the starter motor until the gauge reading stops rising The m...

Page 170: ...ose Remove the cylinder head cover bolts washers and rubber seals Be careful not to Remove the cylinder head cover and gasket damage the wire harness and mating surfaces when removing the cylinder hea...

Page 171: ...e cylinder head cover bolts washers and rubber seals Be careful not to Remove the cylinder head cover and gasket damage the wire harness and mating surfaces when removing the cylinder head cover CAMSH...

Page 172: ...X NOTCH RT mark frol ltc ylinder FT mark with the index notch on the leffhrankcase cover Make sure the piston is at TDC Top Dead Center on heexhaust stroke so the piston is at TDC on the compression s...

Page 173: ...cam sprocket bolt crankcase Attach a piece of Remove the cam sprocket from the camshaft flange wire to the cam surface chain to prevent it from falling into the crankcase Make sure the piston is at T...

Page 174: ...e of insufficientlubrication Measure each cam lobe height SERVICEI IMITS IN 37 16 mm 1 463 in EX 37 58 mm 1 480 in NOTE Check the rocker arm if the cam lobe is worn or damaged CAMSHAFT JOURNAL Che9k t...

Page 175: ...y oil passages with the plastigauge Do not rotate the camshaft during inspection Carefully install the camshaft holder and tighten the camshaft holder bolts and nuts to the specified torque in a criss...

Page 176: ...justing screw for wear or damage Measure the 1 0 of each rocker arm SERVICE LIMIT 12 05 mm 0 474 in ROCKER ARM SHAFT INSPECTION Check the rocker arm shafts for wear or damage Measure each rocker arm s...

Page 177: ...page 6 23 Remove the bolt and water hose joint from the cyl inder Rear cylinder head Disconnect the vacuum hose only Remove the cam chain tensioner bolts and sealing washers Remove the cam chain tens...

Page 178: ...ove the cotters using a special tool so they can be placed back in their TOOL original position Valve spring compressor 07757 0010000 NOTE Compressing the valve spring more than necessary will cause l...

Page 179: ...mm 0 004 in VALVE SPRING Check the valve sp ing for fatigue or damage Measure the free length of each valve spring SERVICE LIMITS IN 40 58 mm 1 598 in EX 44 72 mm 1 761 in VALVE STEM Check each valve...

Page 180: ...I D and record it SERVICE LIMITS IN 5 56 mm 0 219 in EX 5 56 mm 0 219 in Subtract each valve stem O D from the correspond ing guide I D to obtain the stem to guide clearance SERVICE LIMITS IN 0 10 mm...

Page 181: ...s available from welding supply stores to be sure the cylinder head is heated to the proper temperature To avoid burns wear insulated gloves when han dling the heated cylinder head Be careful not to S...

Page 182: ...to remove any metal particles after reaming Reface the valve seat page 9 20 VALVE SEAT INSPECTION REFACING INSPECTION Clean all intake and exhaust valves thoroughly to remove carbon deposits Apply a t...

Page 183: ...f the valve seat width is not within specification reface the valve seat VALVE SEAT REFACING NOTE VALVE SEAT CONTACT WIDTH FolioVI the refacing manufacturer s operating instructions RefaceAhe valve se...

Page 184: ...TOOLS Flat cutter 28 mm IN 07780 0012100 Flat cutter 35 mm EX 07780 0012300 Cutter holder 5 5 mm 07781 0010101 or equivalent commercially available in U S A Using a 600 cutter remove the bottom 1 4 o...

Page 185: ...ng compound can cause damage if it enters between the valve stem and guide After lapping wash any residual compound off the cylinder head and valve Recheck the seat contact after lapping CYLINDER lEAD...

Page 186: ...with tightly wound coils fac ing the combustion chamber Install tile spring retainer Grease the cotters lns 11 the cotters using a special tool SPRING COMPRESSOR to ease installatioh V h e spring comp...

Page 187: ...shop towel overthe cylinder opening to prevent dust or dirt from entering the engine Clean the gasket mating surfaces ofthe cylinder and cylinder head thoroughly being careful not to dam age them Inst...

Page 188: ...he larger fasteners before tightening the smaller fasteners Tighten the bolts and nuts in a crisscross pattern in several steps Install the cam chain tensioner aligning its end with the groove in the...

Page 189: ...ing Camshaft page 9 26 Cylinder head over page 9 31 Intake manifold page 6 23 CAMSHAFT INSTALLATION CAMSHAFT HOLDER ASSEMBLY EXHAUST ROCKER ARM SHAFT INTAKE ROCKER ARM SHAFT EXHAUST ROCKER ARM VALVE A...

Page 190: ...aft holder holes Align the exhaust rocker arm shaft grooves with the camshaft holder holes CAMSHAFT TIMING PROCEDURE NOTE The camshafts are identified by the stamped marks F Front cylinder camshaft R...

Page 191: ...aft If the R mark faces up turn the crankshaft counterclockwise 1 1n 412 turn align the FT mark on the flywheel with the index notch and begin installation of the front camshaft If the R mark faces do...

Page 192: ...rk on the flYWh rl W ththe index notch and begin installation ofthe rear camshaft Ifthe F marKJ cElSd 6 IV11 cannot be seen turn otHe cranksh ft d02kWjse l Sn 668 turn align the RT mark with the index...

Page 193: ...shaft holder bolts and nuts Tighten the bolts and nuts to the specified torque in a crisscross pattern in several steps TORQUE Camsllaft holder bolt 23 N m 2 3 kgf m 17 Ibf ftl Camshaft holder nut 23...

Page 194: ...an O D 2mm pin while holding cam chain tensioner wedge Aand pushing down the wedge B NOTE Be careful not to let an 0 0 2 mm pin fall into the crankcase Do not forget to remove an 0 0 2 mm pin before...

Page 195: ...if necessary Install tl e rubber seals onto the cylinder head cover in the drtection as shown RUBBER SEAL Install the washers InstaUand tighten the cyljnder head cover bolts to the specified torque T...

Page 196: ...Install the rubber seals page 9 32 Install the washers Install and tighten the cylinder head cover bolts to the specifi d torque TORQUE 10 N m 1 0 kgf m 7Ibf ft Connect the crankcase breather hose Ins...

Page 197: ...INDER HEAD VALVE Install the rear right over head cover and tighten the socket bolts to the specified torque TORQUE 10 N m 1 0 kgf m 7Ibf ft Connect the spark plug cap Install the fuel tank page 3 4 9...

Page 198: ...10 CYLINDER PISTON COMPONENT LOCATION 10 2 CYLINDER PISTON REMOVAL 10 4 SERVICE INFORMATION 10 3 CYLINDER PISTON INSTALLATION 10 9 TROUBLESHOOTING 10 3 10 1...

Page 199: ...CYUNDER PISTON COMPONENT LOCATION 10 2...

Page 200: ...ton pin 0 0 17 994 18 000 0 7084 0 7087 17 98 0 708 Piston to piston pin clearance 0 002 0 014 0 0001 0 0006 0 04 0 002 Piston ring end Top 0 15 0 25 0 006 0 010 0 4 0 02 gap Second 0 25 0 40 0 010 0...

Page 201: ...ve the retaining clips Slide the cylinder joint collar toward either the front or rear cylinder Lift the cylinder an d remove it being careful not to damage the piston with the stud bolts NOTE Attach...

Page 202: ...the Push the piston pin out of the piston and connecting crankcase to rod and remove the piston prevent the piston pin clips from falling into the crankcase Do not damage the Spread each piston ring a...

Page 203: ...07mm 0 003 in Insert the piston ring into the bottom of the cylinder squarely Cusing the piston crown Measure the piston ring end gap SERVICE LIMITS Top 0 4 mm 0 02 in Second 0 6 mm 0 02 in Oil side...

Page 204: ...d to piston pin clear ance SERVICE LIMIT 0 06 mm 0 002 in CYLINDER Check the top of the cylinder for warpage with a straight edge and feeler gaiJge across the stud holes SERVICE LIMIT 0 10 mm 0 004 in...

Page 205: ...0 50 mm 0 020 in The piston to cylinder clearance for the oversize pis L ton must be 0 010 0 045 mm 0 0004 0 0018 in CYLINDERS rUD BOLT REPU OEMENI Thread 6 nutsCohto the stud and tighten them STUD BO...

Page 206: ...e spacer first then install the side rails Stllgger the piston ring end gaps 1200 apart from eacn other Stagger the side rail end gaps as shown SECOND RING iii SPACER 71 20 mm 0 8 in OR MORE 71 TOP RI...

Page 207: ...eful not to damage them Install new O rings to the joint collar Install the joint collar to the cylinder Install the dowel pins and a new gasket Apply engine oil to the cylinder wall piston outer surf...

Page 208: ...n the cylinder and connect it Install the retaining clips into the joint collar grooves Front cylinder only Install a new O ring into the water hose joint groove Install and tighten the hose joint bol...

