HRC NSF250R 2012 Owner'S Manual & Parts List Download Page 100 | Manualshive

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(1) VALVE GUIDE REAMER

Valve Seat Inspection/Refacing

This machine's intake and exhaust valves are titani-
um.
If the brown coating of the valve is removed, or the
metal surface is appeared, replace the valve with a
new one.

Clean the intake and exhaust valves thoroughly to
remove carbon deposits.
Ream the valve guide to remove any carbon build-
up.

(1) VALVE LAPPING TOOL

Apply a light coating of Prussian Blue to the valve
seat.

Tap the valves and seats using a rubber hose or
other hand lapping tool.
Remove the valve and inspect the valve seat face.

If a valve face is burned or badly worn or if it con-
tacts the seat unevenly, replace the valve.

The valve seat contact should be within the speci-
fied width and even all around the circumference.

4-34

Engine Servicing

Valve spring

Check the valve springs for fatigue or damage.

(1)

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Summary of Contents for NSF250R 2012

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Page 4: ...ety of others is very important We have provided important safety messages in this manual and on the HRC NSF250R Please read these messages carefully A safety message alerts you to potential hazards that could hurt you or others Each safety message is preceded by a safety alert symbol and one of three words DANGER WARNING or CAUTION These mean You WILL be KILLED or SERIOUSLY HURT if you don t foll...

Page 5: ...ut incurring any obligation No part of this publication may be reproduced without written permission HRC NSF250R Owner s Manual Parts List All information in this publication is based on the latest product information available at the time of approval for printing Honda Racing Corporation reserves the right to make changes at any time without notice and without incurring any obligation No part of ...

Page 6: ... 1 FRAME SERIAL NUMBER The frame serial number is attached on the left side of the main frame as shown 1 ENGINE SERIAL NUMBER The engine serial number is stamped on the left side of the crankcase 1 1 ...

Page 7: ...ints 2 12 Cable Harness Routing 2 15 3 Service And Maintenance Maintenance Schedule 3 1 Pre ride Inspection 3 1 Warming up Inspection 3 2 Ride Inspection 3 2 After Ride Inspection 3 2 Replacement Parts 3 2 Fuel Line 3 4 Air Filter 3 4 Spark Plug 3 4 Valve Clearance 3 5 Engine Oil 3 8 Transmission Oil 3 10 Cooling System 3 12 Clutch System 3 13 Exhaust Pipe Muffler 3 14 Drive Chain 3 15 Drive Chain...

Page 8: ...omes hard to read contact your HRC dealer for a replacement There is a specific symbol on each label The meanings of each symbol and label are as follows RADIATOR CAP SEAL DANGER NEVER OPEN WHEN HOT Hot coolant will scald you Relief pressure valve begins to open at 108 kPa CAUTION LABEL IMPORTANT INFORMATION Operator only No passengers The HRC NSF250R is sold as is without warranty and the entire ...

Page 9: ...mbly and special tools Follow the Maintenance Schedule recommendation page 3 1 to ensure that your NSF250R is always in peak operating condition To The New Owner By selecting a HRC roadracer NSF250R as your new machine you have placed yourself in a distin guished family of owners and riders The NSF250R is a high performance racing machine utilizing the latest racing technology This machine is inte...

Page 10: ...Memo ...

Page 11: ...emoving the radiator cap while the engine is hot will allow the coolant to spray out seriously scald ing you Always let the engine and radiator cool down before removing the radiator cap Failure to bleed the air completely may cause over heating and damage the engine 1 FILLER NECK When filling the cooling system be sure to bleed air completely so that the system can be sufficiently filled Bleed th...

Page 12: ...50R exhaust contains poisonous carbon monoxide gas High levels of carbon monoxide can collect rapidly in enclosed areas such as a garage Do not run the engine with the garage door closed Even with the door open run the engine only long enough to move your NSF out of the garage Cold Engine Starting 1 Turn the engine stop switch to RUN 2 Shift the transmission into second gear 3 With the throttle cl...

Page 13: ...ated to the operating temperature 60 C 140 F Break In Procedure New Machine Use Ultra G1 engine oil for break in Using other engine oil correct break in effect is not obtained Before running check that the engine oil is in proper level through the sight glass Following proper break in procedure helps ensure that the most important and expensive components on your new machine will provide maximum p...

Page 14: ... minutes 1 CLUTCH LEVER Controls Clutch 1 The normal clutch lever free play is 10 20 mm 0 4 0 8 in measured at the tip of the lever 1 LOCK NUT 2 ADJUSTER A INCREASE B DECREASE 2 Minor adjustments can be made with the cable end adjuster Loosen the lock nut and turn the adjuster Turning the adjuster in direction A will increase free play turning the adjuster direction B will decrease free play After...

Page 15: ...thout slipping or dragging 1 THROTTLE GRIP Throttle Grip Throttle Grip Free Play Measure the throttle grip free play at the grip rota tion Free play 2 6 mm 0 08 0 24 in 1 LOCK NUT 2 ADJUSTER A DECREASE B INCREASE Adjustment is made with the upper adjuster Loosen the lock nut Turning the adjuster in direction A will decrease free play turning it in direction B will increase free play Tighten the lo...

Page 16: ...lt in direction A to raise the pedal or in direction B to lower it 2 Tighten the lock nut at the desired pedal height 1 LOCK NUTS 2 CHANGE ROD Gearshift Pedal Height The gearshift pedal height can be adjusted to the rider s preference The gearshift pedal height can be adjusted by changing the length of the change rod on its thread ed ends To adjust the gearshift pedal height 1 Loosen the lock nuts...

Page 17: ...e the steering damper 1 THICK WASHER 2 SPHERICAL BEARING When installing the damper on the frame pay careful attention to prevent the piston rod from being applied with excessive bending force beyond the allowable rotation angle of the spher ical bearing Handle carefully to avoid scratching damaging or leaving foreign substances on the rod Do not try to disassemble the steering damper The steering...

Page 18: ...Memo ...

Page 19: ...gle cylinder inclined 15 from vertical Bore and stroke 78 0 x 52 2 mm 3 07 x 2 06 in Displacement 249 3 cm3 15 21 cu in Compression ratio 12 3 1 Valve train Chain driven DOHC Valve timing Intake opens 25 BTDC at 1 0 mm lift Intake closes 50 ABDC Exhaust opens 50 BBDC Exhaust closes 20 ATDC Lubrication system Semi dry sump forced pressure and wet sump Oil pump type Trochoid Specifications Item Spec...

Page 20: ... labeled as energy conserving on the circular API service label Viscosity SAE 10W 30 JASO T 903 standard MA Transmission oil capacity at disassembly 0 55 liter 0 58 US qt 0 48 Imp qt at oil change 0 49 liter 0 52 US qt 0 43 Imp qt Oil pump tip clearance 0 15 0 006 max body clearance 0 15 0 21 0 006 0 008 side clearance 0 02 0 08 0 001 0 003 Fuel System Throttle grip free play 2 6 0 08 0 24 Throttl...

Page 21: ...pression adjuster 9 clicks out from full hard standard position Rebound adjuster standard 7 clicks out from full hard position Rear Suspension Spring pre load length 147 5 8 Compression adjuster 8th notch out from full hard standard position Rebound adjuster standard 5th notch out from full hard position Unit mm in Unit mm in Item Standard Service Limit Hydraulic brakes Specified brake fluid DOT4 ...

Page 22: ... 24T 23 26 27T C1 gear standard 30T 29 30 31 32T C2 gear standard 32T 27 28 29T C3 gear standard 30T 27 29 31T C4 gear standard 28T 23 25 26 29T C5 gear standard 28T 22 23 24 28T C6 gear standard 24T 26 27T Drive sprocket standard 15T 16 17T Driven sprocket standard 35T 32 33 34 36 37 38 39 40T Top bottom bridge standard 32 5 mm 30 mm Fork spring standard 0 65 kgf mm 0 6 0 7 kgf mm Rear shock abso...

Page 23: ...p 1 14 6 0 6 4 4 Note 3 Crankshaft hole cap 1 30 15 1 5 11 Note 3 Cylinder head hole cap 1 30 15 1 5 11 Note 3 Lubrication Oil pump sprocket bolt 1 5 5 0 5 3 7 Note 2 Oil strainer bolt 1 6 10 1 0 7 Oil separator plate bolt 1 6 10 1 0 7 Note 2 Cooling System Water pump impeller 1 7 12 1 2 9 Note 7 Fuel System Air funnel bolt 2 5 5 1 0 52 3 8 Flame trap set bolt 2 5 5 1 0 52 3 8 Cylinder head valve ...

Page 24: ...t 1 14 69 7 0 51 Note 4 Ignition pulse generator bolt 4 5 5 0 5 3 7 Note 2 Stator mounting bolt 3 5 5 0 5 3 7 Note 2 Crankcase Transmission Drive sprocket bolt 1 8 31 3 2 23 Note 4 Right crankcase oil jet 1 5 2 0 0 2 1 5 Note 2 Bearing set plate bolt Mainshaft Shift drum 4 6 10 1 0 7 Note 2 Transmission holder bolt 6 6 10 1 0 7 Note 4 Bearing set plate screw 1 6 10 1 0 7 Note 2 Left crankcase seal...

Page 25: ...olt 4 8 22 2 2 16 Handlebar pinch bolt 2 8 22 2 2 16 Clutch cable alninum nut 1 8 10 1 0 7 Clutch lever holder bolt 1 5 4 0 4 3 0 Clutch lever pivot bolt 1 6 1 0 0 1 0 7 Front axle nut 1 14 70 7 1 5 2 Note 1 Front axle holder bolt 4 8 22 2 2 16 Front brake disc bolt 6 6 12 1 2 9 Fork bolt 2 39 34 3 5 25 Fork center socket bolt 2 10 34 3 5 25 Note 2 Rear wheel suspension Rear axle nut 1 14 70 7 1 5...

Page 26: ... pin 1 10 17 1 7 13 Rear brake caliper pad pin 2 10 17 1 7 13 Pad pin plug 2 10 2 0 2 1 5 Rear caliper pin Main 1 10 22 2 2 16 Note 2 Sub 1 8 12 1 2 9 Note 2 Front master cylinder holder 2 6 12 1 2 9 SH flange bolt Rear master cylinder push rod 1 8 18 1 8 13 lock nut Rear master cylinder hose 1 4 1 5 0 2 1 1 joint screw washer Other Insulator band 1 5 See illustration Engine stop switch screw 1 2 ...

Page 27: ...center holder 07724 0050002 Clutch center lock nut Gear holder 07724 0010100 Primary drive gear nut Alternator Flywheel holder 07725 0040001 Flywheel nut Flywheel puller adapter 89009 NX7 000 Flywheel Flywheel puller holder 89010 NX7 000 Flywheel puller bolt 89011 NX7 000 Bearing remover set 15 mm 07936 KC10100 Left crankcase cover seal Bearing remove 15 mm 07936 KC10200 Remover weight 07741 00102...

Page 28: ...0 mm 07746 0040500 Pilot 28 mm 07746 0041100 Attachment 24 x 26 mm 07746 0010700 Pilot 17 mm 07746 0040400 Pin spanner 07702 0020001 Rear cushion spring Hydraulic Brake Snap ring pliers 07914 SA50001 Master cylinder snap ring Description Tool number Applicability Front Wheel Suspension Steering Fork seal driver 07KMD KZ30100 Fork Fork seal driver attachment 07916 NX4 700 Fork set collar 51481 NX4 ...

Page 29: ...h gear Each O ring Other rotating and sliding surface Item Material Remarks Left crankcase cover bushing I D Molybdenum disulfide Connecting rod bearing sliding surface oil A 50 50 mixture of Connecting rod small end I D molybdenum disulfide Crankshaft thrust surface grease and Honda Crankshaft bearing sliding surface 4 stroke engine oil Decompressor cam plate sliding surface IN EX camshaft bearin...

Page 30: ...er pipe joint threads Cylinder torx bolt threads Cylinder head cover breather joint threads Oil pump driven sprocket bolt threads Right crankcase oil jet 80 threads Locking agent Do not apply tip of bolt threads Left crankcase cover torx bolt threads Locking agent Item Material Remarks Crankcase mating surface Sealant TB1207B Right crankshaft hole cap threads Multi purpose grease Water pump oil se...

Page 31: ...ase for Left swingarm pivot bearing extreme pressure Right swingarm pivot bearing example EXCELITE Swingarm pivot dust seal lips EP2 manufactured by Swingarm pivot adjusting bolt threads KYODO YUSHI Japan Shock arm needle bearing or equivalent Shock arm dust seal lips Shock link needle bearing Shock link dust seal lips Cable slider sliding surface Handle lever pivot sliding surface Multi purpose g...

Page 32: ...NDENSER 2P BLACK CONNECTOR ENGINE STOP SWITCH 2P GRAY CONNECTOR TACHOMETER 3P GREEN CONNECTOR COOLANT TEMPERATURE METER 2P BLACK CONNECTOR PGM FI INDICATOR 2P GREEN CONNECTOR SHIFT UP INDICATOR 2P BLUE CONNECTOR BANK ANGLE SENSOR CONDENSER BANK ANGLE SENSOR 3P NATURAL CONNECTOR ...

Page 33: ...2 15 Service Data FRONT BRAKE HOSE THROTTLE CABLES CLUTCH WIRE REGULATOR RECTIFIER RADIATOR OVERFLOW CATCH TANK FUEL PUMP 5P BLACK CONNECTOR ...

Page 34: ...2 16 Service Data CLUTCH WIRE FUEL TANK OVERFLOW HOSE FUEL FEED HOSE ALTERNATOR 5P NATURAL CONNECTOR ECT SENSOR COOLANT TEMPERATURE METER WIRE FUEL TANK OVERFLOW CATCH TANK ...

Page 35: ...2 17 Service Data SERVICE CHECK 4P RED CONNECTOR CLUTCH WIRE MAP SENSOR BARO SENSOR MAIN WIRE HARNESS IGNITION COIL CONNECTOR IAT SENSOR THROTTLE CABLES ...

Page 36: ...2 18 Service Data INJECTOR 2P GRAY CONNECTOR THROTTLE SENSOR 3P BLACK CONNECTOR ENGINE BREATHER HOSE FUEL FEED HOSE IACV 4P BLACK CONNECTOR THROTTLE CABLES ...

Page 37: ...2 19 Service Data COOLANT TEMPERA TURE SENSOR ECT SENSOR ALTERNATOR 5P NATURAL CONNECTOR FUEL FEED HOSE IAT SENSOR ...

Page 38: ...2 20 Service Data TRANSMISSION BREATHER HOSE ENGINE BREATHER HOSE CLUTCH WIRE BREATHER HOSE AIR BOX REAR BRAKE RESERVOIR HOSE ...

Page 39: ...2 21 Service Data REAR BRAKE HOSE REAR BRAKE RESERVOIR HOSE ...

Page 40: ...Memo ...

Page 41: ... operation Drive chain for correct slack and adequate lubrica tion Drive chain slider for damage or wear Loose bolts screws and other fasteners particu larly drain bolt lock wire Frequency Each race Remarks Item Fuel Line I Fuel leak or damage Air Filter I Contamination Throttle Operation I Operation and free play Spark plug I Contamination Valve Clearance I Inspect after breaking in Engine Oil R ...

Page 42: ...4 000 km Clack Cylinder Every 4 000 km Wear or damage Cylinder head Every 2 000 km Wear or damage Valve seat Every 4 000 km Wear or damage Crankshaft Every 4 000 km Wear or damage Cam chain and timing sprocket damage Crankshaft bearing Every 4 000 km Wear or damage Connecting rod Every 4 000 km Wear or damage Connecting rod bearing Every 2 000 km Wear or damage Inlet valve Every 2 000 km Wear or d...

Page 43: ...amage bushing Oil strainer Every 4 000 km Wear or damage Oil pressure relief valve Every 4 000 km Wear or damage Drive sprocket Every 2 000 km Wear or damage Each ball bearing Every 4 000 km Wear or damage Each oil seal Every 2 000 km Wear or damage Fuel filter Every 2 000 km Contamination Engine oil Every race Contamination After breaking in Engine oil filter Every race Contamination After breaki...

Page 44: ...ark plug for this machine Specified plug NGK R0452A 10 Iridium Before removing the spark plug clean around the spark plug bases with compressed air and be sure that no debris is allowed to enter the combustion chamber Remove the direct ignition coil and remove the spark plug 1 BOLTS 2 AIR FILTER Air Filter Remove the air box cover page 4 14 Remove the bolts and air filter from the air box Blow off...

Page 45: ... C 95 F Remove the engine from the frame page 4 21 Remove the cylinder head cover page 4 27 Remove the timing hole cap and O ring from the left crankcase cover 1 CRANKSHAFT HOLE CAP 1 INDEX MARK 2 PUNCH MARK Remove the crankshaft hole cap and O ring from the right crankcase cover Turn the crankshaft clockwise from the right crankcase cover side align the T mark on the fly wheel with the index mark...

Page 46: ...rvice and Maintenance 1 INDEX MARK 2 T MARK 1 CAM SPROCKET 1 FEELER GAUGE Measure the valve clearance by inserting a feeler gauge between the valve lifter and cam lobe Valve clearance IN 0 20 0 02 mm 0 008 0 001 in EX 0 30 0 02 mm 0 012 0 001 in Make sure the T mark on the flywheel aligns with the index mark on the left crankcase cover Check that the index lines on the cam sprockets are flush with...

Page 47: ...ake sure of the correct shim thickness by meas uring the shim by micrometer Reface the valve seat if carbon deposit result in a calculated dimension of over 2 800 mm 1 SHIM 2 VALVE LIFTER Install the newly selected shim on the valve retain er Apply molybdenum disulfide oil to the valve lifters and install them into the valve lifter bores Install the shims and valve lifters in their original locati...

Page 48: ...draining 1 Cut the locking wires from the oil filler cap and oil drain plug 2 Remove the oil filler cap 3 Place an oil drain pan under the engine and remove the drain bolt 4 After the oil has completely drained make sure that the sealing washer is in good condition and reinstall the drain bolts Tighten the drain bolt to the specified torque Torque 16 N m 1 6 kgf m 12 lbf ft 2 1 1 2 2 1 2 1 1 CRANK...

