Tecnico cb250 Manual Download Page 177

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Summary of Contents for cb250

Page 1: ... contents on the first page of the section I1ost sections describe the service prccedure throuqh svstern illustration Refer to the next page for details on OW to use thís manual f you dont know the source of the trouble go to sec ion 18 Troubleshooting ALL INFORMATION ILLUSTRATIONS DIREC TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLlCATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT ...

Page 2: ...are diffferentiated from the ones represented alphabetically to notify the reader that they must perform these steps separately For ex ample if the steps prior and up to camshaft rernoval are performed with the engine installed but the subsequent steps like cylinder head removal require engine removal the callouts are grouped in numerical and alphabetical orders The illustrations may contain symbo...

Page 3: ...at 1 mm lift Exhaust valve closes at 1 mm lift Lubrication system Oil pump type I Coolinp system Ai r fi tration Crankshaft type Engine weight Firing order Cylinder arranqernent Cylinder number i I ti FRONT FR RR FR RR FR RR FR RR FR RR 2 090 mm 82 3 in 755 mm 29 7 in 1 090 mm 42 9 in 1 425 mm 56 1 in 755 mm 29 7 in 306 mm 12 0 in 165 mm 6 5 in 132 kg 291 lbs 146 kg 322 lbs 160 kg 352Ibs Diamond T...

Page 4: ...ird reduction Final reduction 2 214 31 14 Gear ratio 1st 2 846 37 13 Gear ratio 2nd 1 777 32 18 Gear ratio 3rd 1 333 28 21 Gear ratio 4th 1 083 26 24 Gear ratio 5th 0 913 21 23 Gear ratio 6th Gear ratio reverse Gearshift pattern Left foot operated return system 1 N 2 3 4 5 Electrical Ignition system CDI Starting system Electric starter Charging sy stem Tripple phase output type Regulator rectifier...

Page 5: ...arance CD body c1earance end clearance 0 15 0 006 0 15 0 18 0 006 0 007 0 03 0 11 0 001 0 004 0 20 O OOS 0 25 0 010 0 14 0 006 r Fuel System Carburetor identification number Main jet VE37E 105 High altitude 2 3 1 4 Front Rear Slow jet Jet needle clip position Pilot screwinitialopening Pilot screw high attitudeadjustrnerrt Pilot screw final opening Air screw initial opening Air screw high altitude ...

Page 6: ...006 0 15 0 18 O OOS 0 007 0 03 0 11 0 001 0 004 Unit mm ir Service Limit 0 20 0 008 0 25 0 010 0 14 0 006 Fuer System Carburetor identification number Main jet High altitude 2 3 1 4 Front Re ar Slow jet Jet needle clip position Pilot screwinitialopening Pilot screw high altitudeadjustment Pilot screw final openinq Air screw initial opening Air screw high altitude adjustment Float level Carburetorv...

Page 7: ... 100 150 C 212 300 F Valve seat width Vert re sprin g free length IN EX inner IN inner EX outer IN outerEX Rocker arm 1 0 IN EX Sub rocker arm 1 0 IN EX RockerarmshaftO D IN EX Sub rocker arrn shaft 0 0 IN EX Rocker arrn to rocker arrn shaft clearance Sub rocker arrn to rocker arrn shaft clearance Valve lifter 0 0 Valve lifter bore 1 0 Hydraulic lash adjuster assist spring freelength Hydrauliclash...

Page 8: ...selsction Standard 53 000 53 010 2 0866 2 0870 IN mark facing toward the intake side 52 970 52 990 2 0854 2 0862 10 mm 0 4 in from the bottom 15 002 15 008 0 5906 0 5909 0 010 0 040 0 0004 0 0016 14 994 15 000 0 5903 0 5906 0 002 0 014 0 0001 0 0006 0 016 0 040 0 0006 0 0016 0 015 0 040 0 0006 0 0016 0 015 0 040 0 0006 0 0016 0 15 0 30 0 006 0 012 0 30 0 45 0 012 0 018 0 2 0 7 0 01 O 03 N mark sid...

Page 9: ... 6502 0 6509 0 020 0 062 0 0008 0 0024 19 959 19 980 0 7858 0 7866 19 959 19 980 0 7858 0 7866 16 446 16 484 0 6475 0 6490 19 959 19 980 0 7858 0 7866 0 040 0 082 0 0016 0 0032 0 040 0 082 0 0016 0 0032 0 032 0 068 0 0013 0 0027 4 93 5 00 0 194 0 197 4 93 5 00 0 194 0 197 4 93 5 00 0 194 0 197 12 000 12 018 0 4724 0 4731 12 000 12 018 0 4724 0 4731 12 000 12 018 0 4724 0 4731 19 976 11 994 0 4715 ...

Page 10: ...ifugal clutch center guide collar heiqht Centrifugal clutch weight lining thickness Centrifugal clutch spring free length Clutch lining thickness Crankshaft O D at clutch center CoolingSystem Coolant capacitoy_ Radiato r and engine Reserve tank Radiator cap relief pressure Thermostat begin to open I Thermostat fully open Thermostat valva lift Drive Train Recommended final drive oil Final drive gea...

Page 11: ...4 1 1 4 Orive chain size link 010 520VC 6 106LE RK 520MO Z9 106LE r r Front Suspension Fork spri ng free length Fork spring free length A 8 Fork spring direction Fork tube runout Recommended fork oil Fork oil level Fork oil level R U Fork oil capacity Fork oil capacity R U _Fork air pressure Steering bearing preload 59 7 2 35 488 7 19 24 Tightly wound coil facing down Forkfluid 162 6 4 150 cm 5 1 ...

Page 12: ... 1 0 caliper piston 0 0 brake drum 1 0 brake lining thickness 4 0 O 16 11 0 11 043 0 4331 0 4348 10 957 10 984 0 4314 0 4324 27 000 27 050 1 0630 1 0650 26 918 26 968 1 0598 1 0617 20 30 3 4 1 1 4 130 5 1 4 0 O 16 3 5 0 14 0 30 0 012 11 05 0 435 10 95 0 431 27 06 1 065 26 91 1 059 131 5 2 2 0 0 08 r r Battery Charging System Alternator chargingcoil resistance At 20 C 68 F Regulator rectifier regul...

Page 13: ...U NIPPONDENSO CR7HSA NGK U22FSR U NIPPONDENSO 0 60 0 70 0 024 0 028 100BTDC 1 500min rpm 10 1 700 min rpm 25 3 000min 1 rpm 25 3 000 min rprn 100 V rninimurn 100 V minimum 0 7V mínimum 50 1800 0 1 0 30 6 5 9 7 kO 2 8 3 4 kO 50 170 O Lights Meters Switches Main fuse Fuse Headlight high low beam Tail brake light License light Position light Front turn signal running light Front turn signallight Rear...

Page 14: ...ce 10 UBS bolt 11 U nut 12 Alock bolt Do not reuse E r ngme I Item O tv Thread dia Tarque Remarks mm N m kqf rn Ib ft Lubrication System Oil pump mounting screw 3 6 10 1 0 7 Cylinder Head Cvlinder Spark plug 2 10 12 1 2 9 Va ve adjusting lock nut I 4 5 10 1 0 7 Cylinder head camshaft holder nut 8 8 I 23 2 3 17 Cvlinder head bolt 3 6 i 12 1 2 9 Cam sprocket bolt 2 7 20 2 0 14 Note 2 Cylinder h d co...

Page 15: ...4 59 6 0 43 Note 11 Rear axle nut 1 14 59 6 0 43 Note 11 Brake arm torque link bolt 2 8 22 2 2 16 Driven sprocket nut 4 10 44 4 5 33 Note 11 Brake system Pad pin plug 1 8 3 0 3 2 2 i Pad pin 1 8 18 1 8 13 o Caliper pin bolt bracket side 1 8 13 1 3 9 Note 2 t caliperside 1 8 23 2 3 17 Note 2 Caliper bleed valve 1 6 6 0 6 4 3 Frorit caliper mounting bolt 30 3 1 22 I 2 10 I Brake disc bolt 4 8 42 4 3...

Page 16: ...ce a mixture of 1 2 engine Camshaft bushing inner surface oil and 1 2 molybdenum Cam lo bes disulfide grease M3 4 gear spline Cl gear Cl bushing sliding surface M4 C3 C5 shift fork grooves Oil passage plate screw threads Locking agent F rarne Location Material Remarks Steering stern bearing Multi purpose grease Wheel bearing Brake lever pivot boltsurface Clutch lever pivot bolt surface Wheel beari...

Page 17: ...E GENERATOR CONNECTOR 14 SIDE STAND SWITCH CONNECTOR CB250 Addendum 1 CARBURETOR HEATER CONNECTOR ___ 2 CARBURETOR HEATER WIRE r Q 3 SIDE STA D V SWITCH WIRE 4 ALTERNATOR WIRE 5 PULSE GENERATOR WIRE 9 CARBURETOR AIR VENT TUBE 10 GROUND CABLE 19 15 j i I L ...

Page 18: ...CB25D Addendum 3 STARTER MOTOR CABLE 5 SIDE STAND SWITCH WIRE 3 STARTER MOTOR CABLE 6 CAR BURETOR DRAIN TUBE M AIR OIL SEPARATOR DRAIN TUBE 0 1 l o g1r 19 16 ...

Page 19: ...oute the tubes and wires properly page 19 15 Requisite Service I Rear fairing removal installation page 2 3 Fuel tank removal installation page 2 4 Carburetor draíning Procedure I Q ty Remarks Removal Order lnstallation is in the reverseorder of removal 1 Carburetor heater 2P connector 1 2 Wire barid Clurnp 1 1 3 Clutch cable 1 4 Th rottle cables 2 5 Choke cable 1 6 Drain tube 1 7 Carburetor mount...