Page 209: ...MEMO...

Page 210: ...LOCATION 11 2 SERVICE INFORMATION 11 3 TROUBLESHOOTING 11 4 RIGHT CRANKCASE COVER REMOVAL 11 5 CLUTCH REMOVAL 11 7 PRIMARY DRIVE GEAR 11 12 GEARSHIFT LINKAGE 11 14 CLUTCH INSTALLATION 11 18 RIGHT CRA...

Page 211: ...CLUTCH GEARSHIFT LINKAGE COMPONENT LOCATION 23 N m 2 3 kgf m 17 IbHt Q 15 N m 1 5 kgf m 11 IbHt tX 12 N m 1 2 kgf m 9 IbHt 10 N m 1 0 kgf m 7 IbHt 11 2...

Page 212: ...clearance 32 000 32 025 1 2598 1 2608 32 09 1 263 Clutch outer 1 0 Clutch outer to outer guide clearance 0 025 0 066 0 0010 0 0026 0 18 0 007 32 025 32 145 1 2608 1 2655 32 16 1 266 Oil pump drive spr...

Page 213: ...ve used Clutch slips No clutch lever freeplay Worn clutch discs Weak clutch springs Clutch lifter sticking Engine oil level too low or oil additive used Hard to shift Improper clutch operation Incorre...

Page 214: ...lts in a crisscross pattern in several steps Remove the clutch cable holder and disconnect the clutch cable Remove the right crankcase cover Be careful not to Remove the dowel pins and clean off the s...

Page 215: ...r fatigue or damage Check the lifter arm sliding surface of the right crankcase cover for wear damage or loose fit Replace these parts if necessary NOTE If the oil seal replacement is required install...

Page 216: ...plate bolts in a crisscross pattern in several steps Remove the lifter plate bearing and clutch springs Be careful not to Unstake the clutch center lock nut damage the mainshaft threads HOld the clutc...

Page 217: ...asher and thrust washer 11 IJ Remove the following Clutch center Pressure plate End clutch disc ClutcD plates Clutch disc A Judder spring Spring seat Remove the thrust washer and clutch outer Remove t...

Page 218: ...the bearing with your finger The bearings should turn smoothly and quietly Also chec that the bearing outer race fits tightly in the lifter plate Remove and discard the bearing if the races do not tur...

Page 219: ...clutch Check the clutch plate for discoloration discs and plates as Check tl e clutch plate warpage on a surface plate aset using a feeler gauge SERVICE LIMIT 0 30 mm 0 012 in CLUTCH CENTER Check the...

Page 220: ...k the oil pump drive sprocket for wear or dam age Measure the 1 0 of the drive sprocket SERVICE LIMIT 32 16 mm 1 266 in Calculate the oil pump drive sprocket to clutch outer guide clearance SERVICE LI...

Page 221: ...se generator and grom mets Temporarily install the clutch outer guide oil pump r drive sprocket and clutch outer onto the mainshaft page 11 18 Hold the primary drive gear using a special tool and remo...

Page 222: ...mage INSTALLA rlON Install the primary drive gear on the crankshaft NOTE Install the primary drive gear aligning its wide groove with the wide tooth of the crankshaft Install the primary drive gear wi...

Page 223: ...2 5 07724 0010100 or 07724 001A100 U S A only Tighten the bolt to the specified torque TORQUE 88 N m 9 0 kgf m 65 Ibf ft Remove the gear holder and temporarily installed parts Install the ignition pul...

Page 224: ...Remove the gearshift spindle from the crankcase while unhooking the shifter arm from the gearshift cam plate DUST SEALS INSPECTION Remove the bolt and stopper plate Apply grease to the Check the gear...

Page 225: ...Check the gearshift pedal rod for damage or loose lock nuts Replace the rod if necessary LOCK NUTS INSTALLATIOI l Install the gearshift spindle aligning the return spring ends with the gearshift spind...

Page 226: ...dustsealsandpivot collar to the gearshift pedal 4 r PIVOT COLLAR DUST SEALS Install the gearshift pedal washer and pivot bolt Tighten the pivot bolt to the specified torque TORQUE 39 N m 4 0 kgf m 29...

Page 227: ...hain drive sprocket and driven sprocket as a set NOTE Install the oil pump driven sprocket with the 0 marks side facing inside Align the flat surfaces of the driven sprocket hole and oil pump shaft en...

Page 228: ...outer onto the mainshaft Install the thrust washer onto the mainshaft Coat the clutch discs and plates with engine oil Install the sprIng seat and judder spring to the clutch center as shown End clutc...

Page 229: ...washer with its OUT SIDE mark facing out Apply engine oil to the threads and seating surface of a new clutch center lock nut and install it onto the mainshaft Hold the clutch center using a special t...

Page 230: ...ttern in several steps to the specified torque iTORQUE 12N m 1 2 kgf m 9Ibf ft If the oil pump drivensprocket is removed tighten the oil pump driven sprocket bolt to the specified torqlJi l TORQUE 15N...

Page 231: ...ng by inserting its short end into the clutch lifter arm groove Install the snap ring to the clutch lifter arm groove securely Hook the long spring end to the cover tab Install the clutch lifter piece...

Page 232: ...ect the clutch cable Install the right crankcase cover clutch cable holder and tighten the bolts in a crisscross pattern in sev eral steps Install the oil seal rubber to the clutch cover with its smai...

Page 233: ...MEMO...

Page 234: ...12 ALTERNATOR STARTER CLUTCH 12 4 SERVICE INFORMATION 12 3 FLYWHEEL STARTER CLUTCH 12 5 TROUBLESHOOTING 12 3 STATOR INSTALLATION 12 11 COMPONENT LOCATION 12 2 STATOR REMOVAL EI 12 1...

Page 235: ...ALTERNATORISTARTER CLUTCH COMPONENT LOCATION 30 N m 3 1 kgf m 22 IbHt 12 N m 1 2 kgf m 9 IbHt 128 N m 13 1 kgf m 94 IbHt 12 2...

Page 236: ...74 46 2 931 TORQUE VALUES Stator socket bolf Flywheel bolt Stator wire holder socket bolt Starter one way clutch outer socket bolt TOOLS Flywheel holder 07725 0040001 or equivalent commercially avail...

Page 237: ...ontainer under the left crankcase cover to catch the engine oil Loosen the bolts in Remove the bolts clamps and left crankcase cover a crisscross pattern NOTE in several steps The left crankcase cover...

Page 238: ...LYWHEEL REMOVAL For alternator Remove the left crankcase cover page 12 4 charging coil inspection page 18 9 Remove the starter reduction gear and shaft Remove the starter idle gear and shaft The flvwh...

Page 239: ...Y key from the crankshaft NOTE Durtng woodruff key removal be careful not to damage the key groove and crankshaft Do not lose the woodruff key STARTER IDLE REDUCrION GEAR INSPECTION STARTER IDLE GEAR...

Page 240: ...the starter driven gear from the flywheel while turning the driven gear counterclockwise Remove the socket bolts while holding the flywheel using a special tool TOOL Flywheel holder 07725 0040001 or...

Page 241: ...way clutch assembly with a new one Check the starter clutch outer inner contact surface for wear or damage Measure the starter clutch outer 1 0 ONE WAY CLUTCH SERVICE LIMIT 74 46 mm 2 931 in STARTER D...

Page 242: ...ter clutch outer one way clutch to the flywheel Hold the flywheel using a special tool TOOL Flywheel ho lder 07725 0040001 or equivalent com mercially avail able in U S A Clean and apply a locking age...

Page 243: ...ligning the key groove of the flywheel with the woodruff key on the crankshaft Hold the flywheel using a special tool TOOL Flywheel holder 07725 0040001 or equivalent com mercially avail able in U S A...

Page 244: ...t to the bolt threads page 1 19 Install and tighten the stator socket bolts to the specified torque TORQUE 12 N m 1 2 kgf m 9 lbf tt Install the grommet into the grooves in the left crankcase cover Cl...

Page 245: ...ing the organic solvent Install the dowel pins The left crankcase Install the left crankcase cover cover stator is Apply locking agent to the one left crankcase cover magnetically bolt marked 8 thread...

Page 246: ...and bind the wires with clamps and wire properly bands page 1 22 Connect the alternator 3P Natural connector Install the following Left crankcase rear cover page 3 5 Left side cover page 3 3 Seat page...

Page 247: ...MEMO...

Page 248: ...VICE INFORMATION 13 3 TROUBLESHOOTING 13 8 CRANKCASE SEPARATION 13 9 CRANKSHAFT CONNECTING ROD 13 10 CRANKPIN BEARING 13 13 MAIN JOURNAL BEARING 13 16 TRANSMiSSiON 13 20 OUTPUT GEAR 13 28 CRANKCASE BE...