Page 49: ... higher except oils labeled as energy conserving on the circular API service label JASO T 903 standard MA Capacity 1 16 liter 1 23 US qt 1 02 Imp qt at draining 1 20 liter 1 27 US qt 1 06 Imp qt at filter change 1 37 liter 1 45 US qt 1 21 Imp qt at disassembly Install the oil filler cap Secure the filler cap and drain bolt using a locking wire 1 2 1 1 1 SPRING 2 OIL FILTER 3 OUTSIDE MARK 1 NEW O R...

Page 50: ...e drain bolts Tighten the drain bolt to the specified torque Torque 16 N m 1 6 kgf m 12 lbf ft 5 Pour the recommended transmission oil slowly through the oil filler hole Suggested transmission oil Honda 4 stroke motorcycle oil or equivalent Viscosity SAE 10W 30 API Classification SG or higher except oils labeled as energy conserving on the circular API service label JASO T 903 standard MA Capacity...

Page 51: ...aining be sure to install the drain plug securely 1 OIL FILLER CAP 6 Install the oil filler cap 7 Secure the oil filler cap and drain plug with lock wire 1 1 1 RADIATOR 2 OVERFLOW TUBE Coolant Cooling System Inspection 1 Check the cooling system for leaks 2 Check water hoses for cracks deterioration and clamp bands for looseness 3 Check the radiator mount for looseness 4 Make sure the overflow tub...

Page 52: ...e air flow through the radiator and make sure the water temperature stays within the operat ing temperature range Normal operating temperature 65 75 C 149 167 F The water temperature will only display in a range from 25 C to 99 C 77 F to 210 F The figure disappears within 30 minutes after the engine stop button is turned off 1 INSPECTION HOLE 6 Check the water pump inspection hole front side of th...

Page 53: ...RADIATOR 2 COVERING If the indication never changes from C check the radiator coolant level and temperature 25 99 C 77 210 F and then inspect the water temperature sensor and harness page 6 9 1 1 EXHAUST PIPE 2 MUFFLER Exhaust Pipe Muffler Inspection Check the muffler for clogging Check for loose or missing bolts and nuts Check for exhaust pipe muffler for cracks or defor mation Loss of power will...

Page 54: ...mbly into the outer body 1 RIVET 5 Drive 7 stainless pop rivets 4 8 mm through the holes in the outer body after applying epoxy based adhesive 1 RIVET Glass Wool Replacement The silencer consists of an inner pipe outer body noise absorbing glass wool front outer rear outer and exhaust pipe To replace the glass wool 1 Drill off the heads of 8 rivets at the front end of the front outer Press the riv...

Page 55: ...d proper adjustment will help to extend the service life of the drive chain Turn the engine off and place the machine on the maintenance stand Push the upper section of the drive chain make sure the lower chain line is straight With the transmission in neutral measure chain slack at the lower section midway between the sprockets by pushing the chain downward Drive chain slack 11 14 mm 0 4 0 6 in R...

Page 56: ...If the drive chain roller is wear or damage replace the drive chain roller with a new one Tighten the drive chain roller mounting bolt nut In the illustration above the handlebar is turned too far toward the right In the illustration above rear wheel is not yet aligned 3 Position the front wheel straight ahead by turning the handlebars and noting the distance between the outer edges of the front a...

Page 57: ...page 3 15 Shift the transmission into low gear apply the rear brake Remove the following Drive sprocket bolt Drive sprocket collar Spring washer Drive sprocket 1 BOLT 2 SPROCKET COLLAR 3 SPRING WASHER 4 DRIVE SPROCKET 2 3 1 4 1 SPROCKET COLLAR 2 OUTSIDE MARK Install the spring washer with its OUTSIDE mark facing outward Install the sprocket collar with its OUTSIDE mark facing outward 1 SPRING WASH...

Page 58: ...and relief the vacuum pressure in the reservoir Remove the master cylinder cover set plate and diaphragm If the fluid level is lower than the lower level check for the brake pad wear Replace the brake pad if necessary Refer to page 5 32 for brake pad replacement Also check the brake system for leaks Check that the brake hose do not bind or kink in all steering position and is not pulled when the s...

Page 59: ...ment Replace the brake fluid every 3 races Do not service the brake system in high humidity Replace the brake fluid after riding in the rain Brake fluid DOT 4 Only The vinyl tube will harden over time so it should be replaced every 6 months 1 1 1 1 BRAKE DISC Brake System Refer to page 1 6 for Brake Lever Adjustment Refer to page 1 6 for Brake Pedal Height Adjustment Brake Discs Measure the brake ...

Page 60: ...handlebar to the right and left to check for roughness in the steering head bearings Stand in front of the machine and grab the fork at the axle then push the fork in and out toward the engine to check for play in the steering head bearings If any roughness or play is felt adjust or replace the steer ing head bearings 1 TORQUE ROD Rear Brake Torque Rod A floating type torque rod is used for the re...

Page 61: ... 8 kg cm2 26 psi Recommended cold tire air pressure Front 170 190 kPa 1 7 1 9 kg cm2 24 27 psi Rear 180 200 kPa 1 8 2 0 kg cm2 26 28 psi Inspect the wheel for damage Check the wheel runout If runout is noticeable replace the wheel with a new one Check the axle for runout Check the condition of the front and rear wheel bear ings 2 1 1 REBOUND ADJUSTER 2 PRELOAD ADJUSTER Fork The machine is shipped ...

Page 62: ... information Make all compression and rebound damping adjustments in one click increments Adjusting two or more clicks at a time may cause you to pass over the best adjustment Test ride after each adjustment If you become confused about adjustment set tings return to the standard position and start over 1 COMPRESSION ADJUSTER For optimum fork performance we recommended that you disassemble and cle...

Page 63: ...rm bearings There should be no movement If movement is felt replace the pivot bearings page 5 27 1 2 Cleaning Clean your NSF regularly to protect the surface fin ishes and inspect damage wear and oil seepage When washing your NSF always use water and a mild detergent such as diswashing liquid to avoid discoloring decals High pressure water or air can damage certain parts of the motorcycle Throttle...

Page 64: ...t you take certain steps to reduce the effects of non use In addition necessary repairs should be made BEFORE storing your NSF otherwise these repairs may be forgotten by the time your NSF is removed from storage Preparing The Motorcycle For Storage 1 Completely clean all parts of your NSF Wash with fresh water and wipe dry 2 Drain the fuel from the system into an approved gasoline container Gasol...

Page 65: ... 1 ENGINE OIL FILLER CAP 1 NG 2 OK Use new 0 8 mm 0 03 in stainless steel wire Secure the bolt as shown so that it cannot come loose Twisting the wire too tightly will break the lock ing 1 1 1 TRANSMISSION DRAIN PLUG 1 TRANSMISSION OIL FILLER CAP 1 1 1 2 ...

Page 66: ...3 26 Service and Maintenance 1 OIL LINE PLUG BOLT A 1 OIL LINE PLUG BOLT B 1 1 1 1 OIL FILTER COVER BOLTS ...

Page 67: ...g Lubrication Diagram CAMSHAFT PISTON PISTON JET PISTON JET CRANKSHAFT OIL FILTER PRESSURE RELIEF VALVE OIL STRAINER OIL FEED PUMP COUNTERSHAFT CLUTCH MAINSHAFT PRIMARY DRIVE GEAR BALANCER GEAR WATER PUMP GEAR SCAVENGE PUMP ...

Page 68: ...AINER 3 OIL PUMP COVER 1 PRESSURE RELIEF VALVE 1 RELIEF VALVE PISTON Remove the bolt oil pump driven sprocket and drive chain Remove the bolt and then remove the oil strainer from the oil pump cover Remove the oil pump cover and dowel pins Remove the pressure relief valve from the left crankcase Check the relief valve piston operation by pushing the relief valve piston 1 BOLT 2 OIL SEPARATOR PLATE...

Page 69: ... pump driven sprock et bolt threads Installation Apply grease to the new O ring then install it into the groove of the relief valve Install the relief valve to the left crankcase Install the dowel pins Install the oil pump cover Apply grease to the O ring and install it oil strainer flange Install the oil strainer to the oil pump cover Install and tighten the oil pump cover bolts in a crisscross p...

Page 70: ...se Apply a locking agent to the oil separator bolt threads Install and tighten the oil separator plate bolt to the specified torque Torque 10 N m 1 0 kgf m 7 lbf ft Install the flywheel page 4 68 1 INNER ROTOR 2 OUTER ROTOR Oil Pump Disassembly Remove the engine from the frame page 4 21 Remove the oil pump cover page 4 2 Separate the crankcase halves page 4 68 Remove the right crankcase side scave...

Page 71: ...nto the crankcase Measure the oil pump tip clearance Standard 0 15 mm 0 006 in maximum Remove the oil pump shaft feed pump inner rotor and outer rotor from the outside of the left crankcase Remove the scavenge pump inner and outer rotors from inside of the left crankcase Measure the oil pump body clearance Standard 0 15 0 21 mm 0 006 0 008 in Measure the oil pump side clearance using a straight ed...

Page 72: ...e left crankcase Install the relief valve page 4 2 Install the feed pump outer and inner rotor out side of the left crankcase Install the oil pump shaft by aligning its flat with the inner rotors Install the dowel pins Install the oil pump cover and temporarily tighten the cover bolt Place the left crankcase with the oil pump cover side facing down Install the right crankcase side scavenge pump in...

Page 73: ...nector with a shop towel or an equivalent 4 Hold the quick connector with one hand and push the retainer tabs with the other hand then remove it from the lock groove Disconnect the connector and remove the retainer from the joint 1 RUBBER CAP 2 RETAINER 3 QUICK CONNECTOR Injector side 1 Check the fuel feed hose quick connector for dirt clean if necessary Cover the quick connector with a shop towel...

Page 74: ...ainer Connect the 12V battery to the DLC connector Turn the engine stop switch ON and operate the fuel pump about 2 seconds Repeat this procedure 2 3 times and check that there are no fuel leaks If there are fuel leaks replace the fuel feed hose with a new one Always replace the retainer when the fuel feed hose is removed 1 RETAINER 2 FEED HOSE 1 FEED HOSE 2 RETAINER 1 RUBBER CAP 2 RETAINER 3 FEED...

Page 75: ... Connect the fuel pump 5P Black connector Start the engine and read the fuel pressure at idle Idle speed 3 000 300 min 1 rpm Fuel pressure 314 382 kPa 3 2 3 9 kgf cm2 46 56 psi If the fuel pressure too high check the following Pressure regulator Fuel pump page 4 10 If the fuel pressure too low check the following Fuel leaks from fuel line Clogged fuel filter Pressure regulator Fuel pump page 4 10 ...

Page 76: ... seconds at 12 V If the fuel flow is less than specified inspect the fol lowing pinched or clogged fuel hose clogged fuel filter pressure regulator fuel pump page 4 10 1 FUEL FEED HOSE 2 5P BLACK CONNECTOR After inspection remove the temporarily installed fuel hose and reconnect the fuel feed hose to the fuel pump joint Connect the fuel pump 5P Black connector Start the engine and check for fuel l...

Page 77: ... disconnect the fuel hose page 4 7 1 FUEL PUMP ASSEMBLY Remove the fuel tank from the frame Remove the fuel pump base bolts and pump base Remove the fuel pump from the fuel tank being careful not to damage the pump and pump wires 1 WIRE TERMINALS 2 FUEL PUMP MOTOR FILTER Fuel Filter Cleaning Push the three retainers between the fuel pump base unit and holder the remove the holder from the base uni...

Page 78: ...w O rings to the fuel pump base Route the fuel pump motor wire through the fuel pump base grooves then connect to the pump motor terminals Install a new O ring to the fuel pipe Install the fuel pump motor to the holder Be careful not to damage the pump wire 1 FUEL PUMP BASE 2 HOLDER 3 RETAINER Install the fuel pump holder to the fuel pump base Make sure the retainers are locked properly and seat t...

Page 79: ...e fuel pump mounting bolts Align the index mark on the fuel pump base with the fuel hose joint and also align the arrow mark on the pump base facing to the front Tighten the fuel pump mounting base bolt in the numerical order shown in the illustration Torque 4 2 N m 0 43 kgf m 3 1 lbf ft 1 FUEL TANK 2 CLIP 3 BREATHER HOSE Set the fuel tank onto the frame install the fuel tank clip Connect the brea...

Page 80: ... BLACK CONNECTOR 2 CLIP Connect the fuel pump 5P Black connector Install the harness clip to the fuel pump base 1 BARO sensor connector 2 MAP sensor connector 3 IAT sensor connector 4 retainers Throttle Body Air Box Removal Remove the fuel tank page 4 10 Remove the radiator page 4 24 Disconnect the BARO MAP and IAT sensor connec tors Remove the seven air box cover retainers 1 CONNECTOR RUBBER 2 FU...

Page 81: ...move the bolts and then remove the air duct for ward 1 THROTTLE SENSOR CONNECTOR 2 IACV CONNECTOR 1 INJECTOR CONNECTOR 2 FUEL FEED HOSE Disconnect the MAP sensor vacuum hose then remove the air box cover assembly Remove the bolts and air filter Disconnect the throttle sensor and IACV connectors from the throttle body Disconnect the injector connector and fuel feed hose from the throttle body 2 1 1...

Page 82: ...l feed hose from the air box 1 CRANKCASE TRANSMISSION BREATHER HOSE 1 INSULATOR MOUNTING NUTS 2 INSULATOR 3 AIR BOX 1 GROMMET Remove the grommet located on left front of the air box Install the long type phillips screwdriver through the grommet hole then loosen the insulator band Remove the crankcase transmission breather hose from the air box Remove the insulator mounting nuts Remove the air box ...

Page 83: ...eplace the IACV if the valve has excessive wear or damage Throttle Body Disassembly Assembly Bend up the flame trap mounting bolt retainer tabs Remove the mounting bolts retainers and flame trap Remove the bolts and air funnel Remove the injector holder bolts Remove the injector holder injector O ring and seal ring Remove the screws retainer plate and IACV 1 2 1 2 2 1 3 1 1 2 3 ...

Page 84: ...tighten the screws Install the new o ring and cushion ring to the injec tor Install the injector onto the throttle body Install the injector holder Install and tighten the injector holder bolts to the specified torque Torque 5 1 N m 0 52 kgf m 3 8 lbf ft Install the air funnel to the throttle body then install and tighten the mounting bolts Install the flame trap and new retainers Install and tigh...

Page 85: ... Assembly 1 O RING 2 INSULATOR Installation is in the reverse order of removal Replace the insulator O ring with a new one Refer to page 4 7 for fuel hose installation AIR FILTER THROTTLE BODY AIR BOX AIR DUCT 1 2 INSULATOR ...

Page 86: ...t pipe mounting bolt then remove the muffler Remove the radiator lower mounting bolt nut Remove the Ty Raps and exhaust pipe heat protec tor Remove the exhaust pipe joint bolts and exhaust pipe Install the exhaust pipe and muffler in the reverse order of removal Replace the exhaust pipe gasket with a new one Install the muffler and exhaust pipe mounting bolts and nuts loosely tighten the exhaust p...

Page 87: ...ck nut for the engine adjust ing bolt Tool Lock nut wrench 07907 NX5 010 Gently tap the lower engine hanger bolt and turn the adjusting bolt counterclockwise to release the engine mounting from the frame then remove the hanger bolt distance collar and shim Gently tap the upper engine hanger bolt and turn the adjusting bolt counterclockwise to release the engine mounting from the frame then remove ...

Page 88: ...1 kgf m 30 lbf ft 1 REAR LOWER HANGER BOLT 2 ENGINE 3 SHIM 4 DISTANCE COLLAR Temporarily install the rear lower engine hanger distance collar Measure the clearance between the distance collar and frame using a feeler gauge Measure the old shim thickness and adjust the clear ance to zero 0 by selecting shim Engine mount shim 0 2 mm 90510 NX4 000 0 6 mm 90511 NX4 000 1 0 mm 90512 NX4 000 1 5 mm 9051...

Page 89: ...m 4 1 kgf m 30 lbf ft Tighten the rear lower engine hanger nut to the specified torque Torque 40 N m 4 1 kgf m 30 lbf ft 1 FRONT ENGINE HANGER BOLT 2 FRONT ENGINE HANGER COLLAR 3 SHIM 4 HANGER NUT Measure the clearance between the distance collar and frame using a feeler gauge Measure the old shim thickness and adjust the clear ance to zero 0 by selecting shim Engine mount shim 0 2 mm 90510 NX4 00...

Page 90: ...UPPER RADIATOR HOSE 2 UPPER MOUNTING BOLT 1 UPPER MOUNTING BOLT 2 RADIATOR ASSEMBLY Radiator Removal Installation Drain the coolant Disconnect the ECT sensor and thermo sensor con nectors Disconnect the lower radiator hose Remove the radiator lower mounting bolt nut Disconnect the upper radiator hose Remove the radiator left upper mounting bolt Remove the right upper mounting bolt then remove the ...

Page 91: ...L 1 DRIVER 2 ATTACHMENT PILOT Apply lithium base multi purpose grease to the water seal lips then drive the seal using the special tool Tool Water seal driver 07936 KA30000 Apply multi purpose grease to the oil seal lips the install it into the right crankcase cover Drive the new bearing to the right crankcase cover tools page 2 9 1 WATER PUMP SHAFT GEAR 2 IMPELLER 3 COPPER WASHER Hold the water p...

Page 92: ...smission oil page 3 10 Fill the cooling system and bleed the air page 1 1 1 WATER PUMP SHAFT GEAR 2 NEW COPPER WASHER 3 IMPELLER Install the water pump shaft and new copper wash er to the right crankcase cover Hold the water pump gear using a suitable tool then install and tighten the impeller to the specified torque Be careful the water pump impeller has left hand threads Torque 12 N m 1 2 kgf m ...