Page 20: ...CB25ü Addendum bly Assembly sem __ Carburetor Dlsas 3 1 I 8 1 9 A 4 11 19 18 ...

Page 21: ... the piston almost full open to avoid pinching the diaphragm with chamber 3 Spring 1 4 Diaphragm vacuum piston 1 5 Jet needle holder 1 6 Spring 1 7 Jet needle 1 Float Chamber Disassernblv Order Assembly is in the reverse order of disassembly 8 Carbu reto r heate r 1 9 Collar _1 10 Float chamber cover screws 4 At installation first tightenthe two screws on the dowel pin side 11 Float chamber 1 12 F...

Page 22: ...N Darnaqe to the pilot screw seat will occur if the pilot screw is tightened against the seat Initial Opening 1 5 8 turns out 2 Warm up the engine to operatinp temperature Stop and go riding for 10 minutes is sufficient 3 Attach a tachometer according to its manufacturer s instructions 4 Adjust the idle speed to thespecified rpm with the throttle stop screw Idle Spe ed 1 500 100 rnirr rpm 5 Turn p...

Page 23: ... Brown Black and Yellow Brown terminals 00 CB250 Addendum If the carburetor heater resistance is out of specification remove the carburetor page 19 17 and replace the carbu retor heater 1 COLLAR 2 CARBURETORHEATER I L Check the voltage between the Brown Blue and Green ter minals with the ignition switchis ON There should be battery voltage 1 CONNECTOR 19 21 ...

Page 24: ...CB25ü Addendum Clutch Primary Drive Gear Removal lnstallation 8 OUT SIDE e9 9 6 17 5 ISTOOl 1 page 19 24 O 74 7 6 55 20 O 53 5 4 39 Is oll page 19 24 1 El 12 1 2 9 19 22 ...

Page 25: ...T SIOE mark facing out 7 Clutch center 1 8 Judder spring 1 Install as shown on page 19 22 9 Spring seat 1 10 Clutch plate 6 Coat with c1ean engine oil before assembly 11 Clutch friction disc 6 Coat with clean engine oil before assembly 12 Pressure plate 1 13 Spline washer 1 14 Clutch outer 1 15 Clutch outer guide 1 Coatwith clean engine oil before assembly 16 Thrust washer 1 Primary Orive Gear Rem...

Page 26: ...clutch center as sh own 2 LOCK NUT WRENCH 3 EXTENSION BAR 07GMB KT70100 07716 0020100 07716 0020500 Clutch center holder Lock nut wrench 20 x 24 mm Extension bar Stake the lock nut Primary And Gil Purnp Orive Gears Removal 1 GEARHOLDER Insert the gear holder as shown Remove the prímary drive gear nut and lock washer Remove the clutch assembly page 19 22 Rernove the oíl pump drive gear and primary ...

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Page 28: ...every service proce dure that is of a specific nature to this particular model Basic service procedures that are common to other Honda Motorcycle Motor Scooter ATVs are covered in the Corn mon Service Manual This Model Specific Service Manual should be used together with the Common Service Manual in order to provide complete service information on all aspects of this motorcvcle Performing the firs...

Page 29: ...rom the ones represented alphabetically to notify the reader that they must perform these steps separately For exarnple if the steps prior and up to camshaft removal areperformed with the engine installed but the subsequent steps like cylinder head removal require engine rernoval the callouts are grouped in numerícal and alphabetical orders The i lustrations may contain symbols to indicate necessa...

Page 30: ...ease Lithium based multi purpose grease NLGI 2 or equivalervt T Use molybdenum disulfide grease containing more than 3 molybdenum disulfide NLGI 2 or equivalent Example Molykote BR 2 plus manufactured by Dow Corning U S A Multi purpose M 2 manufactured by Mitsubishi Oil Japan Use molybdenum disulfide paste corrtaininq more than 40 molybdenum disulfide NLGI 20r equivalent Example Molykote G n Paste...

Page 31: ...e gas that may cause loss of consciousness and may lead to death 1 l L Run the engine inan open areaor with an exhaust evacua tion system in an enclosed area Gasoline Work in a well ventílated area Keep cigarettes flames or sparks away from the work area or where gasoline is stored 6 Gasoline is extrernelv flammable and is explosive un der certain conditions KEEP OUT OF REACH OF CHILDREN Hat Compo...

Page 32: ...d to the upper right rear frame tube as shown When ordering color coded parts always speci fy the designated color codeo General lnformation 1 FRAME SERIAL NUMBER The frame serial number is stamped on the right side of the steering head 3 CARBURETOR IDENTIFICA FION NUMBER The carburetor identification number is stamped on the left side of the carburetor bodv ...

Page 33: ... capacity FR RR FR RR FR RR FR RR Diamond T elescopic fork 140 mm 5 5 in Swingarm 110 mm 4 3 in Conventional type oil damper 90 1 00 18 54S 120 90 16 635 K300MNK327AG Hvdrauiic single disc Interna expanding shoe 28 30 109 mm 4 3 in 16 e 4 2 US gal 3 5 Imp gal 3 e 0 8 US gal 0 7 Imp gar L L L L Engine 1 4 Bore and stroke Dispfacement Compression ratio Valve train Intake valve opens at 1 mm Iift Int...

Page 34: ... Third reduction Final reduction 2 214 31 14 Gear ratio 1st 2 846 37 13 Gear ratio 2nd 1 778 32 18 Gear ratio 3rd 1 333 28 21 j Gear ratio 4th 1 083 26 24 Gear ratio 5th 0 913 21 23 Gear ratio 6th Gear ratio reverse Gearshift pattern Left foot operated return system 1 N 2 3 4 5 Electrical Ignition system COI Startlng system Electric starter Charging system Tripple phase output type Regulator recti...

Page 35: ...iscosity SAE 10W 40 Other viscosities shown in the chart may be used when the average temperature in your riding area is within the indicated range Llni mm in Service Limit l o 10 20 2040 eo 80 Oil pr essure at oil pressure switch Oil pump rotor tip clearance G body c1earance 0 end clearance fe 0 15 0 006 0 15 0 18 0 006 0 007 0 03 0 11 0 001 0 004 0 20 0 008 0 25 0 010 0 14 ro oósi L 1 6 VE37A 11...

Page 36: ...0 oC 212 300 F Valve seat width Valve spring free length IN EX inner IN inner EX outer IN outer EX Rocker arm I D IN EX Sub rocker arrn 1 0 IN EX Rocker arm shaft O D IN EX Sub rocker arm shaft O D IN EX Rocker arrn to rocker arm shaft c1earance Sub rocker arrn to rocker arm shaft clearance Valve lifter O D Valve lifter bore l D Hydraulic lash adjuster assist spring free length Hydraulic íash adju...

Page 37: ...4 0 0016 14 994 1 5 000 0 5903 0 5906 0 002 0 014 0 0001 0 0006 0 016 0 040 0 0006 0 0016 0 015 0 040 0 0006 0 0016 0 015 0 040 0 0006 0 0016 0 15 0 30 0 006 0 012J 0 30 0 45 0 012 0 018 0 2 0 7 0 01 0 03 N mark side facing up N mark side facing up 0 10 0 004 14 98 0 590 0 07 0 003 0 10 0 004 0 10 0 004 0 10 0 004 0 45 0 018 0 60 0 024 0 90 0 036 J Crankshaft Connecting rod small end l 0 Connectin...

Page 38: ...0 784 M5 dt Countershaft O D at Cl gear at C4 gear 6 446 16 484 0 6475 0 6490 19 959 19 980 0 7858 0 7866 16 41 0 646 19 91 0 784 Gear to shaft clearance at M5 gear at C4 gear Gear bushing to shaft clearance at C1 gear Shift fork claw thickness L C R Shift fork I D L C R Shift fork shaft O D L C R 0 040 0 082 0 0016 0 0032 0 040 0 082 0 0016 0 0032 0 032 0 068 0 0013 0 0027 4 93 5 00 0 194 0 1971 ...

Page 39: ...ide 1 0 0 0 Centrifugal eluteh eenter guide collar_ height Centrifugal c1uteh weight lining thickness Centrifugal c1uteh spring free length Cluteh lining thiekness Crankshaft 0 0 at eluteh center r r Cooling System Coolant capacitv Radiator and engine Reserve tank Radiator cap relief pressure Therrnostat begin to open Thermostat fully open Thermostat valve lift r t Drive Train Reeommended final dr...

Page 40: ...teering bearinqpreload r t Rear Suspension Shock absorber spring free length Shock absorber spring free length A B Standard 200 kPa 2 00 kg cm2 29 psi 200 kPa 2 00 kq crn 29 psi 200 kPa 2 00 kg cm2 29 psi 200 kPa 2 00 kq crn 29 psi 20 30 3 4 1 1 4 520VC 6 106LE 520MO Z9 106LE 59 7 2 35 488 7 19 24 Tightly wound coil facing down Fork fluid 162 6 4 150 ce 5 1 US oz 5 3 Imp oz 0 1 0 15 kg m General l...

Page 41: ...11 000 11 043 0 4331 0 4348 10 957 10 984 0 4314 0 4324 27 000 27 050 1 0630 1 0650 26 935 26 968 1 0604 1 0617 20 30 3 4 1 1 4 130 5 1 4 0 0 16 U j rllm in Service Limit To the groove CD 3 EU 0 14 i Oe 3_0itO 012 11 06 0 435 10 88 0 428 27 06 1 065 26 89 1 059 131 5 2 2 0 0 08 I I lo l I L 0 6A l0h 3 AI1 0 h 13 13 2 V Below 12 3 V 0 2 0 6 n 13 5 14 0 V l A 12 V 6 Ah Battery Charging System Altern...

