Honda CB-1 1989 Скачать руководство пользователя страница 1 | Manualshive

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Содержание CB-1 1989

Страница 1: ...I 1 ri i1 in I ffl 1 r lilt 1 I it i S i ifSittBm i HIM M im t ill sjUlifli Ml Vi illUBIlIl1 Jii 1 18 I i m t 1 i J 1 is i iiiili A 1 1 4 f m i 4 I A f m i r J T I a 1 I1 a li r I I u m Ilk i ufSLL I...

Страница 2: ...es for removal installation of com ponents that may be required to perform service de scribed in the following sections While section 4 through 18 desetibe parts of the motor cycle grouped according t...

Страница 3: ...rs The illustrations may contain symbol marks to indicate necessary service procedures and precautions that need to be taken Refer to the next page for the meaning of each symbol mark Also in the illu...

Страница 4: ...grease Lithium based multi purpose grease NLGI 2 or equivalent Use molybdenum disulfide grease containing more than 3 molybdenum disulfide NLGI 2 or equivalent Example Molykote 1 BR 2 plus manufacture...

Страница 5: ...of cunsciuusness and may lead to death Run the engine in an open area or with an exhaust evacua tion system in an enclosed area Brake Dust Never use an air hose or dry brush to clean brake assemb lies...

Страница 6: ...prevent the possibility of an explosion release the ni trogen by pressing the valve core Then remove the valve stem from the shock absorber reservoir Dispose of the oil in a manner acceptable to the E...

Страница 7: ...er is stamped on the right side of the crankcase The Vehicle Identification Number VIN is located on the safety certification label on the right side of the frame tube I 4 CARBURETOR IDENTIFICATION NU...

Страница 8: ...ar Tire brand IRC Front Rear Front brake Rear brake Caster angle Trail length Fuel tank capacity Fuel tank reserve capacity Hydraulic disc brake Hydraulic disc brake 25u30 99 mm 3 9 in 11 5 lit 3 04 U...

Страница 9: ...Gear ratio 5th Gear ratio 6th Gear ratio reverse Gearshift pattern Wet multi plate Mechanical type 6 speed constant mesh 2 181 96 44 2 733 41 15 3 307 43 13 2 352 40 17 1 875 30 16 1 590 35 22 1 434 3...

Страница 10: ...0 02 0 07 0 001 0 003 0 15 0 006 0 35 0 014 0 10 0 004 3 y Fuel system Carburetor identification number VG06B VG06C 105 I California Main jet High altitude 2 3 1 4 Front Rear Slow jet Jet needle crip...

Страница 11: ...041 3 775 3 790 0 1486 0 1492 3 755 3 770 0 1478 0 1484 3 800 3 812 0 1496 0 1253 3 800 3 812 0 1496 0 1253 3 70 0 146 3 69 0 145 3 89 0 153 3 89 0 153 0 04 0 002 0 05 0 002 EX Valve guide I D IN EX S...

Страница 12: ...0 0 04 0 002 0 06 0 002 0 08 0 003 0 08 0 003 0 5 0 02 0 5 0 02 1 1 0 04 13 994 14 000 0 5509 0 5512 0 002 0 014 0 0001 0 0006 0 016 0 040 0 0006 0 0016 0 015 0 050 0 0006 0 0020 0 015 0 050 0 0006 0...

Страница 13: ...9 27 92 1 099 22 07 0 869 25 07 0 987 0 10 0 004 0 10 0 004 0 10 0 004 0 10 0 004 0 10 0 004 21 93 0 863 21 93 0 863 M6 C2 C3 C4 Transmission gear bushing O D M5 M6 C2 C3 C4 Transmission gear busing I...

Страница 14: ...hing O D Centrifugal clutch center guide I D O D Centrifugal clutch center guide collar height Centrifugal clutch weight lining thickness Centrifugal clutch spring free length Clutch lining thickness...