Page 93: ...ioner lifter sealing bolt and sealing washer Turn the tensioner lifter clockwise fully and secure it with the stopper tool This tool can be easily be made from a thin 1 mm thick piece of steel 1 2 1 2 1 TIMING HOLE CAP O RING 1 CRANKSHAFT HOLE CAP O RING Remove the timing hole cap and O ring from the left crankcase cover Remove the crankshaft hole cap and O ring from the right crankcase cover 1 1 ...

Page 94: ...ure the T mark on the flywheel aligns with the index mark on the left crankcase cover 1 CAM SPROCKETS 2 INDEX LINES Check that the index lines on the cam sprockets are flush with cylinder head upper surface and facing outward each other piston at top dead center on a compression stroke If the index lines are facing inward turn the crank shaft one full turn 360 and align it index lines 1 BOLTS 2 CA...

Page 95: ...e other sprocket bolts Make sure the piston at TDC Top Dead Center on the compression stroke remove the camshaft hold er bolts and copper washers then remove the camshaft holder A and B Remove the intake camshaft and exhaust camshaft Suspend the cam chain with a piece of wire to pre vent the cam chain falling into the crankcase 1 1 1 2 3 4 1 2 1 PACKING 2 PACKING B 1 BOLTS 2 BREATHER SEPARATOR Dis...

Page 96: ...er then remove the decompression cam plate and spring from the exhaust camshaft Check the decompression cam plate for wear or damage Replace the decompression cam plate if necessary Apply molybdenum disulfide grease to the sliding surface of the decompression cam plate assemble the decompression cam plate in the reverse order of disassembly 1 VALVE LIFTER 2 SHIM Cylinder Head Removal Remove the ca...

Page 97: ...nuts and washers then remove the cylinder head 1 2 3 1 GASKET 2 DOWEL PINS Remove the gasket and dowel pins 1 BOLT COLLAR 2 CAM CHAIN GUIDE 3 BOLT COLLAR 4 CAM CHAIN TENSIONER 5 CAM CHAIN Remove the flywheel page 4 67 Remove the pivot bolt cam chain guide and pivot collar Remove the pivot bolt cam chain tensioner and pivot collar Remove the cam chain from the cam chain drive sprocket on the cranks...

Page 98: ...vent loss of tension do not compress the valve springs more than necessary 1 RETAINER 2 OUTER VALVE SPRING 3 INNER VALVE SPRING 4 SPRING SEAT 5 INTAKE VALVE 6 STEM SEAL Remove the following spring seat retainer outer and inner valve spring valve spring seat intake valve stem seal 1 RETAINER 2 VALVE SPRING 3 SPRING SEAT 4 EXHAUST VALVE 5 STEM SEAL Remove the following spring retainer valve spring v...

Page 99: ...gasket surface Check the spark plug hole and valve area for cracks 1 VALVE This machine s intake and exhaust valves are titani um with a special coating If the brown coating of the valve is removed or the metal surface is appeared replace the valve with a new one Check the valve for wear or damage 1 VALVE LIFTER Check that the top and outer surface of the valve lifter for wear or damage 1 1 ...

Page 100: ...ide to remove any carbon build up 1 VALVE LAPPING TOOL Apply a light coating of Prussian Blue to the valve seat Tap the valves and seats using a rubber hose or other hand lapping tool Remove the valve and inspect the valve seat face If a valve face is burned or badly worn or if it con tacts the seat unevenly replace the valve The valve seat contact should be within the speci fied width and even al...

Page 101: ... guide and cam chain ten sioner for excessive wear or damage replace if nec essary Check that the cam chain guide B for excessive wear or damage replace if necessary 1 2 1 1 TENSIONER LIFTER Tensioner lifter Check the tensioner lifter operation as follows The tensioner shaft should not go into the body when it is pushed When it is turned clockwise with a screwdriver the tensioner shaft should be p...

Page 102: ...NG SEAT 2 STEM SEAL 3 VALVE 4 VALVE SPRING 5 RETAINER Install the spring seats and new stem seals Lubricate the valve stem sliding surface with molyb denum solution Insert the exhaust valves into the guide while turn ing it slowly to avoid damage to the stem seals Install the valve spring with the tightly wound coils facing the combustion chamber Install the spring retainers 4 5 1 2 6 3 1 4 3 5 2 ...

Page 103: ... bolt to the speci fied torque Torque 12 N m 1 2 kgf m 9 lbf ft 1 PLASTIC PIN DRIVER Tap the valve stems gently with plastic pin driver as shown to seat the cotters firmly Support the cylinder head so the valve heads do not contact anything that may damage them 1 1 PIVOT COLLAR 2 CAM CHAIN TENSIONER 3 PIVOT BOLT Apply molybdenum solution to the sliding surface of the cam chain tensioner Apply a lo...

Page 104: ...d seating surface then install the sealing washers and nuts install the cylinder head mounting 6 mm bolts Tighten the cylinder head nuts in a crisscross pat tern in 2 3 steps then tighten the nuts to the spec ified torque Torque 39 N m 4 0 kgf m 29 lbf ft Tighten the cylinder head 6 mm bolts 2 1 3 2 1 1 SHIM 2 VALVE LIFTERS Camshaft Cylinder Head Cover Installation Apply molybdenum solution to the...

Page 105: ...are flush with upper surface of the cylinder head and facing outward as shown Install a new O ring to the camshaft holder B groove Apply molybdenum oil solution to the camshaft journals 1 2 3 2 1 3 1 CAMSHAFT HOLDER A 2 CAMSHAFT HOLDER B 3 HOLDER BOLTS 4 COPPER WASHERS BOLTS Apply engine oil to the camshaft holder bolt threads Install the camshaft holder A and B to the cylinder head then install t...

Page 106: ...ue 22 N m 2 2 kgf m 16 lbf ft Turn the crankshaft one full turn 360 tighten the other cam sprocket bolts to the specified torque Torque 22 N m 2 2 kgf m 16 lbf ft 1 1 1 2 1 GASKET 2 CHAIN TENSIONER LIFTER 1 BOLTS 2 SEALING WASHER 3 SEALING BOLT Install the gasket and cam chain tensioner lifter to the cylinder Install and tighten the cam chain tensioner lifter mounting bolts Release the cam chain t...

Page 107: ...st the clearance loosen the lock nut turning the adjuster After adjustment hold the adjuster and tighten the lock nut to the specified torque Torque 1 0 N m 0 1 kgf m 0 7 lbf ft 1 O RING 2 ADJUSTER HOLE CAP 2 1 1 2 Apply multi purpose grease to the threads and seat ing surface of the cam chain adjuster hole cap Apply grease to a new O ring and Install it to the cam chain adjuster hole cap Install ...

Page 108: ...1 2 1 2 Install the washers with it s UP mark facing up Install and tighten the cylinder head cover bolt to the specified torque Torque 10 N m 1 0 kgf m 7 lbf ft 1 TIMING HOLE CAP 2 O RING Apply grease to the new O ring and install it onto the crankshaft hole cap Install and tighten the crankshaft hole cap to the specified torque Torque 15 N m 1 5 kgf m 11 lbf ft Apply grease to the new O ring and...

Page 109: ... Removal Place a clean shop towel over the crankcase to pre vent the clip from falling into the crankcase Remove the piston pin clips with pliers Press the piston pin out of the piston and remove the piston The piston pin clip fitting area has plating process ing Do not use tool which may damage a piston ring groove or piston pin clip Replace the piston with a new one whenever the piston pin clip ...

Page 110: ...nder bore for wear or damage Piston Piston Ring Remove the carbon deposits from the piston head or piston ring grooves using old piston rings Inspect the piston for damage and the ring grooves for wear If the cylinder stud bolt was removed install the stud bolts as shown Tighten the stud bolts to the specified torque Torque 12 N m 1 2 kgf m 9 lbf ft Reference value 105 6 1 mm 4 16 0 04 in 1 Refere...

Page 111: ... the upper side rail with its gap facing exhaust side and the lower side rail facing intake side Install the expander gap facing the piston pin direction and being careful not to overlap the gap For easy piston installation apply grease to the expander gap after the oil ring is installed After installation the rings should rotate freely in the ring grooves Piston Ring Installation Clean the piston...

Page 112: ...nstall new piston pin clip gap facing up and then install the gap side first then install the opposite side into the groove Do not use tool which may damage a piston ring groove or piston pin clip Do not rotate the piston pin clip after installation To prevent damage the piston ring groove plating install opposite side of the piston pin clip before installing the piston pin 1 DOWEL PINS 2 NEW GASK...

Page 113: ...ifter piece needle bearing and thrust washer from the pressure plate Remove the following six clutch disc A six clutch plate clutch disc B judder spring judder spring seat 2 1 1 3 2 1 2 1 1 LOCK WASHER 2 PLAIN WASHER 3 CLUTCH CENTER 1 CLUTCH CENTER HOLDER 2 LOCK NUT Hold the clutch center using the following tool and loosen the clutch center lock nut Tool Clutch center holder 07724 0050002 Remove ...

Page 114: ... needle bearing and clutch outer guide 1 CLUTCH CENTER 2 CLUTCH OUTER 3 OUTER GUIDE 4 NEEDLE BEARING Inspection Check the following items specifications 2 2 Clutch outer for wear cracks or indentation by the clutch discs Clutch center grooves for damage crack or inden tation by the clutch plates Clutch outer needle bearing for wear or damage Clutch spring free length Clutch disc thickness Clutch p...

Page 115: ...enum oil solution to the clutch outer guide sliding surface Apply engine oil to the clutch outer sliding surface Install the clutch outer guide and needle bearing to the mainshaft Install the clutch outer and thrust washer 1 2 2 3 1 1 4 1 2 1 JUDDER SPRING SEAT 2 JUDDER SPRING 3 CLUTCH DISC B 4 CLUTCH PLATE 5 CLUTCH DISC A 1 JUDDER SPRING SEAT 2 JUDDER SPRING 3 CLUTCH DISC B 4 CLUTCH PLATE 5 CLUTC...

Page 116: ... 4 50 Engine Servicing 1 LIFTER PIECE 2 NEEDLE BEARING 3 THRUST WASHER Apply engine oil to the clutch lifter piece needle bearing Install the thrust washer thrust needle bearing and lifter piece to the mainshaft 1 PRESSURE PLATE 2 SPRINGS BOLTS Install the pressure plate assembly Install the clutch springs and spring bolts Tighten the clutch spring bolts gradually then tight en them to the specifi...

Page 117: ...all it into the clutch cover groove Install the clutch cover to the right crankcase cover Install and tighten the bolts in a crisscross pattern in 2 3 steps 2 1 1 2 1 2 3 Right Crankcase Cover Removal Drain transmission oil page 3 10 Drain coolant page 1 1 Disconnect the lower radiator hose from the water pump cover Disconnect the clutch cable from the release arm Remove the bolts water pump cover...

Page 118: ...PUMP COVER 3 BOLTS Install the right crankcase cover while aligning the water pump drive and driven gear by turning the water pump impeller Check the clutch cover O ring condition replace if necessary Install the dowel pins and clutch cover onto the right crankcase cover Install the right crankcase cover bolts Install the water pump cover page 4 26 Install the right crankcase cover water pump cove...

Page 119: ...gear while aligning its wide serration between the balancer drive gear and the crankshaft Align the punch marks between the balancer drive and driven gear 1 2 Apply engine oil to the primary drive gear bolt threads and seating surface Install the washer and primary drive gear bolt Hold the primary drive and driven gear with gear holder and tighten the primary drive gear bolt to the specified torqu...

Page 120: ...AR 2 BALANCER DRIVEN GEAR 1 BALANCER SHAFT 1 BALANCER SHAFT Inspection Turn the balancer shaft bearing inner race with your finger Check that the bearing turns smoothly and quietly Replace the bearing if it does not turn smoothly or loosely fits in the crankcase Check the balancer shaft for damage Remove the water pump drive gear and balancer driven gear from the balancer shaft Separate the crankc...

Page 121: ...e aligning the punch marks between the balancer drive and driven gear Install the water pump drive gear while aligning the punch mark on the balancer shaft with the cut out in the water pump drive gear 1 2 3 1 1 GEAR HOLDER 2 LOCK NUT Apply engine oil to the balancer driven gear lock nut threads and seating surface Install the lock washer and lock nut to the balancer shaft Hold the primary drive a...

Page 122: ... the bolt nut and gearshift arm from the gearshift spindle 1 GEARSHIFT SPINDLE 1 BOLTS 2 TRANSMISSION ASSEMBLY 1 DOWEL PINS 1 SHIFTER COLLAR 2 BOLTS 3 GUIDE PLATE ASSEMBLY 4 56 Engine Servicing Remove the gearshift spindle and washer from the crankcase Remove the bolts and transmission assembly from the crankcase Remove the dowel pins Remove the shifter collar Remove the bolts and guide plate asse...

Page 123: ...e drum center and dowel pin Remove the stopper arm bolt stopper arm return spring and washer 1 SHIFT FORK SHAFTS 2 SHIFT FORKS 3 SHIFT DRUM Remove the shift fork shafts and shift forks Remove the mainshaft countershaft as an assembly from the transmission holder Check the transmission bearing and replace if nec essary page 4 59 77 1 2 3 1 3 2 1 2 ...

Page 124: ...ft spline and gear rotation surface Countershaft spline and gear rotation surface Main countershaft bushing and collar sliding surface Apply transmission oil to the gear contact surface and other sliding surface When installing the C5 and C6 gears to the coun tershaft make sure to align the oil holes of the C5 C6 gears and countershaft Also align the oil holes of M5 collar and main shaft Mainshaft...

Page 125: ...he mainshaft bearing using the following tools Tools Bearing remover set 07936 3710001 remover handle 07936 3710100 bearing remover 07936 3710600 remover weight 07741 0010201 Turn the mainshaft and countershaft bearing inner race with your finger Check that the bearing turns smoothly and quietly Replace the bearing if it does not turn smoothly or loosely fits in the bearing holder Remove the bolts...

Page 126: ...the following tools Tools Driver 07749 0010000 Attachment 37 x 40 mm 07746 0010200 Pilot 17 mm 07746 0040400 1 SHIFT DRUM BEARING SET PLATES BOLTS 2 MAINSHAFT BEARING SET PLATES BOLTS Apply a locking agent to the shift drum bearing and mainshaft bearing set plate bolt threads Install the set plates and bolts then tighten the bolts to the specified torque Torque 10 N m 1 0 kgf m 7 lbf ft 1 2 1 1 2 ...

Page 127: ...AWL 5 GUIDE PLATE If the shift drum has been removed install the gearshift linkage as follows Apply clean transmission oil to the ratchet pawls plungers springs and drum shifter Apply transmission oil to the drum shifter each ratchet pawl and plunger sliding surfaces then assemble them 1 RIGHT SHIFT FORK 2 CENTER SHIFT FORK 3 LEFT SHIFT FORK 1 SHIFT DRUM 2 SHIFT FORKS 3 SHIFT FORK SHAFTS Apply mol...

Page 128: ...FT DRUM ASSEMBLY 3 BOLTS Place the shift drum center position other than neu tral Hold the ratchet pawls in the drum shifter install the guide plate ratchet pawl assembly into the shift drum center Apply a locking agent to the guide plate bolt threads Install and tighten the guide plate bolts to the spec ified torque Torque 10 N m 1 0 kgf m 7 lbf ft Apply transmission oil to the shifter collar sli...

Page 129: ...kgf m 7 lbf ft 1 WASHER 2 GEARSHIFT SPINDLE 3 STOPPER PIN 4 SHIFTER COLLAR Install the washer onto the gearshift spindle Install the gearshift spindle by aligning the spring ends with the stopper pin and also aligning the shift arm groove with the shifter collar Check that the gearshift linkage operate properly 1 GEARSHIFT ARM 2 BOLT NUT Install the gearshift arm and tighten the bolt nut Install t...

Page 130: ...GASKET 2 DOWEL PINS 3 OIL COLLARS 1 BOLTS 2 IGNITION PULSE GENERATORS 3 SOCKET BOLTS 4 STATOR Disassembly Assembly Remove the ignition pulse generator flange bolts Remove the stator mounting socket bolts Remove the stator ignition pulse generator from left crankcase cover Remove the bolts and left crankcase cover Remove the gasket dowel pins and oil collars 2 2 1 3 4 1 2 1 3 2 1 ...

Page 131: ...nkshaft busing using the following tools Tools Bearing remover shaft 15 mm 07935 KC10100 remover head 15 mm 07936 KC10200 remover weight 07741 0010201 1 BUSHING 2 O RING 3 WASHER 4 SNAP RING Apply grease to a new O ring the install it into the crankshaft bushing groove Install the crankshaft bushing into the left crankcase cover Install the washer and snap ring 1 2 1 2 1 3 4 ...

Page 132: ...ing bolts to the specified torque Torque 5 N m 0 5 kgf m 3 7 lbf ft Apply sealant to the grommet Install it into the left crankcase cover groove 1 DOWEL PINS 2 OIL COLLAR 3 NEW GASKET Installation Install the dowel pins and new gasket Apply grease to new O rings then install them into the grooves of the oil collar Install the oil collars 1 LEFT CRANKCASE COVER 2 BOLTS Install the left crankcase co...

Page 133: ...crankcase cover page 4 64 Hold the flywheel with a flywheel holder Loosen the flywheel nut Tool Flywheel holder 07725 0040001 1 FLYWHEEL PULLER ADAPTER 2 FLYWHEEL PULLER HOLDER 3 FLYWHEEL PULLER BOLT 4 FLYWHEEL 1 WOODRUFF KEY Remove the flywheel using the special tool Tools Flywheel puller adapter 89009 NX7 000 Flywheel puller holder 89010 NX7 000 Flywheel puller bolt 89011 NX7 000 Remove the wood...

Page 134: ...nkcase Separation Disassembly Remove the engine from the frame Remove the following cylinder head cylinder piston clutch gearshift linkage transmission flywheel and stator primary drive gear balancer drive gear crankcase breather hose Remove the countershaft collar and O ring Installation Clean any oil off from the crankshaft taper Install the woodruff key onto the crankshaft groove Install the fl...