Page 42: ...r exciter coil resistance At 20 C 68 F Ignition coil resistance Primary at 20 0CI68 F Secondary withplug cap Secondary without plug cap Pulse generator resistance At 20 Cl68 F Ignition System Spark plug Standard Lights Meters Switches Main fuse Fuse Headlight high low beam Tail brake light Liéense light Position light Front turn signal running light Front turn signal light Rear turn signai liqht I...

Page 43: ... flange surface 10 UBS bolt 11 U nut 12 Alock bolt Do not reuse l l Engine Thread Torque Item Q ty dia mm N m kq rn ft Ib Rernarks Lubricatíon System Oil pump mounting screw 3 6 10 1 0 7 Cylinder Head Cylinder Spark plug 2 10 12 1 2 9 Valve adjusting lock nut 4 5 10 1 0 7 Cylinder head camshaft holder nut 8 8 23 2 3 17 Cylinder head bolt 3 6 12 1 2 9 Cam sprocket bolt 2 7 20 2 0 14 Note 2 Cylinder...

Page 44: ...4 60 6 0 43 Note 11 Rear axle nut 1 14 60 6 0 43 Note 11 Brake arm torque link bolt 2 8 22 2 2 16 Driven sprocket nut 4 10 45 4 5 33 Note 11 Brake system Pad pin plug 1 8 3 0 3 2 2 Pad pin 1 8 18 1 8 13 Caliper pinbolt bracket side 1 8 13 1 3 9 Note 2 caliper sidel 1 8 23 2 3 17 Note 2 Caliper bleed valve 1 6 6 0 6 4 3 Front caliper mourrtinq bolt 2 10 31 3 1 22 Brake disc bolt 4 8 43 4 3 31 Maste...

Page 45: ...mover set 15 mm 07936 KC10000 Bearing remover 15 mm 07936 KC10000 Remover assembly 15 mm 07936 KC10500 Remover shaft 15 mm 07936 KC1 01 00 Remover head 15 mm 07936 KC10200 Remover weight 07741 0010201 Attachment 32 x 35 mm 07746 0010100 Attachment 42 x 47 mm 07746 001 0300 Attachment 52 x 55 mm 07746 0010400 Attachment 62 x 68 mm 07746 001 0500 Pilot 20 mm 07746 0040500 pjlot 25 mm 07746 0040600 P...

Page 46: ...7914 3230001 Charging System Alternator Flywheel holder 07725 0040000 Flywheel puller 07733 0020001 Electrical Equipment Digital multimeter KOWA 07411 0020000 P ak voltage adaptor 07HGJ 0020100 or Imrie diagnostic tester Model625 Analog tester 07308 0020001 SANWA or TH 5H KOWA ll o __ 1 17 ...

Page 47: ...ixture ofl 2 engine oil Carnshaft bushing inner surface and 1 2 molybdenum Cam lobes disulfide grease M3 4 gear spline C1 gear C 1 bushing sliding surface M4 C3 C5 shift torkqrooves Oil passage plate screw threads Locking agent F r r rame Location Material Remarks Steering stem bearing Multi purpose grease Wheel bearing 8rake lever pivot bolt surface Clutch lever pivotbolt surface Wheel bearing du...

Page 48: ...ABLE 11l9P RED CQNNECTOR STARTER SWITCH ENGINE STOP SWITCH 10 POSITION L1GHT CONNECTORS E type only General Information 1 SPEEDOMETER CABLE 2 BRAKE HOSE 7 IGNITION SWITCH CONNECTORS 8 9PcBLACK CONNECTOR TURNSIGNAL SWITCH DIMMER SWITCH HORN SWITCH 9 3P CONNECTOR NEUTRAL INDJCATOR SIDE STAND INDICATOR 1 19 ...

Page 49: ...General Information 1 CHOKE CABLE 6 CLUTCH CABLE srTACHOMETER H fó CABLE 1 1 2 THROTTLE CABLE b P t 1 h J f 3 SPEEDOMETER CABLE 4 BRAKE HOSE 10 BRAKE HOSE 9 SPEEDOMETER CABLE 1 20 J ...

Page 50: ...NECTOR 1 PULSE GENERATOR CONNECTOH 3 NEUTRAL SWITCH CONNECTOR 8 GROUND CABL E__ i 131 AIR CLEANER DRAIN TUBE 7 SIDE STAND SWITCH CONNECTOR 12 AlR OIL SEPARATOR DRAIN TUBE 9 CARBURETOR AIR VENT TUBE 10 GROUND CABLE 11 CARBURqOR DRAIN TUBE ...

Page 51: ...General Information 1 SIDE STAND SWITCH WIRE 3 STARTER MOTOR CABLE 1 22 4 RIGHT TURN SIGNAL WIRE 6 TAILlBRAKE LiGHT CONNECTOR 5 LEFT TURN SIGNAL WIRE ...

Page 52: ...the work area or wheregasoline is stored can cause a fire or explosion This section covers rernoval and installation of the frame bodv panels fuel tank and exhaust system Always replace the exhaust pipe gaskets when removingthe exhaust pipe from the engine Wheninstalling the exhaust pipe first install al the fasteners loosely Next tiqhten the exhaust clamps Then tighten the mounting fasteners If y...

Page 53: ...removed índividually Procedure Q ty Remarks Removal Order Installation is in thereverse order of removal 1 Exhaust pipe joint nut T At installation install all fasteners loosely and tighten the 2 Mufflér mounting bolt exhaust pipe joint nuts first 3 Passengerfootpeg 2 At installation align thepassenger footpeg groove with the collar as shown 4 Collar 2 5 Muffler assembly I 6 Joint band bolt 1 Only...

Page 54: ...hooks with the frame hooks and push the seat forward Press the rear of the seat down firmly and be sure the seat is íockedon securely CAUTION Be careful not to pinch the wire harness between the séat and frame 2 LEVER 3 SEAT LOCK HELMET HOLDER Rear Fairing Removal lnstallation 2 BüLTS l i3 I 1 COLLARS h 4 Remove the seat above Install the rear fairing in the reverse order of removal Remove the bol...

Page 55: ...in conditions Remove the seat page 2 3 Turn the fuel valve OFF Disconnect the fuel tube Remove the mounting bolt and collar Remove the fuel tank InstalJ the fuel tank in the reverse order of removal After installation turn the fuel valve ON and check the fuer line for leakaqe InstalJ the seat 2 4 2 BOLTI COLLAR 3 FUEL TUBE L ...

Page 56: ...ide MaintenanceSchedule Service Information 3 1 3 2 3 4 Air Cleaner 1 Valve Clearante Oif Filter Screen Cleanirig 3 5 3 5 3 6 Refer to Common Service Manual for items not included in this manual Refer to Specifications Section 1 for maintenance data 3 1 ...

Page 57: ...nation clogging replacernent Parts Rear Fairing r The part required to be removedfor service Seat 13 ClUTCH LEVER Free play 12 STEERING HEAD BEARINGS Damage 11 CARBURETOR CHOKE Operationl 10 HEADLlGHT Aim 9 SUSPENSION Looss wear damage 8 SPARK PlUG Wear damage color 7 ENGfNE OIL DRAIN BOLT Oil replacement 3 2 1 TIMING HOlE CAP Ignition timing 2 FUEl UNE Damage leakage 3 AIR ClEANER Contarnination ...

Page 58: ...on free play 3 BRAKE LEVER Air bubblesin system 4 BRAKE CALlPER Padwear 11 TIRE Wear damage pressure 10 BRAKE L1GHT SWITCH Operation 9 BRAKE PEDAL Free play height 8 THROTTLE STOP SCREW Odie speed adjustment 5 TIRE Wear damage pressure 6 WHEEL Damage runout 7 OIL FILER CAP LEVEL GAUGE l evel check repJacement 3 3 ...

Page 59: ... ldle Speed I I I I I 1 I Note 6 Orive Chain EVERY 600 mi 1 000 krnlI L Note 5 Brake Fluid Note 4 I I R I I H Note 5 Brake Shoe I I I I I I Note 5 Brake System 1 I I I I Note 5 Brake Light Switch 1 I I I I Note 5 Headlight Aim I I I I I Note 5 Clutch System I I 1 1 I 1 1 i Note 5 I Side Stand 1 I I 1 Note 5 Suspension 1 I 1 Note 5 Nuts Bolts Fasteners I I 1 1 14 WheelslTires I I I Note 5 Steering ...

Page 60: ...mpressing the set spring as shown Connect the tube Install the removed parts in the reverse order of removal Maintenance 1l AIR CLEANER CASE COVER 1l SET PLATE 2 TUBE Valve Clearance NOTE Inspect or adjust the valve clearance while the engine is cold below 35 C 95 F Remove the cylinder head cover page 7 2l Remove the crankshaft andtiming holecap Turn the crankshaft counterclockwise and align the T...

Page 61: ...Valve adjusting wrench B Torque 10 N m 1 0 kq rn 7 ft lb Recheck the valve clearances 07708 0030100 07708 0030400 or 07908 KE90200 2 VALVE ADJUSTINc JWRENCH 8 x 9 mm Turn the crankshaft counterclockwise one full turn 360 degrees and align the T mark with the index mark again and check the valve clearances of the other cylinder Install the cylinder head cover page 7 6 Install the crankshaft and tim...