Страница 15: ...5 5 8 1 DID525V8 104 RK525SM4 104 Front suspension Fork spring free length Fork spring free length A 318 12 5 324 5 12 78 B Fork spring direction Fork tube runout Recommended fork oil Furk oil level F...

Страница 16: ...caliper piston O D brake drum I D brake lining thickness 4 8 5 2 0 19 0 20 4 0 0 16 0 4 0 02 14 06 0 554 13 95 0 549 38 24 1 506 38 09 1 500 14 000 14 043 0 5512 0 5529 13 957 13 984 0 5495 0 5506 38...

Страница 17: ...i III II 30 A 1 illli 10 A 4 IrHlJlll HI 12 V iMi ih iijij Hllll Hjlll l ill l i 1 ill ii j i l lilllili Ii 11ii l i ii mi i ll llh ill l l iill lili IIIplitl lll il l i 1 ll i i IP 5 12 V 2 I I i 11...

Страница 18: ...l filter boss Oil filter Cylinder head cylinder piston Cylinder head cover bolt Camshaft holder bolt Cylinder head cover breather plate bolt Cylinder head special nut Cylinder head mounting bolt Cylin...

Страница 19: ...sorber lower joint lock nut Swingarm pivot nut Brake Front caliper pad pin plug pad pin bracket bolt pin bolt bracket pin bolt Front mo3tcr cylinder reservoir cover screw Front brake disc bolt Rear ca...

Страница 20: ...protector Valve spring compressor Valve spring compressor attachment Valve guide reamer 3 8 mm 3 I 4 ror equivalent commer daily available in JU S A 4 4 14 16 5 5 6 6 U S A only U S A only I 6 8 07JM...

Страница 21: ...49 3710001 07746 0010200 07946 MB00000 07746 0050500 07746 0010700 07746 0040400 07746 0041000 07GME 0010000 1 1 11 11 1 1 12 12 12 12 Not available in U S A 07959 3290001 12 screw assembly Shock abso...

Страница 22: ...sealant to the oil pressure switch thread head as shown Gear teeth Shaft journals Sliding surface Engine oil FRAME Material Point Remarks Center stand pivot Side stand pivot Brake pedal pivot Gearshif...

Страница 23: ...BLACK CONNECTOR IGNITION SWITCH ft 4 6P GREEN CONNECTOR TURN SIGNAL SWITCH 4 5 9P RED CONNECTOR STARTER SWITCH ENGINE STOP SWITCH 7 BRAKE HOSE I 8 CLUTCH CABLE O fa1 15 THROTTLE CABLE 9 LEFT HANDLEBAR...

Страница 24: ...OSE oO 8 No 2 No 3 SPARK PLUG WIRES 16 SET THE No 2 No 3 SPARK PLUG WIRES SECURELY 7 Cl lITCH CABLE O o c 10 THROTTLE CABLES t TD 11 SET THE No 1 J No 4 SPARK PLUG WIRES SECURELY 9 CHOKE CABLE a Q 5sJ...

Страница 25: ...CH WIRE ALTERNATOR WIRE O 7 CLAMP MAIN WIRE HARNESS REAR BRAKE LIGHT SWITCH WIRE 9 No 1 No 4 SPARK PLUG WIRES 6 RESFRVDIR HOSE v 10 AIR HOSE 11 SIDE STAND LS SWITCH 3P 36 CONNECTOR 8 PULSE GENERATOR N...

Страница 26: ...2 50 1 WIRE GUIDE IGNITION COIL WIRE NEUTRAL SWITCH OIL PRESSURE SWITCH WIRE PULSE GENERATOR WIRE SIDE STAND SWITCH WIRE ALTERNATOR WIRE 9 PULSE GENERATOR WIRE 8 NEUTRAL SWITCH WIRE 7 SIDE STAND SWIT...

Страница 27: ...UBE 7 No 4 TUBE 4 AIR SUCTION VALVE I 6 No 1 TUBE b RADIATOR RESERVE TANK OVERFLOW TUBE 12 No 3 INTAKE MANIFOLD 11 No 4 INTAKE MANIFOLD 18 TO PCV 19 TO AVCV 10 No 10 TUBES 13 0 RINGS 14 AIR INJECTION...