Page 135: ...R HOLDER 2 WATER PUMP DRIVE GEAR 3 BALANCER DRIVEN GEAR Hold the primary drive and driven gear with the gear holder Tool Gear holder 07724 0010100 Loosen the balancer drive gear lock nut 1 PRIMARY DRIVE GEAR 2 BALANCER DRIVE GEAR 3 WATER PUMP DRIVE GEAR 4 BALANCER DRIVEN GEAR Remove the primary drive gear washer primary driven gear and balancer drive gear from the crank shaft Remove the balancer d...

Page 136: ...valve stopper Loosen the crankcase bolts in a crisscross pattern in 2 3 steps then remove the bolts Place the left crankcase facing down remove the right crankcase from the left crankcase Remove the dowel pins Remove the crankshaft and balancer shaft from the left crankcase Remove the scavenge pump inner and outer rotor from the oil pump shaft Remove the bolt and oil pump cover 1 1 2 1 2 1 1 2 2 1...

Page 137: ...nkshaft Inspection Remove the connecting rod bolts bearing cap and connecting rod Remove the pressure relief valve Remove the oil pump shaft feed pump inner and outer rotor Remove the scavenge pump inner and outer rotor from the inside of the left crankcase Remove the bolt and piston jet 80 from the left crankcase Check the oil jet 80 for clog Clean the oil jet passage 2 5 4 1 3 2 1 1 2 1 1 2 ...

Page 138: ... crankpins Set the connecting rod onto the crankpin Put ta strip of plastigauge lengthwise on crankpin avoiding the oil hole Do not rotate the crankshaft during inspection 1 BEARING CAP 2 CONNECTING ROD BOLT Carefully install the connecting rod bearing cap aligning the dowel pins with the holes in the con necting rod Apply oil to the connecting rod bearing cap bolt threads and sating surfaces and ...

Page 139: ...CODE Bearing Selection The crankpin bearing must be selected if the crank shaft and or connecting rod are replaced Record the connecting rod I D code letter 1 2 or 3 or measure the I D with the connecting rod bearing cap installed without bearing inserts Numbers 1 2 or 3 on the connecting rods are the codes for the connecting rod I D 1 1 CRANKPIN O D CODE If you plan to replace the crankshaft reco...

Page 140: ...e connecting rod and crankpin codes to determine the replacement bearing color Crankpin bearing selection table Oil Clearance 0 030 0 048 mm 0 0012 0 0019 in Bearing thickness A Blue Thickest B Black C Brown D Green E Yellow Thinnest 1 COLOR CODE After selecting new bearings recheck the clear ance with a plastigauge Incorrect clearance can cause severe engine damage Connecting Rod I D Code 1 2 3 3...

Page 141: ...l clear ance Main Journal Bearing Selection Table Oil clearance 0 020 0 038 mm 0 0008 0 0015 in Bearing thickness A Blue Thickest B Black C Brown D Green Thinnest Main journal O D Code 1 2 3 37 994 38 000 mm 37 988 37 994 mm 37 982 37 988 mm 1 4958 1 4961 in 1 4956 1 4958 in 1 4954 1 4956 in Crankcase A 43 000 43 006 mm D C B I D 1 6929 1 6931 in Code B 43 006 43 012 mm C B A 1 6931 1 6934 in 1 CO...

Page 142: ... 1 BEARING HOLDER ASSEMBLY 2 MAIN JOURNAL BEARING 1 BEARING HOLDER ASSEMBLY 2 BEARING FIT SPINDLE 3 MAIN JOURNAL BEARING Set the selected main journal bearings into the bear ing holder tool lightly tighten the holder bolts Push the bearing using the 7 mm side of the bearing fit spindle as shown Tools Bearing holder assembly 89020 NX7 000 Bearing fit spindle 89023 NX7 000 Crankcase Bearing Replacem...

Page 143: ... Remove the right balancer bearing and countershaft bearing using the special tools Right balancer bearing Driver 07749 0010000 Attachment 32 x 35 mm 07746 0010100 Pilot 15 mm 07746 0040300 Countershaft bearing Driver 07749 0010000 Attachment 37 x 40 mm 07746 0010200 Pilot 20 mm 07746 0040500 1 2 5 4 6 7 9 10 11 8 3 Apply locking agent To be bottomed To be bottomed To be bottomed To be bottomed To...

Page 144: ...ring in using the following tools Tools Mainshaft bearing Driver 07749 0010000 Attachment 37 x 40 mm 07746 0010200 Pilot 17 mm 07746 0040400 Countershaft bearing Driver 07749 0010000 Attachment 42 x 47 mm 07746 0010300 Pilot 20 mm 07746 0040500 1 SET PLATE 2 SCREW Apply a locking agent to the countershaft bearing set plate screw threads Install the countershaft bearing set plate and tighten the sc...

Page 145: ...ing surfaces before assembling and check for wear or damage If the minor roughness or irregularities on the crankcase mating surfaces dress them with an oil stone 1 OIL SEAL 2 O RING 3 COUNTERSHAFT COLLAR 1 BALANCER OIL SEAL 2 CRANKSHAFT OIL SEAL Apply grease to the new dust seal lips Install the countershaft oil seal Install the new O ring into the countershaft collar Install the countershaft col...

Page 146: ...ll the oil pump shaft by aligning its flat with the inner rotors 1 OIL JET If the oil jet is removed apply a locking agent to the oil jet threads Do not apply locking agent to the tip of the oil jet Install the oil jet to the right crankcase Tighten it to the specified torque Torque 2 0 N m 0 2 kgf m 1 5 lbf ft 1 INNER ROTOR 2 OUTER ROTOR Apply engine oil to each pump rotors Install the scavenge p...

Page 147: ...OR 2 OUTER ROTOR Place the left crankcase with the oil pump cover side facing down Install the right crankcase side scavenge pump inner and outer rotor onto the inside of the left crankcase 1 DOWEL PINS 1 OIL PUMP COVER 2 BOLT Install the dowel pins Install the oil pump cover and temporarily tighten the cover bolt 2 1 2 1 1 2 1 ...

Page 148: ...e mating surface Do not apply sealant to the oil passage area as shown Install the dowel pins Engine Servicing 4 82 1 1 1 17 20 mm 0 7 0 8 in 1 REED VALVE 2 REED VALVE STOPPER 1 REED VALVE REED VALVE STOPPER 2 BOLT Check the reed valve for damage Apply a locking agent to the reed valve stopper bolt threads Install the reed valve reed valve stopper and tighten the stopper bolt to the specified torq...

Page 149: ...mary drive gear bolt threads and seating surface Install the washer and primary drive gear Install the balancer driven gear and water pump drive gear Apply engine oil to the balancer driven gear lock nut threads and seating surface Install the lock washer and lock nut 1 2 3 4 3 1 2 1 GEAR HOLDER 2 WATER PUMP DRIVE GEAR 3 BALANCER DRIVEN GEAR Hold the primary drive and driven gear with the gear hol...

Page 150: ...Memo ...

Page 151: ...ever after the front wheel is removed The caliper pistons will move and make reassembly difficult Disassembly Assembly 1 SNAP RING IN 35 mm 2 SIDE COLLAR 3 SNAP RING EX 26 mm 4 RIGHT WHEEL BEARING 6202U 5 DISTANCE COLLAR 6 LEFT WHEEL BEARING 6202U 7 BRAKE DISC 8 FLANGE BOLT 6X20 mm 8 1 4 2 3 6 7 Less than 60 g Chamfered side facing in Torque 12 N m 1 2 kgf m 9 lbf ft To be bottomed to wheel hub 2 ...

Page 152: ... mark a paint dot or circle on the side wall must be located next to the valve stem Remount the tire if necessary 1 INSPECTION STAND Mount the wheel tire and brake disc assembly in an inspection stand Spin the wheel allow it to stop and mark the lowest heaviest part of the wheel with chalk Do this two or three times to verify the heaviest area If the wheel is balanced it will not stop consistently...

Page 153: ...side 1 AXLE NUT 2 AXLE HOLDER BOLTS Hold the axle and tighten the axle nut to the speci fied torque Torque 70 N m 7 1 kgf m 51 lbf ft Tighten the right axle holder bolts to the specified torque Torque 22 N m 2 2 kgf m 16 lbf ft 1 AXLE HOLDER BOLTS With the front brake applied pump the fork up and down several times to seat the axle and check the front brake operation Tighten the left axle holder b...

Page 154: ... scratch the slider A scratched slid er will damage the seal causing an oil leak To avoid damaging the outer tube install the fork set collar on the axle holder Hold the outer tube remove the fork bolt and slide the outer tube down onto the fork set collar Tool Fork set collar 51481 NX4 610 When the fork bolt is removed from the outer tube the slider can move up and down freely in the outer tube A...

Page 155: ...D ADJUSTER 1 DAMPER ROD 1 AXLE HOLDER Hold the axle holder in a vise protected with a piece of wood or soft jaws to avoid damage Do not overtighten Loosen and remove the fork bottom socket bolt and sealing washer If the socket bolt turns together with the fork damper temporarily install the fork spring spacer and fork bolt Remove the following spring seat stopper spring collar spring joint plate f...

Page 156: ...check the outer tube Remove the fork set collar Remove the slider from the outer tube 1 STOP RING 1 SLIDER BUSHING 2 GUIDE BUSHING 3 BACK UP RING 4 OIL SEAL 5 STOP RING Remove the slider bushing by prying the slot with a screw driver until the bushing can be pulled off by hand Remove the following guide bushing back up ring oil seal stop ring Be careful not to scratch the teflon coating of the gui...

Page 157: ...or scratches Remove any metal powder from the guide bushings with a nylon brush and fork fluid If copper appears on the entire surface replace the bushing Replace the back up ring if there is any distortion at the points shown 1 OIL LOCK VALVE Check the oil lock valve for wear or damage 1 2 1 1 OUTER TUBE 2 FORK DAMPER Outer Tube Fork Damper Check the outer tube for damage or deformation Check the...

Page 158: ...ial SAE 5W Showa SS05 Operation Oil or equivalent Vegetable oils is harmful to the oil seals resulting in oil leaks 1 NEW SLIDER BUSHING 2 GUIDE BUSHING 3 BACK UP RING 4 NEW OIL SEAL 5 STOP RING Wrap the end of the slider with a tape Install the stop ring Coat the new oil seal lips with recommended fork fluid and install with its seal mark facing the stop ring Remove the tape Install the back up r...

Page 159: ...set collar and lower the outer tube gently onto the tool Tool Fork set collar 51481 NX4 610 1 CENTERING PLATE 2 FORK DAMPER 1 NEW SEALING WASHER 2 SOCKET BOLT Drive in the guide bushing into the outer tube with the back up ring Drive in the oil seal until the stop ring groove is vis ible Tools Fork seal driver 07KMD KZ30100 Fork seal driver attachment 07916 NX4 700 Install the oil seal stop ring i...

Page 160: ...nded fork fluid Honda Ultra Cushion Oil Special SAE 5W Showa SS05 Operation Oil or equivalent Bleed the air as follows 1 Extend the fork Cover the top of the outer tube with your hand and compress the fork slowly The fork fluid will spill out of the oil hole in the slider Do not pull up the outer tube more than 225 mm 8 8 in from the axle holder to extend the fork 2 Pump the outer tube and damper ...

Page 161: ...r while holding the rebound damping adjuster and pulling down the spring seat stopper Place a 17 mm open end wrench on the cut out of the rebound damping adjuster while holding the fork bolt and pulling down the spring seat stopper Hold the rebound adjuster and tighten the fork bolt to the specified torque Torque 34 N m 3 5 kgf m 25 lbf ft 1 FORK BOLT 1 ADJUSTING PLATE Apply recommended fork fluid...

Page 162: ...T 2 TOP BRIDGE PINCH BOLT Tighten the fork bolt to the specified torque Torque 34 N m 3 5 kgf m 25 lbf ft Tighten the top bridge pinch bolt to the specified torque Torque 23 N m 2 3 kgf m 17 lbf ft Adjust the handlebar position tighten the pinch bolt to the specified torque Torque 23 N m 2 3 kgf m 17 lbf ft Overtightening the top bridge and handlebar pinch bolts can deform the outer tube It may ca...

Page 163: ... 2 THROTTLE PIPE 1 SCREW 2 ENGINE STOP SWITCH 1 SCREW 2 CLUTCH LEVER BRACKET Handlebar Removal Remove the screws and throttle housing cover Disconnect the throttle cable from the throttle pipe Remove the bolts and throttle housing Remove the throttle pipe Remove the front brake master cylinder page 5 35 Remove the two screws and engine stop switch Remove the two screws and clutch lever bracket 1 2...

Page 164: ...kgf m 17 lbf ft Top bridge pinch bolt 23 N m 2 3 kgf m 17 lbf ft Steering stem bolt 60 N m 6 0 kgf m 43 lbf ft 1 STEM BOLT 2 TOP BRIDGE Steering Stem Removal Remove the following upper cowl front wheel page 5 1 steering stem bolt fork legs page 5 4 top bridge 1 ADJUSTING NUT 2 STEERING STEM SOCKET 1 DUST SEAL 2 UPPER BEARING 3 STEERING STEM 4 LOWER BEARING Remove the lock washer Remove the stem be...

Page 165: ...4 003 driver attachment 51 mm 07914 NX4 003 driver shaft 07915 NX4 003 1 DRIVER SHAFT 2 NUT 3 COLLAR 4 DRIVER ATTACHMENT 47 MM 5 UPPER OUTER RACE Install a new upper outer race and the ball race driv er as shown Holding the driver shaft 1 with a wrench turn nut 2 gradually until the groove in the driver attach ment 4 aligns with the upper end of the steering head to install the upper outer race 1 ...

Page 166: ...DUST SEAL 2 NEW LOWER BEARING Install the following new dust seal new lower bearing Press the lower bearing in using the special tool and a hydraulic press Tool Steering stem driver 07946 MB00000 1 LOWER BEARING 2 STEERING STEM 3 NEW UPPER BEARING 4 NEW DUST SEAL Installation Apply grease to the upper and lower bearings and races Slide the steering stem through the steering head from the bottom In...

Page 167: ...stem socket 07916 KA50100 Torque 15 N m 1 5 kgf m 11 lbf ft 1 STEERING STEM 2 Move the steering stem right and left lock to lock several times to seat the bearings Make sure that the steering stem moves smooth ly without play or binding 1 BEARING ADJUSTING NUT 3 Loosen the bearing adjusting nut so that the adjusting nut turns by hand Do not loosen the adjusting nut more than neces sary 4 Retighten...

Page 168: ...fork legs page 5 12 handlebar top bridge steering stem bolt Apply grease to the steering stem bolt threads Tighten the steering stem bolt to the specified torque Torque 59 N m 6 0 kgf m 43 lbf ft Install the front wheel page 5 2 Install the upper cowl 8 Further tighten the adjusting nut to the specified torque using the special tool If a torque wrench is not available further tighten the nut about...

Page 169: ...r piston will move and make reassembly difficult See page 5 2 for inspection Disassembly Assembly 1 SIDE COLLAR 2 DRIVEN FLANGE 3 DRIVEN FLANGE BEARING 6904UU 4 O RING 5 DRIVEN SPROCKET BOLT 6 DRIVEN SPROCKET 7 REAR WHEEL DAMPER 8 SNAP RING 9 LEFT WHEEL BEARING 6202UU 10 DISTANCE COLLAR 11 RIGHT WHEEL BEARING 6202UU 12 BRAKE DISC 13 BRAKE DISC BOLT 1 Less than 60 g 1 2 5 6 11 10 9 8 13 12 7 3 4 To...

Page 170: ...3 8 Tighten the axle nut to the specified torque while holding the rear axle Torque 70 N m 7 1 kgf m 51 lbf ft 1 BOLT NUT 2 DRIVE CHAIN ROLLER 3 LOWER MOUNTING BOLT NUT Rear Shock Absorber Removal Remove the seat cowl Support the machine using a maintenance stand If you will replace the spring loosen the lock nut and adjuster before removing the rear shock absorber Remove the nut bolt and drive ch...

Page 171: ...r rod on a scale and measure the force required to compress the damper until the 10mm 0 4 in mark is flush with the damper body Compression force 150 195 N 15 4 20 0 kg If the force required is less than 150 N 15 4 kg nitrogen is leaking Fill the reservoir with 980 1 280 kPa 10 0 13 0 kg cm2 142 185 psi of nitrogen gas 1 RESERVOIR 2 VALVE CORE Nitrogen Releasing Procedure High pressure gas can cau...

Page 172: ...o the groove Press the new spherical bearing using the special tool Tool Spherical bearing driver 07946 KA30200 Install the opposite side stop ring into the upper joint groove securely Install the pivot collars 1 AIR TOOL Inspect the spherical bearing prior to extensive use If the movement is not smooth be sure to perform braking in procedures to the extent that the parts may be rotated by hand Un...

Page 173: ... 1 PRELOAD LENGTH 2 ADJUSTER 3 LOCK NUT Note the direction of the rebound adjuster Adjust the spring preload length page 7 16 Hold the spring adjuster and tighten the lock nut to the specified torque Torque 50 N m 5 0 kgf m 36 lbf ft 1 REBOUND ADJUSTER 1 UPPER MOUNTING BOLT NUT 2 REAR SHOCK ABSORBER Installation Install the rear shock absorber with its tension adjuster facing to the right Install ...

Page 174: ... bearing driver 07946 MJ00000 driver shaft 07946 MJ00100 driver head 07946 MJ00200 Apply grease to the bearing rollers then press the bearing into the shock link so that it is 5 1 5 4 mm 0 20 0 21 in below the shock arm end Press the bearings with their marked side Tools Driver 07749 0010000 Attachment 24 x 26 mm 07746 0010700 Pilot 17 mm 07746 0040400 Apply grease to the dust seal lips install th...

Page 175: ...ten the shock linkage mounting nuts Tighten the rear shock absorber lower mounting nut 1 TIE WRAPS Swingarm Removal Remove the following rear wheel page 5 19 rear brake caliper bracket page 5 33 rear brake hose tie wraps 1 BOLT NUT 2 DRIVE CHAIN ROLLER 1 LOWER MOUNTING BOLT NUT 2 SHOCK ARM PLATE BOLT NUT 3 SHOCK ARM PLATES Remove the bolt nut and drive chain roller Remove the following shock absor...