Page 62: ...viced with the engine in the frame The service procedures in thís section rriust be performed after the engine oil is drained When removing and installing the oi purnp use care not to allow dust or dirt to enter the engine If any portian of the oil purnp is wornbeycind the specified service lirnits replace the oil pump as an assembly After the oil pump has been installed check that thereare no oil...

Page 63: ...Lubricatioh System Lubrication System Diagram 4 2 4 ülLFILTER SCREEN _ 7 1 OILPUMP DRIVE GEAR 2 OIL ORIFICE COLLAR 3 OIL PUMP l i I L i I l I L 1 ...

Page 64: ...n check that there are nooil leaks Requisite Service Engine oil drainingfrefill Right crankcase cover removalfinstaHation page 8 2 Brake pedal removalfinstallation page 12 10 Procedure Q ty Remarks Removal Order Installation is in the reverse order of removal 1 Di pump mounting screw 3 2 Oil pump assembly 1 Disassemblv assernbíy page 4 4 3 O ring 1 4 3 ...

Page 65: ...formatian Refer to page 1 6 for specifications Requisite Service Oilpump removalfinstallation page 4 3 Procedure Q ty Remarks Disassembly Order Assembly is in the reverse order of disassembly 11 Oil pump plate screw 2 2 Oil pump plate 1 3 Gasket 1 4 Dowel pin 1 5 Inner rotor 1 Install aligning the cut out with the rotor shaft cut out 6 Outer rotor 1 IIJ 7 Oil pump gear cover bolt 2 8 Oil pump gear...

Page 66: ...sure to rernove the diaphragms before c1eaning air and fuel passages with compressed airo The diaphragms might be damaged Refer to sectíon 2 for fuel tank removal and installation When disassembling fuel system parts note the locations of the O rings Replace them with new ones on reassembly Before removing the carburetor place an approved gasoline container under thecarburetor drain tube loosen th...

Page 67: ...Bystarter valve in ON position Float val ve faulty Float level too high Air jets clcpqed Air cleaner element contaminated Flooded carburetor Engine StaHs Hard To Start Rough Idling Fuel line restricted Ignitlon malfunction Fuel mixture too lean rich Fue contaminated deteriorated Intake air lea k Idle speed misadjusted Float level misadjusted Fuel tank breatherhole clogged Pilot screw misadjusted S...

Page 68: ...or explosion NOTE l Befare removal turn the fue valve OFF RequísiteService Rear faíring removal ínstaflatíon page 2 3 Fuel tank removal installatian page 2 4 Carburetor draíning Procedure Q ty Remarks Removal Order lnstallation is in the reverse order of moval 1 Clutch cable 1 2 Throttle cables 2 3 Choke cable 1 4 Air vent drain tu be 2 5 Carburetor mountíng nut 2 6 Connectíng tube band screw 1 On...

Page 69: ...Fuel System Carburetor DisassemblyIAssembly 18 z C1 DOWEL PIN SIDE 71 5 61 ti 8 1 2 L L L I I L I I L i L i 9 5 4 ...

Page 70: ...installation hold the piston almost full open to avoid pinchíng the diaphragm with the chamber 3 Spring 1 4 Diaphragm vacuum piston 1 5 Jet needle holder 1 6 Spring 1 7 Jet needle 1 Float Chamber Disassernblv Order Assembly Is in the reverse order of disassembly 8 Float chamber cover screws 4 At installation fírst tighten the two screws on the dowel pin side 9 Float chamber 1 10 Float pin 1 11 Flo...

Page 71: ...lation page 3 5 Procedure Q ty Remarks Removal Order Installation is in the reverse arder of rernoval 1 Battery stay mounting bol 2 2 Battery stay 1 3 CDI unit 1 4 Connecting tube band screw 1 Only loosen 5 Air oil separator mounting screw 1 6 Air oil separator 1 Remove the air oil separator from the air c1eaner case 7 Air cleaner case mounting bolt 1 8 Air cleaner case assembly 1 Move the air c1e...

Page 72: ...o the pilot screw seat willoccur if the pilot screw is tightened against the seat Initial Opening 1 7 8 turns out 2 Warmup the engine to operating temperature Stop and go riding for 10 minutes is sufficient 3 Attach a tachometer according to its manufacturer s instructions 4 Adjust the idle speed to the specified rpm with the throttle stop screw Idle Speed 1 500 100 min 1 rprn 5 Turn pilot screw i...

Page 73: ...ng engine removal instaHation be careful not to damage the wire harnesses or cables by pinching them between the engine and frame The following components can be serviced with the engine installedin the frame üil pump Section 4 Camshaft Section 7 Clutéh gearshift linkage Section 8 Alternator Section 13 Starter clutch Section 15 The followinq components require engine removal for service Cylinder h...

Page 74: ...Engine Removal lnstallation Engine Removalllnstallation 24 22 t I 85 8 5 61 iflj t L f J r 2 i rt 1 lrl t I 20 I 21 26 20 6 2 11 7 t fa 1 O 12 1 2 9 22 14 ...

Page 75: ...Engine Removal lnstallation Engine Removal lnstallation j 1 I I f i I I I I 22 14 10 12 1 2 9 11 26 _ t 15 20 22 T tJ 85 8 5 61 10 IJ 20 6 2 I i 1 jfz e ...

Page 76: ... cable 1 3 Alternator connector 1 4 Side stand switch connector 1 5 Pulse generator connector 1 6 Neutral switch connector 1 7 Excitor coil connector 1 B Gear shift pedal 1 9 Orive sprocket cover 1 10 Orive sprocket bolt 2 11 Orive sprocket 1 Loosen the drivechain 12 Orive chain 1 13 Left footpeg mounting bolt 2 14 Left footpeg 1 15 Clutch cable 1 16 Tachometer cable 1 17 Brake pedal 1 18 Right fo...

Page 77: ... rod or stethoscope If performance is poor atlow speeds check for white smoke in the craokcase breather tube If the tube is smoky check for a seized piston ringo Compression Too low Hard Starting Or Poor Performance At Low Speed Valves Incorrect valve adjustment Surned or bent valves Incorrect valve timing Broken valve spring Uneven valve seating Cylinder head Leaking or damaged head gasket Warped...

Page 78: ...Cvlinder Head Cylinder Piston Camshaft Removal 2 mm PIN 1 14 8 17 7 2 ...

Page 79: ... Timing hale cap o ring 1 7 Camshaft holder nut T See next page 8 Cylinder head bolt Only loasen 9 Washer 8 10 Camshaft holder 2 Disassembly assembly page 7 5 11 Dowel pin 4 12 Carn sprocket bolt 2 NOTE Release the cam chain tensioner by pulling wedge A straight up while holding wedge B down Then secure wedge A with a 2 mm pin as shown Be careful not to let the bolts and pin fall into the crankcas...

Page 80: ...fully Turn the crankshaft counterc ockwise and align the T mark on the flywheel with the index mark on the left crankcase cover Loosen the camshaft holder nuts and cylinder head bolts in sequence shown in 2 3 steps Remove the nuts and camshaft holders 7 4 1 INDEX MARK 2 T MARK I L iI L L L ...

Page 81: ...shaft removal page 7 2 Procedure Q ty Remarks Disassembly arder Assemblyis in the reverse order of disassembly 1 Rocker arm shaft 4 Thread a 5 mm screw into each of the rocker armshafts and pull the rockej arrn shaft out of the carnshaft holder O At installation insert the rocker arm shafts with the threadedend facing out 2 Rocker arm 4 3 Rocker arm spring 4 JI ...

Page 82: ...Cylinder Head Cylinder Piston Camshaft Installation t 10 012 1 2 9 JI 11 23 2 3 17 8 Zt 6 E 20 2 0 14 15 14 EJ 10 1 0 7 7 6 ...

Page 83: ...t bushings 2 Thrust washer 1 Align the tab with the groove in the camshaft end 3 Snap rjng 1 4 Cam sprocket 1 Installation see next page 5 Camshaft 1 6 Cam sprocket bolt 2 7 Dowel pin 4 8 Camshaft holder 2 9 Washer 8 10 Cylinder head bolt 3 11 Camshaft holder nut 8 12 Gasket 1 13 Cvlinder head cover 1 14 Cylinder head cover bolt 2 15 Spark plug cap 2 16 Crankshaft hole cap o rino 1 17 Timing hale ...

Page 84: ...rocket on the camshaft flange and align the cam sprocket bolt holes in the sprocket and camshaft Apply a locking agent to the threads of one cam sprocket bolt and install and tighten the sprocket bolt Turn the crankshaft counterclockwise 360 0 Apply a locking agent to the threads of the other cam sprockét bolt Install the other cam sprocket bolt and tightenit to the specified torque Torque 20 N m ...

Page 85: ...own in 2 3 steps Torque Nut 23 N m 2 3 kg m 17 ft Ibl Bolt 12 N m 1 2 kq rn 9 ft Ibl Pour fresh oil into the oil pockets in the cylinder head until the cams are submerged Pour fresh oil into the oil pockets in the cylinder head until the cams are submerged Cylinder Head Cylinder Piston 7 9 ...

Page 86: ...e removal inst allation page 6 2 Procedure Q ty Remarks Removal Order Installation is in the reverse order of removal 1 Spark plug 2 2 lntake pipe nut 4 3 Intakepipe 1 4 O ring 2 5 Cam chain tensioner mounting bolt 2 6 Washer 2 7 Cylinder head bolt 3 Cylinder head bolt tighting page 7 9 S Nut 1 9 Cylinder head 1 Disassembly assembly page 7 11 l 10 Gasket 1 11 Dowel pin 2 7 10 ...

