Honda XL350R 1984 Shop Manual Download Page 69

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Summary of Contents for XL350R 1984

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Page 3: ...this page then turn to the table of contents on page 1 of that section Most sections start with an assembly or sys tem illustration general instructions specifi cations torque va lues tools and troub...

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Page 5: ...ks near the battery especially while charging it 1 Use genuine HONDA or HONDA recommended parts and lubricants or their equivalent Parts that do not meet HONDA s design specifications may damage the m...

Page 6: ...cation number VIN is on the left side of the steering head The engine serial number is stamped on bottom of the left crankcase 1 2 rz n cover The frame serial steering head is attached to th T 0 ident...

Page 7: ...342 8 cm2 53 1 sq in Rear brake swept area Internal expanding shoes 86 3 cm 2 13 3 sq in Fuel capacity 11 0 lit 2 9 U S gal 2 4 Imp gaLl Fuel reserve capacity 2 0 lit 0 5 U S gal 0 4 Imp gal Caster 3...

Page 8: ...Gear ratio VI 0 926 Final reduction 2 857 Gear shift pattern Left foot operated return system ELECTRICAL Ignition C D 1 Ignition timing Initial aO BTDC at 1 300 rpm Full advance 28 BrDC at 4 000 rpm A...

Page 9: ...21 6 8 12 10 8 1 2 6 9 Dram plug 1 12 20 30 2 0 3 0 14 22 Drive sprocket bolt 2 6 8 12 0 8 1 2 6 9 Primary drive gear lock nut 1 18 60 70 6 0 7 0 43 501 Crankcase bolt I 6 8 12 10 8 1 2 6 9 Oil pump...

Page 10: ...disc nut 6 14 160 4 1 6 10 12 Brake pipe 1 10 30 40 3 0 4 0 22 29 Brake hose joinl 2 10 12 15 1 2 1 5 9 11 Caliper oil pipe boh 1 10 30 40 13 0 4 0 22 291 Side stand pivot bolt 1 10 35 45 3 5 4 5 25 3...

Page 11: ...8 3 11 7 Remover handle 07936 3710100 A mbly coli 07931 K FOO100 10 9 Crankshaft assembly tool kit 07931 KFOOOOO Threaded adaptor 07931 KFOO200 10 9 Shaft puller 07931 KF40000 10 9 rBearing remover 0...

Page 12: ...0010200 11 7 8 13 9 Pilot 12 mm 07746 0040200 11 7 Attachment 32 x 35 mm 07746 0010100 12 9 13 7 Pilot 17 mm 07746 0040400 11 7 8 12 19 13 9 Attachment 42 x 47 mm 07746 0010300 11 8 13 9 Pilot 15 mm 0...

Page 13: ...I 0 ro 000 _ ooeo _ OJ J JIi l ll Tf J _ _ _ c It 0030Z KL3 6700 Cl m Z m 0 l r Z o 0 l o z...

Page 14: ...I o n _ f r rl cf _ 1 _ I r l lr i _ 6l J 11th IIlHfI11 l r 1 m e 00 r b I 1 I r I I I I I I I I I I _ Jilt I _ _ e _ _ e j l z j5 j l 0 3 0030Z KL3 7701 m Z m r Z o o z...

Page 15: ...ner Clean the attaching surface thoroughly before applying tape Do not use wires or harnesses with damaged in sulation Repair by wrapping them With a protec tille tape or replace them Route wire harn...

Page 16: ...GENERAL INFORMATION MAIN LIGHT SWITCH WIRE 1 12 HARNESS BATTERY BREATHER TUBE BATTERY POSITIVE CABLE THROTTLE CABLES RIGHTTUAN SI iNA LWIRE SIGNAL WIRE...

Page 17: ...s toxic Honda Motor Co Ltd utilizes lean carburetor settings as well as other systems to reduce carbon monoxide and hydrocarbons EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is...

Page 18: ...RING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED Federal law prohibits the following acts or the caus ing there of 1 The removal or rendering inoperative by any person other than for purposes of main...

Page 19: ...MEMO 1 15...

Page 20: ...LUBRICATION Oi l DRAW SHIFT FORK SH FT 2 0 Oil FILTER CRANKSHAFT OIL STRAINE R SCREEN MAINSHAFT CAM SHAFT...

Page 21: ...9 liter 2 0 U s qt 1 7 Imp qt at engine as sembly 1 65 liter 1 74 U S qt 1 44 Imp qt at oil change Use HONDA 4 STROKE OIL or equivalent API SERVICE CLASSIFICATION SE or SF VISCOSI TY SAE 20W 50 1rJN 4...

Page 22: ...he oil filler cap dipstick and drain plug After the oil has drained check that the drain plug sealing washer is in good condition and install the plug TORQUE 20 30 N m 12 0 3 0 kg m 14 22 ft Ibl NOTE...

Page 23: ...de with the rubber seal is facing out toward the oil filter cover ENGINE OIL STRAINER CLEANING NOTE Clean the oil strainer whenever the right crankcase has been removed Remove the oil strainer and cle...

Page 24: ...clutch con trol cables at their upper ends Thoroughly lubricate the cables and their pivot points with a commercial Iy available cable lubricant 2 4 SWING ARM PI VOT BEARINGS ISPECIAL LUBRICANT I SHOC...

Page 25: ...D WEAR 3 5 BRAKE FLUID 3 6 BRAKE SYSTEM 3 7 BRAKE LIGHT SWITCH 3 7 HEADLIGHT AIM 3 7 CLUTCH 3 8 SIDE STAND 3 9 SUSPENSION SPARK ARRESTER CLEANING 3 9 U S A OnIV NUTS BOLTS FASTENERS WHEEL SPOKES STEER...

Page 26: ...oke nipple Vallie adjusting screw lock nut Side stand pivot bolt TOOL Wrench 10 12 mm Adjusting wrench B 3 2 30 40 mm 1 1 4 1 5 8 in 20 30 mm 3 4 1 114 in 10 20 mm 3 8 3 4 in 3 5 kg 6 6 11 0 Ibl Front...

Page 27: ...0 km 3 10 DRIVE CHAIN SLIPPER I I I I I 3 12 BATTERY MONTH I I I I I I I 3 12 BRAKE PAD SHOE WEAR I I I I I 3 12 BRAKE FLUID FRONT MONT H I I I I R I I 3 13 2 YEARS R BRAKE SYSTEM I I I I I I 3 13 BRA...

Page 28: ...valve body Reinstall the fuel cup making sure the new O ring is in place Hand tighten the fuel cup and then torque it to specification TORQUE 3 5 N m 0 3 0 5 k t m 2 4 ft lb NOTE Do not overtighten th...

Page 29: ...Recheck throttle operation Major adjustments are made with the lower adjuster Remove seat and fuel tank Adjust free play by loosening the lock nut and turn ing the adjuster Tighten the lock nut Reche...