Страница 28: ...GENERAL INhORMATION I m i 09 m 1 No 5 TUBES I 2 AIR INJECTION TUBE NO 15 r 4 No 4 TUBE 3 No 1 TUBE I 6 PCV 5 AVCV n P J Ml 9 No 10 TUBE 7 No 4 TUBE 8 3 WAY JOINT I 1 9 1...

Страница 29: ...ffect I SOURCE OF EMISSIONS I The combustion process produces carbon monoxide and hydrocarbons Control of hydrocarbons is very important because under certain conditions they react to form photochemic...

Страница 30: ...of the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor This model has the air suction valve it cons...

Страница 31: ...CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than fo...

Страница 32: ...n update label on the rear fender as shown 3 VACUUM HOSE ROUTING DIAGRAM LABEL California model only I VACUUM HOSE ROUTING DIAGRAM LABEL California model only t VACUUM HOSE ROUTING 0 I AG RAM ENGINE F...

Страница 33: ...is damaged Generally speaking plastic body panels cannot be repaired and therefore must he replaced It is possible that a front end collosion will bend the steering head of the frame but not the fork...

Страница 34: ...and push the seat forward Press the rear of the seat down and lock the scot securely i 2 LEVER CAUTION 3 HOOKS Apply grease to the seat locking Be careful not to pinch the wire harness between the se...

Страница 35: ...ver in the reverse order of removal NOTE It is not necessary to remove the bolt as shown 3 BOLT 2 BOLTS I EXHAUST SYSTEM REMOVAL INSTALLATION 1 RADIATOR Remove the radiator lower mounting bolts and lo...

Страница 36: ...parks in the work area or where gasoline is stored can cause a fire or explo sion NUT c Remove the seat page 2 2 Turn the fuel valve OFF Remove the fuel tank mounting bolts and lift the tank up Discon...

Страница 37: ...AIR CLEANER 3 1 SPARKPLUG 3 2 VALVE CLEARANCE 3 4 CARBURETOR SYNCHRONIZATION 3 5 SIDE STAND 3 5 3 5 3 8 3 8 I SERVICE INFORMATION Refer to the Common Service Manual for items not included in this man...

Страница 38: ...eplacement Fuel tank Reserve Tank Cap Coolant filler Seat _ Throttle Grip Operation free play Master Cylinder Level check fluid replacement Brake Pedal Air bubbles in system Brake Hose Leakage degrada...

Страница 39: ...olant level Headlight Aim 0 U Steering Head Bearings Damage Valve Clearance page 3 5 Suspension Loose wear damage jV Jy o 0 u X Drive Chain Free play lubrication replacement Suspension Loose wear dama...

Страница 40: ...COOLING SYSTEM SECONDARY AIR SUPPLY SYSTEM I NOTE 5 NOTE 4 I EVAPORATIVE EMISSION CONTROL SYSTEM DRIVE CHAIN NOTE 5 I I NOTE 4 sami NOTE 5 US NOTE 5 NOTE 3 I I Y R li J BRAKE FLUID 5 I i i i NOTE 5 1...

Страница 41: ...ide cover J 2 PLUG WRENCH Remove the front side covers page 2 3 The spark plug wrench is included in the tool kit Insert the plug wrench between the heat guard plate and cyl inder head cover as shown...

Страница 42: ...cylinder piston Is at TDC Top Dead Center on the compression stroke go to Step 0 1 T MARK YELLOW COLORED LINE w 9jf o J x 2 INDEX MARK I Step 1 Insert the feeler gauge between the cam lobe and valve...

Страница 43: ...er and record it NOTE 5 Sixty five different shims are available in thickness in tervals of 0 025 mm The thinnest is 1 200 mm the thickest is 2 800 mm To confirm your shim choice you may use the follo...