Page 87: ...e off easier soaked in solvent For valve guide replacement see section 9 of the Common Service Manual Requisite Service Cylinder head removal installation page 7 10 Procedure Q ty Remarks Disassembly Order Assembly is in the reverse order of dit assembly 1 Valvespring cotter 8 NOTE To prevent loss of tension do not compressthe valve spring more than necessary 2 Retainer 4 3 Outer valve Spring 4 TI...

Page 88: ...Cylinder Head Cy inder Piston CylinderI Pistan Removal lnstaHation 2 J 3J 1 4 7 7 12 f UIÜhlfd di 12 8 d A _ _ 9l A óo ID 1oi 11 0_ ...

Page 89: ... Dowel pin 2 5 Piston pin clip 4 6 Piston pin 2 7 Piston assembly 2 NOTE At installation install the piston with the IN mark fa e ing towards the intake side Piston Ring Removal arder Installation ls in the reverse order of removal 8 Top ring 2 NOTE USe tare when removing or installing the rings Insert the outside surface of the ring into the proper ring groove and roll the ring around the groovet...

Page 90: ... Pull In Darnaqed kinked or dirty c1utch cable lmproperly routed c1utch cable Damagedclutch lifter mechanism Faulty clutch lifter plate bearing Clutch WiII Not Disengaged Or Motorcycle Creeps With Clutch Disenqaqed Too much c1utch lever free play Clutch plates warped Oil level too high improper oil viscosity or additive used Check f or oil additive Clutch Slips Clutch lífter sticking Worn clutch d...

Page 91: ...Clutch Gearshift Linkage Right Crankcase Cover Removal lnstallation 11 6 5 e 8 4 2 7 ___ 9 3 ...

Page 92: ... is in the reverse arder of removal 1 Clutch cable 1 2 Screw 1 3 Tachometer cable 1 4 Oil cap level gauge 1 5 Crankcase cover bolt 10 6 Clutch cable stay 1 7 Right crankcase cover 1 8 Gasket 1 9 Dowel pin 2 CI tct Yft t Arm Removal Order lO Clutch lifter 1 11 Clutch lifter arm 1 12 Return spring 1 13 Oil seal 1 Á _ 1 l I l L 8 3 ...

Page 93: ...lutch Gearshift Linkage Clutch Primary Drive Gear Removal lnstallation 8 9 r 15 19 r _ 2_3_ _ 9 22 OUT 18 17 SIDE 5 IS7c OL 1 page 8 6 O 53 5 3 38 12 20 54 5 4 39 S7c OL I page 8 6 1 _11 E t12 1 2 9 8 4 ...

Page 94: ...and OUT SIDE markfacing out 7 Clutchcenter 1 8 Judder spring 1 Install as shown on page 8 4 9 Spring seat 1 10 Clutch plate 6 Coat with olean enpine oil before assembly 11 Clutch friction disc 6 Coat with clean engine oH before assernblv 12 Pressure plate 1 13 t Spline washer 1 14 Clutch outer 1 1 5 Clutch outer guide 1 Coat with c1ean engine oil beforeassernblv 16 Thrust washer 1 Primary Drive Ge...

Page 95: ...the c1utch center as shown 07GMB KT70100 07716 0020100 07716 0020500 J S OL Clutch center holder Lock nut wrench 20 X 24 mm Extension bar 3 EXTEf SION BAR 2 LOCK NUT WRENCH Primary And Oil Purnp Drive Gears Removal Insert the gear holder as shown Remove the primary drive gear nutand lock washer Remove theclutch assembly page 8 4 Remove the oii pump drive gear and prirnarvdrive gear 1 GEAR HOLDER 0...

Page 96: ...he reverse order of removal 1 Gearshift pedal bolt 1 2 Gearshift pedal I 1 3 Gearshift spindle assembly i 1 Pull out spindle while pushing the gearshift plate in 4 Stopper arm bolt 1 5 Stopper arm 1 6 Washer 1 7 Spring 1 8 Shift drum stopper plate bolt 1 9 Shift drum stopper plate 1 Align the hales with the dowel pins 10 Dowelpin 4 Install into the shift drum 11 Spring stopper pin bolt 1 8 7 ...

Page 97: ...re the bearing inserts to be sure of their correct locations for reassernblv If the inserts are improperly installed they will block the oil holes causing insufficient lubrication and eventual engine seizure Troubleshooting Excessive Noise Worn connecting rod big end bearing Sent connecting rod Worn crankshaft main bearing Worn transmissionbearing Hard To Shift Improper clutchoperation Incorrect e...

Page 98: ...arts before separating the crankcase Procedure Q ty Remarks Separation order Assembly is in the reverse order of separation 1 Side stand bracket bolt 2 2 Side stand assembly 1 3 Leftcrankcase bolt 6 x 40 mm 2 4 Right crankcasebolt 6 x 40 mm 6 5 Right crankcase bolt 6 x 65 mm 2 6 Right crankcase 1 7 Gasket 1 8 Dowel pin 2 al I r ...

Page 99: ...mended engine oil while turning the shaft Requisite Service Crankcase separation page 9 2l Procedure I Q ty Remarks Removal Order Installation is in the reverse order of removal 1 Shift fork shaft 1 2 Shift fork 3 Install them with the identification mark R Right C Center L Left side facing theleft side as shown 3 Shift drum 1 4 Mainshaft countershaft assembly I 1 1 NOTE Do not forget the thrust w...

Page 100: ...not use worn snap rinqs which could easily spinin the groove They may be too loose to properly seat in the groove Align the gap in the snap ring with the groove of spline Requisíte Service Transmission removal installation page 9 3 Procedure Q ty Remarks Mainshaft DisassemblyOrder Assembly ls in the reverse order of disassembly 1 Thrust washer 1 2 M2 gear 18T 1 3 M5 gear 23T 1 41 Spline washer 1 I...

Page 101: ...rshaft Disassembly Orderc Assembly is in the reverse order of dísassembly n Collar 1 2 1 gear 37Tl 1 3 é bushing 1 4 C3 gear 28T 1 5 Snap ring 1 Align gap with groove of spline as shown above 6 Spline washer 1 Install with beveled outer edge toward gear as shown abbve 71 C4 gear 26T 1 8 C5 gear 21T 1 9 Countershaft 1 ...

Page 102: ...earing inspection quisite Service fransmission removal installation page9 3l Procedure oiv Remarks Removal Order Installation is in the reverse order of removal Crankshaft mounting nut 1 Crankshaft mounting bolt 5 Crankshaft 1 Clip 1 I Washer 1 Cam chain tensioner assembly 1 Cam chain 1 Removallinstallation page 9 7 Oil passage plate mounting screw 3 Oil passage plate 1 J1t O ring 1 6 ...

Page 103: ... as shown Pass the cam chain between the guide insertion part and crank balancer weight then pass it between the cam chain tensioner pin and crank balancer weight Installatian ls in the reverse arder of removal CrankshaftlTransmission 1 BALANCER WEIGHT 3 TENSIONER PIN ...

Page 104: ...e the normal rotating direction When servicing the front wheel fork or steering stem support the motorcycle securely with a jackor other support under the engine Troubleshooting 11 Hard Steering Steering head bearing adjustment nut too tight Faulty steering head bearings Insufficient tire pressure Faulty tire Steers To One Side Or Does Not TrackStraight Bent fork Bent front axle Wheel installed in...

Page 105: ...Front Wheel Suspension Steering Handlebar Removal 7 5 _r 15 1 12 ...

Page 106: ...ebar end weight 2 7 Handle grip 1 8 Brake switch wires 2 9 Right handlebar switch housing screw 2 10 Right handlebar switch housing 1 11 Throttle cable end 2 Disconnect from the throttle grip flange 12 Throttle grip 1 13 Master cylinder bolt 2 14 Master cylinder holder 1 15 Front brake master cylinder assembly 1 CAUTION Keep master cylinder upriqht to prevent air from enter ing the system 16 Handl...

Page 107: ...Front Wheel Suspension Steering Handlebar lnstallation 20 lL 1 7 f 18 19 24 2 4 17 3 7 20 D 111 Sl 18 8 ...

Page 108: ...t then the rear bolts 4 Handlebar weight assembly 2 5 Front brake master cylinder assembly 1 CAUTION Keep master cvlinder upriqht to prevent air from entering the system 6 Master cylinder holder 1 7 Master cylinder bolt 2 8 Throttle grip 1 9 Throttle cable end 2 10 Right handlebar switch housing 1 11 Right handlebarswitch housing screw 2 Tighten the front screw first then the rear screw 12 Brake s...

Page 109: ...Frorrt WheellSuspension Steering Front Wheel Removal lnstallation 6 8 7 10 h 031 3 1 22 3 5 60 6 0 43 ...

Page 110: ...depress the brake lever when the caliper is removed or it will be difficult to refit the disc between the brake pads Procedure Q ty Remarks Removal arder Installation is in the reverse order of removal 1 Speedometer cable screw 1 2 peedometer cable 1 3 Brake caliper mounting bolt 2 4 Front brake caliper 1 CAUTION Do not hanq the caliper from the brake hose 5 Axle nut washer 1 1 6 Front axle 1 7 Fr...

Page 111: ...assembly Order Assembly is in the reverse order of disassembly 1 Dust seal 2 At installation apply grease to the dust seal lips 2 Speedometer gear retainer 1 At installation align the tabs with the slots in the wheel hubo 3 Brake disc bolt 4 4 Brake dise 1 5 Right wheel bearing 6302 U 6 Distance collar 1 7 Leh wheel bearing 6302 U 1 NOTE At assembly drive in the leh side bearing first then the rig...