Page 30: ...oke valve stroke Install the fuel tank and seat AIR CLEANER Remove the left side cover Remove the air cleaner cover screws and the cover Remove the element holder and air cleaner element Wash the elem...

Page 31: ...d high X27EPR U9 NO speed riding DPA9EA 9 NGK Make sure the sealing washer is in good condition InstaU the spark plug tighten it by hand then tighten with a spark plug wrench Connect the spark plug ca...

Page 32: ...the lock nut TOROUE 15 18 N m 1 5 18 kg m 1 13 ft Ibl Recheck the valve clearance Adjust starter decompressor valve lifter lever free play Install parts in the reverse order of di ssembly STARTER DEC...

Page 33: ...hin specifica tions The engine must be warm for accurate idle inspection and adjustment Ten minutes of stop and go riding is sufficient Warm up the engine shift to neutral and hold the motorcycle upri...

Page 34: ...gonn Tighten the 8xle nut TORQUE 80 110 N m 18 0 11 0 kg m 58 80 ft Ib Replace the drive chain when the red zone on the label aligns with the center of the napper pin after the chain has been adjusted...

Page 35: ...ive chain and O rings for possible wear or damage Rep lace the chain if it is worn excessill Iy or damaged Lubricate the drive chain with SAE 80 or 90 gear oil Inspeet the sprocket teeth for excessive...

Page 36: ...ry and add distilled water to the upper level mark CAUTION Add only distilled water Tap water will short en the service life oftile battery The battery electrolyte contains sulphuric acid Protect your...

Page 37: ...has been turned so that the reservoir is level Do not mix different ty pes of fluid they are not compatible with each other BRAKE SYSTEM FRONT BRAKE LEVER FREE PLAY Front brake lever adjuster The fro...

Page 38: ...ust the rear brake pedal free play after ad justing the brake pedal height Measure the rear brake pedal free play FREE PLAY 20 30 mm 3 4 1 1 4 in Adjust the free play by turning the adjuster BRAKE LIG...

Page 39: ...and regulations An improperly odjusled headlight may blind oncoming drivers or it may jail to light the distance CLUTCH Measure the clutch free play at the lever end FREE PLAY 10 20 mm 3 8 3 4 in Min...

Page 40: ...nd loss of tension Check the side stand for damage and freedom of movement Make sure the force required to fold up the side stand is within 3 0 5 0 kg 6 6 11 0 Ibl when pull ing with a spring scale Lu...

Page 41: ...Place the vehicle on a support to raise the rear wheel Move the rear wheel sideways with force to see if the swing arm bearings are worn Replace if excessively worn Check the entire suspension system...

Page 42: ...form this operaTion in Q well V nti ated area free from the hazord Use adequate eye protection After cleaning the spark arrester install the muffler lids and gasket NOTE Check that the muffler lid and...

Page 43: ...imbedded nails or other sharp objects T ighten the wheel spokes periodically More fre Quent inspection is necessary when riding off road TORQUE 2 5 5 0 N m 25 50 kg em 29 57 in lbl STEERING HEAD BEARI...

Page 44: ...FUEL SYSTEM 4 0 I I I I I...

Page 45: ...note the locations of the O rings Replace them with new ones on reassembly When disassembling the primary and secondary carburetors at the same time make sure to reassemble the parts correctly The car...

Page 46: ...tor touch point too late Secondary carburetor not closed properly Fuel tank breather tube clogged lean Mixture Carburetor fuel iets clogged Fuel cap vent blocked Fuel filter clogged Fuel line kinked o...

Page 47: ...securing the carburetor bands Remove the carburetor NOTE 00 not pry between the insulator and engine Carefully pull it back away from the engine FLOAT CHAMBER FLOAT JETS FLOAT REMOVAL Remolle the floa...

Page 48: ...are fully press it out from the piston valve side Remove the air screw if necessary Page 4 11 NOTE Count the number of turns required to re move the air screw so it can be returned to its original set...

Page 49: ...OAT LEVEL ADJUSTMENT Measure the float levels with the float tip just con tacting the float valve FLOAT LEVEL 18 0 mm 0 71 in Adjust the float level by bending the float arm if not within the specific...

Page 50: ...ve is installed only in the primary carburetor Remove the cover screws then remove the air cut off valve cover Remove the O ring spring and diaphragm Check the diaphragm for cracks or damage AIR CUT O...

Page 51: ...E On secondary carburetor Remove the throt tle link mounting screw then remove the throttle link Remove the screws link arm joint and set plate Remove the jet needle from the throttle valve NOTE Do no...

Page 52: ...dle spring on the jet needle set the link arm and tighten the screw securely NOTE To install the link arm place the setting hole facing to the cut out of throttle valV8 as shown When you install the t...

Page 53: ...washer and screw then secure with screw InstaU the gasket and carburetor top cover then tighten the cover mounting screw securely CARBURETOR ASSEMBLY Assembly is the reverse order of separation NOTE M...

Page 54: ...With the idle SlOp screw unscrewed until it no longer contacts Ihe primary carburetor crank and the throttle fully closed measure the clear ance between the primary carburetor crank and the secondary...

Page 55: ...e Page 4 10 1 Turn the new air screw clockwise until it seats lightly and back it out to the specif ication given This is an initial setting prior to the final air screw adjustment INITIAL OPENING 2 1...

Page 56: ...stall the new jet as shown Turn the air screw counterclockwise 1 2 turn Reassemble and install the carburetor Warm up the engine to operating temperature Stop and go driving for 10 minutes is sufficie...

Page 57: ...k that fuel flows out of the fuel valve freely If flow is restricted clean the fuel strainer FUEL TANK INSTALLAT ION Install the fuel tank with the two mounting bolts Connect me fuel tube Install the...

Page 58: ...air cleaner connecting tube bands Remove the air cleaner mounting bolts Remove the air cleaner case Refer to page 3 6 for air cleaner service procedures Install the air cleaner case in the reverse ord...

Page 59: ...R Route the crankcase breather tube as shown Route the breather separator drain tube as shown See page 3 7 for crankcase breather separator serv ice dli fiYlr DRAIN PLUG FUEL SYSTEM AlA CLEANER BREATH...

Page 60: ...oes to the left carburetor cap Apply the specified vacuum to the PCV SPECIF IED VACUUM 250 mm 9 8 in Hg The specified vacuum should be maintained Replace the PCV if vacuum is not maintained Connect a...

Page 61: ...MEMO 4 17...

Page 62: ...ENGINE REMOVAL INSTALLATION 5 0 8 12 N m 0 8 1 2 kg m 6 9 ft Ib 55 65 N m 5 5 6 5 kg m 40 47 ft lb 8 12 N m 0 8 1 2 kg m 6 9 ft Ib...