Страница 44: ...CARBURETOR No 2 CARBURETOR 1 PLUGS I 1 SYNCHRONIZATION SCREWS IV u 2 No 4 SCREW 4 No 1 SCREW 3 No 3 SCREW SIDE STAND 1 SIDE STAND SWITCH m 7 Check the side stand ignition cut off system Place the moto...

Страница 45: ...on refer to section 25 of the Common Service Manual When removing and installing the oil pump use care not to allow dust or dirt to enter the engine After the oil pump hoa been installed check that th...

Страница 46: ...fit tffi if 2 INTAKE CAMSHAFT J J L0 3 PISTON 4 CONNECTING ROD ll 5 CRANKSHAFT My 6 OIL PRESSURE SWITCH r I 14 OIL ORIFICE 7 OIL ORIFICE i 13 MAINSHAFT ill i s 12 COUNTER SHAFT WB 8 OIL PUMP 4 I 11 OI...

Страница 47: ...ge 9 8 PROCEDURE Q ty REMARKS REMOVAL ORDER Oil pan bolt Installation is in the reverse order of removal At installation tighten the bolts in a gradual crisscross pattern 1 12 2 Oil pan Gasket Relief...

Страница 48: ...n I REQUISITE SERVICE Oil pump removal installation page 4 3 REMARKS Q ty PROCEDURE Assembly is in the reverse order of disassembly NOTE Install the dowel pins then tighten the screws DISASSEMBLY ORDE...

Страница 49: ...or cap except to refill or drain the system All cooling system service can be done with the engine in the frame Avoid spilling coolant on painted surfaces For coolant replacement refer to section 5 of...

Страница 50: ...COOLING SYSTEM SYSTEM FLOW PATTERN I 3 RADIATOR CAP 2 THERMOSTAT 4 THERMO SENSOR 5 SIPHON TUBE 1 COOLING FAN s 6 RESERVE TANK o t 9 RADIATOR CL S o 8 FAN MOTOR SWITCH I 7 WATER PUMP I I R 9...

Страница 51: ...completely from the system NOTE California model has the only left drain bolt 1 CYLINDER DRAIN BOLTS SFALING WASHERS Place a suitable tray under the siphon tube joint of the re serve tank and disconn...

Страница 52: ...val installation page 2 4 Coolant draining page 5 3 REMARKS Q ty PROCEDURE Installation is in the reverse order of removal REMOVAL ORDER Ihermostat cover mountiny bolt Siphon tube Radiator ho3c Thermo...

Страница 53: ...t refill section 5 of the Common Service Manual PROCEDURE Q ty REMARKS REMOVAL ORDER Radiator hose Fan motor switch connector Radiator lower mounting bolt Radiator upper mounting bolt nut Fan motor co...

Страница 54: ...tabs with the shroud grooves At installation align four grille grooves with the radiator lugs At installation install the fan motor ground wire terminal properly as shown 2 2 1 Radiator grille 3 1 2...

Страница 55: ...nual Coolant refill section 5 of the Common Service Manual Gearshift spindle joint removal installation page 9 6 Water pump side cover removal installation page 7 2 PROCEDURE Q ty REMARKS DISASSEMBLY...

Страница 56: ...maged NOTE If vehicle is to be stored for more than one month drain the float chambers Fuel left in the float chambers may cause clogged jets resulting in hard starting or poor driveability When disas...

Страница 57: ...idling Fuel line restricted Ignition malfunction Fuel mixture too lean rich Fuel contaminated deteriorated Intake air leak Idle speed misadjusted Fuel pump malfunction Pilot screw misadjusted Slow ci...

Страница 58: ...t with the ft mark forwards and with the TOP mark facing up 4 1 5 Air cleaner case bolt collar Crankcase breather tuhe Air hose Air injection tube No 15 Air cleaner case 2 2 6 2 7 Except California Mo...

Страница 59: ...FUEL SYSTEM CARBURETOR REMOVAL INSTALLATION I 7 California Model Only AVCV 1 3 5 PCV 6 ey 4 w 1 8 0 D 2 tfup MARK I l fi ZL...