Page 249: ...I CRANKSHAFTITRANSMISSION COMPONENT LOCATION 23 N m 2 3 kgf m 17 Ibf ft I 33 N m 3 4 kgf m 24 Ibf ft CRANKCASE SOLT 23 N m 2 3 kgf m 17 Ibf ft 13 2...

Page 250: ...les After selecting new bearings recheck the oil clearance Incorrect oil clearance can cause major engine damage Prior to assembling the crankcase halves apply sealant to their mating surfaces Wipe of...

Page 251: ...Gear busing 0 0 M3 M5 27 959 27 980 1 1007 1 1016 27 S4 1 100 C1 C4 30 950 30 975 1 2185 1 2195 30 93 1 218 C2 23 959 23 980 0 9433 0 9441 23 94 0 943 Gear to bushing M3 M5 C2 0 020 0 062 0 0008 0 002...

Page 252: ...kgf m 54 Ibf ft 98 N m 10 0 kgf m 72 Ibf ft 73 N m 7 4 kgf m 54 Ibf ft 98 N m 10 0 kgf m 72 Ibf ft 49 N m 5 0 kgf m 36 Ibf ft Apply engine oil to the threads and seating surface Apply locking agent to...

Page 253: ...g remover set 20 mm 07936 3710600 Attachment 42 x 47 mm 07746 0010300 Pilot 22 mm 07746 0041000 Pilot 30 mm 07746 0040700 Remover weight 07741 0010201 or 07936 371020A or 07936 3710200 U S A only Atta...

Page 254: ...lder handle 07PAB 0010400 Lock nut wrench 36 x 47 8 mm 07916 MB00002 Differential inspection tool 07KMK HC50101 or 07KMK HC5010A U S A only Bearing remover set 17 mm 07936 3710300 Oil seal driver 0796...

Page 255: ...orn or damaged output shaft and final drive shaft gears Worn or damaged output gear case bearing Incorrect adjusted shim Hard to shift Improper clutch operation page 11 9 Incorrect engine oil viscosit...

Page 256: ...nsioner setting plates Remove the cam chains SHAFT HOLDER A BOLTIWASHER Hold the output driven gear shaft using the special tools loosen the output drive gear shaft bolt and remove it with the washer...

Page 257: ...g at the points as shown Separate the right crankcase from the left crank case while tapping them at several locations with a soft hammer Remove the dowel pins and pipe seal Clean off the sealant from...

Page 258: ...shaft and connecting rod big end SERVICE LIMIT 0 30 mm 0 012 in CONNEC rlNG ROD REMOVAL Tap the side of the Remove the crankpin bearing cap nuts and the bear CAPS cap lightly if bearing ing caps cap i...

Page 259: ...d cap and bear ing il serts Align 1 11 ti iJ eCl l ig j9serts on the connecting rods ahq caps Dy ligri ijg thetab with the groove Apply molybdenum disulfide oil to the thrust sur face of the crankpin...

Page 260: ...he correct bearing ojJ fJ qrance maynot be obtained resulting in engine damage Rernove the conn cting rod page 13 11 _ _ _ _ c _ _ c CheckthCe b ari ginsertsfor unusual wear damage BEARINGS or peeling...

Page 261: ...ne the oil clearance SERVICE LIMIT 0 07 mm 0 003 in If the clearance exceeds the service limit select the correct replacement bearings as follows BEARING SELECTION Record the connecting rod 1 0 code n...

Page 262: ...learance can cause evereJi t rnage CONNECTING ROD SELECTION An alphabetical weightcode is stamped on the cap Ifa col ln ecting rod requires replacement you shp l Jl tse1 tarod with the same weight cod...

Page 263: ...ling and replace them if necessary Measure the main journal bearing 1 0 at between the bearing groove and crankcase outside end of the bearing and 90 degrees to the index mark Clean off any oil from t...

Page 264: ...al bearing selection Crankshaft and crankcase are replaced Crankcase only is replaced Crankshaft only is replaced Main journal bearings only are replaced Carefully refer to the following instructions...

Page 265: ...2 0859 2 0861 in MAIN JOURNAL 58 010 58 016 mm D C B I D 2 2839 2 2841 in Green Brown Black 58 016 58 022 mm C B A 2 2841 2 2843 in Brown Black Blue 58 022 58 034 mm B A A 2 2843 2 2848 in Black Blue...

Page 266: ...l installer grooves TOOL Metal installer set 070MF MEG0200 Tighten the bolts alternately in several steps to the specified torque TORQUE 23 N m 2 3 kgf m 17 Ibf ft BOLTS AUgn BEARING Set the bearings...

Page 267: ...gns with the index mark on the crankcase Check the oil clearance page 13 16 After selecting new bearings recheck the clear ance Incorrect clearance can cause severe engine damage Install the crankshaf...

Page 268: ...BLY Disassemble the mainshaft and countershaft MAINSHAFT INSPECTION GEARS Check the gear dogs dog slots and teeth for dam age or excessive wear COUNTERSHAFT DOG Measure the I D of each gear SERVICE LI...

Page 269: ...ormal wear or damage Measljretl1e 0 0 of the mainshaft and countershaft at the gear and bushing sliding areas SERVICE LIMiTS Mainshaft at M3 gear bushing 24 94 mm 0 982 in Cauntershaft at C2 gear bush...

Page 270: ...wear or damage Measure the shift fork shaft 0 0 SERVICE LIMIT 12 90 mm 0 508 in SHIFT DRUM SHIFT DRUM BEARING Remove the bolt and gearshift cam plate CAM PLATE BOLT Remove the dowel pinand bearing Re...

Page 271: ...y on the shift drum Check the shift drum end for scoring scratches or evidence of insufficient lubrication Check the shift drum grooves for abnormal wear or damage Measure the shift drum O D at left e...

Page 272: ...G Install the dowel pin into the shift drum hole Install the gearshift cam plate by aligning its hole with the dowel pin Clean and apply a locking agent to the gearshift cam plate bolt page 1 19 Insta...

Page 273: ...r original positions NOTE Check the gears for freedom of movement or rotation on the shaft Install the washers and snap rings with the chamfered edges facing the thrust load side Do not reuse a worn s...

Page 274: ...GEAR 37T INSTALLATION Install the mainshaft and countershaft together into MAINSHAFT the left crankcase Be sure to install the thrust washers of the counter shaft both ends The shift forks have the fo...

Page 275: ...igning the shift fork guide pins with the shift drum guide grooves Apply engine oil to the shift fork shaft whole sur face Insert the shift fork shaft through the shift forks into the right crankcase...

Page 276: ...move the thrust washer and output gear Remove the bushing from the output drive gear BUSHING shaft E Ccept U A Sefthedamper spring compressor onto the damper cam andoutputclrive gears haft Compress th...

Page 277: ...he assembly bolt until the snap ring is visible so it can be remoVed TOQLS AsserntilYcbolt 07965 1660200 Assembly collar 07965 166030A or 07965 1660302 Compressor seat 07967 9690200 Threaded adaptor 0...

Page 278: ...JECTIONS OUTPUT GEAR Check the output gear teeth for damage or exces sive wear and the gear dog holes for damage Measure the output gear I D SERVICE LIMIT 24 04 mm 10 946 in BUSHING Check the output g...

Page 279: ...he output drive and driven gear shafts turn smoothly and quietly withoLlt binding If the shafts do not turn smoothly or quietly the gears and or bearing may be damaged or faulty They must be checked a...

Page 280: ...measurements SERVICE LIMIT 0 10 mOl 0 004 in If the difference in measurements exceeds the ser vice limit it indicates that the bearing is not installed squarely or the case is deformed Inspect the be...

Page 281: ...G fI 7I Description of the tooth COAST SIDE contacts when engine brake is applied DRIVE SIDE contacts when engine power is applied Remove the drive gear assembly from the gear case DRIVEN GEAR TEETH p...

Page 282: ...0 Q_1S in 0 50 mm R O in 0 55 mm O 022 in 0 60 mOl 0 024 in OUTPUT DRIVEN GEAR SHIM REPLACEMENT Hold the output gear case in a vise with soft jaws Remove tne bolts and output driven gear assembly Remo...

Page 283: ...bearing inner race lock nut using the special tools TOOLS Shaft holder A 07PAB 0010100 or 07923 6890101 U S A only Holder handle 07PAB 0010400 Lock nut wrench 36 x 47 8 mm 07916 MB00002 Remove the bea...

Page 284: ...ng a hydraulic press Press the drive gear bearing out of the bearing holder using the special tools and a hYdraulic press TOOLS Driver 07749 0010000 Attacblllent 52 x 55 mm 07746 0010400 PiJot 30mm 07...

Page 285: ...special tools TOOLS Shaft holder A 07PAB 0010100 or 07923 6890101 U S A only Lock nut wrench 36 x 47 8 mm 07916 MB00002 Differential inspection tool 07KMK HC50101 or 07KMK HC5010A U S A only Remove t...