Page 112: ...Front WheeilSuspension Steering Front Wheel DisassernblvIAssembly 5 6 8 1 2 4 ALlGN lit 3 43 4 3 31 10 R ...

Page 113: ...Front Wheef Suspension Steering Fork Removal lnstallation 1 l f I t I I t I 1 2 _ 7 4 3 022 2 2 16 5 6 e24 2 4 17 1 fl 1t1 ...

Page 114: ...arks Removal Order Installation is in the reverse order of removal 1 Hose clamp bolt 1 2 Brake hose clamp 1 CAUTION Do nothang the calíper trom the brake hose 3 Front fender bolt 4 4 Front fender 1 5 Fork top bridge pinch bolt nut 2 2 Only loosen the nuts 6 Fork bottom bridge pinchbcilt 2 Only loosen the bolts NOTE If the fórk leqs wiJl be disassembled temporarily tighten the bottom pinch bolt and...

Page 115: ...I I t1 1 1 31 11 12 L_ _ 16 13 10 9 t 8 7 6 Steeríng l Suspension ront Whee Fork Disassembly 10 12 ...

Page 116: ...llation page 10 10 Procedure Q ty Remarks Disassembly Order 1 Fork cap 1 2 O ring 1 3 Fork spring A 1 4 Joint plate 1 5 Fork spring B 1 After removing pour out any remaining fork oi 6 Dust seal J TWhen removing thern do not damage the fork tube 7 Stopper ring 8 Fork socket bolt 1 9 Sealing washer 1 10 Fork tube 1 11 Fork piston 1 12 Fork piston ring 1 NOTE Do n t remove the piston ring unless must...

Page 117: ...Vh IISuspension Steering Front fi ee 13 e23 2 3 17 17 I ti 1BI si 1 1151 14 pag e 1 16 12le 9 11 10 II I 111 1 111 e 101 I C I paqe 1 161 9 Fork Assembly 8 El20 2 0 14 DOWN 10 14 ...

Page 118: ... the socketbolt turns with the fork pisten temporarily install the fork spring and fork cap and tighten the socket bolt 9 Back up ring 1 10 Oil seal 1 NOTE Wrap vinyl tape around the fork tube top end to avoid damaging the oil seal durinq the oil seal installation Use fork seal driver 07747 00100100 and attach ment 07747 0010400 for fork seal installation 11 Stopper ring 1 12 Dust seal 1 NOTE Afte...

Page 119: ...ront Wheel Suspensíon Steering teering Stem Hernoval lnstallation J 3 0 3 2 2 8 IsTooel page 10 18 6 IsTooL 17 page 1 16 9 0 16 2 75 7 5 54 3 7 11 ...

Page 120: ...bearings 21 12 Lower bearings 21 13 Lower bearing inner race 1 Replace if they were removed 14 Dust seal 1 Use ball race remover 07944 1150001 for upper and 15 Washer 1 lower outer race rernoval 16 Upper bearing outer race 1 17 Lower bearing outer race 1 Installation Order 17 Lower bearing outer race r Replace as a set if necessary 16 Upper bearingouter race Use attachrnént 37 x 40 mm 07746 001020...

Page 121: ... races Install the bear ings onto the upper and lower races making sure you have the correct amount S Ol Steering stem nut wrench Torque 18 N m 1 8 kq rn 13 ft lb Move the steering stem right and left Iock to lock five times to seat the bearings Make sure that the steering stemmoves smoothly without plavor binding tberrloosen the bearinq adjustrnent nut 1 STEERING STEM Retighten the bearing adjust...

Page 122: ...k absorber or swingarm removal a hoist or othersupport is required to support the motorcycle Tubeless tire removal repair and remounting proeedures are coveredinthe seetion 16 of the Common Service Manual When remounting the tire note the normal rotating direetion Refer to the section 12 for brake system information Troubleshooting Soft Suspension Weak spring Oil leakage from damper unit Incorreet...

Page 123: ... ear WheellSuspension Rear Wheel Removal lnstallation 60 6 0 43 12 13 18 4 1 2 10 7 E 22 2 2 16 k 16 15 ...

Page 124: ...ve chain free play after installing the wheel Procedure Q ty Remarks Removal Order Installation is in the reverse order of removal 1 Brake adjustingnut 1 2 Brake red 1 3 Spring 1 4 Brake rod joint piece 1 5 Drive chain adjusting nut 2 Loosen the adjusting nut fully 6 Cotter pin 1 7 Nut 1 81 Washer 1 9 Rubber cushion 1 10 Brake stopper arm pivot bolt 1 11 Brake stopper arm 1 12 Rear axle nut 1 13 W...

Page 125: ...Rear Wheel Suspensión Rear Wheel Disassembly Assembly 1 4 13 12 8 9 _ 5 ...

Page 126: ...o For wheel bearing replacement refer to the section 1 of the Common Service Manual Requisite Service Rear wheel removal installation page 11 2 Procedure Q ty Remarks Disassembly Order Assembly is in the reverse order of disassembly 1 Brake panel assembly 1 Disassembliy paqe 12 8l 2 Snap ring 1 3 Washer 1 4 Driven sprocket assembly 1 5 Driven sprocket nut 4 6 Driven sprocket 1 7 Driven sprocket bo...

Page 127: ... is required to support the motorcycle Requisite Service Rear fairing removal installation page 2 3 Muffler removal installation page 2 2 Procedure Q ty Remarks Removal Order Installation isin thereverse order of removal 1 Shock absorber mounting nut 2 2 Plain washer 2 3 Shock absorber mounting bolt 2 4 Shock absorber assembly 2 11 6 ...

Page 128: ...on page 11 2 Muffler removallinstallation page 2 2 Procedure Q ty Remarks Removal Order Installation isin the reverse order of removal 1 Drive chain cover 1 2 Right footpeg rnountinq bolt 2 3 Right footpeg assembly 1 4 Swinqarrn pivot nut 1 5 Rear brake light switch spring 1 6 Right footpegbracket 1 7 Shock absorber lower mounting bolt 2 8 Swingarm pivot bolt 1 9 Swingarm assembly 1 Disassembly as...

Page 129: ...ly Order Assembly is in reverse order of disassembly 1 Drive chain adjuster 2 2 Cotter pin 1 3 Nut 1 4 Plain washer 1 5 Rubber cushion 1 6 Brake stopper arm bolt 1 7 Brake stopper arrn 1 8 Orive chain slider 1 9 Dust sea 4 Apply grease to the Iips 10 Pivot collar 2 Apply grease to sliding surfaces 11 Pivot bushinq 4 Apply grease to sliding surfaces 11 8 ...

Page 130: ...inated pads shoes and e1ean a contaminated disc drum with a high quality brake degreasing agent Spilled brake fluid will s verely damage meter lenses and painted surfaces It is also harmful to some rubber parts Be very careful whenever you remov the reservoir cap make sure the front reservoir is horizontal first Neve r allow contarninants dirt water etc to get into an open reservoir Once the hydra...

Page 131: ...ake pad dise Misaligned wheel Clogged restrieted brake hose joints Warped deformed brake dise Caliper not slidíng properly Brakes Drag Corrtarninated brake pad disc Misaligned wheel Worn brake pad dise Warped deformed brake disc Caliper not sliding properly 12 2 Rear Brake Poor Brake Performance lmproperly adjusted brake Worn brake linings Worn brake drum Worn brakeeam Improperly ínstálled brake l...

Page 132: ...rnent operate the hrakeIever to seat the caliper pistons against the pads NOTE The brake pads can be replaced without disconnectíng the hydraulic system Replace the brake pads as a seto Apply a thin coat of grease onto the pad pin and pad pin plug threads so as not to rust it Procedure Q ty Remarks Removal Order Installation is in the reverse order of removal 1 Pad pin plug 1 2 Pad pin 1 3 Pad 2 N...

Page 133: ... pad disc Misaligned wheel Cloggedlrestricted brake hose joints Warped deformed brake disc Caliper not sliding properly Brakes Prag Contarnlnated brake pad disc Misaligned wheel Worn brake pad disc Warped deformed brake disc Caliper not slidíng properly 12 2 Rear Brake Poor Brake Performance Improperly adjusted brake Worn brake linings Worn brake drum Worn brake cam Improperly instálled brake lini...

Page 134: ...Brake System Front Brake Caliper Disassembly Assembty 31 35 3 5 25 1 0 6 kg m U18 1 8 13 3 0 3 2 2l cw 23 2 3 17 12 2 S 3 81 71 11 e I el 151 14 131 5 10 5 o31 3 1 22 6 o ta 12 ____ 13 1 3 9 4 12 4 ...

Page 135: ...iniñg air bleeding Procedure Q ty Remarks Disassembly Order Assembly is in the reverse arder of disassembly 1 Brake hose bolt 1 2 Sealing washer 2 3 Brake hose 1 4 Pad 2 Removallinstallation page 12 3 5 Bolt clamp 1 1 i 6 Caliper rnountinq bolt 2 7 Brake caliper assembly 1 8 Pad spring 1 Install as shown 9 Caliper bracket 1 10 Pad retainer 1 11 Caliper pin bolt boot 2 12 Caliper pin bolt 2 Do not ...

Page 136: ...oraxe ov s cern Front Master Cvlinder DisassemblyIAssembly I 1 7 15 14 12 6 t 2 0 2 1 4 9 10 E 35 3 5 25 3 5 12 U6 0 6 4 3 8 ...