Страница 60: ...allation page 6 3 Carburetors draining PROCEDURE Q ty REMARKS REMOVAL ORDER Insulator band Choke cable Throttle cable Fuel tube No 10 vacuum tube from the AVCV No 4 tube from The AVCV and PCV Carburet...

Страница 61: ...FUEL SYSTEM CARBURETOR SEPARATION I No 4 CARBURETOR 14 13 10 5 a 9 2 15 3 4 1 mi 1 I V _ 1 7 J 11 3 20 0 sz I 4 8 a No 3 CARBURETOR 6 17 I 3 No 2 CARBURETOR IB No 1 CARBURETOR 16 f 19 t...

Страница 62: ...arb synchronization spring Air joint pipe 3 way 0 ring Fuel joint pipe 3 way 0 ring 1 1 2 1 3 3 4 1 5 1 6 1 7 1 I 8 1 2 9 1 2 Separate No 3 carb from No 4 carb No 4 carb synchronization spring Thrust...

Страница 63: ...FUEL SYSTEM CARBURETOR DISASSEMBLY ASSEMBLY S m DOWEL 2 PIN SIDE 20 3 21 22 14 5 6 3 a S 8 26 m 25 0 oj V 7 V 24 9 15 18 23 19 17 16 O 14 13 ALIGN DOWEL PIN SIDE OJ 12 c 11 i 10 fi R...

Страница 64: ...nstallation first tighten the two screws on the dowel pin side 2 Vacuum chamber cover Spring Diaphragm vacuum piston Jet needle holder 1 13 1 4 1 5 Turn the holder 90 counterclockwise while pushing it...

Страница 65: ...EL SYSTEM CARBURETOR COMBINATION I No 4 CARBURETOR 14 18 10 11 I 17 No 3 CARBURETOR V 191 22 13 24 2D N V 23 1 15 19 12 L tm 16 X t 20 21 0 s 2CX s W 6 I 7 19 21 5 No 2 CARBURETOR No 1 CARBURETOR i 6...

Страница 66: ...carb with No 4 carb Fuel joint pipe 2 way 0 ring Air vent pipe 3 way 0 ring Air joint pipe rubber Thrust spring No 4 carb synchronization spring Front bracket screw 1 2 10 1 2 11 12 1 13 1 1 14 2 The...

Страница 67: ...No 4 CARBURETOR 3 No 2 CARBURETOR 4 No 3 CARBURETOR 2 No 1 CARBURETOR 1 No 5 TUBE i Y V i 6 No 5 TUBES p i 7 PCV 1 12 No 5 TUBE 9 No fi TUBES 13 No 6 TUBES 11 AVCV 10 PCV 14 AVCV I 15 No 6 TUBfcS 16...

Страница 68: ...l Only 2 PCV 1 AVCV EVAPORATIVE EMISSION CONTROL SYSTEM f PURGE CONTROL VALVE PCV AND AIR VENT CONTROL VALVE AVCV REMOVAL to Remove the following fuel tank page 2 4 air cleaner case page 6 3 carbureto...

Страница 69: ...supply system refer to section 7 of the Common Service Manual P 3 PLUG 4 No 10l TUBE SPECIFIED VACUUM 360 mmHg 14 2 inHg AIR SUCTION VALVE ASV REMOVAL Remove two bolts and air suction valve as an asse...

Страница 70: ...be serviced with the engine installed in the frame alternator Section 14 camshaft Section 8 carburetors Section 6 clutch Secliun 9 gearshift linkage Section 9 oil pump Section 4 pulse generator Secti...

Страница 71: ...0 29 50 5 0 36 8 26 65 6 5 47 20 0 m 1 15 1 5 11 21 I II li 28 K v 24 J3 22 1 15 3 4 23 0 7 24 27 25 6 as 4 0 29 26 5 I c 19 7 45 4 5 33 LX2 DRIVE SPROCKET BOLT 24 17 11 14 40 4 0 29 N W y 0 SPEEDOMET...