Page 286: ...ut of the bearing holder using the special tools and a hydraulic press TOOLS Driver 07749 0010000 Attachment 52 x 55 mm 07746 0010400 Pilot 30 mm 07746 0040700 Remove the driven gear case bearing usin...

Page 287: ...air OUTPUT DRIVEN GEAR ASSEMBLV 71 I O RING 71 31 N m 3 2kgf m 23 IbHt SHIM Drive a new bearing into the gear case with the DRIVER marked side facing up until it is fully seated TOQLS 07749 0010000 r...

Page 288: ...OOLS replaced as a set Driver 40 mm 1 0 07746 0030100 Attachment 30 mm 1 0 07746 0030300 Coat a new O ring with engine oil and install it into 7M O RING the bearing holder groove __ Install the shim N...

Page 289: ...sing the special tools TOOLS Shaft holder A 07PAB 0010100 or 07923 6890101 U S A only Lock nut wrench 36 x 47 8 mm 07916 MB00002 Differential inspection tool 07KMK HC50101 or 07KMK HC5010A U S A only...

Page 290: ...acing up untllitis fully seated TOOLS Driver 07749 0010000 Att cljm nt 62 x 68 mm 07746 0010500 P lot 30 mll1 07746 0040700 Support the bearing inner race and press the output drive gear using the spe...

Page 291: ...with soft jaws Apply engine oil to the threads and seating surface of a new bearing outer race lock nut and tighten it to the specified torque using a special tool TOOL Lock nut wrench 36 x 47 8 mm 0...

Page 292: ...ng with engine oil and install it into the groove in the gear case Install the output gear case assembly into the left 0 crankcase by aligning the dowel pin with the crank 0 case hole Apply sealant to...

Page 293: ...d side facing upward Install the asselT bly bolt hrqugh the assembly col lar and attachit tothetnfe aejed adaptor Center the compressor seat with the damper cam then begin to tighten the 23 mm nut of...

Page 294: ...naft page 13 10 Transmission page 13 20 Output gear page 13 29 Oil pump page 5 6 Turn the inner race of each bearing with your finger The bearipgssh041dturn smoothly and quietly Also checktnatihe bear...

Page 295: ...010000 Attachment 42 x 47 mm 07746 0010300 RIGHT CRANKCASE BEARINGS Drive the bearings out of the right crankcase OUTPUT DRIVE GEAR SHAFT BEARING Drive new bearings into the right crankcase with the m...

Page 296: ...tall the two dowel pins into the left crankcase Coat a new pipe seal with engine oil and install it to theojlpipe NOTE Install a new pipe seal with its tapered side facing out Install the right crankc...

Page 297: ...lt with the washer by hold SHAFT HOLDER A BOLTIWASHER ing the output driven gear shaft using the special tools TOOLS Shaft holder A 07PAB 0010100 or 07923 6890101 U S A only Holder handle 07PAB 001040...

Page 298: ...DRIVE COMPONENT LOCATION 14 2 FINAL DRIVE DISASSEMBLYI INS PECTION 14 8 SERVICE INFORMATION 14 3 FINAL DRIVE ASSEMBLy 14 17 TROUBLESHOOTING 14 6 FINAL DRIVE INSTALLATION 14 22 FII lAL DRIVE REMOVAL 1...

Page 299: ...FINAL DRIVE COMPONENT LOCATION 64 N m 6 5 kgf m 47 Ibf ft 22 N m 2 2 kgf m 16 Ibf ft 14 2...

Page 300: ...I Atdisassembly 170 cm3 5 7 US OZ 6 0 Imp oz Final drive gear backlash 0 05 0 15 0 002 0 006 0 30 0 012 Backlash difference between measurements 0 10 0 004 Ring gear to stop pin clearance 0 30 0 60 0...

Page 301: ...tachment 72 x 75 mm Pilot 19 mm Driver 40 mm 1 0 07746 0010600 07746 0041400 07746 0030100 Attachment 25 mm 1 0 Pinion holder plate Collar set C 07746 0030200 07924 ME40010 07924 ME40020 Oil seal driv...

Page 302: ...emover weight 07741 0010201 or 07936 371020A or 07936 3710200 U S A only Bearing remover 20 mm 07936 3710600 or equivalent commercially available in U S A Bearing driver attachment 07GAD SD40101 Oil s...

Page 303: ...l level too low Worn or damaged pinion gear and or pinion joint splines Oil leak Clogged breather Oil level too high Damaged seals Loose case cover bolts Excessive rear wheel backlash Worn drive shaft...

Page 304: ...FT Remove the spring oil seal and stopper ring from the drive shaft INSPECTION Check the splines of the drive shaft for wear or dam age If the splines of the drive shaft are damaged check the universa...

Page 305: ...ear back and forth to read the back lash STANDARD 0 05 0 15 mm 0 002 0 006 in SERVICELIMIT 0 30 mm 0 012 in Remove the dial indicator and special tools Turn the ring gear 1200 and measure the backlash...

Page 306: ...ve washer GEAR TOOTH CONTACT PATTERN CHECK Description of the tooth COAST SIDE Keep dust and dirt Clean the sealing material off the mating surfaces of Apply Prussian Blue out of the case and the gear...

Page 307: ...through the oil filler hole Contact is normal if the Prussian Blue is transferred to the approximate center of each tooth and slightly towards the face If the patterns are not correct remove and repl...

Page 308: ...ve the oil seal If the bearing remained in the cover remove it as follows Press the ail seal and bearing out of the cover using the special tools and hydraulic press TOOLS Driver 07749 0010000 Oiheal...

Page 309: ...ing into the cover with the marked side facing inside until it is fully seated TOOLS Driver 07749 0010000 Bearing driver attachment 07GAD SD40101 PINION GEAR REMOVAL Hold the gear case in a vise with...

Page 310: ...ssembly shaft 22 x 1 5 x 240 mm 07931 ME4010B and Special nut 07931 HB3020A Pull the pinion gear assembly out of the gear case Check the pinion gear needle bearing in the gear case for wear or damage...

Page 311: ...de facing up TOOLS Driver 40 mm 1 0 07746 0030100 Attach lent 25 mm 1 0 07746 0030200 CASE BEARING REPLACEMENT RING GEAR CASE BEARING Be sure to wear Heat the gear case to 80 C 176 F evenly using a BE...

Page 312: ...5 mm 07945 3330300 Drive a new ring gear case bearing into the gear case with the marked side facing inside until it is fully seated using the special tools TOOLS Driver 07749 0010000 Attachment 52 x...

Page 313: ...371020A or 07936 3710200 U S A only Install a new stopper ring into the groove of a new bearing securely Place the needle bearing in a freezer Heat the gear case to 80 C 176 F Remove the needle bearin...

Page 314: ...nion gear assembly into the gear case using t6e speCial tool _ i g 1 g91 Oil Seal drive 55 7 x 60 3 mm 07965 KE80200 Apply grease to a new oil seal lips 6t iy tH i seal into the pinion retainer with t...

Page 315: ...specified torque using a special tool TOOL Retainer wrench 07910 MA10100 TORQUE 108 N m 11 0 kgf m 80 IbUt Install the lock tab with its tab facing up depending on the position of the pinion retainer...

Page 316: ...40020 TORQUE 108 N m 11 0 kgf m 80 Ibf ft RING GEAR INSTALLATION RING GEAR WAVE WASHER DUST GUARD PLATE BEARING 57 34 I fIOllSEAl a RING It _ GEAR CASE COVER SHIM BEARING 16012 Insta lI thEls hil1 lon...

Page 317: ...hen the gear case cover is heated to the proper temperature remove the stop pin by tapping the cover STOP PIN Select a stop pin shim to obtain the correct c1ear R IN G G E A R ance SHIM THICKNESS A 0...

Page 318: ...tall the bolts and tighten them in a crisscross pattern in several steps until the cover evenly touches the gear case Tighten the two 10 mm bolts to the specified torque in several steps alternately T...

Page 319: ...the top of each stud to the gear case surface as shown Install a new stopper ring into the drive shaft groove Install the spring into the drive shaft Apply 0 5 g of melybdenum disulfide grease to a n...

Page 320: ...case mounting nuts Tighten the gear case mounting nuts in a crisscross pattern in several steps TORQUE 64 N m 6 5 kgf m 47 Ibf ft Tighten the shock absorber lower mounting bolt to the specified torque...

Page 321: ...MEMO...

Page 322: ...15 FRONT WHEEL SUSPENSION STEERING COMPONENT LOCATION 15 2 FRONT WHEEL 15 13 FORK 15 19 SERVICE INFORMATION 15 3 TROUBLESHOOTING 15 5 STEERING STEM 15 28 HANDLEBAR 15 6 15 1...