Page 176: ...t wrench 07908 4690003 1 PIVOT BOLT 2 ADJUSTING BOLT Turn the swingarm pivot bolt and loosen the pivot adjusting bolt Remove the swingarm pivot bolt and swingarm 1 SCREWS 2 DRIVE CHAIN SLIDER 1 SCREWS 2 DRIVE CHAIN SLIDER Disassembly Remove the screws and drive chain sliders Remove the bolts and drive chain guard 1 1 2 1 1 2 1 2 ...

Page 177: ...OT BEARING 20X37X9 mm 6 SNAP RING 7 RIGHT DUST SEAL 8 SHOCK ARM PLATE PIVOT COLLAR 9 DUST SEAL 17X24X5 mm 1 PIVOT COLLAR B 2 DUST SEALS 3 DISTANCE COLLAR 4 SNAP RING Remove pivot collar B Remove the dust seals and distance collar Remove the snap ring 1 4 0 5 0 mm 0 16 0 20 in 2 3 4 5 6 7 5 2 5 7 mm 0 20 0 22 in 9 9 8 10 To be bottomed 10 NEEDLE BEARING 17X24X17 mm 2 4 3 2 1 ...

Page 178: ...TTACHMENT PILOT Press the new right pivot bearings in using the spe cial tools Tools Driver 07749 0010000 Attachment 37 x 40 mm 07746 0010200 Pilot 20 mm 07746 0040500 5 28 Frame Servicing 1 BEARING REMOVER SET 1 NEEDLE BEARING REMOVER 2 DRIVER SHAFT Remove the right pivot bearings using the special tool Tool Bearing remover set 20 mm 07936 3710001 Remove the left pivot bearing using the special t...

Page 179: ... install them Install the pivot collars 1 SNAP RING 2 RIGHT DUST SEAL 3 DISTANCE COLLAR 4 LEFT DUST SEAL 5 PIVOT COLLAR B Assembly Install a snap ring into the swingarm groove secure ly Apply grease to the bearings and lips of a new dust seal and install the dust seal into the right pivot Install the distance collar Apply grease to the left pivot bearing and lips of a new dust seal then install th...

Page 180: ...nstall the swingarm Apply a thin layer of grease to the swingarm pivot bolt surface Install the swingarm and pivot bolt Turn the pivot bolt and tighten the adjusting bolt to the specified torque Torque 15 N m 1 5 kgf m 11 lbf ft 1 LOCK NUT WRENCH Install and tighten the swingarm adjusting bolt lock nut to the specified torque Tool Lock nut wrench 07908 4690002 Torque 44 N m 4 5 kgf m 33 lbf ft 5 3...

Page 181: ...1 SHOCK ARM PLATES 2 SHOCK ARM PLATE BOLT NUT 3 LOWER MOUNTING BOLT NUT Install the following shock arm plates to swingarm bolt nut rear shock absorber lower mounting bolt nut Tighten the shock arm plate bolt Tighten the rear shock absorber lower mounting bolt 1 drive chain roller 2 bolt nut Install the drive chain roller and tighten the bolt nut 1 1 3 2 2 1 ...

Page 182: ...ith a high quality degreasing agent if they are contaminated with oil or grease If the pads cannot be cleaned replace them Remove the brake caliper mounting bolts and caliper 1 BRAKE PADS 1 B CLIP 2 PAD PIN 3 BRAKE PADS Push the pistons all the way in to allow installation of new brake pads Check the brake fluid level in the reservoir as this operation causes the level to rise Remove the B clip Ge...

Page 183: ...ons against the pads 1 PAD PIN PLUGS 2 PAD PINS Rear Brake Pad Replacement Clean the brake disc or pads with a high quality degreasing agent if they are contaminated with oil or grease If the pads cannot be cleaned replace then Remove the rear wheel page 5 19 Remove the brake pad pin plugs and loosen the pad pins Clean the brake caliper inside especially around the caliper pistons Install the new ...

Page 184: ...D SPRING 1 PAD PINS 1 PAD PINS 2 PAD PIN PLUGS Tighten the pad pins Torque 18 N m 1 8 kgf m 13 lbf ft Install and tighten the pad pin plugs Torque 1 5 N m 0 15 kgf m 1 1 lbf ft Install the rear wheel page 5 20 Clean inside the brake caliper especially around the caliper piston Position the pad spring in the caliper as shown Install the new pads by pushing the pads against the caliper to depress th...

Page 185: ...e caliper may damage it Installation Install the caliper assembly over the brake disc so that the disc is positioned between the pads Be careful not to damage the brake pads Install and tighten the brake caliper mounting bolts Install the brake hose eyelet joint with new sealing washers Install and tighten the brake hose bolt to the speci fied torque Torque 24 N m 2 4 kgf m 17 lbf ft Fill the brak...

Page 186: ...bly Assembly 1 CALIPER BRACKET 2 CALIPER PISTON 3 PISTON SEAL 4 DUST SEAL 5 BRAKE PADS 6 PIN BOLT A 7 PIN BOLT 1 4 3 2 6 Torque 12 N m 1 2 kgf m 9 lbf ft 1 5 Apply silicone grease Torque 7 N m 0 7 kgf m 5 1 lbf ft 6 Torque 22 N m 2 2 kgf m 16 lbf ft Apply silicone grease Apply locking agent Torque 1 N m 0 15 kgf m 1 1 lbf ft Torque 18 N m 1 8 kgf m 13 lbf ft 2 3 Apply brake fluid 6 Apply silicone ...

Page 187: ...d and bleed the system 1 OIL BOLT 2 BOLTS 3 HOLDER 4 MASTER CYLINDER Front Master Cylinder Removal Avoid spilling brake fluid on painted plastic or rub ber parts Place a shop rag over these parts when ever the system is serviced When removing the brake hose bolt cover the end of the hoses to prevent contamination Secure the hoses to prevent fluid from leaking out Spilled brake fluid will damage pa...

Page 188: ...JOINT PIN 2 ADJUSTER 3 ADJUSTER ARM 4 PIVOT SCREW If the brake lever was disassembled assemble as follows 1 Install the joint pin with its arrow facing to the adjuster 2 Apply silicone grease to the adjuster rod 3 Apply a locking agent to the pivot screw threads Assemble the adjuster arm and the brake lever tighten the pivot screw 1 9 7 8 2 5 3 4 6 1 2 4 3 ...

Page 189: ...7 lbf ft 1 TIE WRAP 2 JOINT BOLT NUT Rear Master Cylinder Removal Avoid spilling brake fluid on painted plastic or rub ber parts Place a shop rag over these parts when ever the system is serviced Spilled brake fluid will damage painted plastic or rubber parts If fluid does get on these parts wipe it off with a clean cloth Drain the brake fluid from the hydraulic system into a suitable container Re...

Page 190: ...G 1 MASTER CYLINDER 2 BOLTS 3 EYELET JOINT 4 NEW SEALING WASHERS 5 OIL BOLT Installation Install the master cylinder onto the bracket Install and tighten the mounting bolts Connect the brake hose eyelet joint with new sealing washers Install and tighten the brake hose oil bolt to the specified torque Torque 23 N m 2 4 kgf m 17 lbf ft 7 8 1 2 5 3 4 6 4 5 2 1 3 ...

Page 191: ...1 JOINT BOLT NUT 2 VINYL TUBE 3 TIE WRAPS Connect the joint with the brake pedal Install the washer and joint bolt nut then tighten the nut Secure the vinyl tube with a tie wrap Fill the reservoir and bleed the system 3 1 2 ...

Page 192: ...Memo ...

Page 193: ...tural connector and measure the resistance between the terminals of the alterna tor side connector If the measured resistance at regulator rectifier 5P Black connector is incorrect and the alternator 6P Natural connector is correct check the wire har ness If the resistance is still out of specification replace the stator assembly 1 4P RED CONNECTOR Regulated Voltage Inspection Disconnect the servi...

Page 194: ...al 1 33P BLACK CONNECTOR 2 PGM FI IGN UNIT Ignition System Inspection Disconnect the PGM FI IGN unit 33P Black connec tor 1 2P NATURAL CONNECTOR 2 DIRECT IGNITION COIL Disconnect the direct ignition coil 2P Natural con nector Check for continuity between the direct ignition coil 2P Natural connector and PGM FI IGN unit 33P Black connector terminals Connection Yellow Blue Yellow Blue primary coil B...

Page 195: ...n Check the ignition coil resistance at the ECM 33P Black connector page 6 5 Connection Blue yellow Green black White yellow Green black Standard 180 280 Ω 20 C 68 F 2 1 1 2 1 6P NATURAL CONNECTOR If the resistance is out of specification measure the resistance at the alternator 6P Natural connector If the measured resistance at ECM 33P Black con nector is incorrect and the alternator 6P Natural c...

Page 196: ...tems engine does not start in the PGM FI Malfunction Indicator Lamp MIL Failure Code chart on page 6 7 If all items are correct replace the condenser unit with new one and inspect again If the engine starts the replaced condenser is faulty If the engine does not starts check for wire harness 1 2P LIGHT GRAY CONNECTOR Engine Stop Switch Inspection Disconnect the engine stop switch 2P Light gray con...

Page 197: ...side Item No Terminal Standard Ignition pulse generator A 11 Bu Y G B 180 280 Ω 20 C 68 F A 29 W Y G B 180 280 Ω 20 C 68 F INJ Injector A 5 B W P Bu 11 1 12 3 Ω 20 C 68 F Engine stop switch A 23 R ground Continuity is exist only when switch is pushed ECT sensor A 20 P B G O 2 3 2 6 k Ω 20 C 68 F Logic ground A 6 G Ground Continuity Power ground A 12 G Ground Continuity Sensor ground A 22 G O Groun...

Page 198: ...ata the MIL will start blinking when you turn the power switch ON Note how many times the MIL blinks and determine the cause of the problem See next page 1 POWER SWITCH 2 MIL 3 WARNING RESET SWITCH Self diagnosis Reset Procedure Connect the serial USB interface unit assembly to the wire harness and 12 V battery same procedure as Self diagnosis see previous step Before turn ON the power switch turn...

Page 199: ...e 7 Blinks Loose or poor contact on ECT sensor Hard starting at a low temperature Open or short circuit in ECT sensor wire Simulate using numerical values 40 C 104 F Faulty ECT sensor Cooling fan does not stop 8 Blinks Open or short circuit in TP sensor line in the ECM Poor engine response when operating the throttle quickly Faulty TP sensor Simulate using numerical values throttle open 0 9 Blinks...

Page 200: ... the bank angle sensor approximately 65 degrees to the left or right make sure that the engine stops after few seconds If the engine stops the bank angle sensor is normal If the engine does not stop replace the bank angle sensor With the arrow UP mark on the bank angle sensor facing up again restart the engine The engine starts the bank angle sensor is normal 1 ARROW UP MARK 2 BANK ANGLE SENSOR In...

Page 201: ...f specification 1 PGM FI 33P BLACK CONNECTOR Meter Inspection If the water temperature meter does not display inspect the following Disconnect the PGM FI 33P Black connector and water temperature meter 2P Black connector Check the continuity of the green terminal between the ignition control module and water temperature meter connector 1 1 1 If there is no continuity check the wire harness If ther...

Page 202: ...Bl Bl R Gr G G R Bu G G O Y G R Y Lg R Y G O Lg Bl Bl Y Bu Bl W P Bu P Bl G O G O Gr Bu G O R Y Y G Bu G Bl Br O Bl G Bl Y Bu P Bu G Gr Bl Gr Bu Bu Y G Bu R Y Bl R Bl O Bl Y W Bu O P Bl R W G O Bl Bl W O Bl Br Bu Y W Y Gr Lg Bl Lg Y G Bl Bu G Bl Y W G Bl Bu Y W Y G Y W G W Bu Y W Y Bl G G Gr R Bl G Bl G Bl Bl R Bl Y Bl Bu Bl O W G R W G Bu Y Bl G Gr QSSW PA SENSOR PB SENSOR TA SENSOR TW SENSOR GND...

Page 203: ...NX4 681 24 28 1 166 OP M3 23441 NX4 000 C3 P3 23453 NX4 681 23 29 1 260 M4 C4 23461 NX4 681 24 28 1 166 OP M3 23441 NX4 000 C3 P3 23453 NX4 681 23 29 1 260 M4 C4 P2 23462 NX4 681 24 29 1 208 OP M3 P2 23442 NX4 000 C3 P2 23452 NX4 681 20 27 1 350 M4 C4 23461 NX4 681 24 28 1 166 OP M3 P2 23442 NX4 000 C3 P2 23452 NX4 681 20 27 1 350 M4 C4 P2 23462 NX4 681 24 29 1 208 OP M3 23443 NX4 000 C3 23451 NX4...

Page 204: ... 1 150 OP M3 P2 23447 NX4 000 C3 P2 23452 NX4 681 20 27 1 350 M4 P4 C4 P4 23464 NX4 681 21 26 1 238 OP M3 P2 23447 NX4 000 C3 P2 23452 NX4 681 20 27 1 350 M4 P4 C4 P5 23465 NX4 681 21 25 1 190 OP M3 P2 23448 NX4 000 C3 P2 23452 NX4 681 20 27 1 350 M4 P6 C4 P6 23466 NX4 681 20 23 1 150 OP M3 P4 23449 NX4 000 C3 P4 23454 NX4 681 22 31 1 409 M4 C4 23461 NX4 681 24 28 1 166 OP M3 P4 23449 NX4 000 C3 P...

Page 205: ...3461 NX4 681 24 28 1 166 OP M3 P6 23444 NX4 610 C3 P6 23456 NX4 681 21 27 1 285 M4 C4 P2 23462 NX4 681 24 29 1 208 OP M3 P6 23445 NX4 610 C3 P6 23456 NX4 681 21 27 1 285 M4 P3 C4 P3 23463 NX4 681 22 25 1 136 OP M3 P6 23446 NX4 610 C3 P6 23456 NX4 681 21 27 1 285 M4 P4 C4 P4 23464 NX4 681 21 26 1 238 OP M3 P6 23446 NX4 610 C3 P6 23456 NX4 681 21 27 1 285 M4 P4 C4 P5 23465 NX4 681 21 25 1 190 OP M3 ...

Page 206: ...50 154 156 158 160 163 164 23 30 1 304 148 152 156 158 160 162 164 166 21 27 1 285 150 154 158 160 162 164 167 168 23 29 1 260 153 157 161 163 165 167 170 172 4th 21 26 1 238 156 160 164 166 168 170 173 175 24 29 1 208 160 164 168 170 173 175 177 179 21 25 1 190 162 166 171 173 175 177 180 182 24 28 1 166 165 170 174 176 179 181 184 186 20 23 1 150 168 172 177 179 181 183 186 188 22 25 1 136 170 1...

Page 207: ... 175 177 178 179 23 30 1 304 168 169 170 172 174 175 176 179 180 181 21 27 1 285 170 171 173 174 176 178 179 182 183 184 23 29 1 260 173 175 176 178 180 181 182 185 186 187 4th 21 26 1 238 177 178 180 181 183 185 186 189 190 191 24 29 1 208 181 182 184 186 188 189 190 194 195 196 21 25 1 190 184 185 187 188 191 192 193 196 198 199 24 28 1 166 187 189 191 192 195 196 197 200 202 203 20 23 1 150 190...

Page 208: ...89 190 195 195 201 207 23 30 1 304 185 186 186 191 192 197 197 203 210 21 27 1 285 188 188 189 194 194 200 200 206 213 23 29 1 260 191 192 193 198 198 204 204 210 217 4th 21 26 1 238 195 196 196 201 202 208 208 214 221 24 29 1 208 200 200 201 206 207 213 213 219 226 21 25 1 190 203 203 204 210 210 216 216 223 230 24 28 1 166 207 208 208 214 214 221 221 227 234 20 23 1 150 210 211 211 217 217 224 2...

Page 209: ...start from standard setting when adjusting the suspension If you become confused about adjustment settings return to the standard setting and start over Fork Shock Absorber 147 mm 5 8 in 27 5 mm 1 08 in Height adjuster Spring installed length 18 mm 0 7 in 15 mm 0 6 in ...

Page 210: ...top surface of the axle holder Right 9 5 mm 0 37 in Left 14 5 mm 0 57 in Rear Top indicator groove of the damper case 1 SUSPENSION STOPS POSITION 2 FULLY STROKE POSITION Inspect the stroke from stop position Set the full stroke position depending upon test runs so that it is near but not at the stop position How To Obtain The Correct Suspension Stroke As the first step in setting the suspension be...

Page 211: ... Compression Damping Adjustment The adjuster is located at the bottom of the axle holder Using a flathead screwdriver turn the adjuster clockwise to increase damping counter clockwise to decrease damping There are 12 16 clicks between minimum and maximum Do not force the adjuster past its limits Standard setting 9 clicks back from maximum 1 PRELOAD ADJUSTER Spring Preload Adjustment Turn the Prelo...

Page 212: ... bridge pinch bolts and pull the outer tube down onto the fork set collar 1 SPRING COLLAR 2 SPRING SEAT STOPPER 3 FORK BOLT Push down on the spring collar and spring seat stop per and hook them under lock nut Hold the cut out of the rebound adjuster with a 17 mm spanner then loosen the fork bolt Be careful not to lose the rebound adjuster lock nut 1 SPRING SEAT STOPPER 2 SPRING COLLAR 3 JOINT PLAT...

Page 213: ...od down until it comes into con tact with the bottom of the fork tube 1 OIL LEVEL Oil Level Characteristics Optional Spring Characteristics Measure the distance between the top of the fluid and the top of the fork tube Standard fluid level Right 106 mm 236 cm3 Left 101 mm 236 cm3 Recommended fork fluid Honda Ultra Cushion Oil Special SAE5W Showa SS05 Operation Oil or equivalent Fork fluid replacem...