Страница 72: ...2 1 3 1 4 1 1 5 On the starter motor 6 1 2 2 7 8 1 0 At Installation align the punch marks on the joint and spindle 1 Water pump side cover Speedometer cable Drive sprocket cover 10 1 11 1 12 1 CAUTIO...

Страница 73: ...same order they were installed so they can be reinstalled in the original posi tions E TROUBLESHOOTING ft Engine top end problems usually affect engine performance These can be diagnosed by a compres...

Страница 74: ...val 1 1 2 At installation tighten the bolts in a gradual crisscross pattern Install them with the UP mark facing up Install with the mark forward NOTE Apply Three Bond 1521 or equivalent to the head c...

Страница 75: ...the compres sion stroke r o 3 EX MARK LINE 4 IN MARK Csfits LINE I O 5 T MARK mi Yellow colored line ft JM i J lO 6 INDEX MARK Install the dowel pins onto the camshaft holders and install the camshaft...

Страница 76: ...nut Cylinder head mounting bolt Cylinder head assembly Gasket Dowel pin Camshaft idle gear case bolt Camshaft idle gear ease dowel pin Sealing washer Camshaft idle gear case Carburetor insulator Inst...

Страница 77: ...ith the gear case held the gear case should be lifted up slightly from the cylinder 3 TIMING GEAR Install a new sealing washer and mounting bolts Tighten bolts in a gradual as shown 1 BOLTS T ft 5 he...

Страница 78: ...emoval installation page 7 2 Camshaft removal installation page 8 2 Cylinder head removal installation page 8 4 PROCEDURE Q ty REMARKS DISASSEMBLY ORDER Valve bucket Assembly is in the reverse order o...

Страница 79: ...linder head bucket sliding surface LO VALVE BUCKET HOLE PROTECTOR 07JMG KY20100 r v 1 VALVE BUCKET HOLE PROTECTOR Install The valve spring compressor onto the valve and com press the valve spring Remo...

Страница 80: ...CYLINDER HEAD CYLINDER PISTON CYLINDER PISTON REMOVAL INSTALLATION C10 1 0 7 g 4 1 5 o o 2 o o 7 6 3 o SO 11 12 o o o ijCl 3 5 TOOL 1 16 V o o 10 o o 7 cb 9 f i m 8 r 8 8...

Страница 81: ...nt O ring Cylinder mounting bolt Cylinder Gasket Dowel pin Piston pin clip Piston pin Piston Piston top ring Piston second ring Piston oil ring set side rails and spacer Installation is in the reverse...

Страница 82: ...crankcase Section 10 If it is no longer clear which bolt belongs in which hole insert all bolts in the holes and check the exposed length each should be exposed the same amount ft TROUBLESHOOTING Clut...

Страница 83: ...CLUTCH GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL INSTALLATION i 2 I 6 Q 1 I I 6 4 3 5 A 10 1 0 7 114 4 ijiyj 13 10 c O Y0 7 0 7 5 12 ID 8 n 1 7 Q_9...

Страница 84: ...2 1 3 NOTE At installation apply a locking agent to the two bolt threads Disconnect or connect the Alternator 3P connector 14 I 4 Right crankcase cover Gasket Dowel pin 1 5 1 6 2 Clutch lifter pin Ret...

Страница 85: ...r spring clutch friction disc C clutch plate B clutch frictin disc B clutch plate A clutch friction disc A pressure plate 7 1 8 1 9 1 1U Larger I D disc Color black Color gray Smaller I D disc Color s...

Страница 86: ...0A U S A only 2 CLUTCH LIFTER PLATE BOLTS 3 NUT WASHER Temporarily remove the tool and tighten nuts then reinstall the clutch center holder onto the hosses Use at least two clutch lifter plate bolts t...

Страница 87: ...AGE GEARSHIFT LINKAGE REMOVAL INSTALLATION ALIGN I GUIDE PLATE DRUM SHIFTER ASSEMBLY A t g12l 2 9lj o OF a b Tr p 0 o o mto n NO 22 19 20 15 14 18 21 O f 9 6 5 0 4 o 17 16 k 7 8 10 11 SPINDLE ASSEMBLY...