Page 137: ...ten cups and spring must be installed as a seto Requisite Service Front brake fluid draining air bleeding Procedure Q ty Remarks Disassembly Order Assembly is in the reverse arder of disassembly 1 Rear view mirror 1 2 Brake switch wires 2 3 Brake hose bolt 1 4 Sealing washer 2 5 Brake hose 1 6 Master cylinder bolt 2 7 Master cylinder holder 1 Remove the master cylinder assernbly from the handlebar...

Page 138: ...reasing agent Requisite Service Rear wheel removallinstallation page 11 2 Procedure I Q ty Remarks Disassembly Order Assembly is in the reverse order of disassembly 1 Brake arm pinch bolt nut 1 1 2 Brakearm 1 3 Brakevvearindicator 1 At installation allgnthe wide tooth with the wide slotin the brake cam 4 Feltseal 1 5 Cotter pin 1 Install with endless side facing out 6 Washer 1 7 Brake shoe 2 8 Sho...

Page 139: ...Brake System Brake Pedal Removalllnstallation 3 12 10 11 14 o 13Ig e60 6 0 43 6 i 1 I 1 ...

Page 140: ...dal slit 6 Swingarm pivot nut 1 7 Right footpeg mounting bolt 2 8 Right footpeg assembly 1 9 Right passenger footpeg mounting bolt 1 10 Right passenger footpeg 1 11 Brake switch spring 1 12 Right footpeg bracket brake linkage assembly 1 13 Cotter pin 1 14 Clevis pin 1 At assembly align the cutout of the c1evis pin with the boss in the brake rod 15 Brake roc 1 16 Brake pedal return spring 1 17 Brak...

Page 141: ...CAUTION The battery caps should not be removed Attempting to remove the sealing caps from the cells may damage the battery The battery can be damaged if over charged or undercharged OT of leftto discharge for long periods These same condi tions contribute to shorteningthe Iife span of the battery Even under normal use the performanceof the battery dete riorates after 2 3 years Battery voltage may ...

Page 142: ... rlélrglflg o vsterru A n rflél1 0r System Location System Diagram 4 ALTERNATOR 3 MAIN FUSE lNTO STARTER RELAY SWITCH y y y G 1 REGULATOR RECTIFIER __ 4 ALTERNATOR 13 2 2 BATTERY ...

Page 143: ...the regulated voltage page 13 5 lncorrect Correet Ineorreet Correct L Shorted wire harness Faulty ignition switch Faulty requlator rectifier Cheek the battery using a Honda Battery Tester Open cireuit in wire harness Poorly connectedconnectors Not charging Check the voltages of the regulatorlrectifier battery eharging line and ground line page 13 6 Normal Abnormal Incorreet Correet t Electric syst...

Page 144: ...irst then remove the positive terminal Requisíte Service Rear fairing rernoval installation page 2 3 Procedure Q ty I Remarks Removal Order I Installation is in the reverse order of removal 1 Negative terminal 1 2 Positive terminal 1 3 Battery holderbolt nut 1 1 4 Battery holder 1 5 Battery case 1 61 Batterv 1 13 4 ...

Page 145: ... do not turn the ignition switch ON A sudden surge of current may blow out the fuse in the testero Specified Current Leakage 1 mA max If current leakage exceeds the specified value a shorted cir cuit is Iikely Locate the short by disconnectinq connectors one by one and measuring the current Regulated Voltage Ampere Inspectíon NOTE Before performing this test be sure the battery is fully charged an...

Page 146: ...tween the battery positive terminal and the positive cable a sudden surge of current to the starter motor could damage the ammeter Always turn the ignitíon OFF when conducting the test Disconnectíng the ammeter or wires when current is flowinqrnav darnaqe the amm ter Regulated Voltage 13 5 14 0 V 1 500 rpm Charging current 1 A Regulator Rectifier System Inspection Remove the fuel tank Ipaqe 2 4 Di...

Page 147: ...e readings Check the battery if the test results are not as expected When using the KOWA rnultirneter remember va ue that all readings should be multiplied by 100 Replace the regulator rectifier unit if the resistance value between the terminals is abnormal Removal Remove the fuel tank page 2 4 Disconnect the regulatorlrectifier connector Remove the mounting bolts and regulator rectifier unit Inst...

Page 148: ...Charging System Alternator Alternator Pulse Generator Removalllnstallation 5 6 12 6 0 6 4 3 21 6 0 6 4 3 22 10 18 4 17 14 O 60 6 0 43 Is ToOL 1 page 1 17 15 S700L paqe 17 l5 13 1 1 13 8 ...

Page 149: ...le clamp J 9 Drive sprocket cover 1 10l Neutral switch wire connector 1 11 Leftcrankcase cover bolt 7 12 Left crankcase cover assembly 1 13 Gasket 1 Flywheel Removal Order InstaJlation is in the reverse order of rernoval 14 Alternator rotor bolt 1 Use flywheel holder O7725 0040000 15l Washer 1 16 Flywheel 1 Use rotor puller O7733 0020001 17 Woodruff key 1 L Crankcase Cover Disassembly Order Assemb...

Page 150: ...Always turnoff the ignition switch beforeservicing Ignition timing cannot be adjusted since the CDI unit is non adjustable If ignition timing is incorrect check the system components and replace any faulty parts A faulty ignition system is often related to poorly connected or corroded connectors Check those connections before proceeding Use spark plugs of the correct heat range Using spark plugs w...

Page 151: ...TOP SWITCH 5 BATTERY 6 CDI UNIT 7 MAlN FUSE 20 A 8 FUSE 10 A 9 ClUTCH SIDE STAND DIODE 11 NEUTRAL SWITCH 10 SIDE STAND SWITCH System Diagram j 14 IGNITION COll SIN 6 CDI UNIT Y SI 15 IGNITION 7 MAIN SWITCH FUSE tilREE e INDICATOR 5 BATTERY _ n _ G 19 R 11 NEUTRAL SWITCH 8l FUSE Sr Su 1 NEUTRAL lNDICATOR 4 NEUTRAL DIODE 14 2 ...

Page 152: ...se when above No j are normal j lncorrect peak voltage adaptor connections 0Short circuir in engine stop switch wire Faulty ignition switch or engine stop switch Loose or poorly connected COI unit connector Open circuir or poor connection in ground wire of the COI unit Faulty side stand switch circuito j F aulty peak voltage adaptor Faulty excitercoil Measure the peak voltage Faulty pulse generato...

Page 153: ... When the side standis up the side stand switch line b of the COI unit passesto ground via the side stand switch The COI unit monitors lines a and b and provides spark onlv when one or both of those lines is connected to ground via the neutral switch or the side stand s w i t c h Check the side stand indicator function Normal 1 Short circuit in Green White wire Abnormal Normal Checkthe side stand ...

Page 154: ...ings Check thatthe cylinder compression is normal and the spark plug is installed correctlv in all cylinders Place the motorcycle on its center stand and shift into neutral Remove the spark plug caps from the plugs on cylinder head install a known good sparkp lugs to the plug caps and ground it to the engine as shown Connect the peak voltaqe adaptor EB probe to the ignition coil primary black yell...

Page 155: ...ound In the same manner as at the CDI unit connector measure the peak voltage and compare it to the voltage measured at the CDI unit connector If the peak voltage measured at the CDI unit is abnormal and the ene measured at the exciter coil is normal the wire harness has an open circuir or loose connectíons If both peak voltages measured are abnormal check each ítem in the troubleshooting chart If...

Page 156: ...rmal and the one rneasured at the pulse generator is normal the wire harness has an open circuit or loase connections If both peak voltages measured are abnormal check each item in the troubleshooting chart If all items are normal the pulse generator is faulty Ignition Coil Inspection Remove the fuel tank page 2 4l Disconnect the ignition coil primary terminals and measure the primary coil resista...

Page 157: ...w and Green White terminals Standard 50 170 rl 20 C 68 F Exciter Coil Inspection NOTE Itis not necessary remove the exciter coil from the engine Remove the fuel tank page 2 4 J Disconnect the exciter coil connector Measure the resistance between the Black Red and body ground Standard 50 180 rl 2 0 C168 F Ignition Timing Warm up the engine Stop the engineand connect a timing light to the No 1 cylin...

Page 158: ...th Start the engineand allow it to idle lnspect the ignition timing The timing is correet if the F mark aligns with the index mark on the crankcase at idle speed Ignition System 1 INDEX MARK Idle Speed 1 500 100 min rpml Check the F mark begins to movewhen the engine speed reaches the advance start rpm At 3 000 rnirr rpm the ignition timing is correct if the in dex mark is between the to advance m...

Page 159: ...rter motor to turn it while the engine is not cranking over the starter motor may be damaged For the following component inspections refer to the following pages for the parts locations see page 15 2 or this manual System Location Clutch switch diode Section 24 of the Common Service Manual Starter motor Section 24 of the Common Service Manual Startérrelav switch Section 24 of the Common Service Ma...

Page 160: ...11 NEUTRAL SWITCH la SIDE STAND SWITCH 6 MAlN FUSE 20 A ST ARTER RELA Y SWITCH 7 FUSE 10 A System Diagram 9 NEUTRAL DIO DE 8 CLUTCH SIDE STAND DIODE 15 2 6 STARTER RELAy SWITCHI MAIN PUSE 20 A 4 STARTER MOTOR 8 CLUTCH SIDE STAND DIODE r Hil H G R e 1 0 110 Y R To Regulator Rectifier 1 NEUTRAL INDICATOR Lg R 10 SIDE STAND SWITCH ...