Page 323: ...FRONT WHEEL SUSPENSION STEERING COMPONENT LOCATION 30 N m 3 1 kgf m 22 IbHt 22 N m 2 2 kgf m 161bHt 103 N m 10 5 kgf m 761bHI II I 15 2...

Page 324: ...Fluid level 100 3 9 Fluid capacity 478 2 5 em 16 2 0 08 US OZ 16 8 0 09 Imp oz Steering head bearing pre load 8 5 12 7 N 0 9 1 3 kgf TORQUE VALUES Handlebar upper holder bolt Handlebar lower holder n...

Page 325: ...400 Pilot 20 mm 07746 0040500 Bearing remover shaft 07GGD 0010100 Bearing remover head 20 mm 07746 0050600 Spoke wrench 07JMA MR60100 Slider weight 07947 KA50100 Driver attachment 07947 KF00100 Attach...

Page 326: ...ingarm pivot components page 16 22 Front wheel wobbles Bent rim Worn wheel bearings Faulty tire Unbalanced tire and wheel Axle fastener not tightened properly Wheel hard to turn Faulty wheel bearings...

Page 327: ...r switch wires from the wire clips Remove the pivot bolt nut and clutch lever from the clutch lever bracket Disconnect the clutch switch connectors from the clutch switch Remove the bolts holder and c...

Page 328: ...ER HOLDER tors from the switch Keep the reservoir Remove the bolts holder and master cylinder upright to prevent assembly air from entering the hydraulic system Remove the right handlebar switchlthrot...

Page 329: ...N STEERING Loosen the handlebar lower holder nuts Remove the bolt caps Remove the bolts upper holders and handlebar Remove the lower holder nuts washers setting rubbers and handlebar lower holders BOL...

Page 330: ...facing up as shown Install the handlebar lower holders washers and nuts onto the top bridge Place the handlebar on the lower holders aligning the punch mark on the handlebar with the top sur face of...

Page 331: ...RETAINER RING bar Straighten the weight retainer tabs by the screw driver or punch Remove the inner weight assembly from the han RUBBER CUSHIONS dlebar Discard the retainer ring Check the rubber cush...

Page 332: ...ide surface of the handlebar and throttle pipe Wait 3 5 minutes and install the grip Allow the adhesive Rotate the grip for even application of the adhesive to dry for 1 hour before using Apply grease...

Page 333: ...lt first then tighten the lower bolt TORQUE 12 N m 1 2 kgf m 9Ibf ft Connect the front brake light switch connectors Set the housing cap Install the left handlebar switch housing and LEFT HANDLEBAR fl...

Page 334: ...ly grease to the Install the clutch lever onto the bracket and tighten clutch lever pivot the clutch lever pivot bolt to the specified torque bolt sliding surface TORQUE 1 N m 0 1 kgf m 0 7 Ibf ft Tig...

Page 335: ...e the axle and front wheel Remove the side collars INSPECTION AXLE Set the axle in V blocks Turn the axle and measure the runout using a dial indicator Actual runout is 1 2 the total indicator reading...

Page 336: ...in the hub page 15 15 DISASSEMBLY Remove the dust seals from both sides of the hub Do not reuse the Remove the bolts in a crisscross pattern in several bolts steps and remove the brake disc Replace th...

Page 337: ...it is seated on the collar TOOLS Driver Attachli1ent 42 x 47 mm Pilot 20 mm 07749 0010000 07746 0010300 07746 0040500 WHEEL CENTER ADJUSTMENT 42 N m 4 3 kgf m 31 Ibf ft BRAKE DISC Measure the distanc...

Page 338: ...paint dot on the side wall must be located next to the valve stem Remount the tire if necessary Mount the wheel tire and brake disc assembly on an inspection stan t Spin the wpeel al pvvitt9 stop and...

Page 339: ...eel between the fork legs so the damage the pads brake disc is positioned between the brake pads Apply thin coat of grease to the axle sliding surface Insert the axle froro the left side Tighten the a...

Page 340: ...fender page 3 6 Right fork only Remove the bolts and brake caliper assembly Do not reuse NOTE caliper mounting bolts Support the brake caliper so it does not hang from the brake hose BRAKE CALIPER ASS...

Page 341: ...ove the fork leg FORKLEG DISASSEMBLY Remove the dust seal Do not scratch the Remove the oil seal stopper ring fork tube sliding surface The fork cap is Remove the fork cap and O ring under spring O RI...

Page 342: ...n the fork slider If the fork piston Remove the fork center socket bolt and sealing turns with the fork washer center socket bolt temporarily install the fork spring spring seat spacer and fork cap Do...

Page 343: ...ecially the pulled off by hand sliding surface To Remove the following prevent loss of tension do not Guide bushing open the bushing Back up ring more than Oil seal necessary BACK UP RING OIL SEAL SLI...

Page 344: ...Replace any damaged component if necessary REBOUND SPRING Set the fork tube in V blocks and measure the fork r tube runout with a dial indicator Actual runout is 1 2 the total indicator reading SERVI...

Page 345: ...slit more age the coating of the bushing if it has been than necessary removed Remove the burrs from the bushing mating surface being careful not to peel off the coating Install the oil seal Apply fo...

Page 346: ...FORK PISTON I OIL LOCK PIECE Hold the fork slider in a vise with soft jaws C y SOCKET BOLT Apply locking agent to the fork center socket bolt threads Install the socket bolt with a new sealing washer...

Page 347: ...the fork tube fully Measure the fluid level from the top of the fork tube FORK FLUID LEVEL 100 mm 3 9 in Pull the fork tube up and install the fork spring with FORK SPRING the tightly wound coil side...

Page 348: ...at a new dust seal lips with fork fluid and install it INSTALLATION Install the fork leg into the steering stem and top bridge Align the fork tube top end surface with the top bridge as shown Tighten...

Page 349: ...ng bolts and tighten the bolts TORQUE 30 N m 3 1 kgf m 22 Ibf ft Install the following Front fender page 3 6 Front wheel page 15 18 STEERING STEM REMOVAL Remove the following TOP BRIDGE Handlebar pl t...

Page 350: ...Remove the steering top thread lock nut and lock washer Loosen the steering top thread using the special tool TOOL Steering stem socket 07916 3710101 or 07916 3710100 U S A only While holding the stee...

Page 351: ...ring temover 07946 3710500 Install the steering stem nut onto the steering stem to prevent the threads from being damaged when removing the lower bearing inner race Remove the lower bearing inner race...

Page 352: ...UST SEAL UPPER INNER RACE UPPER STEERING HEAD BEARING UPPER OUTER RACE Iliiijjlll LOWER OUTER RACE LOWER STEERING HEAD BEARING ARINJ3S DUSTSEAL L5 LOWER INI IER RACE JI IlIijjlII DUSTSEAL Apply 3 5 g...

Page 353: ...times to seat the bearings Retighten the steering top thread to the specified torque TORQUE 25 N m 2 5 kgf m 18 Ibf ft Install a new lock washer aligning its bent tabs with the grooves in the steerin...

Page 354: ...he steering stem and top bridges page 15 27 Tighten the stem nut to the specified torque TORQUE 03 N m 10 5 kgf m 76 Ibf ft Turn the steering stem left and right lock to Iock several times to make sur...

Page 355: ...sition the steering stem straight ahead Hook a spring scale to the fork tube between the fork top and bottom bridges Pull the spring scale keeping it at a right angle to the steering stem Read the sca...

Page 356: ...16 REAR WHEEL BRAKE SUSPENSION COMPONENT LOCATION 16 2 REAR BRAKE 16 14 SERVICE INFORMATION 16 3 BRAKE PEDAL 16 17 TROUBLESHOOTING 16 5 SHOCK ABSORBER 16 21 REAR WHEEL 16 6 SWINGARM 16 22 16 1...

Page 357: ...REAR WHEEL BRAKE SUSPENSION COMPONENT LOCATION 103 N m 10 5 kgf m 76 IbHt 64 N m 6 5 kgf m 47 IbHt 22 N m 2 2 kgf m 161bHt 88 N m 9 9 kgf m 65 IbHt...

Page 358: ...actual and indicated SPECIFICArlONS Unit mm in ITEM STANDARD SERVICE LIMIT Minimum tire tread depth 2 0 0 08 Cold tire pres I Up to 90 kg 200 Ibs load 200 kPa 2 00 kgf cm2 29 psi sure I Up to maximum...

Page 359: ...10000 Attachment 37 x 40 mm 07746 0010200 Attachment 42 x 47 mm 07746 0010300 Pilot 20 mm 07746 0040500 Bearing remover shaft 07GGD 0010100 Bearing remover head 20 mm 07746 0050600 S W _ Spoke wrench...

Page 360: ...ding shock abs orber case Worn shock absorber rubber mounts Faulty rear shock absorber Rear wheel wobbles Bentrim Unbalanced rear tire and wheel Insufficient tire pressure Faulty swingarm pivot bearin...