Page 63: ...S Engine hanger bolu Engine hanger plate bolt Engine hanger bolt Front lower Rear Front upper Top Right foot peg bolt Muffler band Exhaust joint nut Brake pedal pivot boh Section 10 Section 11 36 8 kg...

Page 64: ...nuts located under the rear fender Remove the seat Turn the fuel valve OFF and disconnect the fuel rube from the carburetor then remove the fuel tank Remove the spark plug cap Loosen the muffler bands...

Page 65: ...emove the drive sprocket cover Loosen the rear axle nut and drive chain adjusters Push the rear wheel forward and diseng ge the drive chain from the drive sprocket Remove the engine hanger bolts and h...

Page 66: ...erly Page 11 and 12 Perform the following inspections and adjustments Engine oil Page 2 2 Throttle grip free play Page 3 4 Drive chain Page 3 101 Rear brake pedal free play Page 3 14 Clutch lever free...

Page 67: ...MEMO 5 5...

Page 68: ...g m 17 2 2 ft lb 25 30N m 2 5 30 k g m 18 22 ft lb 20 25 N m 2 0 25 k f bl t Si8 Si 15 g m 14 18 25 30 N m 2 5 30 k 1 g m 18 22 ft Ibl 18 N m 1 5 18k g m l 131t 15 20N m 1 5 2 0 k 9 4 o 6 0 8 17 23 N...

Page 69: ...PECI FICATI ONS ITEM STANDARD SERV ICE LIM IT Cylind er compression 1 400 kPa 14 0 kg cm 2 199 psi Camshaft Cam lobe height I IN 30 569 mm 1 2035 in 30 37 mm 1 195 in I EX 30 575 mm 1 2037 in 30 38 mm...

Page 70: ...in 5 S00 5 512 mm 10 2165 0 217 in 0 010 0 037 mm 0 0004 0 0015 in 0 023 0 045 mm 0 0009 0 0018 inl 1 2 1 4 mm 0 05 0 06 in 1 2 1 4 mm 0 05 0 06 in 25 30 N m 2 5 3 0 kg m 18 22 ft bl 25 30 N m 2 5 3...

Page 71: ...aking or damaged head gasket Warped or cracked cylinder head Cylinder and piston Refer to Section 7 Decompressor out of adjustment High Compression Excessive carbon build up on piston crown or combust...

Page 72: ...ankcase cover Turn the crankshaft counterclockwise and align the Too mark on the alter rotor with the index mark on the left crankcase cover Verify the engine is at T n C on the compression stroke by...

Page 73: ...the cylinder head cover ROCKER ARM AND SUB ROCKER ARM INSPECTION Inspect the rocker arms and sub rocker arms for damage wear or clogged oil holes NOTE If any rocker arm or subrocker arm is worn or da...

Page 74: ...KE R ARM SHAFT INSPECTION Inspeet rocker arm shafts and sub rocker arm shafts for wear or damage Measure the 0 0 of the shaft SERVICE LIMITS ROCKER ARM SUB ROCKER ARM 1 41 mm 0 449 in IN 7 92 mm 0 312...

Page 75: ...nkcase Pu II the cam sprocket off the camshaft and remove the cam chain from the cam sprocket Suspend the cam chain with a piece of wire to keep it from falling into the crankcase Pull the camshaft up...

Page 76: ...196 in Check camshaft runout w ith a dial indicator Support both ends of the camshaft with V blocks Use 1 2 of the total indicator reading to determine runout SERVICE LIMIT 0 04 mm 0 002 in CAMSHAFT...

Page 77: ...e shaft The tensioner shaft should turn clockwise freely and should not turn counterclockwise CYLINDER HEAD REMOVAL Remove the cylinder head cover page 6 4 Remove the camshaft Page 6 6 Remove the exha...

Page 78: ...the cylinder head mating surfaces CYLINDER HEAD DISASSEMBLY Remove the valve spring cotten retainers springs and valves with a valve spring compressor CAUTION To prevem loss of tension do not compress...

Page 79: ...HEAD INSPECTION Check the spark plug hole and valve areas for cracks Check the cylinder head in several places for war page with a straight edge and a feeler gauge SERVICE LIMIT 0 10 mm 0 004 in VA L...

Page 80: ...0 218 in NOTE Ream the guides to remove carbon build up before checking the valve guide 1 0 Calculate the stem toiluide clearance SERVICE LIMITS INTAKE 0 065 mm O D026 in EXHAUST 0 080 mm 0 0031 in NO...

Page 81: ...spect the valve guide tor damage Ream the new valve guides after installation NOTE Use cutting oil on the reamer during this oper ation Rotate the reamer in the cutting direction while inserting and r...

Page 82: ...nit I oll e conllot be ground If tile valve face is burned or badly worn or if it contacts the seat unevenly reploce the Qlve Measure the valve seat width SERVICE LIMIT 2 0 rnm 0 08 in If the seat is...

Page 83: ...material Using a 60 degree cutter remove the bottom 1 4 of the old seat Using a 45 degree cutter cut the seat to the proper width NOTE Make sure that aU pitting and irregularities are removed Refinish...

Page 84: ...t be lowered us ing a 32 degree flat cutter If the contact area is too low on the valve the seat must be raised using a 60 degree inner cutter Re finish the seat to specifications using a 45 degree fi...

Page 85: ...he valve cotters using the valve spring com pressor CAUTtON To prevent loss o tension do not compress the valve spring more than necessary Tap the vallie stems gently with a plastic hammer to firmly s...

Page 86: ...ten the cylinder head bolts in a criUoCross pat tern in two or more steps TORQUE 47 53 N m 14 1 5 3 kg m 34 38 ft Ibl Install the cylinder head bolt hole cap Install the intake manifold using a new O...

Page 87: ...oner s lever straight down Place the tensioner holder tool s pin into the hole in the ten sioner which will be facing up Slowly release the tensioner lever until the tool rests against the cylinder he...

Page 88: ...rotating the sprocket Position the cam sprocket onto the shoulder of the camshaft Install the cam sprocket bolts and tighten them to the specified torque TORQUE 11 23 N m 1 7 2 3 kg m 12 17 ft lbl Re...

Page 89: ...ER ARM SHAFT 25 30 N m 2 S 3 0 kg m 18 22 ft Ibl SUB ROCKER ARM SHAFT IN 25 30 N m 12 5 3 0 kg m 18 22 ft Ib EX 20 25 N m 2 0 2 5 kg m 14 18 ft lb Apply clean engine oil to the rocker arms and shafts...

Page 90: ...t 8 12 N m 0 8 1 2 kg m 6 9 ft lb Tighten the head cover bolts in 8 criss cross pattern in two or more steps Adjust the valve clearance Page 3 8 Make sure the a ring is property seated in the groove o...