Страница 88: ...Gearshift spindle Spindle return spring Washer 1 4 1 5 1 6 Shifter collar Guide plate mounting bolt Guide plate dium shifter assembly guide plate ratchet pawl plunger spring drum shifter Collar Dowel...

Страница 89: ...CLUTCH GEARSHIFT LINKAGE CLUTCH INSTALLATION E 15 1 5 11 5 wm O 1 m a 6 2 7K 2 4 J 9 10 15 12 16 14 18 18 19 IS TOOlr page 9 10 16 c 17 7 e 15 a 21 85 8 5 61 0 ry 20 23 22 Q_Q...

Страница 90: ...the judder spring to the outside 1 11 4 12 4 13 1 14 1 15 1 16 1 17 1 18 Lock washer Clutch center lock nut Clutch spring Clutch lifter plate Clutch lifter plate bearing Clutch lifter plate bolt 1 Wit...

Страница 91: ...7HGB 001000A U S A only 2 CLUTCH LIFTER PLATE BOLTS 3 NUT WASHER Hold the clutch center holder and torque the clutch center lock nut as shown a TORQUE 85 N m 8 5 kg m 61 ft lb 0A O Stake the lock nut...

Страница 92: ...se halves apply a sealant to their mating surface Wipe off excess sealant thoroughly Mark and store the bearing inserts to be sure of their correct locations for reassembly If the inserts are improper...

Страница 93: ...CRANKSHAFT TRANSMISSION CRANKCASE SEPARATION 3 3 2 a a r RL a jj L tl 2 B S 2 4 2 0 Zt 6 5 b 5 1 10 9...

Страница 94: ...n the crankcase have sealing washers Bolts 12 psc have sealing washers 2 Lower crankcase bolt 6 mm 13 3 Lower crankcase bolt 8 mm Lower crankcase Dowel pin Oil orifice 13 4 1 5 3 6 2 I CRANKCASE BOLTS...

Страница 95: ...ANKSHAFT TRANSMISSION CRANKSHAFT CONNECTING ROD REMOVAL INSTALLATION m f c s Icr O 7 I r A 0 6 0 D V 24 2 4 17 7J 0 0 7K 2 o d i 5 Ax jjO I 0 Oi m o 9 t 77 l OIL HOLE FACING TO INTAKE SIDE o 4 I 3 10...

Страница 96: ...rod Connecting rod bolt Connecting rod bearing Crankshaft Crankshaft main journal bearing 1 8 I 2 4 3 4 4 8 Do not remove them without necessary Wipe all oil from the bearing seating areas 8 5 6 1 7...

Страница 97: ...nk weight NOTE Numbers 1 or 2 on the crank weight are the codes for the main journal O D s from the left w m 1 MAIN JOURNAL O D CODE Cross reference the case and journal codes to determine the replace...

Страница 98: ...on the upper crankcase are the codes for the crankpin O D s from the left n N 1 CRANKPIN O D CODE ft Cross reference the ciankpin and rod codes to determine the replacement bearing color code 1 CONNE...

Страница 99: ...CRANKSHAFT TRANSMISSiON TRANSMISSION REMOVAL INSTALLATION i i OUT I to I II MI 19 I 15 i 18 11 A 14 5 16 9 0 6 2 13 12 0 7 BEND THE TABS UP ac 10 A A o pj o iO A 8 A r S3 i 4 3 H M I I 10 8...

Страница 100: ...face the M6 gear engagement dogs for ward the M4 gear Mainshaft assembly Center shift fork bolt 8 I 1 9 1 Remove after bending down the lock washer tab Install and bend new lock washer tabs as shown I...

Страница 101: ...ion 13 of the Common Service Manual for inspection information REQUISITE SERVICE Transmission removal installation page 10 8 PROCEDURE Q ty REMARKS MAINSHAFT DISASSEMBLY ORDER Needle bearing Thrust wa...