Page 361: ...ground Remove the adjusting nut joint pin and spring Remove the cotter pin nut washer rubber washer and bolt Loosen the pinch bolt and remove the axle and right SiDE COLLAR side collar Move the rear w...

Page 362: ...in Axial 2 0 mm 0 08 in FINAL DRIYEN FLANGE Check the driven flange splines for wear or damage Ifdamaged check the splines of the ring gear also WHEEL BALANCE For wheel balance page 15 17 Do not add...

Page 363: ...e brake panel assembly from the right wheel hub Remove the O ring Remove the final driven flange from the left wheel hub Remove the thrust washer 00 not reuse the Remove the bolts in a crisscross patt...

Page 364: ...e rubber dampers for deterioration or dam dampers as aset age Replace the wheel Install the remover head into the bearing bearings in pairs From the opposite side of the wheel install the Do not reuse...

Page 365: ...Drive in a new right bearing squarely with the marked side facing up until it is fully seated Install the distance collar Drive in new left bearing squarely with the marked side facing up until it is...

Page 366: ...ench 07JMA MR60100 I TORQUE 4 2 N m 0 4 kgf m 3 1 Ibf ft Install the stopper Install the stopper plate aligning the arrow between plate with the OUT the projections on the wheel hub SIDE mark facing A...

Page 367: ...driven flange side Apply 0 5 1 0 g of molybdenum disulfide past to the rear wheel hub mating surface of the final driven flange Coat a new O ring with molybdenum disulfide paste and install it into th...

Page 368: ...O ring guide and driven flange Hold the wheel Place the rear wheel into the swingarm and engage securely and be the driven flange spline with the ring gear spline careful not to damage the gear case...

Page 369: ...el with bolt rubber washer washer and nut Tighten the nut to the specified torque TORQUE 22N m 2 2 kgf m 16Ibf ft Inst 1Ia new cotter pin Installthe spring joint pin and adjusting nut Install the exha...

Page 370: ...E Always replace the brake shoes as a set When the brake shoes are reused mark all parts before disassembly so they can be installed in their original locations Remove the brake shoes and springs Remo...

Page 371: ...0 5 1 0 g of grease to the brake cam sliding surface Install the brake cam into the brake panel Apply engine oil to a new felt seal and install it onto thebrake panel Install the wear indicator plate...

Page 372: ...f r a e to the brake shoe to anchor pir l llgin ace Ins1 an tK l l rake sa idSprings NOTE j If t l l bfake shoesar reused the shoes and sptiflg jjios be plaCJ ir back in their original locations irist...

Page 373: ...pivot and dust seals Check the dust seals for wear or damage Unhook the brake pedal and rear brake light switch return springs Remove the snap ring washer and brake pedal assembly Remove the dust seal...

Page 374: ...middle rod joint and pivot for wear or damage Check the joint pins for wear or damage Replace these parts if necessary MIDDLE ROD JOINT INSTALLATION BRAKE ROD r o DUST SEALS lfi ly i j J iQ 1fjs It C...

Page 375: ...l the washer and snap ring NOTE Install the washers and snap rings with the chamfered edges facing the thrust load side Do not reuse worn snap ring which could easily spin in the groove Check that the...

Page 376: ...using a hoist or equivalent em9 cthe rnounting bolts washers and the shock absorber Replace the shock Check for deformation or oil leakage absorber as an Check the rubber mounts and collars for wear o...

Page 377: ...se page 14 7 Remove the right shock absorber lower mounting bolt California type only Disconnect the EVAP canister air vent hose from the EVAP c nister Remove the both pivot bolt caps Loosen the right...

Page 378: ...se Remove the left and right pivot bolts and swingarm from the frame Remove the universaljoint from the output shaft Remove the following Cotter pin Nut Washer Spring washer Bolt Stopper arm Remove th...

Page 379: ...lders for damage or deforma as a set if any part tion is damaged or worn PIVOT BEARING OUTER RACE REPLACEMENT Punch or drill an appropriate hole into the grease holder Insert a suitable driver through...

Page 380: ...EARING SPRING WASHER STOPPER ARM Appl l q 1 gcQfspecified grease page 1 19 to tb rieeqlerpJler n fdustseallips of each bearing Inlrianihel iVof ri 9SilJtothe swingarm pivots e 1 Insti311 th pintqppynt...

Page 381: ...to the output shaft Set the swingarm into the frame and hold it Install the joint bo otovert le output gear case Insta ILthe ett al1dr igh Il M ofbolts C 0 _ Tighten the left piv Pt bolt tdthe specifi...

Page 382: ...nut wrench 07908 4690003 TORQUE Actual 103 N m 10 5 kgf m 76 Ibf ft Indicated 93 N m 9 5 kgf m 69 Ibf ft Install the both pivot bolt caps Connect the EVAP canister air vent hose to the EVAP canister...

Page 383: ...MEMO...

Page 384: ...7 HYDRAULIC BRAKE 17 7 COMPONENT LOCATION 17 2 BRAKE PAD DISC SERVICE INFORMATION 17 3 MASTER CYLINDER 17 8 TROUBLESHOOTING 17 4 FRONT BRAKE CALIPER 17 13 BRAKE FLUID REPLACEMENT AIR BLEEDING 17 5 17...

Page 385: ...HYDRAULIC BRAKE COMPONENT LOCATION 1 5 N m 0 2 kgf m 1 1 Ibf ft 12 N m 1 2 kgf m 9Ibf ft 34 N m 3 5 kgf m 25 Ibf ft 34 N m 3 5 kgf m 25Ibf ft 2 5 N m 0 3 kgf m 1 8Ibf ft 17 2...

Page 386: ...efore riding the motorcycle SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Recommended brake fluid DOT 4 Front Brake disc thickness 5 8 6 2 0 23 0 24 5 0 0 20 Brake disc warpage 0 30 0 012 Mast...

Page 387: ...ng properly Low brake fluid level Clogged fluid passage Warped deformed brake disc Sticking worn caliper pistons Sticking worn master piston Bent brake lever Brake lever hard Clogged restricted hydrau...

Page 388: ...to the bleed valve Loosen the bleed valve and pump the brake lever until no more fluid flows out of the bleed valve Tighten the bleed valve r SCREWS BMKE FLUID FILLING BLEEDING Fill the reservoir wit...

Page 389: ...ed container Connect a bleed hose to the bleed valve Pressurize the system with the brake lever until lever resistance is felt Do not release the 1 Squeeze the brake lever open the bleed valve 1 4 lev...

Page 390: ...level in the fation of new brake pads reservoir as this operation causes the level to rise Remove the pad pin plug and loosen the pad pin Pull the pad pin out of the caliper body while push ing in th...

Page 391: ...for damage or cracks Measure the brake disc thickness at several points SERVIC LIMIT 5 0 mm 0 20 in Measure the brake disc warpage with a dial indica tor SERVICEUMIT 0 30mm 0 012 in Checkthe bearing...

Page 392: ...AKE Remove the bolts holder and master cylinder MASTER CYLINDER Remove the nut pivot bolt and brake lever LEVER PIVOT BOLT NUT Remove the screw and front brake light switch SCREW SWITCH Remove the boo...

Page 393: ...master pis ton in clean brake fluid INSPECTION Check the piston cups and boot for wear deteriora tion or damage Check the spring for fatigue or damage Check the master cylinder and piston for scoring...

Page 394: ...he master cyl inder Install the washer on the piston Install the snap ring into the groove in the master cylinder using a special tool 1 9 OL Snap ring pliers 07914 SA50001 Instal1 the snap ring and w...

Page 395: ...ft Install the holder Install the master cylinder with the holder and two with its UP mark bolts facing up Align the edge of the master cylinder with the punch mark on the handlebar and tighten the u...

Page 396: ...e 17 7 When removing the Remove the oil bolt and sealing washers oil bolt cover the end of hose to prevent contamination Do not reuse the Remove the caliper mounting assembly bolts B AKE CALIPER ASSEM...

Page 397: ...e piston facing the nozzle too close down and apply small squirts of air pressure to the the inlet fluid inlet to remove the pistons Be careful not to Push the dust and piston seals in and lift them o...

Page 398: ...ET 17 15 PAD PIN PLUG iiiSiIt BRACKET PIN BOOT PAD SPRING BRAKE PADS Co to Vvpi ton seals with clean brake fluid new PISTON SEALS I I du si I wIth silicone grease and install them into these aFgrooves...

Page 399: ...CKET Check the bracket pin boot and replace it if it is hard deteriorated or damaged Apply 0 4 g of silicone grease to the inside of the bracket pin boot Install the bracket pin boot and pad spring in...