Page 91: ...compression is not leaking at the gauge connection COMPRESSION 1 400 kPa 14 0 kg eml 199 psi Low compression can be caused by Improper valve adjustment Valve leakage Leaking cylinder head gasket Worn...

Page 92: ...CYLINDER PISTON 47 53 N m 14 7 5 3 34 38 ft lb 10 14 N m 1 0 1 4 kg m 7 10 ft Ib 7 0...

Page 93: ...10 0079 0 0157 in Oil Side Rail 0 2 0 9 mm 0 007 0 035 in Piston ring to groove Top 0 030 0 065 mm 0 0012 0 0026 in clearance Second 0 015 0 045 mm 0 0006 0 0018 in Cylinder to piston clearance 0 015...

Page 94: ...cylinder piston or piston rings Improper installation of piston rings Scored or scratched piston of cylinder wall Overheating Exceuive carbon build up on piston crown or combustion chamber Knocking o...

Page 95: ...ECTION Inspect the cylinder bore tor wear or damage Measure the cylinder 1 0 SERVICE LIMIT 84 1 mm 3 311 in NOTE Check for out of round on the X and Y axis at three locations Calculate the taper and o...

Page 96: ...leln any gasket material from the crankcase and cylinder NOTE Place a 5hop towel in the crankcase to prevent gasket materials from falling in PISTON REMOVAL Remove the piston pin clip with pliers NOTE...

Page 97: ...pistons for damage and the ring grooves for wear NOTE Do not damage the piston rings during remev I Clean the piston ring grooves thoroughly Check for cleanliness by holding a ring in the grooves whil...

Page 98: ...m 3 302 in Calculate the piston to cvlinder clearance SERVICE LIMIT 0 10 mm 0 004 in Mea5Ure the piston pin hole 1 0 SERVICE LIMIT 19 08 mm 0 751 in Measure the piston pin O D SERVICE LIMIT 18 96 mm 0...

Page 99: ...rings with the marks facing up NOTE Avoid piston and piston ring damage during lnl allation Install the oil ring spacer first then install the side rails Space the piston ring end gaps 120 degrees apa...

Page 100: ...iston pin clip end gaps in the 12 o clock position Remove the shop towel from the crankcase Install the cylinder base gasket and dowel pins Coat the cylinder bore piston and piston rings with clean en...

Page 101: ...it the cam chain guide tab in the cylinder cutout as shown Push the guide in until it bottoms in the crankcase guide hole Install the dowel pins in the top of the cylinder Install a new cylinder head...

Page 102: ...CLUTCH OIL PUMP KICK STARTER 10 14 N m 1 0 14 7 10ft lb 8 12 N m 1 2 kg nl 6 9 ft Ib 20 35 N m 12 0 3 5 kg m 14 25 ft Ib 8 0 6 0 0 N m 6 0 7 0 kg m 43 50 ft Ibl N m 1 0 1 4 kg m 7 10 ft tbl...

Page 103: ...106 in Plate warpage 0 3 mm 0 01 in Clutch outer I D 28 000 28 021 mm 1 1024 1 1032 in 28 04 mm 1 104 in Clutch outer guide 0 0 27 959 27 998 mm 1 1007 1 1023 in 27 05 mm 1 065 in 1 0 22 010 22 035 m...

Page 104: ...1 0 1 4 kg m 7 10ft lb 10 14 N m 1 0 1 4 kg m 7 10 ft lb 20 35 N m 2 0 3 5 kg m 14 25 ft Ib 55 65 N m 5 5 6 5 kg m 40 47 h lb 15 25 N m 1 5 2 5 kg m 11 18 ft lb 07923 KE10001 07936 KC10500 07936 37106...

Page 105: ...DLE BEAR ING REPLACEMENT Remove the circlip and remove the decompressor lifter cam spring and lifter arm Remove the kick starter needle bearing with the bearing remover Coat a new bearing with grease...

Page 106: ...er Install the new bearing with the mark facing out Apply grease to the bearing Install the dust seal and liher arm Inuallthe spring and spring pin DECOMPRESSOR LIFTER ARM REPLACEMENT Install the deco...

Page 107: ...UODER SPRING SEAT IDll IDll CLUTCH DISC A 5 p I PRESSURE PLATE REMOVAL CLUTCH LIFTER PLATE Remove the clutch lifter plate and springs bV re moving the four bolts NOTE Loosen the bolts in a criss cross...

Page 108: ...f each spring SERVICE LIMIT 33 7 mm 1 l3 in Replace if shorter than the service limit NOTE Clutch spring should be replaced as II set if one or more is beyond the service limit CLUTCH DISC Replace the...

Page 109: ...r nicks cuts and indentations made bv the clutch discs Replace if necessary Measure the 1 0 of the clutch outer SERVICE LIMIT 28 04 mm 1 104 in Measure the 0 0 and 1 0 of the outer guide SERVICE LIMIT...

Page 110: ...lutch center NOTE Stack the discs and plates alternately II shown Coat new clutch discs with engine oil Install the judder spring i th the dished lace towards the inside 85 shown CLUTCH DISC B Install...

Page 111: ...bolt NOTE Tighten the bolu in a criss cross pattern in two or more steps Instal the washer bearing and stopper ring on the lifter plate if removed Install the right crankcase cover Page 8 81 OIL PUMP...

Page 112: ...emove the screw and oil pump cover Remove the oil pump body screws Separate the main and sub oil pumps and disas semble the oil pumps OIL PUMP INSPECTION Measure the outer rotor to body clearance SERV...

Page 113: ...rotor to cover clearance SERVICE LIMIT 0 12mm 0 005 in Oil PUMP ASSEMBLY Install the pump shaft gear in the sub oil pump body then install the inner and outer rotors Install the dowel pin in the pump...

Page 114: ...oil pick up pipe is removed set the washer on the left side of the oil pipe apply grease 10 the O ring and install the pipe Install the O ring Install the oil pump TORQUE 10 14 N m 1 0 1 4 kg m 7 10 f...

Page 115: ...lse rotor with the OUTSIDE mark facing outward and the CUtout aligned with the shaft Install the oil pump drive gear on the crankshaft Install the lock washer with the mark OUTSIDE facing out Hold the...

Page 116: ...is position pull the kick starter assembly out so that the ratchet clears the ratchet guide then return the kick shaft and unhook the kick starter spring from the crankcase Remove the kick starter ass...

Page 117: ...tarter idle gear and bushing Inspect the ratenet guide tor abnormal wear or dam IOLE GEAR INSPECTION Measure the idle gear 1 0 and bushing 0 0 and I D SERVICE LIMITS GEAR 1 0 17 12 mm 0 674 in BUSHING...