Page 214: ... full hard 1 REBOUND ADJUSTER Rebound Damping Adjustment The rebound damping adjuster is at the base of the shock absorber Turn the dial toward the H mark to increase damping Turn the dial toward the S mark to decrease damping The dial has 12 16 notches with a detent every 60 degree Standard position 5th notch back from full hard 1 LOCK NUT 2 ADJUSTER Spring Preload Adjustment Loosen the lock nut ...

Page 215: ... on the side is 30 mm 1 2 in If extend ed any further the upper joint may slip out while riding After adjustment tighten the lock nut to 64 N m 6 5 kgf m 47 lbf ft 1 PRELOAD LENGTH Spring Replacement Remove the rear shock absorber then remove the spring page 5 20 Spring specifications Spring rate Identification Pre load Color 6 5 kg mm Black 8 5 mm 7 0 kg mm Green 7 9 mm 7 5 kg mm Blue 7 4 mm 8 0 ...

Page 216: ...ork projected length Lower preload Change to a softer spring Increase preload Change to a stiffer spring Raise rear ride height with ride height adjuster Increase preload of rear spring Lower preload of front Increase front fork projected length Reduce rear damping force rebound Increase damping force Either increase or reduce damping force rebound to shift res onance point Lower preload Symptom S...

Page 217: ...SHIFT DRUM 8 31 E 15 THROTTLE BODY 8 33 FRAME GROUP F 1 METER 8 35 F 2 HANDLE LEVER SWITCH CABLE 8 36 F 3 FRONT BRAKE MASTER CYLINDER 8 38 F 4 HANDLE PIPE TOP BRIDGE 8 40 F 5 STEERING STEM STEERING DAMPER 8 41 F 6 FRONT FENDER 8 42 F 7 FRONT FORK 8 43 F 8 FRONT BRAKE CALIPER 8 45 F 9 FRONT WHEEL 8 46 F 10 REAR BRAKE CALIPER 8 47 F 11 REAR BRAKE MASTER CYLINDER 8 49 F 12 REAR WHEEL 8 50 F 13 FUEL T...

Page 218: ...O OOO OOO Example Bolts nuts and other standard parts OOOOO OOOOO OO Function and component No Model code No Modification designation Subcontractor designation Function and component No Dimension ISO Chemical surface treatment Abbreviations The following abbreviations are used in this parts list ASSY Assembly ADJ Adjuster BRG Bearing COMP Complete EXH Exhaust FR Front L Left mm Millimeter R Right ...

Page 219: ...1 95001 35003 60M 3 95001 35xxx 5x 95001 35001 50M 3 5 1 95001 35003 50M 3 95001 35xxx 6x 95001 35001 60M 3 5 1 95001 35003 60M 3 95001 45xxx 2x 95001 45001 50M 4 5 1 95001 45003 50M 3 95001 45001 60M 1 95001 45xxx 3x 95001 45003 60M 4 5 3 95001 45008 60M 8 95001 45001 60M 1 95001 45xxx 4x 95001 45003 60M 4 5 3 95001 45008 60M 8 95001 45xxx 5x 95001 45001 50M 4 5 1 95001 45003 50M 3 95001 45001 60...

Page 220: ...3 40xxx 60 95003 40001 60M 12 0 16 0 1 95003 40003 60M 3 95003 43001 10M 1 95003 43xxx 1x 95003 43003 10M 13 0 15 0 3 95003 43008 10M 8 95003 43001 10M 1 95003 43xxx 20 95003 43003 10M 13 0 15 0 3 95003 43008 10M 8 95003 45001 10M 1 95003 45xxx 1x 95003 45003 10M 14 0 18 0 3 95003 45008 10M 8 95003 45001 10M 1 95003 45xxx 20 95003 45003 10M 14 0 18 0 3 95003 45008 10M 8 95003 50xxx 1x 95003 50001 ...

Page 221: ...ngth Diameter m mm 95005 45001 10M 1 95005 45xxx 4x 95005 45003 10M 4 5 3 95005 45008 10M 8 95005 45xxx 5x 95005 45001 50M 4 5 1 95005 50xxx 3x 95005 50001 30M 5 0 1 95005 50003 30M 3 95005 50xxx 5x 95005 50001 50M 5 0 1 95005 55001 10M 1 95005 55xxx 1x 95005 55003 10M 5 3 3 95005 55008 10M 8 95005 55xxx 2x 95005 55001 20M 5 3 1 95005 55003 20M 3 95005 55001 10M 1 95005 55xxx 4x 95005 55003 10M 5 ...

Page 222: ... and general purpose hose 30 3 0 mm 11 11 mm 35 3 5 mm 91 12 mm outside dia 15 mm 45 4 5 mm 92 12 mm outside dia 16 mm 50 5 0 mm 12 12 mm outside dia 17 mm 55 5 3 mm 5 5 mm 14 14 mm 65 6 5 mm 17 17 mm 70 7 0 mm 75 7 3 mm 7 5 mm 80 8 0 mm ID OD code vinyl hose 01 ID 2 9 OD 6 8 mm 14 ID 6 0 OD 9 0 mm 37 ID 11 0 OD 15 0 mm 03 ID 3 0 OD 6 0 mm 17 ID 7 0 OD 9 0 mm 38 ID 12 0 OD 13 0 mm 05 ID 3 5 OD 6 5...

Page 223: ...GASKET CYLINDER HEAD 1 4 12310 NX7 000 COVER COMP CYLINDER HEAD 1 5 12316 NX7 000 PLATE BREATHER 1 6 12391 NX7 000 GASKET COMP A HEAD COVER 1 7 12394 NX7 000 GASKET B HEAD COVER 1 8 12395 KSE 670 GASKET PLUG HOLE 1 9 31910 NX7 003 SPARK PLUG R0452A 10 1 10 89005 NX7 000 FLAT CUTTER IN SEAT 1 11 89006 NX7 000 FLAT CUTTER EXH SEAT 1 12 90011 NX7 000 BOLT FLANGE 6X35 4 13 90012 NX7 000 BOLT FLANGE 6X...

Page 224: ...R MOUNT 2 20 91356 425 005 O RING 29 7X2 4 1 21 92900 06018 0E BOLT STUD 6X18 3 22 94301 12200 PIN DOWEL 12X20 2 23 96001 06012 00 BOLT FLANGE SH 6X12 2 24 96001 06065 00 BOLT FLANGE SH 6X65 2 8 8 E 1 4 5 6 7 3 2 19 23 23 21 22 14 19 17 16 20 15 10 1 11 24 18 12 13 13 12 8 12 13 9 12 18 13 14 F 15 F 22 ...

Page 225: ... 5 14210 NX7 000 CAM SHAFT COMP EXH 1 6 14321 NX7 010 SPROCKET CAM 2 7 14711 NX7 000 VALVE IN 2 8 14721 NX7 000 VALVE EXH 2 9 14731 NX7 000 LIFTER VALVE 4 10 14751 NX7 000 SPG IN VALVE OUTER 2 Blue paint 11 14752 NX7 000 SPG IN VALVE INNER 2 Blue paint 12 14761 NX7 000 SPG EXH VALVE 2 Red paint 13 14771 NX7 000 RETAINER VALVE SPG 4 14 14775 NX7 000 SEAT VALVE SPG 4 15 14781 ML0 720 COTTER VALVE 8 ...

Page 226: ... 013 SHIM TAPPET 1 45 4 14912 KT7 013 SHIM TAPPET 1 475 4 14913 KT7 013 SHIM TAPPET 1 50 4 14914 KT7 013 SHIM TAPPET 1 525 4 14915 KT7 013 SHIM TAPPET 1 55 4 14916 KT7 013 SHIM TAPPET 1 575 4 14917 KT7 013 SHIM TAPPET 1 60 4 14918 KT7 013 SHIM TAPPET 1 625 4 14919 KT7 013 SHIM TAPPET 1 65 4 14920 KT7 013 SHIM TAPPET 1 675 4 14921 KT7 013 SHIM TAPPET 1 70 4 14922 KT7 013 SHIM TAPPET 1 725 4 14923 K...

Page 227: ... KT7 013 SHIM TAPPET 2 025 4 14935 KT7 013 SHIM TAPPET 2 05 4 14936 KT7 013 SHIM TAPPET 2 075 4 14937 KT7 013 SHIM TAPPET 2 10 4 14938 KT7 013 SHIM TAPPET 2 125 4 14939 KT7 013 SHIM TAPPET 2 15 4 14940 KT7 013 SHIM TAPPET 2 175 4 14941 KT7 013 SHIM TAPPET 2 20 4 14942 KT7 013 SHIM TAPPET 2 225 4 14943 KT7 013 SHIM TAPPET 2 25 4 14944 KT7 013 SHIM TAPPET 2 275 4 14945 KT7 013 SHIM TAPPET 2 30 4 149...

Page 228: ...3 SHIM TAPPET 2 575 4 14957 KT7 013 SHIM TAPPET 2 60 4 14958 KT7 013 SHIM TAPPET 2 625 4 14959 KT7 013 SHIM TAPPET 2 65 4 14960 KT7 013 SHIM TAPPET 2 675 4 14961 KT7 013 SHIM TAPPET 2 70 4 14962 KT7 013 SHIM TAPPET 2 725 4 14963 KT7 013 SHIM TAPPET 2 75 4 14964 KT7 013 SHIM TAPPET 2 775 4 14965 KT7 013 SHIM TAPPET 2 80 4 14966 KT7 013 SHIM TAPPET 2 825 4 14967 KT7 013 SHIM TAPPET 2 85 4 14968 KT7 ...

Page 229: ...SSY TENSIONER 1 5 14526 NX7 000 BOLT TENSIONER ADJUSTING 1 6 14560 MEN 671 GASKET TENSIONER LIFTER 1 7 14621 NX7 010 GUIDE A CAM CHAIN 1 8 14630 NX7 000 GUIDE COMP B CAM CHAIN 1 9 90004 GHB 600 BOLT FLANGE NSHF 6X10 1 10 90004 GHB 630 BOLT FLANGE NSHF 6X16 2 11 90041 NX7 000 BOLT TENSIONER TORX 6X25 1 12 90088 MEB 670 BOLT FLANGE 6X25 1 13 90442 397 000 WASHER SEALING 6mm 1 14 91301 216 000 O RING...

Page 230: ...on Reqd No Remarks No 8 14 4 1 3 2 5 CYLINDER 2012 NSF250R 1 12101 NX7 000 CYLINDER 1 2 12191 NX7 003 GASKET 0 20 CYLINDER 1 3 12192 NX7 003 PLATE 0 20 SPACER 1 4 90023 NX7 000 BOLT SEALING 10X8 1 5 94301 12200 PIN DOWEL 12X20 2 E 4 ...

Page 231: ...LIFER COMP CLUTCH 1 6 22816 NX7 000 SPG CLUTCH LEVER 1 7 90087 NX7 000 CAP 30mm 1 8 90525 GC4 700 WASHER BRAKE ARM 1 9 90702 MB0 000 PIN DOWEL 8X8 2 10 91007 KA3 740 BRG BALL 12X24X6 1 11 91201 965 000 OIL SEAL 12X22X5 1 12 91204 KK0 003 OIL SEAL 12X18X5 1 13 91211 KSE 671 SEAL WATER PUMP 1 14 91307 035 000 O RING 18X3 1 15 91311 KS6 700 O RING SPECIAL 1 16 91356 425 005 O RING 29 7X2 4 1 17 94301...

Page 232: ...K B CLUTCH FRICTION 1 6 22321 KF0 770 PLATE CLUTCH 6 7 22351 NF4 760 PLATE CLUTCH PRESSURE 1 8 22352 NX7 000 PIECE CLUTCH LIFTER 1 9 22401 KSC 670 SPG CLUTCH 5 Yellow paint 10 22402 435 000 SPG JUDDER 1 11 28237 NX4 000 COLLAR DISTANCE 20X26X26 1 12 90047 PH7 000 BOLT WASHER 6X22 5 13 90235 KA4 000 NUT 18mm 1 14 90432 428 000 WASHER LOCK 1 15 90451 NX4 000 WASHER THRUST 20mm 1 16 90452 147 003 WAS...

Page 233: ...7 000 SPROCKET OIL PUMP DRIVEN 1 6 15150 NX7 000 STRAINER COMP OIL 1 7 15220 NX7 000 VALVE ASSY RELIEF 1 Blue paint 8 15401 HN8 A61 CHAIN OIL PUMP DRIVE 1 9 15661 NX7 000 PLATE OIL SEPARATER 1 10 90013 NX7 000 BOLT FLANGE 5X10 1 11 90018 NX7 000 BOLT FLANGE 6X55 1 Black paint 12 91302 ZE9 003 O RING 11 8X2 4 1 13 91308 PH9 000 O RING 8 8X1 9 1 14 94301 08100 PIN DOWEL 8X10 2 15 96001 06012 00 BOLT...

Page 234: ...X7 000 COVER WATER PUMP 1 3 19229 NX7 000 GASKET WATER PUMP COVER 1 4 19231 NX7 000 GEAR WATER PUMP DRIVE 1 16T 5 19240 NX7 000 GEAR COMP WATER PUMP DN 1 25T 6 90447 KE1 000 WASHER SEALING 7mm 1 7 90463 ML7 000 WASHER SEALING 6 5mm 1 8 90702 MB0 000 PIN DOWEL 8X8 2 9 96001 06028 00 BOLT FLANGE SH 6X28 2 10 96001 06055 00 BOLT FLANGE SH 6X55 1 11 96001 06060 00 BOLT FLANGE SH 6X60 1 ...

Page 235: ...00 GASKET L COVER 1 6 15410 NX7 003 ELEMENT COMP OIL FILTER 1 7 15414 NX7 000 SPG OIL FILTER 1 8 15611 NF4 900 CAP OIL FILLER 1 9 90021 NX7 000 BOLT SEALING 6X8 1 10 90022 NX7 000 BOLT SEALING 8X9 5 1 11 90024 NX7 000 BOLT FLANGE SH 6X16 1 12 90025 NX7 000 BOLT FLANGE SH 6X75 1 13 90084 MEN 670 CAP 14mm 1 14 90405 NX7 000 WASHER 15X26 1 15 90475 703 000 WASHER C 8mm 1 16 90543 273 000 PACKING FR F...

Page 236: ... 25 26 25 25 25 25 25 20 16 26 22 22 23 23 22 21 14 24 22 11 LEFT CRANKCASE COVER 2012 NSF250R 21 91308 PW4 003 O RING 21 8X1 9 1 22 91313 MN5 004 O RING 7 8X1 9 4 23 94301 08140 PIN DOWEL 8X14 2 24 94520 26000 CIRCLIP IN 26 1 25 96001 06025 00 BOLT FLANGE SH 6X25 6 26 96001 06032 00 BOLT FLANGE SH 6X32 3 ...

Page 237: ...FLYWHEEL COMP 1 2 31120 NX7 003 STATOR COMP 1 3 32112 MEN A30 CLAMPER CORD 1 4 89009 NX7 000 ADAPTER FLYWHEEL PULLER 1 5 89010 NX7 000 HOLDER FLYWHEEL PULLER 1 6 89011 NX7 000 BOLT FLYWHEEL PULLER 1 7 90005 896 000 BOLT FLANGE 5X16 4 8 90102 V02 000 BOLT SOCKET 5X25 3 9 90201 NX7 000 NUT FLANGE 14mm 1 10 90432 KR8 750 WASHER 14mm 1 ...

Page 238: ...ER 1 No sale by HRC 4 11121 NX7 000 HOLDER TRANSMISSION 1 5 11200 NX7 000 CRANKCASE LEFT 1 6 11210 NX7 000 JET COMP PISTON 1 7 11221 NX7 003 REED VALVE 1 8 11230 NX7 000 STOPPER COMP REED VALVE 1 9 89020 NX7 000 BRG HOLDER ASSY 1 10 89023 NX7 000 SPINDLE BRG FIT 1 11 90003 KRN 670 SCREW FLAT SPECIAL 6X12 1 12 90017 NX7 000 BOLT FLANGE DR 8X25 2 13 90019 NX7 000 BOLT WASHER 6X14 1 14 90022 NX7 000 ...

Page 239: ...Y4 900 BRG BALL RADIAL 6905U 1 25 91005 NX7 003 BRG BALL RADIAL 10X22X6 1 26 91012 KA3 710 PLATE C SHAFT BRG 1 27 91201 KS6 004 OIL SEAL 26X37X7 1 28 91201 KSE 671 OIL SEAL 32X48X7 5 1 29 91203 HP1 601 OIL SEAL 20X33X7 5 1 30 91203 KK3 830 OIL SEAL 14X22X5 1 31 94303 08100 DOWEL PIN 8X10 2 32 94303 08140 DOWEL PIN 8X14 2 33 96001 06012 00 BOLT FLANGE SH 6X12 4 34 96001 06016 00 BOLT FLANGE SH 6X16...

Page 240: ... 35 36 27 30 36 36 36 40 41 41 42 42 41 41 39 39 39 26 3 15 21 43 20 15 12 31 24 43 16 33 33 16 33 16 22 32 17 12 22 17 32 29 28 25 16 33 23 31 34 38 38 37 37 38 F 16 F 15 CRANKCASE 2012 NSF250R 41 96001 06065 00 BOLT FLANGE SH 6X65 5 42 96001 06075 00 BOLT FLANGE SH 6X75 2 43 96120 62030 00 BRG BALL RADIAL 6203 2 ...

Page 241: ...ONNECTING 1 7 13213 MFL 003 BOLT CONNCTING ROD 2 8 13214 NX7 003 BRG A CONNECTING ROD 2 13215 NX7 003 BRG B CONNECTING ROD 2 13216 NX7 003 BRG C CONNECTING ROD 2 13217 NX7 003 BRG D CONNECTING ROD 2 13218 NX7 003 BRG E CONNECTING ROD 2 9 13310 NX7 010 CRANKSHAFT COMP 1 10 13312 NX7 003 BRG A CRANKSHAFT 4 13313 NX7 003 BRG B CRANKSHAFT 4 13314 NX7 003 BRG C CRANKSHAFT 4 13315 NX7 003 BRG D CRANKSHA...