Page 161: ...ess No continuity Disconnect starter relay switch connector and check the relay coíl ground wire lines as below for continuity 1 Green Red terrninal clutch switch diode neutral switch line with transrnission in neutral and clutch lever released 2 Green Red terrninal clutch switch side stand switch line in any gear except neutral and with the c1utch lever pulled in and the side stand up Continuity ...

Page 162: ...e stand switch Check the side stand switch Normal 1 1 Open circuir in wire harness Loose or peor contact connector Starter Motor Turns Slowly Low specific gravity in battery or dead battery Poorly connected battery terminal cable Poorly connectedstarter motor cable Faulty starter motor Poorly connected battery ground cable Starter Motor Turns But Engine DoesNot Turn Starter motor is running backwa...

Page 163: ...zm Turn the ignition switch OFF Requisite Service Alternator removal installation page 13 8 I Procedure Q ty Remarks I Removal Order lnstallation is in the reverse arder of removal 1 Starter motor cable 1 2 Starter motor mounting bolt 4 3 Starter motor 1 4 O ring 1 15 5 ...

Page 164: ...Electric Starter Starter Clutch Starter Motor Disassembly Assembly 15 1 14 16 5 6 7 V 181 04 9 10 12 13 17 2 15 6 ...

Page 165: ... 1 3 O ring 1 4 Separator 1 5 Brush terminal holding nut 1 6 Washer 1 7 Insulated washer Iarger 1 8 Insulated washer smaller 2 9 O ring 1 10 Brush holder assembly 11 Brush and terminal 1 Align the holder tab with the rear cover groove 12 Spring 2 13 O ring 1 14 Rear cover 1 15 Shims Record and store the shims in the same order they were installed so they can be reinstalJed in the original pcsition...

Page 166: ... ty Remarks Disassembly Order IAssembly is in the reverse orderof disassembly 1 Starter c1utch mounting screw 3 NOTE Remove the clutch mounting screws with a impact driver At installation apply a locking agent to the threads Stake the clutch mounting screws 2 Starter clutch side plate 1 3 Dowel pin 1 4 Roller 3 5 Plunger 3 6 Spring 3 i 7 Starter clutch outer 1 ...

Page 167: ...rnator removal installation page 13 8 2 ciecmc tarter tarter Clutch 3 L Procedure Q ty Remarks Removal Order lnstatlatlonisin the reverse order of removal 1 Starter drívegear 1 2 Starter dríven gear setting plate 1 3 Starter driven gear 1 4 Starter drive chain 1 5 Dowel pin 2 6 Sidespacer 1 7 Gasket 1 ...

Page 168: ...mponent locations see page 16 2 of this manual System Location for Inspections refer to the ap plicable pages Component Inspection method Remarks Clutch switch Section 2 pf the Common Service Manual Front br ake light switch Section 25 of the Common Service Manual Horn Section 25 of the Common Service Manual Handlebar switches Check for continuity on the continuity chart of the Switch connectors a...

Page 169: ...Lights Meters Switchés System Location 1 IGNITION SWITCH lO CLUTCH SWITCH 9 NEUTRAL SWITCH 16 2 2 FRONT BRAKE L1GHT SWITCH 8 SIDE STAND SWITCH 3 BATTERY 7 REAR BRAKE L1GHT SWITCH L L L L L L ...

Page 170: ...ation is in the reverse order of removaL 1 Screw 2 2 Setting collar 2 3 Headlight bulb socket 1 4 Position light bulb socket 1 5 Headlight assembly 1 6 Connectors Connection page 1 19 7 Headlight case bolt 2 8 Headlight case nut 2 9 Collar 2 10 Gasket 2 1 1 Headlight case 2 Align the index marks on the case and br acket 16 3 ...

Page 171: ... is inthe reverse order of removal 1 Screw 2 2 Setting collar 2 3 Headlight bulb socket 1 4 Headlight assemblv 1 5 Connectors Connection page 1 19 6 Headlight case bolt 2 7 Headlight case nut 2 8 Collar 2 9 Gasket 2 10 Headlight case 2 Align the index marks on the case and bracket L I 1 L i I L L 16 4 ...

Page 172: ...ing it counterclock wise and replace with a new one Installation is in the reverse order of removal Turn Signal Bulb Remove the mounting screw and turn signal lens Remove the bulb from the socket by turning itcounterclock wise and replace with a new one Installa tion isin the reverse order of removal Lights Meters Switches 1 BULB 2 SOCKET 1 SCREW 3 LENS 2 BULB 16 5 ...

Page 173: ...re Q ty Remarks Removal Order Installation is in the reverse arder of removal 1 Meter connector 4 2 Speedometer tachometer cable 111 3 Meter mounting nut 4 4 Washer 4 5 Collar cushion rubber 4 4 6 Bulb socket 2 7 Speedometer assembly 1 8 Tachometer assembly 1 9 Meter cushion rubber 2 I 10 Nut 2 I I 1 1 Washer 2 I 12 Meter cover 2 I L 16 6 ...

Page 174: ... or 16 4 Lights Meters Switches 1 4 1 Procedure Q ty Remarks Removal Order Installation is in the reverse order of removal 1 Ignition switch connector 3 2 Indicator cover screw 2 3 lndicator cover 1 4 Ignition switch mountingscrew collar 2 2 5 Ignition switch 1 a Indicator connector 4 b Indicator base 1 16 7 ...

Page 175: ...move the fu el tank page 2 4 Disconnect the side stand connector Remove the side stand switch mounting bolt and the side stand switch Install the switch in the reverse order of removal Torque 30N m 3 0 kg m 22 ft Ib NOTE Align the switch pin with the side stand holeandalign the switch groove with the side stand return spring holding pin Route the side stand switch wire harness properly page 1 2 1 ...

Page 176: ...I O 01 f 8 11 10 __ 2 SID STAND INOICATDR 1 V W I Y NEUTRAL INOICA OR 00 r w uv3 4W a HIGH SEAM INOICATOR I 0 1ZI13 4W B l URN SIGNAL INDICATOR UV3 4W rr g I I r J 8 0 1 r r f f f 1 1 I u H EADL10HlG t I I 1 lo G mttt rI ov aW co J I H l 00 1 W I I I M d POSIT ION L1GHT 1 1 I t 8 v w T n I 1 Itttttth I l 1 n I SWIT H I I w 1 I u r 1 SWITCH CONTINUllY _ _ 0 J I _ _ COLOAl o I I e DIMM IA SWITC H Hl...

Page 177: ...horted spark plug wire Broken or shorted ignition coil Faulty ignitíon switch Faultv pulse generator Faultv exciter coil F aulty engine stop switch Loose or disconnected ignition system wires Compression Normal 3 Test cylinder compression Low Compression Valve stuck open Worn cylinder and piston ring Leaking damaged eylinder head gasket Seized valve Improper valve timing Engine Does Not Fire J 5 R...

Page 178: ...d fuel flow Clogged muffler Pinched fuel tank breather 5 Check ignition timing 4 Incorrect Faulty COI unit Faulty pulse generator Normal Correct t 6 Test cylinder compression 4 Incorrect Valve stuck open Worn cylinder andpiston rings Leaking Oamaged head gasket Improper valve timing 7 Check carburetor for clogging Clogged 1 _ Carburetor not serviced frequently enough Not clogging t 8 Remove spark ...

Page 179: ...re PoorPerformance at Low and Idle Speeds Possible Cause 1 Check ignition timing 4 Incorrect _ Improper ignítion timing Faulty COI unit Correct t 2 Check carburetor pilot screw Incorrect See page section 5 adjustment Correct t 3 Check for leaking intake pipe _ Leaking Loose carburetor mounting nut Oamaged insulator No Leak r 4 Perform spark test Weak or Intermittent Faulty carbonor wet fouled spar...

Page 180: ...d jets Not Clogged t 4 Check valve timing i _ Incorrect Cam sprocket not installed properly Correó f 5 Check valve springs Weak Faulty spring Not Weak Poor Handling Possible Cause 1 If steering is heavy Steering stem adjusting nut too tight Damaged steering head bearings 2 If either wheel is wobbling Excessive wheel bearing play Bent rirn lrnproperlv instalied wheel hub Swingarm pivot bushing exce...

Page 181: ...N 1 O REGULATORI RECTIFIER 1 LEFT FRONT TURN SIGNAL UGHT CLUTCH SWITCH SWITCH CONTlNUITY j UGHTING swnJ HORN SWITCH FREE I PUSH COLOR DIMMER SWITCH HL I HI 1 LO HI ioto N 0 0 0 LO o H o COLOR ISU W Bu 1 W O R TURN SIGNAL SWITCH R L N COLOR I IGNITION SWITCH BAn BAT IG I E OFF I 0 0 1 oto I I A 1 SI BI w1 G COLOR eNGlN E STOP SWITCH OFF 0 0 IG E RUN OFF c o COLOR BIIW G STARTER SWITCH ...

Page 182: ...b c JcJ lb I t t g BRAKE TAIL L1GHT I I B r i B Wr1 1 l I GiY t j h L GiY 2V S 21W r J o D l o Il uJ 1 I I 1 I l L I i i1 1 i I I SPARK PL B I I II fL f i E TURNSIGNALLlGHT _ L ii 12V21W IG TION C J 9 ALTERNATOR NEUTAAL SWITCH r I I I I I l I I I SIGNAL BI BLACK Br BROWN y YELLOW O ORANGE Bu BLUE Lb L1GHT BLUE G GREEN Lg L1GHTGREEN R RED P P1NK W WHITE Gr GRAY 0030Z KBG 6200 I I PASSING SWITCH 1 H...

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