Page 118: ...the tip of the return spring into the hole in the shaft Then slip the collar over the shaft and under the spring aligning the collar groove with the spring end Press firmly on the collar to snap the...

Page 119: ...or wear or damage ASSEMBLY Install the dowel pin and gearshih stopper plate on the shift drum Tighten the stopper plate bolt TORQUE 10 14 N m 0 0 1 4 kg m 1 10 ft Ibl Install the stopper arm on the cr...

Page 120: ...s TORQUE 8 12 N m 10 8 1 2 kg m 6 9 ft lb Install the kick starter and tighten the bott TORQUE 20 35 N m 12 0 3 5 kR m 14 25 ft Ib Install the right footpeg TORQUE 55 65 N m 5 5 6 5 kg m 40 47 h Ib NO...

Page 121: ...MEMO 8 19...

Page 122: ...10 14 N m 1 0 1 4 kg m 7 10 ft lb 9 0 8 12 N m 0 8 1 2 kg m 6 9 ft lb 35 45 N m 3 5 4 5 kg m 25 33 ft lbl 8 12 N m 0 8 1 2 kg m 6 9 ft lb 1 20 N m 10 0 12 0 kg 72 87 ft lb 7 I r 8 12 N m 0 8 1 2 kg m...

Page 123: ...alternator inspection refer to section 16 TOROUE VA LUES Alternator rotor bolt Left crankcase cover bolt Gearshift pedal pinch boh Drain plug Drive procket bolt Neutral switch Stator bolt TOOLS Commo...

Page 124: ...neutral switch wire LOO5en the left crankcase cover bolts snd lift the cover to drain the residual oil Remove the left crankcase cover ALTERNATOR REMOVAL Hold the flywheel with a flywheel holder and...

Page 125: ...move the stator attaching bolts and wire holder Remove the stator Installation is the reyetse order of removal NOTE Apply Loclite or equivalent to the stator attaching bolts and tighten them to specif...

Page 126: ...0 8 1 2 ko m 6 9 ft Jb NOTE Be careful not to pinch the alternator or neu tral switch wire during installation Connect the neutral switch wire to the neutral switch tenninal Install the drive sprocke...

Page 127: ...MEMO 9 5...

Page 128: ...CRAN KCASE CRAN KSHAFT BALANCER 8 12 N m 0 8 1 2 kg m 6 9 ft Ib 8 12 N m kg m 6 9 ft lb N m 1 0 1 4 kg m 7 1aft fb 10 0...

Page 129: ...t SPECIFICATI ONS ITEM Crankshaft Connecting rod big end side clearance Connecting rod big end radial clearance Connecting rod small end 1 0 Crankshaft runout Crankshaft bearing plav 8alancer shaft jo...

Page 130: ...ive Noise Crankshaft Worn connecting rod big end bearing Bent connecting rod Worn crankshaft bearing Worn connecting rod small end Balancer Improper timing adjustment Abnormal vibration Improper balan...

Page 131: ...following cylinder head and cylinder clutch kick starter shaft stopper arm and shift plate drive gear and chain cam chain guide oil pump alternator drive sprocket STOPPER ARM PLATE DR IVE GEAR Remove...

Page 132: ...CER REMOVAL Remove the dowel pins and gasket Remove the transmission Remove the crankshaft and balancer from the left crankcase bV using a hydraulic press NOTE Hold the crankshaft and balancer to pre...

Page 133: ...shaft CRANKSHAFT INSPECTION Set the crankshaft on 8 truing nand or V blocks and measure the runout using a dial indicator SERVICE LIMIT 0 10 mm 0 004 in Measure the connecting rod big end side clearan...

Page 134: ...ICE LIMIT 0 05 mm 0 002 in Spin the crankshaft bearing by hand and check for play The bearing must be replaced if it is noisy or ha excessive play BALANCER DRIVE GEAR REMOVAL Remove the map ring and r...

Page 135: ...14 95 mm 0 589 in Left 11 95 mm 0 471 in BALANCER SHAFT INSTALLATION Install the springs in the outer drive gear Install the outer drive gear aligning the line on the inner gear with the line on the...

Page 136: ...the crankshaft in the right crankcase Install the balancer in the right crankcase aligning the marks on the crankshaft gear and balancer gear Assemble the right and left crankcases and loosely install...

Page 137: ...ckwise to pull the crankshaft completely into the bearing TOOL CRANK ASSEMBLY KIT ASSEMBLY COL LAR THREADED ADAPTER SHAFT PULLER 07931 KFOOOOO 07931 KFOO100 07931 KFOO200 07931 ME40000 Rotate the cran...

Page 138: ...ble the right and left crankcase halves being careful to align the dowel pins and shafu Tighten the right crankcase bolt TORQUE 8 12 N m 10 8 1 2 kg m 6 9 ft lb Tighten the left crankcase bolts TOROUE...

Page 139: ...stall the removed parts in the reverse order of remo lal clutch oil pump Adck starter Section 8 alternator Section 9 cylinder piston Section 7 cylinder head Section 6 CRAN KCAS E CRAN KSHAFTI BALANCER...

Page 140: ...TRANSMISSION 11 0...

Page 141: ...6680 0 6687 in Shaft to gear clearance M6 C2 0 040 0 082 mm 0 0016 0 0032 in Gear to bushing clearance M5 Ct C3 0 015 0 057 mm 0 0006 0 0022 in Bushing to shaft clearance Cl 0 020 0 054 mm 10 0008 0 0...

Page 142: ...ver handle 07936 3710200 07936 KC10500 07936 37 101 00 Common Attachmcnt 37 x 40 rnm Attachment 42 x 47 mm Attachment 52 x 55 mm Driver 07746 0010200 07746 0010300 01746 0010400 07749 0010000 TROUBLES...

Page 143: ...Remove the gasket and dowel pins Remove the shift fork shaft Remove the shift forks and gearshift drum Remove the shift spindle Remove the mainshaft and countershaft TRANSMISSION SH IFT FORK SHAFT DOW...

Page 144: ...e and replace if necessary Check the gear teeth for wear or damage Check the engagement dogs of gears for wear or damage Measure the 1 0 of each spinning gear SERVICE LIM ITS M5 C3 C2 24 10 mm 0 949 i...

Page 145: ...ountershaft bush ings SERVICE LIMITS I D el 0 0 MS Cll el 17 08 mm 0 672 in 23 93 mm 0 942 in 21 93 mm 0 863 in SHIFT FORK SHIFT FORK INSPECTION Check that the shift forks are not bent worn or damaged...

Page 146: ...O 5OS in GEARSHIFT DRUM INSPECTION Inspect the drum grooves and replace the drum if it is damaged or snows excessive wear Refer to page 8 17 for gearshift drum plate and stopper arm inspection TR ANSM...