Page 400: ...hose to the caliper body with the oil bolt and new sealing washers and tighten the oil bolt to the specified torque TORQUE 34 N m 3 5 kgf m 25 Ibf ft Install the brake pads page 17 7 Fill and bleed th...

Page 401: ...MEMO...

Page 402: ...YICHARGING SYSTEM BATTERY 18 6 SYSTEM LOCATION 18 2 SYSTEM DIAGRAM 18 2 CHARGING SYSTEM INSPECTION 18 7 SERVICE INFORMATION 18 3 REGULATOR RECTIFIER 18 8 TROUBLESHOOTING 18 5 ALTERNATOR CHARGING COIL...

Page 403: ...BATTERYICHARGING SYSTEM SYSTEM LOCATION ALTERNATOR SYSTEM DIAGRAM MAIN FUSE 30A Y Y YR W G ffi e REGULATOR RECTIFIER BATTERY ALTERNATOR 18 2 Y Yellow G Green R Red W White...

Page 404: ...ter 2 3 years Battery voltage may recover after battery charging but under heavy load the battery voltage will drop quickly and eventually die out For this reason the charging system is often suspecte...

Page 405: ...eds charging Below 12 4 V Charging current Normal 1 1 A 5 10 h Quick 5 5 A 1 0 h Alternator Capacity 0 35 kW 5 000 rpm Charging coil resistance 20 C 68 F 0 1 1 0 n TORQUE VALUE Battery case cover scre...

Page 406: ...NO Shorted wire harness Faulty ignition switch 4 ALTERNATOR CHARGING COIL INSPECTION Check the alternator charging coil page 18 8 Is the alternator charging coil resistance within 0 1 1 0 n 20OCI68 F...

Page 407: ...ble Remove the battery from the battery case Install the battery in the reverse order of removal NOTE Connect the positive cable first then connect the negative cable After connecting the battery cabl...

Page 408: ...IED CURRENT LEAKAGE 1 mA maximum If current leakage exceeds the specified value a shorted circuit is the probable cause Locate the short by disconnecting connections one by one and measuring the curre...

Page 409: ...__ There should be battery voltage at all times GROUND LINE Check for continuity between the Green wire termi nal of the wire harness side connector and ground There should be continuity at all times...

Page 410: ...move the seat page 3 3 With the ignition switch turned to OFF disconnect the alternator 3P Natural connector Measure the resistance between the Yellow wire terminals of alternator stator side connecto...

Page 411: ...MEMO...

Page 412: ...IGNITION SYSTEM SYSTEM LOCA ION 19 2 IGNITION COIL 19 8 ICM 19 9 SYSTEM DIAGRAM 19 2 SERVICE INFORMATION 19 3 IGNITION TIMING 19 9 TROUBLESHOOTING 19 4 TP SENSOR 19 10 IGNITION SYSTEM INSPECTION 19 5...

Page 413: ...o 0 BIIW currC sw eI 1 ENGINE STOP SWITCH 9Y TTERY BI BI To Neutral indicator J 6P BLUE DIODEr 4 LgIR p DOWN GIW p SIDESTAND 6 SWITCH GIW e o Lg G _ NEUTRAL SWITCH L BVW L L L lIC M J L L L J ll1k IG...

Page 414: ...ctions Check those connections before proceeding Make sure the battery is adequately charged Using the starter motor with a weak battery results in a slower engine cranking speed as well as no spark a...

Page 415: ...t circuit in the ignition primary coil 6 Faulty sidestand switch or neutral switch 7 Loose or poor connection or an open circuit in No 6 related wires Sidestand switch line Greenlwhite wire Neutral sw...

Page 416: ...t ava ilable in U S A W 90 f l C ia 1 a lI If digital multimeter implicl ilcf 10MfiI minimum or Igtlitiolll l atJ pe kv ft gf tester MTP07 0286 U S A only IGNITION COIL PRIMARY PEAK VOLTAGE NOTE Check...

Page 417: ...AR Yellow blue ground Turn the ignition switch to ON with the engine stop switch at 0 Check the initial voltage at this time The battery voltage should be measured If the initial voltage cannot be mea...

Page 418: ...nerator peak voltage PEAK VOLTAGE 0 7 V minimum If the voltage measured at the CM connector is abnormal measure the peak voltage at the ignition pulse generator connector Remove the steering side cove...

Page 419: ...coil in the reverse order of plug wires properly removal page 1 22 REAR lGl JtTION GOIL REMOVAL INSTALLATION Remove the right side cover page 3 3 Remove the fuse box turn signal relay with the stay f...

Page 420: ...ION TIMING Start the engine warm it up to normal operating temperature and then stop it Remove the socket bolts and alternator cover Remove the timing hole cap Connect a tachometer Read the Cormect th...

Page 421: ...the alternator cover and tighten the socket bolts to the specified torque TORQUE 10 N m 1 0 kgf m 7 Ibf ft a RING INDEX NOTCH TPSENSOR INSPECTION Remove the ICM page 19 9 Measure the resistance betwe...

Page 422: ...rement at the ICM is abnormal and the one at the TP sensor is normal check for an open or short circuit or loose or poor connec tions in the wire harness If both measurements are abnormal remove the c...

Page 423: ...MEMO...

Page 424: ...20 ELECTRIC STARTER SYSTEM LOCATION 20 2 STARTER MOTOR 20 6 SYSTEM DIAGRAM 20 2 STARTER RELAY SWiTCH 20 15 SERVICE INFORMATION 20 3 DIODE 20 16 TROUBLESHOOTING 20 4 20 1...

Page 425: ...ER RELAY SWITCH SYSTEM DIAGRAM IGNITION SWITCH R C o RlBI 6P RED JSUB FUSE MAIN FUSE 30A Y R 0 0 BI W 0 0 BI G JL L BI 10A STARTER ENGINE v r SWITCH STOP SWITCH STARTER GlR RELAY SWITCH 6P BLUE CLUTCH...

Page 426: ...n the troubleshooting flow chart page 20 4 A weak battery may be unable to turn the starter motor quickly enough or supply adequate ignition current Refer to the following components information Ignit...

Page 427: ...starter relay switch connector and check the relay coil ground lines as below for con tinuity 1 Green red terminal diode neutral switch line with the transmission in neutral and clutch lever released...

Page 428: ...ge 21 19 Is the clutch switch operation normal NO Faulty clutch switch YES GO TO STEP 2 2 Sidestand Switch Inspection Check the sidestand switch operation page 21 20 Is the sidestand switch operation...

Page 429: ...ge 18 6 Open the terminal cover and remove the terminal nut Disconnect the starter motor cable Remove the bolts and ground cable Remove the starter motor from the crankcase Remove the a ring from the...

Page 430: ...and O ring Remove the armature from the rear cover REAR COVER O RING ARMATURE STARTER MOTOR CASE Remove the brushes and springs from the brush holder Remove the stopper from the rear cover Check for c...

Page 431: ...uld be no continuity Check for continuity between negative brushes and rear cover There should be continuity Check for continuity between positive and negative brushes There should be no continuity Re...

Page 432: ...INAL BOLT INSPECTION Measure each brush length SERVICE UMIT 6 5 mm 0 26 in Check the wear commutator for damage or abnormal ARMATURE Do not use emery or sand paper on the commutator Check the commutat...

Page 433: ...al com q NO CONTINUITY COMMUTATOR BAR mutator bar and the armature shaft There should be no continuity Check the dust seal and ball bearing for wear or damage Check the ball bearing rotates smoothly C...

Page 434: ...IbHt NEGATIVE BRUSHES SPRING BRUSH HOLDER ELECTRIC STARTER Install the brush holder positive brushes and termi BRUSH HOLDER nal bolt TERMINAL BOLT 20 11 ASSEMBLY 11 O RING II O RING ARMATURE POSITIV I...

Page 435: ...ely Install the negative brushes and tighten the screw to the specified torque TORQUE 3 7 N m 0 4 kgf m 2 7Ibf ft Install the brush springs to the brush holder grooves Install the stopper to the rear...

Page 436: ...its groove with the stopper on the rear cover assembly I NOTICE I The coil may be damaged if the magnet pulls the armature against the case Install a new O ring to the starter motor case Install the f...

Page 437: ...BOLTS INSTALLATION Apply engine oil to a new O ring and install it to the cF ri O RING starter motor groove Install the starter motor onto the crankcase from the right side Connect the ground cable In...

Page 438: ...k for continuity between the Green red wire ground line terminal and ground If there is continuity when the transmission is in neutral or when the clutch is disengaged and the sidestand is retracted t...

Page 439: ...ry is disconnected REMQVALIINSTALLATION Remove the following Right side cover page 3 3 Fuseboxlturn signal relay page 19 8 Turn the ignition switch to OFF Disconnect the battery negative cable page 18...

Page 440: ...ECTRIC STARTER Check for continuity between the diode terminals DIODE When there is continuity a small resistance value will register If there is continuity in one direction the diode is normal B 20 1...