Page 242: ...5 4 3 3 1 7 8 9 13 18 17 16 19 15 12 10 10 10 10 14 8 11 E 8 CRANKSHAFT PISTON 2012 NSF250R 15 13615 NX7 000 GEAR PRIM DRIVE 1 21T 16 90013 NN4 000 BOLT SPECIAL 12X27 1 17 90301 KSE 670 NUT HEX 12mm 1 18 90401 NX7 000 WASHER 12X20 1 19 90402 KY4 900 WASHER PLAIN 12mm 1 ...

Page 243: ...annot be used 3 23225 NX4 000 COLLAR C SHAFT 1 4 23411 NX4 000 GEAR C 1ST 1 30T 23412 NX4 000 GEAR C 1ST PLAN 2 1 31T 23413 NX4 000 GEAR C 1ST PLAN 3 1 32T 23414 NX4 000 GEAR C 1ST PLAN 4 1 30T 23415 NX4 000 GEAR C 1ST PLAN 5 1 29T 5 23421 NX4 000 GEAR M 2ND 1 21T 23422 NX4 000 GEAR M 2ND PLAN 2 1 18T 23423 NX4 000 GEAR M 2ND PLAN 3 1 19T 23424 NX4 000 GEAR M 2ND PLAN 4 1 17T 23425 NX4 000 GEAR M ...

Page 244: ... 2 4TH P 3 1 20T 22T 23444 NX4 610 GEAR M 3RD P 6 4TH 1 21T 24T 23445 NX4 000 GEAR M 3RD 4TH P 4 1 23T 21T 23445 NX4 610 GEAR M 3RD P 6 4TH P 3 1 21T 22T 23446 NX4 000 GEAR M 3RD 4TH P 6 1 23T 20T 23446 NX4 610 GEAR M 3RD P 6 4TH P 4 1 21T 21T 23447 NX4 000 GEAR M 3RD P 2 4TH P 4 1 20T 21T 23447 NX4 610 GEAR M 3RD P 6 4TH P 6 1 21T 20T 23448 NX4 000 GEAR M 3RD P 2 4TH P 6 1 20T 20T 23449 NX4 000 G...

Page 245: ...sed 23464 NX4 681 GEAR C 4TH PLAN 4 1 26T 23464 NX4 680 Cannot be used 23465 NX4 681 GEAR C 4TH PLAN 5 1 25T 23465 NX4 680 Cannot be used 23466 NX4 681 GEAR C 4TH PLAN 6 1 23T 23466 NX4 680 Cannot be used 13 23471 NX4 000 GEAR M 5TH 1 26T 23472 NX4 000 GEAR M 5TH PLAN 2 1 25T 23473 NX4 000 GEAR M 5TH PLAN 3 1 23T 23474 NX4 000 GEAR M 5TH PLAN 4 1 20T 14 23478 NX4 770 COLLAR M 5TH GEAR 1 15 23481 N...

Page 246: ...4 000 Cannot be used 18 23802 KSC 670 COLLAR DRIVE SPRKT 1 19 23802 NX4 780 SPROCKET DRIVE 15T 1 15T 23803 NX4 780 SPROCKET DRIVE 16T 1 16T 23804 NX4 780 SPROCKET DRIVE 17T 1 17T 20 90020 NX7 000 BOLT UBS 8X22 1 21 90402 NX7 000 WASHER SPRING 24X40 1 22 90403 NX7 000 WASHER THRUST 17mm 1 23 90452 115 000 WASHER 17mm 2 24 90461 444 000 WASHER SPLINE 20mm 2 25 90464 444 000 WASHER SPLINE 22mm 1 26 9...

Page 247: ...T SHIFT FORK C 1 L 93 8 6 24311 NX4 000 DRUM GEAR SHIFT 1 7 24312 KA3 741 CENTER SHIFT DRUM 1 8 24315 HA0 000 PIN SHIFTER 1 9 24321 KZ4 620 SHIFTER DRUM 1 10 24322 HA0 000 COLLAR SHIFTER 1 11 24324 KA3 711 PAWL A RATCHET 1 12 24325 KA3 711 PAWL B RATCHET 1 13 24326 KBH 901 PLUNGER PAWL 2 14 24328 NX4 000 PLATE GUIDE 1 15 24329 KA3 740 SPG PAWL PLUNGER 2 16 24430 KA3 740 STOPPER COMP DRUM 1 17 2443...

Page 248: ... 14 5 1 2 6 3 4 7 8 9 18 25 10 15 11 13 15 12 13 14 23 20 16 21 17 19 22 24 GEARSHIFT DRUM 2012 NSF250R 21 90435 HB3 000 WASHER 6 1mm 1 22 90451 155 000 WASHER 14mm 1 23 93301 06012 0A BOLT HEX 6X12 2 24 94510 14000 CIRCLIP EX 14 1 25 96220 40080 ROLLER 4X8 1 ...

Page 249: ...MP THROTTLEBODY 1 6 16218 NX7 000 BAND INSULATOR 1 7 16400 NX7 003 THROTTLEBODY ASSY 1 8 16422 MEN A31 JOINT INJECTOR 1 9 16430 NX7 003 MOTOR ASSY 1 10 16433 HN8 A61 SCREW TORX 2 11 16433 MEW 921 PLATE IACV 1 12 16450 HN8 A61 INJECTOR ASSY FUEL 1 13 16472 MCW 000 SEAL RING INJECTOR 1 14 16473 P7A 004 GROMMET 1 15 90089 NX7 000 BOLT SOCKET 5X10 2 16 91301 NX7 000 O RING 47X2 5 1 17 91301 P7A 004 O ...

Page 250: ...Part No Description Reqd No Remarks No 8 34 E 15 6 2 9 4 3 1 5 7 8 13 12 17 14 19 18 15 20 20 10 21 10 11 16 22 F 13 F 15 THROTTLE BODY 2012 NSF250R 21 94050 06000 NUT FLANGE 6mm 3 22 94101 06800 WASHER PLAIN 6mm 3 ...

Page 251: ...TER ASSY TACHO 1 4 37460 NX4 701 METER ASSY WATER TEMP 1 5 37564 NX7 003 INDICATOR SHIFT UP 1 6 37565 NX7 003 INDICATOR FI WARNING 1 7 37569 NX7 003 LENS COMP SHIFT UP 1 8 37604 HN1 A70 LENS COMP REVERSE INDICATOR 1 9 50810 NX7 000 STAY COMP FR CTR COWL 1 10 50811 NX7 000 CLAMP CTR COWL STAY 1 11 50816 NX4 000 CLIP XMAS TREE 3 12 50819 NX7 000 PANEL METER 1 13 90004 GHB 670 BOLT FLANGE NSHF 6X25 1...

Page 252: ...P L HANDLE 1 9 53167 MEB 672 HOUSING UP THROTTLE 1 10 53168 MEB 671 HOUSING UND THROTTLE 1 11 53169 MEB 670 SLIDER THROTTLE CABLE 1 12 53172 430 003 BRKT L HANDLE LEVER 1 13 53173 376 000 HOLDER LEVER BRKT 1 14 53178 399 700 LEVER L STRG HANDLE 1 15 53192 KA3 700 BOLT WIRE ADJUST 1 16 90114 310 000 BOLT HANDLE LEVER PIVOT 1 17 90302 NX5 000 U NUT HEX 6mm 1 18 90321 KF0 000 NUT FIXING 1 19 90651 NC...

Page 253: ...escription Reqd No Remarks No 8 37 21 93500 04045 0G SCREW PAN 4X45 1 22 93500 05016 0A SCREW PAN 5X16 2 23 96001 06018 07 BOLT FLANGE SH 6X18 2 F 2 8 3 2 9 6 7 5 1 4 14 12 16 13 22 22 15 11 10 23 18 17 20 21 19 HANDLE LEVER SWITCH CABLE ...

Page 254: ... 5 43517 KS6 701 CIRCLIP RR M C 1 6 45125 NX4 861 HOSE FR BRAKE 1 7 45500 NX4 861 M C ASSY FR 1 8 45504 410 003 BOOT COMP 1 9 45511 KV3 016 OIL CUP COMP 1 10 45512 NX4 861 HOSE M C OIL CUP 1 11 45513 KV3 006 CAP OIL CUP 1 12 45514 KV3 006 CLAMP M C OIL HOSE 2 13 45517 166 006 HOLDER M C 1 14 45518 KV3 006 PLATE DIAPHRAGM 1 15 45520 KV3 006 DIAPHRAGM 1 16 45530 471 831 CYLINDER SET MASTER 1 17 4553...

Page 255: ...ANDLE LEVER 1 22 90145 MS9 612 OIL BOLT 10X22 1 23 90145 NF4 650 BOLT OIL BLEEDER 1 24 90301 MG3 000 NUT U 6mm 1 25 90302 NX5 000 U NUT HEX 6mm 1 26 90473 147 000 WASHER 6X16 1 27 90601 ZE1 000 WASHER PLUG DRAIN 10mm 4 28 90651 MA5 671 CIRCLIP 1 29 91212 422 006 O RING 14 8X2 4 1 30 93600 04050 1G SCREW FLAT 4X50 2 31 96001 06025 00 BOLT FLANGE SH 6X25 2 32 96300 06012 07 BOLT FLANGE DR 6X12 1 33 ...

Page 256: ... 770 CAP HANDLE PIPE 2 2 53110 NX4 000 HOLDER R HANDLE 1 3 53111 NX4 000 PIPE HANDLE 2 4 53120 NX4 000 HOLDER L HANDLE 1 5 53300 NX7 000 BRIDGE FORK TOP 32 5 1 53300 NX7 610 BRIDGE FORK TOP 30 1 6 90303 NX4 000 BOLT STRG STEM 1 7 95801 08030 00 BOLT FLANGE 8X30 2 8 95801 08032 00 BOLT FLANGE 8X32 2 9 96001 06022 00 BOLT FLANGE SH 6X22 2 ...

Page 257: ...P STRG 30 1 3 53214 430 003 DUST SEAL STRG HD 1 4 53214 KZ4 701 DUST SEAL STRG HD 1 5 53229 NX4 000 THREAD STRG 1 6 53700 NF4 900 DAMPER ASSY STRG 1 7 90465 MC4 000 WASHER 8mm 2 8 90506 NX4 000 STOPPER STRG THREAD 1 9 90651 NC8 000 TY LAP 3 6X281 2 10 91015 425 831 BRG HEAD PIPE UP 1 11 91015 KZ4 701 BRG HEAD PIPE 1 12 91060 NL0 003 BRG SPHERICAL 8mm 2 13 92201 08032 0A BOLT HEX 8X32 2 14 94102 08...

Page 258: ...Block No Ref Part No Description Reqd No Remarks No 8 42 F 6 2 2 1 FRONT FENDER 2012 NSF250R 1 61100 NX4 860 FENDER FR 1 2 90108 GK1 000 BOLT FLANGE SH 6X12 4 ...

Page 259: ...PLATE COMP SPG ADJ 2 4 51404 NX4 003 COLLAR SPG 2 5 51405 NX4 003 PLATE SPG JOINT 2 6 51406 NX4 003 STOPPER SPG SEAT 2 7 51410 NX4 861 TUBE OUTER 2 8 51412 422 003 RING BACK UP 2 9 51414 NX4 702 BUSH GUIDE 2 10 51415 NX4 702 BUSH SLIDE 2 11 51420 NX7 003 PIPE COMP R SLIDE 1 12 51421 MW4 003 PLATE CENTERING 2 13 51422 NF5 611 ADJUSTER SPG 2 14 51423 NF5 611 RING B STOPPER 2 15 51430 NX7 003 DAMPER ...

Page 260: ...ORK 2012 NSF250R 19 51500 NX7 003 FORK ASSY L FR 1 20 51520 NX7 003 PIPE COMP L SLIDE 1 21 52442 KA3 711 WASHER SPECIAL 10mm 2 22 90107 KF0 000 BOLT FLANGE 8X40 4 23 90126 MR7 003 BOLT SOCKET 10X35 2 24 91255 NX4 771 OIL SEAL 35X48X11 2 25 91311 MR7 003 O RING 13 8X2 4 2 26 91351 NF5 611 O RING 23 7X2 4 2 27 91356 KA4 711 O RING 35 2X2 4 2 ...

Page 261: ...0 1 3 06455 NX7 006 PAD SET FR 1 4 43352 568 003 SCREW BLEEDER 1 5 43353 461 771 CAP BLEEDER 1 6 45100 NX7 006 CALIPER ASSY R FR 1 7 45103 MR7 006 SEAL JOINT 1 8 45106 NX4 860 SPG PAD 1 9 45107 NX4 860 PISTON B 2 10 45117 MR7 006 PISTON A 2 11 45150 NX4 860 CALIPER SUB ASSY R FR 1 12 45215 NX4 860 PIN HANGER 1 13 90107 NX4 860 BOLT TORX 8X38 4 14 90131 NX4 860 BOLT FLANGE 10X75 2 15 90701 NX4 860 ...

Page 262: ...sale by HRC 2 42753 ML7 003 VALVE RIM BS 1 3 44301 NX4 000 AXLE FR WHEEL 1 4 44303 NF4 000 COLLAR FR WHEEL SIDE 1 5 44601 NX4 811 WHEEL FR 2 50X17 1 6 44620 NF4 000 COLLAR FR AXLE DISTANCE 1 7 44711 NX7 003 TIRE ASSY FR BS 1 No sale by HRC 8 45120 NX7 003 DISK COMP R FR BRK 1 9 90103 NX7 000 BOLT BRK DISK 6X17 6 10 90305 GE8 003 NUT U 14mm 1 11 90651 NF4 000 CIRCLIP EX 26mm 1 12 90652 NF4 000 CIRC...

Page 263: ...06 SEAL DUST 1 5 43111 NX4 000 ROD RR BRAKE TORQUE 1 6 43209 MA3 006 SEAL PISTON 1 7 43352 568 003 SCREW BLEEDER 1 8 43353 461 771 CAP BLEEDER 1 9 45107 GM9 711 PISTON 1 10 45108 GM9 741 SPG PAD 1 11 45131 166 016 PIN BOLT 1 12 45131 HA5 672 PIN BOLT A 1 13 45132 166 016 PIN BUSH 1 14 45133 MA3 006 BOOT B 1 15 45203 MG3 016 PIN PLUG 2 16 45215 GE2 016 PIN HANGER 2 17 90475 425 000 WASHER THRUST 30...

Page 264: ...1 5 25 22 18 20 19 18 22 24 21 10 16 14 12 13 11 9 15 17 23 19 20 21 F 11 REAR BRAKE CALIPER 2012 NSF250R 21 94050 08000 NUT FLANGE 8mm 2 22 94102 08000 WASHER PLAIN 8mm 2 23 94510 30000 CIRCLIP EX 30mm 1 24 95801 08035 00 BOLT FLANGE 8X35 1 25 95801 08045 00 BOLT FLANGE 8X45 1 ...

Page 265: ...370 419 700 PLUG BREATHER TUBE 1 5 19105 MR8 300 CUSH TANK RESERVE 1 6 43310 NX4 003 HOSE RR BRAKE 1 7 43500 NF4 771 M C ASSY RR 1 8 43503 NX4 000 V TUBE 9X13X275 1 9 43504 NF4 770 ROD ASSY 1 10 43541 ND5 750 CLAMP 1 11 46182 MEL D21 CIRCLIP M C 1 12 90145 MS9 612 OIL BOLT 10X22 2 13 90601 ZE1 000 WASHER PLUG DRAIN 10mm 4 14 90651 NC8 000 TY LAP 3 6X281 1 15 91058 MG9 681 BAND SELF LOCK 2 16 95002...

Page 266: ...08 NX7 000 SPROCKET FINAL DRIVEN 38T 1 41209 NX7 000 SPROCKET FINAL DRIVEN 39T 1 41210 NX7 000 SPROCKET FINAL DRIVEN 40T 1 2 41241 NX7 000 DAMPER RR WHEEL 3 3 42301 NX4 000 AXLE RR WHEEL 1 4 42304 NX7 000 COLLAR RR WHEEL SIDE 1 5 42601 NX4 811 WHEEL RR 3 50X17 1 6 42611 NX7 000 FLANGE FINAL DRIVEN 1 7 42620 NX4 000 COLLAR RR WHEEL DISTANCE 1 8 42711 NX7 003 TIRE ASSY RR BS 1 No sale by HRC 9 42721...

Page 267: ...2012 NSF250R 12 90102 NX7 000 BOLT SOCKET 10X16 3 13 90105 KR3 000 BOLT FR DISK 8X24 3 14 90305 GE8 003 NUT U 14mm 1 15 90411 NX4 000 WASHER 14X32X1 1 16 90456 NX4 000 WASHER 18X32X1 1 17 90652 NF4 000 CIRCLIP IN 35 1 18 91051 NX7 003 BRG BALL RADIAL 620UU 2 19 91052 NF4 000 BRG BALL RADIAL 6904UU 1 20 91357 964 006 O RING 31 1 ...

Page 268: ...O RING 8 6X1 9 1 5 16711 MEN A30 O RING 3 7X73 9 1 6 16712 MEN A30 O RING 2 4X88 4 1 7 16719 HN8 A61 RUBBER FUEL JOINT 1 8 16920 SE0 931 CLIP FUEL PUMP 1 9 17503 MBT D50 FILM PROTECTOR 2 10 17507 NX7 000 PLATE SETTING 1 11 17510 NX7 000 TANK COMP FUEL 1 12 17515 NX5 770 PKG FUEL CAP 1 13 17516 NX4 860 MARK R WING 1 14 17517 NX4 860 MARK L WING 1 15 17521 NX4 680 CAP FUEL TANK 1 16 17522 NF5 690 SP...

Page 269: ... 1 24 17625 NF4 003 VALVE COMP CHECK 1 25 17629 NX4 000 PIN TANK MT 1 26 17711 S0X 931 RETAINER 1 27 17711 S0X A31 RETAINER 1 28 19130 NX5 770 TANK CATCH 1 29 80115 GS3 000 SIDE COLLAR RR FENDER 1 30 87208 ND4 000 MARK CAUTION 1 J 57270 NX4 910 LABEL CAUTION 1 ED 87560 GBF B60 LABEL CAUTION 1 AC 31 90443 GC8 000 WASHER SPECIAL 8mm 1 32 90651 NC8 000 TY LAP 3 6X281 2 33 90652 ND5 000 TY LAP 2 4X92 ...