Page 147: ...ver weight INSTALLATION Attachment 52 x 55 mm Pilot 20 mm Driller 07936 37 10300 07936 3710100 07936 3710200 07746 0010200 07749 0010000 07746 0040400 07936 37 10600 07936 37 10100 07936 37 10200 0774...

Page 148: ...55 mm Pilot 22 mm Driver Countershaft Bearing INSTALLATION Anachment 37 x 40 mm Pilot 17 mm Driver 07746 0010400 07746 0041000 07149 0010000 07746 0010200 07746 0040400 07749 0010000 Right Balancer S...

Page 149: ...eturn spring snap rings and spring on the gear shift spindle TRANSMISSION ASSEMBLY Assemble the transmission gears and shafts NOTE Coat each gear with transmission oil before assembling After installi...

Page 150: ...ll tile shIft forks wilh their marks lacing toward the left crallkcase Slide the shift fork shaft through the shift forks and into the left crankcase Assemble the left and right crankcases Page 10 9 A...

Page 151: ...MEMO 11 11...

Page 152: ...ION STEERING 35 45 N m 3 5 4 5 kg m 25 33 ft fbl N m 5 0 8 0 kg m 36 58 ft lb 10 14 N m 1 0 1 4 kg m 7 10 ft lbl 12 0 18 30 N m kgofTl 13 22 ft Ib 80 120 N m 8 0 12 0 kg m 58 87 ft Ib 24 30 N m 2 4 3...

Page 153: ...bearing attachment Common Radial Axial STANDARD 571 4 mm 122 50 in 07947 4630100 07916 3710100 07946 MBOOOOO 07953 KASOOOO or 07953 4250002 07914 3230002 GN HT 54 U S A onlv 12 1 12 2 12 3 12 6 12 11...

Page 154: ...4 N m 1 0 1 4 kg m 7 10 ft lb 15 30 N m 1 5 3 0 kg m 11 22 ft lb 18 30 N m 1 8 3 0 kg m 13 22 ft lb 80 120 N m 8 0 12 0 kg m 58 87 ft lb 15 25 N m 1 5 2 5 kg m 11 18 ft lb 30 35 N m 3 0 3 5 kg m 22 25...

Page 155: ...holder bolts and the handle bar INSTALLATION Install the handlebar on the lower handlebar hold ers Align the punch mark on the handlebar with the top of the lower holders Place the upper holders on t...

Page 156: ...left handlebar switch bracket with the hole of the handlebar and tighten the forward screw first then rearward screw Install the left turn signal Align the split in the bracket with the punch mark on...

Page 157: ...tch wires Install the engine stop switch Position the lower half of the switch so the align ment pin fits into the hole in the handlebar Tighten the forward screw first then tighten the rear screw App...

Page 158: ...e the front fork guard from the left fork leg Loosen the axle shaft holder nuts and remove the front axle Remove the front wheel NOTE 00 not depress the brake lever when the wheel is off the motorcycl...

Page 159: ...wheel bearing play by placing the wheel on a truing stand and spinning the wheel by hand Replace the bearings with new ones if they are noisy or have excessive play FRONT WHEEL DISASSEMBLY Remove the...

Page 160: ...oved they must be replaced with new one5 ASSEMBLY SPEEDOMETER GEARBOX _w f fj jJ DUST SEAL I GEAR RETAINER 12 8 BEARING REMOVER EXPANDER 07746 0050100 OR EQUIVALENT COMMERCIALLY AVAILABLE IN U S A BEA...

Page 161: ...s TORQUE 14 16 N m 1 4 1 6 kg m 10 12 h lb Install the dust seal in the wheel hub Alter 84 Install the front wheel hub cOlier and tighten its screws Install the dUst seal in the wheel hub Lubricate th...

Page 162: ...er over the disc taking care not to dam age the brake pads Clean the axle and holder Install the holder with the UP mark facing up wards Install the axle holder nuts but do not tighten at this time NO...

Page 163: ...light Page 18 5 Loosen the fork boot clamp screw Remove the speedometer cable from the clamp on the right fork Remove the brake caliper bracket bolts and hose clamp bolt from the left fork Page 14 5 R...

Page 164: ...s Hold the tube in a vise with soft jaws or a shop towel avoiding the sliding surface Remove the fork cap bolt The cop boils are under spring pressure Use corl hen removing and wear eye and ace protec...

Page 165: ...spring then sepa rate the slider and fork tube 84 Remove the dust seal foam washer plastic washer and circlip After 84 Remove the dust seal and circlip Remove the oil seal and back up ring NOTE Avoid...

Page 166: ...in FORK TUBE FORK PISTQNfSlIDER Check the fork tube fork slider and piston for score marks scratches excessive or abnormal wear Replece if necessary Set the fork tube on V blod s and measure the run o...

Page 167: ...n the fork slider Place the fork slider in a vise with soft jaws or a shop towel Apply a locking agent to the socket bolt threads and torque the bottom socket bolt NOTE Temporarily install the fork sp...

Page 168: ...t seal Pour in the specified amount of ATF SPECIFIED FLUID ATF CAPACITY 41 1 cc 114 0 oz Compress the front fork and measure the oil level from the top of the tube NOTE Be sure the oil level is the sa...

Page 169: ...e clamps Install the front wheel Page 12 10 Raise the front wheel off the ground by placing a box or work stand under the engine Add air pressure to each fork as necessary and re install the air valve...

Page 170: ...the steering stem to prevent it from falling Remove the steering adjustment nut Remove the steering stem and upper bearing Check the upper and lower bearings and outer race for wear or damage Replace...

Page 171: ...er race using the special tools Install the bearing adjustment nut on the top end of the steering stem to prevent damage to the thread Remove the lower bearing and dust seal using a punch or driver Re...

Page 172: ...ENT Install the bearing adjustment nut and torque with the steering stem socket TORQUE 1 2 N m 0 1 0 2 kg m 0 7 1 4 ft lb Turn the steering stem lock to lock five times to seat the bearings Repeat the...

Page 173: ...ION Install the fork bridge Install the front forks Tighten the steering stem nut TORQUE 80 120N m 8 0 12 0 kg m 58 87 ft lbJ SOCKET WRENCH 30 x 32 mm 077 16 0020400 OR EQU IVALENT TOOL COMME RCIALLY...

Page 174: ...WHEEL BRAKE SUSPENSION 20 30 N m 12 0 3 0 kg m 14 22 ft lb 13 0 90 120 N m 9 0 12 0 kg m 65 87 ft lb 35 45 N m 3 5 4 5 kg m 25 33 ft Ib 40 5QN m 80 100 N m 18 10 kg m 58 72 ft lbl 14 0 5 0 kg m 29 36...

Page 175: ...absorber spring free length Rear wheel runout Radial Axial Rear axle runout ReBr brake drum I D Rear brake shoe thickness Rear suspension damper compression TOOLS Special Bearing remover set 07936 37...