Page 441: ...MEMO...

Page 442: ...7 LICENSE LIGHT 21 8 SPEEDOMETER VS SENSOR 21 9 COOLANT rEMPERATURE INDICATORI ECT SENSOR SWITCH 21 12 FAN MOTOR SWITCH 21 14 OIL PRESSURE INDICATOR 21 15 IGNrnON SWITCH 21 16 HANDLEBAR SWITCH 21 17...

Page 443: ...LIGHTS METERS SWITCHES SYSTEM LOCATION FRONT BRAKE LIGHT SWITCH LEFT HANDLEBAR SWITCH CLUTCH SWITCH HORN FAN MOTOR SWITCH REAR BRAKE LIGHT SWITCH SIDESTAND SWITCH NEUTRAL SWITCH EOP SWITCH 21 2...

Page 444: ...55 W Brake taillight 12V 21 5W License light 12 V 5 W Front turn signal position light 12V 21 5Wx2 Rear turn signal light 12V 21 Wx2 Instrument light LEDx6 Turn signal indicator LED High beam indicato...

Page 445: ...LIGHTS METERS SWITCHES TOOL Inspection test harness 07GMJ ML80100 21 4...

Page 446: ...h the grooves in the headlight unit Hook the retainer Install the dust cover with its TOP mark facing up Connect the headlight 3P connector Install the headlight unit into the headlight case by aligni...

Page 447: ...new one Make sure the lens gasket is installed in position and is in good condition and replace it with a new one if necessary Install the lens aligning its slot with the tab of the turn signal light...

Page 448: ...lace it with a new one if necessary Install the removed Pl Irts in the removal reverse order of GASKET SCREWS LIGHTS METERS SWITCHES Align TURN SIGNAL LIGHT Route the turn signa light wire properly pa...

Page 449: ...bf ft COLLAR BRAKEfTAIL LIGHT LICENSE LIGHT BULB REPLACEMENT Remove the screws and license light cover LICENSE LIGHT COVER Remove the bulb and replace it Make sure that the lens gasket is installed in...

Page 450: ...If there is no voltage check the following Open circuit in the Pink wire Blown sub fuse 10A ODOMETER Open circuit in the Red wire BROWN SPEEDOMETER CONNECTORS viewed from the wire harness side SPEEDO...

Page 451: ...r and disconnect the speedome ter 12P connector Remove the screws switch cover and trip meter reset switch Remove the screws clamp speedometer and 0 ring Check the O ring is in good condition replace...

Page 452: ...re should be battery voltage If there is no voltage check for an open circuit in the Brown and Green black wires Support the motorcycle securely and raise the rear wheel off the ground Connect the tes...

Page 453: ...the indica tor If the indicator comes on inspect the ECT sensor switch If the indicator does not come on check for an open circuit in the Green blue wire If the wire is OK replace the speedometer pag...

Page 454: ...s up NOTE Soak the ECT sensor switch in coolant up to its threads with at least 40 mm 1 6 in from the bot tom of the pan to the bottom of the switch Keep temperature constant for 3 minutes before test...

Page 455: ...e fan motor does not start Before testing check for a blown sub fuse 20 A FAN Disconnect the connector from the fan motor switch and ground it Turn the ignition switch to ON and check the fan motor If...

Page 456: ...connect the EOP switch wire by removing the terminal screw Ground the wire terminal Turn the ignition switch to ON and check the oil pressure indicator If the indicator comes on replace the EOP switch...

Page 457: ...on switch cover Remove the bolts and ignition switch assembly Remove the bolts ignition switch collar and switch base from the stay Install the switch base ignition switch and collar to the stay Tight...

Page 458: ...e Check for continuity between the connector termi nals in each switch position Continuity should exist between the color coded wires as shown in the charts 2P CONNECTOR RIGHT HANDLEBAR SWITCH ENGINE...

Page 459: ...nnector and check for continuity between the switch side connector terminals There should be continuity with the brake pedal depressed and no continuity with the pedal released REAR BRAKE LIGHT SWITCH...

Page 460: ...al switch connector Check for continuity between the switch terminal and engine ground There should be continuity when the transmission is in neutral and no continuity when the transmis sion is in gea...

Page 461: ...d retracted and no continuity with the sidestand low ered REMOVALlINSTAlLATION Remove the following Seat page 3 3 Left side cover page 3 3 Left crankcase rear cover page 3 5 Support the motorcycle sec...

Page 462: ...its flat with the horn stay Install and tighten the bolt to the specified torque TORQUE 21 N m 2 1 kgf m 15Ibf ft Connect the connectors _ TURN SIGNAL RELAV Turn signal light does not blink Remove th...

Page 463: ...MEMO...

Page 464: ...22 WIRING DIAGRAMS WIRING DIAGRAM WIRING DIAGRAM California type 22 4 49 states ICanada type 22 3 e 22 1...

Page 465: ...NT OPTION TURN SIGNAL LIGHT 12V2115W mOP 1 a YJR LEFT FRONT BIIW 12V2115W OPO g g BllBu 0 g t I I t l 11ttttt HORN 3 3 0 ill a Omm 9 9 ml5 It lD I h TI I P 2P I L qh iii It lD III I I 81 0 IGNITION SW...

Page 466: ...TCH J I i t REAR BRAKE l ID I t 1t GRAY Q1 b RIGHT REAR TURN SIGNAL LIGHT aP 12V21W f GlY uJ GIY f GIY G G G L Br Br p Br BRAKEITAIL LIGHT 12V211SW 2P c OJ LICENSE LIGHT 12V5W I c g OJ g MaP 2PO LEFT...

Page 467: ...TRUMENT LIGHT ENGINE smP STARTEF FRONT BRAKE D LED X LIGHT SWITCH W mm TRIP RESET SWITCH l JRN FOG LAMP RIGHT FRONT OPTION l JRN SIGNAL LIGHT 12V2115W CLUTCH SWITCH l JRN SIGNALoDlMMERoHORN SWITCH VS...

Page 468: ...ITCH IIGNALRELAY BfiAKEITAIL LIGHT 12V2115W 2 c ill LICENSE LIGHT 12V5W g illg I 2P o LEFT REAR iii Ol TURN SIGNAL LIGHT 12V21W o FANMOTOR SIDESTAND SWITCH B SJ ALTERNATOR CH EOP SWITCH NEUTRAL SWITCH...

Page 469: ...23 TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD POOR PERFORMANCE AT TO START 23 2 HIGH SPEED 23 6 ENGINE LACKS POWER 23 3 POOR HANDLING 23 7 POOR PERFORMANCE AT LOW AND IDLE SPEED 23 5 23 1...

Page 470: ...ark YES Faulty sparkplug Fouled spark plug loose or disconnected ignition system wires Faulty ignition pulse generator Faulty ignition coil Faulty ICM Faulty engine stop switch NO GO TO STEP 4 4 Cylin...

Page 471: ...ch discs plates Warped clutch discs plates Weak clutch spring Additive in engine oil YES GO TO STEP 4 4 Engine Performance Inspection Accelerate lightly Does the engine speed increase NO SE valve ON p...

Page 472: ...10 10 Lubrication Inspection Remove cylinder head cover and inspect lubrication Is the valve train lubricated properly NO Clogged oil passage Clogged oil orifice YES GO TO STEP 11 11 Over Heating Insp...

Page 473: ...YES Loose insulator bands Damaged insulator Faulty O ring NO GO TO STEP 3 3 Spark Test Perform spark test Is there weak or intermittent spark YES _ Faulty spark plug Fouled spark plug Loose or discon...

Page 474: ...rburetor Inspection Check carburetor for clogging Is the carburetor clogged YES Carburetor not serviced frequently enough NO GO TO STEP 4 Ignition Timing Inspection Check ignition timing Is the igniti...

Page 475: ...ng head bearings Low tire pressure Either wheel is wobbling Excessive wheel bearing play Bent rim Improperly installed wheel hub Excessively worn swingarm pivot bearings Bentframe Motorcycle pulls to...

Page 476: ...MEMO...

Page 477: ...SPECIFICATIONS 1 8 CYLINDER PISTON INSTALLATION 10 9 CYLINDER PISTON REMOVAL 10 4 CYLINDER PISTON SPECIFICATIONS 1 8 DIODE 20 16 ELECTRIC STARTER SPECIFICATIONS 1 12 EMISSION CONTROL SYSTEMS 1 39 ENGI...

Page 478: ...SIDE COVER 3 5 STEERING STEM 15 28 SUB AIR CLEANER 4 8 SUSPENSiON 4 24 SWINGARM 16 22 SYSTEM DIAGRAM BATTERY CHARGING SYSTEM 18 2 ELECTRIC STARTER 20 2 IGNITION SYSTEM 19 2 SYSTEM FLOW PATTERN 7 2 SY...

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