Page 270: ...16 18 34 17 34 18 34 8 14 25 9 12 15 24 38 38 40 38 13 41 32 32 28 18 18 19 39 33 30 37 29 31 36 11 10 9 23 26 6 6 1 5 5 E 15 FUEL TANK FUEL PUMP 2012 NSF250R 39 95002 50000 CLIP C9 TUBE 1 40 95003 10003 31 V TUBE 5X8X30 1 No sale by HRC 41 95003 10047 31 V TUBE 5X8X470 1 No sale by HRC ...

Page 271: ...5 1 2 7 4 SEAT SEAT COWL 2012 NSF250R 1 33712 KC5 003 GROMMET T L MT 2 2 61104 KA4 700 COLLAR FENDER MT 2 3 77210 NX7 000 COWL SEAT 1 4 77220 NX4 000 RUBBER SEAT 1 5 77221 NF5 760 RUBBER SEAT BACK 1 6 90108 GK1 000 BOLT FLANGE SH 6X12 2 7 96001 06020 00 BOLT FLANGE SH 6X20 2 ...

Page 272: ...ER AIR BOX 1 6 17235 MEE D00 C CLIP 7 7 17240 NX7 000 COVER AIR BOX 1 8 17250 NX7 000 SEAL AIR BOX 1 9 17370 419 700 PLUG BREATHER TUBE 1 10 17371 NX7 000 TUBE LWR ENG BREATHER 1 11 17372 NX7 000 TUBE UP ENG BREATHER 1 12 17373 NX7 000 TUBE MISSION BREATHER 1 13 17414 PC6 660 JOINT 2WAY 1 14 17930 NX7 000 GROMMET THROTTLE CABLE 1 15 37830 MEL 003 SENSOR ASSY MAP 2 16 37880 P05 A00 SENSOR ASSY TA 1...

Page 273: ...OX 2012 NSF250R 21 91565 SEL 003 CLIP WPC COUPLER 1 22 91611 SE3 000 GROMMET RR DOOR 1 23 93911 25480 SCREW TAPPING PO 5X16 2 24 93911 25580 SCREW TAPPING PO 5X20 2 25 95001 35080 40 TUBE FUEL 3 5X80 1 26 95001 35160 40 TUBE FUEL 3 5X160 1 27 95002 02100 CLIP B10 TUBE 1 28 95002 02120 CLIP B12 TUBE 4 29 95002 80000 CLIP C12 TUBE 2 30 95003 23004 31 V TUBE 8X12X40 1 No sale by HRC ...

Page 274: ... 18325 NX7 000 BAND MUFFLER 1 7 18326 NX7 000 STAY EXH 1 8 18332 KS6 000 SPG EXH PIPE 1 9 18334 KA3 830 RUBBER SILENCER 1 10 18334 ML3 680 RUBBER SILENCER 1 11 18336 KS6 700 COLLAR SILENCER MT 1 12 18336 NX7 300 PACK GLASS WOOL 1 13 19052 MB4 880 COLLAR CANISTER MT 2 14 90506 430 000 WASHER FENDER MT 1 15 91080 NX7 300 RIVET 4 8X9 6 14 16 94050 06000 NUT FLANGE 6mm 1 17 94101 05000 WASHER PLAIN 5m...

Page 275: ...Block No Ref Part No Description Reqd No Remarks No 8 59 F 16 4 6 9 5 7 1 3 2 8 15 17 13 10 13 21 11 16 14 20 19 18 12 EXHAUST MUFFLER 2012 NSF250R 21 96001 06032 00 BOLT FLANGE SH 6X32 1 ...

Page 276: ...3 24710 NX4 000 ARM GEAR CHANGE 1 4 24711 NX4 710 ROD END 6mm A 1 5 24712 NX4 710 ROD END 6mm B 1 6 46500 NF4 780 PEDAL COMP BRK 1 7 46501 ND4 750 RUBBER PEDAL 2 8 90201 KV3 700 NUT TIE ROD B 1 9 90211 NX4 771 BOLT SOCKET 6X25 2 10 90301 473 003 NUT U 6mm 4 11 94001 06200 0S NUT HEX 6mm 1 12 94101 06000 WASHER PLAIN 6mm 4 13 96001 06022 00 BOLT FLANGE SH 6X22 1 14 96001 06028 00 BOLT FLANGE SH 6X2...

Page 277: ...o 8 61 F 18 3 2 5 5 1 1 6 6 5 4 5 2 3 4 6 6 STEP 2012 NSF250R 1 50600 NX4 770 HOLDER STEP 2 2 50610 NL5 760 ARM STEP 2 3 50612 NL5 760 END STEP ARM 2 4 50643 NX4 770 BOSS PEDAL PIVOT 2 5 90504 MA6 000 WASHER 8 5X26 4 6 95701 08030 00 BOLT FLANGE 8X30 4 ...

Page 278: ...5 40545 NX4 000 BOLT CHAIN ADJUSTER 2 6 52101 NX4 680 BOLT SWINGARM PIVOT 1 7 52102 NX4 000 COLLAR DIST SWINGARM 1 8 52106 NX4 000 COLLAR B PIVOT 1 9 52109 NX4 000 BOLT ADJUSTER PIVOT 1 10 52110 NX7 000 SWINGARM COMP RR 1 11 52156 GAN 670 GUARD CHAIN 1 12 52158 HB5 003 ROLLER CHAIN 1 13 52159 NX7 000 COLLAR CHAIN ROLLER 1 14 52161 NF5 710 HOSE BASE SADDLE 2 15 52170 NX4 000 SLIDER CHAIN 2 16 90101...

Page 279: ...01 KZ4 890 WASHER 18X32X2 1 23 90522 028 000 WASHER CHAIN CASE SETTING 2 24 91071 MR7 003 BRG NEEDLE 1 25 91071 MY1 005 BRG NEEDLE 17X24X17 1 26 91072 MR7 003 BRG BALL RADIAL 20X37X9 2 27 91080 NF5 710 RIVET 4 0X8 6 2 28 91202 MR7 003 DUST SEAL 28X37X4 1 29 91214 MR7 003 DUST SEAL 26X37X5 1 30 91262 KV3 831 DUST SEAL 17X24X5 2 31 94102 08000 WASHER PLAIN 8mm 2 32 94520 37000 CIRCLIP IN 37mm 1 33 9...

Page 280: ...int 52403 NX4 003 SPRING RR CUSHION S 1 K 7 5 Blue paint 52404 NX4 701 SPRING RR CUSHION 7 0 1 K 7 0 Green paint 52405 NX4 701 SPRING RR CUSHION 6 5 1 K 6 5 Black paint 3 52410 NX7 003 DAMPER COMP RR 1 J 52410 NX7 651 DAMPER COMP RR 1 ED 52410 NX7 671 DAMPER COMP RR 1 AC 4 52411 NX7 003 COLLAR DAMPER 4 5 52420 NX4 013 JOINT COMP UPPER 1 6 52422 NX4 862 BRG SPHERICAL 2 7 52424 GC4 831 RING STOPPER ...

Page 281: ...R WARNING 1 ED 87516 MBL 610 LABEL RR DAMPER WARNING 1 AC 15 90110 MR8 000 BOLT SOCKET 10X52 1 16 90128 GN1 000 BOLT FLANGE DR 10X61 1 17 90154 HA8 000 BOLT FLANGE 10X52 3 18 90304 GA6 003 NUT FR AXLE 5 19 90306 NF5 951 NUT LOCK 1 20 90510 NX4 000 SHIM ENG MT 0 2 N 90511 NX4 000 SHIM ENG MT 0 6 N 90512 NX4 000 SHIM ENG MT 1 0 N 90513 NX4 000 SHIM ENG MT 1 5 N 21 91071 MY1 005 BEARING NEEDLE 17X24X...

Page 282: ...161 NX7 000 SENSOR COMP BANK ANGLE 1 7 35163 MGC 003 GROMMET 2 8 35170 NX7 000 SW ASSY PIT 1 9 35400 NX7 000 SW MODE 1 10 35701 MG9 950 BAND TY RAP 4 11 38770 NX7 033 UNIT COMP PGM FI IGN 1 12 38771 MEN A30 SUSPENSION UNIT COMP PGM FI 1 13 38771 NX7 000 CD ROM HRC DATA SETTING TOOL 1 14 38880 N1C 770 UNIT ASSY SERIAL USB I F 1 15 90303 HW1 671 NUT SELF LOCK 6mm 2 16 90672 MCW 000 CABLE STRAP 1 17 ...

Page 283: ...Block No Ref Part No Description Reqd No Remarks No 8 67 F 21 10 7 1 4 3 5 10 2 18 11 21 15 12 20 9 8 18 14 13 18 6 10 10 19 16 17 F 24 WIRE HARNESS 2012 NSF250R 21 95701 06025 08 BOLT FLANGE 6X25 2 ...

Page 284: ...3 SET NUT 2 5 19037 GEE 710 CAP COMP RADIATOR 1 J AC 19037 MCA G61 CAP COMP RADIATOR 1 ED 6 19051 KA3 830 RUBBER RADIATOR MT 3 7 19052 KA3 830 COLLAR RADIATOR MT 2 8 19502 NX7 000 HOSE A WATER 1 9 19503 NX7 000 HOSE B WATER 1 10 19504 KY1 003 CLAMP WATER HOSE D25 4 11 19602 NF4 810 TANK CATCH 250 1 12 37870 MBG 003 SENSOR ASSY TW 1 13 37870 NF4 611 SENSOR ASSY TW 1 14 90004 GHB 630 BOLT FLANGE NSH...

Page 285: ... 14 10 10 10 17 17 17 10 23 15 22 14 21 20 4 4 18 16 12 13 E 1 F 16 F 21 E 8 RADIATOR 2012 NSF250R 19 94050 06000 NUT FLANGE 6mm 1 20 95002 45000 CLIP C8 TUBE 1 21 95003 10023 31 V TUBE 5X8X230 1 No sale by HRC 22 96001 06025 00 BOLT FLANGE SH 6X25 1 23 96001 06028 00 BOLT FLANGE SH 6X28 1 ...

Page 286: ...310 NX7 000 GUARD ASSY EXH 1 7 77105 NX4 000 RUBBER SEAT RAIL 2 8 87131 NX7 000 PLATE FRAME NO 1 No sale by HRC 9 90004 GHB 620 BOLT FLANGE NSHF 6X14 4 10 90102 GW2 000 BOLT FLANGE 10X183 2 11 90105 KJ9 000 BOLT FLANGE 10X210 1 12 90124 NX4 000 BOLT ENG MT ADJ 18X34 5 2 13 90301 NX4 000 NUT LOCK M18X1 4 2 14 90510 NX4 000 SHIM ENG MT 0 2 N 90511 NX4 000 SHIM ENG MT 0 6 N 90512 NX4 000 SHIM ENG MT ...

Page 287: ...PER 1 6 64120 NX7 000 COWL LOWER 1 7 64200 NX4 860 SCREEN FR 1 8 64210 NX4 000 STAY FR COWL SIDE 2 9 64240 NX4 860 STAY FR COWL UP 2 10 77103 MFL 300 CUSION SEAT SINGLE 2 11 90004 GHB 620 BOLT FLANGE NSHF 6X14 2 12 90106 NF4 770 BOLT COWL SET 6X13 5 13 90653 NC8 000 SPG FASTNER 35 6 14 90654 NC8 000 GROMMET FASTNER 6 15 90655 NC8 000 STUD FASTENER 35 6 16 90656 NX4 000 RIVET 4X7 7 17 91080 NC8 300...

Page 288: ... 12 13215 NX7 003 E 12 13216 NX7 003 E 12 13217 NX7 003 E 12 13218 NX7 003 E 12 13310 NX7 010 E 12 13312 NX7 003 E 12 13313 NX7 003 E 12 13314 NX7 003 E 12 13315 NX7 003 E 12 13331 360 000 E 12 13411 NX7 000 E 12 13421 NX7 000 E 12 13431 NX7 000 E 12 13615 NX7 000 E 12 14105 NX7 000 E 2 14106 MBN 670 E 2 14110 NX7 000 E 2 14210 NX7 000 E 2 14321 NX7 010 E 2 14401 NX7 003 E 3 14510 NX7 010 E 3 1451...

Page 289: ...50 NX7 000 E 7 15220 NX7 000 E 7 15401 HN8 A61 E 7 15410 NX7 003 E 9 15414 NX7 000 E 9 15604 MG7 000 F 13 15611 NF4 900 E 5 E 9 15661 NX7 000 E 7 15772 292 010 F 15 16141 NX7 000 E 15 16169 NX7 003 E 15 16190 NX7 000 E 15 16193 NX7 000 E 15 16210 NX7 000 E 15 16218 NX7 000 E 15 16400 NX7 003 E 15 16422 MEN A31 E 15 16430 NX7 003 E 15 16433 HN8 A61 E 15 16433 MEW 921 E 15 16450 HN8 A61 E 15 16472 M...

Page 290: ...13 23213 NX4 000 E 13 23214 NX4 000 E 13 23215 NX4 000 E 13 23221 NX4 010 E 13 23225 NX4 000 E 13 23411 NX4 000 E 13 23412 NX4 000 E 13 23413 NX4 000 E 13 23414 NX4 000 E 13 23415 NX4 000 E 13 23421 NX4 000 E 13 23422 GB4 770 E 13 23422 NX4 000 E 13 23423 NX4 000 E 13 23424 NX4 000 E 13 23425 NX4 000 E 13 23431 NX4 700 E 13 23432 NF4 750 E 13 23432 NX4 700 E 13 23433 NX4 700 E 13 23434 NX4 700 E 1...

Page 291: ...3 F 21 31110 NX7 003 E 10 31120 NX7 003 E 10 31517 NX7 000 F 24 31600 MEN A31 F 21 31700 NN4 003 F 21 31910 NX7 003 E 1 32100 NX7 010 F 21 32112 MEN A30 E 10 33712 KC5 003 F 14 34908 NX7 003 F 1 34909 NX7 003 F 1 35130 NX7 003 F 2 35161 NX7 000 F 21 35163 MGC 003 F 21 35170 NX7 000 F 21 35400 NX7 000 F 21 35701 MG9 950 F 21 37250 NF4 771 F 1 37460 NX4 701 F 1 37564 NX7 003 F 1 37565 NX7 003 F 1 37...

Page 292: ... 10 45150 NX4 860 F 8 45203 MG3 016 F 10 45215 GE2 016 F 10 45215 NX4 860 F 8 45500 NX4 861 F 3 45504 410 003 F 3 45511 KV3 016 F 3 45512 NX4 861 F 3 45513 KV3 006 F 3 45514 KV3 006 F 3 45517 166 006 F 3 45518 KV3 006 F 3 45520 KV3 006 F 3 45530 471 831 F 3 45530 NF4 650 F 3 45550 NX4 861 F 3 46182 MEL D21 F 11 46500 NF4 780 F 17 46501 ND4 750 F 17 50100 NX7 000 F 23 50180 NX4 000 F 23 50180 NX7 0...

Page 293: ...741 F 2 53166 KT8 710 F 2 53167 MEB 672 F 2 53168 MEB 671 F 2 53169 MEB 670 F 2 53170 MW0 006 F 3 53172 430 003 F 2 53173 376 000 F 2 53178 399 700 F 2 53192 KA3 700 F 2 53200 NX4 000 F 5 53200 NX4 610 F 5 53214 430 003 F 5 53214 KZ4 701 F 5 53229 NX4 000 F 5 53300 NX7 000 F 4 53300 NX7 610 F 4 53700 NF4 900 F 5 57270 NX4 910 F 13 61100 NX4 860 F 6 61104 KA4 700 F 14 64109 NF5 750 F 24 64110 NX7 0...

Page 294: ...01 NX7 000 E 10 90202 NX7 000 E 1 90211 NX4 771 F 17 90235 KA4 000 E 6 90301 473 003 F 17 F 19 90301 KSE 670 E 12 90301 MG3 000 F 3 90301 NX4 000 F 23 90302 NX5 000 F 2 F 3 90303 HW1 671 F 21 90303 NX4 000 F 4 90304 GA6 003 F 20 90305 GE8 003 F 9 F 12 90305 KZ4 891 F 19 90306 NF5 951 F 20 90321 KF0 000 F 2 90355 NX4 000 F 19 90401 KZ4 890 F 19 90401 NX7 000 E 12 90402 KY4 900 E 12 90402 NX7 000 E ...

Page 295: ...91104 PL9 008 E 6 91201 965 000 E 5 91201 KS6 004 E 11 91201 KSE 671 E 11 91202 MR7 003 F 19 91203 HP1 601 E 11 91203 KK3 830 E 11 91204 KK0 003 E 5 91211 KSE 671 E 5 91212 422 006 F 3 91214 MR7 003 F 19 91255 NX4 771 F 7 91262 KV3 831 F 19 F 20 91301 216 000 E 3 91301 NX7 000 E 15 91301 P7A 004 E 15 91302 PA9 003 E 9 91302 PL4 003 E 9 91302 ZE9 003 E 7 91303 377 000 E 9 91303 PK2 005 F 15 91307 0...

Page 296: ... 95003 10003 31 F 13 95003 10023 31 F 22 95003 10047 31 F 13 95003 23004 31 F 15 95701 06014 00 E 3 95701 06025 08 F 21 95701 08020 00 F 16 95701 08030 00 F 18 95801 06020 00 F 11 95801 06050 00 F 19 95801 08028 00 F 5 95801 08030 00 F 4 95801 08032 00 F 4 95801 08035 00 F 10 95801 08045 00 F 10 96001 06012 00 E 1 E 7 E 11 96001 06016 00 E 7 E 11 F 16 96001 06018 07 F 2 96001 06020 00 F 14 96001 0...

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