Page 176: ...ve binding Bent shock absorber rod Swing arm pivot bearings damaged Suspension Noise Faulty rear damper loose fasteners Worn suspension linkage pivot bushings Poor Brlke Performance Improper brake adj...

Page 177: ...chain adjusters and move the wheel for ward Detail the drive chain from the driven sprocket Lift the stopper plate clear of the pin on the swing arm s right side Remove the rear wheel with the rear a...

Page 178: ...L BEARING Check the wheel bearing play by placing the wheel in a truing stand and spinning the wheel by hand Replace the bearings with new ones if they are noisy or have excessive play REAR WHEEL AIM...

Page 179: ...damaged Never install a new drive chain on worn sprockets or a worn chain on new sprockets Both chain and sprocket must be in good condition or the new replacement chain or sprockets will wear rapidly...

Page 180: ...se to the face of the brake cam and to the anchor pin erNSt on the broke linings will reduce stop ping pOWlr KeqJ Irea u xrease the brake linings Wipe ex Ihe cam ond anchor pin Install the new brake s...

Page 181: ...E If the bearings are removed they should be replaced with new ones REAR WHEEL BRAKE SUSPENSION DAMPER RUBBERS D RING RETAINER WRENCH ATTACHMENT 07710 0010200 RETAINER WRENCH BODY 07710 0010401 WHEEL...

Page 182: ...aring Remove the driven sprocket REAR WHEE L ASSEMB LY DISTANCE TUBE 13 8 DUST SEAL CIRCLIP I DRIVEN SPROCKET TORQUE 24 28 N m 2 4 2 8 kg m 17 20 h lb FINAL DRI VEN FLANGE Oil the bolt threads before...

Page 183: ...grease off the brake drum Grease and install the bearing retainer with the re tainer wrench and body Install the drillen sprocket on the driven flange TORQUE 24 28 N m 2 4 2 8 kg m 17 20 ft lb NOTE Oi...

Page 184: ...the brake panel chain adjusters stopper plate and rear axle to the rear wheel Place the rear wheel into the swing arm locating the lang on the swing arm Place the slot of the brake panel over the tan...

Page 185: ...arm Adjust the brake pedal free play Page 3 14 REAR WHEEL BRAKE SUSPENSION AXLE NUT ADJUSTER PLATE BRAKE ROD ADJUSTING NUT BRAKE ARM SHOCK ABSORBER AIR CLEANER CASE REMOVA L Raise the rear wheel off t...

Page 186: ...ion Remove the lower mounting bolt and remolle the shock absorber CAUTtoN I Do not let the rear wheel all DISASSEMBLY Hold the upper mount of the shock in a vise with soft jaws or a shop towel Loosen...

Page 187: ...d measure the force required to compress the damper 10 mm 0 4 in COMPRESSION FORCE 28 29 kg 62 64Ib If the force required is less than 28 kg 62 Ib gas is leaking Examine the damper rod and replace the...

Page 188: ...in from standard spring length or dam age to IIe spring could result To reduce spring preload loosen the adjusting nut to increase spring length 5 mm 1 4 in and tighten the lock nut CAUTION Do not ri...

Page 189: ...36 ft Ibl Install and torque the rear shock absorber upper mount bolt TORQUE 40 50 N m 4 0 5 0 kg m 29 36 ft lbl Install the removed parts in the reverse order of removal SWING ARM REMOVAL Raise the...

Page 190: ...ve the dust seal and pivot collar Install the bearing remover in the swing arm pivot bearing and expand the tool behind the bearing Drive the bearing and thrust bushing out with a slide hammer NOTE Ne...

Page 191: ...10300 AND PI LOT 20 mm 07746 0040500 DUST SEALS FOOT PEGS FOOT GUARD Install the foot guard chain guide foot peg and I chain guide slider Apply grease to the lip of the dust seal and install the dust...

Page 192: ...f re moval SUSPENSION LINKAGE REMOVAL Remove the rear shock absorber Page 13 111 Remove the shock arm pivot bolt and shock link bolts Remove the shock arm and shock link INSPECTION Remove the dust sea...

Page 193: ...kg m 29 36 ft lb Install the shock arm on the swing arm and tighten the shock arm pivot bolt TORQUE 90 120 N m 9 0 12 0 kg m 65 87 ft Ibl Connect the shock lin k to the shock arm with the pivot bolt...

Page 194: ...29 ft lbl 14 0 15 20 N m 5 2 0 kg ffi 11 14 ft lbl 20 30 N m 12 0 3 0 kg m 14 22 ft Ib 12 15 N m 11 2 1 5 J 9 11 ft It J_ 15 20 N m 11 5 2 0 kg m 11 14 ft lbJ 20 25N m 2 0 2 5 kg m 12 15 N m 1 2 1 5...

Page 195: ...ess Front disc runout Front master cylinder I D Front master piston 0 0 Front caliper piston 0 0 Front caliper cylinder 1 0 TORQUE VALU ES 8rake pipe bolt Front brake caliper bracket Brake caliper pin...

Page 196: ...Brake Lever Pedal Too Hard Sticking piston s Clogged hydraulic system Pads glazed or worn excessively Brakes Drag Hydraulic system slicking Sticking piston s 14 2 Brakes Grab or Pull to One Side Disc...

Page 197: ...c or pad reduces Slopping power Discord contaminated pads and clean a contaminated disc with a high quality brake creal il gagent BRAKE FLUID FILLI NG NOTE Do not mi x different types of fluid They ar...

Page 198: ...Bleeder or equivalent to the bleed valve Pump the brake bleeder and loosen the bleeder valve Add fluid when the level in the master cylinder re servoir is low NOTE If air is entering the bleeder hose...

Page 199: ...brake hose clamp Remove the caliper bracket mounting bolts Remove the caliper from the fork slider CAUTION Support the caliper assembly so that it does not hang from the brake line Remove the caliper...

Page 200: ...Position the pad spring and pad shim in the caliper as shown Innall new pads in the caliper Push the piston all the way into the caliper NOTE Check the brake fluid level in the master cyl inder reserv...

Page 201: ...the caliper bracket pins Assemble the cal iper and bracket as shown Install the caliper so that the brake disc is position ed between the pads making sure not to damage the pads Tighten the caliper b...

Page 202: ...n the wheel Install the front wheel Page 12 10 MASTER CYLINDER DISASSEMB LY Remove the headlight Page 18 5 and meter brack Drain the brake system Page 14 3 Loosen the brake hose jOint Disconnect the b...

Page 203: ...ler do no lose the lever adjuster and push rod Remove the master cylinder Remove the bool and circlip from the master cyl inder body Remove the master cylinder piston and spring Clean the inside of th...

Page 204: ...in ASSEMB LY Blowout the inside of the master cylinder and reser voir with compressed air CAUTtON Handle the master cylinder piston cyliflder and spring as Q set Assemble the master cylinder Coat the...

Page 205: ...l line Tighten the joint nut TOROUE 12 15 N m 1 2 1 5 kg m 9 1 ft Ib Install the headlight and meter Fill the reservoir to the upper level and bleed the brake system according to page 14 4 BRAKE CALIP...

Page 206: ...h pressu air or bring the noz zle too close 0 the inlet NOTE Place a shop towel over the pistons to prevent them from flying out Examine the pistons and cylinders for scoring scratches or other damage...

Page 207: ...ther faults Measure the caliper cylinder bore SE RVICE LIMIT 25 45 mm 11 002 in ASSEMBLY Th seals must be replaced with new ones whenever they are removed Coat the seals with brake fluid before assemb...

Page 208: ...t the disc is positioned between the pads CAUTION 1 Be careful IIot to damage the pads Install the caliper bracket bolts and tighten TORQUE 20 30 N m f2 0 J O kg m 14 22 ft lb Install the brake hose c...

Page 209: ...f Disconnect the taillight and rear turn signal wires Remove rear fender Installation i5 the reverse order of disassembly NOTE Before installing the seat check that the rear fender is set on the frame...

Page 210: ...he el haust pipe Remove the muHler clamp bolts and remove the ex haust pipe Install in the reverse order of disassemblv NOTE After installing make sure that there are no gas leaks 20 30 N m 2 0 3 0 kg...

Page 211: ...MEMO 15 3...

Page 212: ...BATTERY CHARGING SYSTEM AEGlUU TO AIFIECTIFIEA A C REGULATOR ALrER A1COR A I r r I n S REGULATOR REGULATOR RECTIFIER 0_ ALTERNATOR 16 0...

Page 213: ...eter Digital meter TROUBLESHOOTING No Power Key Turned On Dead battery Battery not charged 1 300 rpm maximum 5 5 amperes maximum at 8 000 rpm 2 7 amperes minimum at 2 500 rpm l 2V 3AH Main l OA Transi...

Page 214: ...be recharged if the speci fie gravity is below 1 23 The specific gravity varies with the temper ature as shown Replace the battery if sulfation is evident The battery must be replaced if there is sedi...

Page 215: ...in good condition be fore performing this test Warm up the engine Remove the right side cover and seat Disconnect the battery positive terminal and con nect the ammeter positive wire to battery cable...

Page 216: ...ire RESISTANCE IN NORMAL DIRECTION 0 2 2 0 n LAMP COIL The lamp coil is good if there is continuity between the white yellow wire and ground RESISTANCE IN NORMAL DIRECTION 0 1 1 0 n If there is no con...

Page 217: ...ltmeter Switch the dimmer to HI position G 00 00 00 0 2 10 Start the engine and check the meter readings while increasing engine speed slowlV SPECIFIC VOLTAGE 13 5 14 5V at 5 000 rpm INSPECTION Check...

Page 218: ...GNITION SYSTEM IGNITION COil PULSE GENERATOR ALTERN HeiR IGNITION SWITCH t II IG AT ENGINE STOP SWITCH ll II u E bi L II 1m lEi JJ 0 1 Jcj C D I UNIT GENERATOR SPARK IGNITION ALTERNATOR PLUG COIL 17 0...

Page 219: ...2 at 1 300 rpm 28 2 at 4 000 rpm For extended high speed riding ND NGK X27EPR UQ DPA9EA 9 Special Multimeter Digital multi meter 07308 0020000 or Kowa TH 5H 1 07406 0050000 or KS AHM 32 003 U S A only...

Page 220: ...rpm To check the advance raise the engine speed to 4 000 rpm The index notch should be between the advance marks If the ignition timing is incorrect check the COl unit pulse rotor and pulse generator...

Page 221: ...e COl unit if the readings do not fall within the limits shown in the table NOTE The COl unit is fully transistorized For accurate testing it is necessary to use a specified electric tester Use of an...

Page 222: ...IGNITION SYSTEM PULSE GENERATOR INSPECTION Disconnect the pulse generator wire coupler Measure the resistance between the Blue Yellow and Green white wires SPECIFICATION 460 580 n 17 4...

Page 223: ...de without removing the part from the motorcycle by simply d isconnectmg the wires and connecting a continuity tester or voltmeter to the terminals or connections SPECI FICATIONS Headlight Tail stopli...

Page 224: ...e the headlight Page 18 5 Disconnect the Ignition switch wire coupler Remove the ignition switch mounting bolts and ignition switch Install the ignition switch in the reverse order of reo moval CONTAC...

Page 225: ...ontinuity between the interconnected circles HORN SWITCH HO BAT FREE PUSH 0 0 Color Lg BI DIMMER SWITCH HL HI LO Lo IN 0 Hi 0 Color W Y Bu W Continuity should exist between color coded wires indicated...

Page 226: ...ont brake light switch for continuity with the front brake applied The switth is normal if there is continuity with the brake applied REAR BRAKE LIGHT SWITCH Check the rear brake light switch for cont...

Page 227: ...emove the headlight shell number plate Remove the head light Disconnect the all wires at their couplers and con nectors HEADLI GHT REPLACEM ENT When installing the headlight bulb make sure the top mar...

Page 228: ...adlight page 18 51 Gently remove the bulb 50 et from the back of the instrument Replaes the bulb SPEEDOME TER REMOVAL INSTALLATION Disconnect the speedometer cable Remove the speedometer attadling nut...

Page 229: ...oat valve 4 Clogged fuel tank cap breather tube WEAK OR NO SPARK 1 Faulty spark plug 2 Fouled spark plug 3 Faulty COl unit 4 Broken or shorted high spark p lug wire 5 Faulty alternator 6 Broken or sho...

Page 230: ...tight 4 Rear axle nut excessively tight ened PRESSURE TOO LOW 1 Punctured tire and tube 2 Faulty tire valve ENG INE SPEED DOES NOT 1 Clutch slipping CHANGE WHEN CLUTCH 2 Worn clutch disc plate IS REL...

Page 231: ...uel air mixture too lean 13 Use of improper grade of fuel 14 Excessive carbon build up n combustion chamber IS Ignition timing 100 advanced Faulty COl unit POOR PERFORMANCE AT LOW AND IDLE SPEEDS Chec...

Page 232: ...line 3 Clogged fuel tank breather tube ClOGGED _ 1 Clean INCORAECT fl Cam sprocket not installed pro perly WEAK _ 1 Faulty spring POOR HANOllNG ch k Ii P Probable Cause 1 If steering is heavy 1 Steeri...

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Honda XL350R 1984, Shop Manual

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Summary of Contents for XL350R 1984

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