Страница 102: ...gear 30T J3 spline bushing Lock washer Spline washei C4 gear 35T C4 spline bushing Spline washer Snap ring C6 shifter gear 32T Snap ring Spline washer C2 bushing C2 geai 40T Thrust washer Oil seal Be...

Страница 103: ...CRANKSHAFT TRANSMISSION CRANKCASE INSTALLATION p 27 2 7 20 24 2 4 17 e 1 3 f SI a 4 c 4 12 1 2 9 12 1 2 9 3 C A 4 l 12 1 2 9 1 2 d r0 j O LCT 0 sO ey i 2 M i Q O G f 7 012 1 2 9 10 19...

Страница 104: ...3 3 1 i 4 13 12 Crankcase installation see below 5 6 1 7 6 I CRANKCASE INSTALLATION Apply a light but thorough coating of sealant to the upper crankcase mating surface except to the main bearing jour...

Страница 105: ...ly g 4 C5 SHIFTER IN O o n n r 5 M3 M4 SHIFTER Install the crankcase bolts and sealing washers as shown 1 BOLTS 26 psc JEM5 4 j jj NOTE Four 6 mm bolts marked A on the crankcase have sealing washers T...

Страница 106: ...n the section 16 of the Common Service Manual If the motorcycle has been involved in an accident inspect the frame very carefully at the steering head and at the engine mounts These are the areas most...

Страница 107: ...the reverse order of removal 2 1 2 1 Align the holder end with the punch mark on the handle bar and face the holder UP mark upward Tighten the upper bolt first then the lower bolt Tighten the front sc...

Страница 108: ...with the punch mark on the handle bar and face the holder UP mark upward Tighten the upper bolt first then the lower bolt Tighten the front screw first then the rear screw Left handlebar switch housi...

Страница 109: ...um cleaner or alternate method approved by OSHA designed to minimize the hazard caused by airborne asbestos fibers CAUTION Do not use the oil filter as a jack point NOTE Do not depress the brake lever...

Страница 110: ...ervice Manual REQUISITE SERVICE Front wheel removal installation page 11 4 ft Q ty ASSEMBLY REMARKS PROCEDURE Assembly is in the reverse order of disassembly Longer collar Shorter collar Wipe off all...

Страница 111: ...FRONT WHEEL SUSPENSION STEERING FORK REMOVAL INSTALLATION f 6 rm f GROOVE n 18 c11 1 1 8 TOP BRIDGE UPPER SURFACE D 7 c 9 50 5 0 36 3 4 27 2 7 20 m D 2 5 11 6...

Страница 112: ...lebar removal installation page 11 2 Left handlebar removal installation page 11 3 REMARKS Q ty PROCEDURE Installation is in the reverse order of removal REMOVAL ORDER Front fender bolt Front fender B...

Страница 113: ...FRONT WHEEL SUSPENSION STEERING FORK DISASSEMBLY iD D 2 n 10 t 3 0 U 12 4 0 18 17 5 e 13 6 CD 71 119 14 t SB 16 A 8 4 14 0...

Страница 114: ...remaining fork oil When removing them do not damage the fork tube 5 1 6 1 IT 7 1 8 NOTE Temporarily install the spring and fork cap bolt if difficulty is encountered in removing the socket bolt 1 Seal...

Страница 115: ...FRONT WHEEL SUSPENSION STEERING FORK ASSEMBLY 2 3 17 19 12L S 1 18 4 17 3 161 Tighter Coils Down I 15 7 14 14 1 13 131 12 S TOOL ii 12 I page 1 17 diH in j 10 10 8 9 2 0 14 2 2 18 11 1n...

Страница 116: ...bolt is tightened 1 1 10 Slider bushing Back up ring Oil 6eal ID 1 NOTE Wrap vinyl tape around the fork tube top end to avoid damaging the oil seal during the oil seal installation Drive in it secure...

Страница 117: ...ING STEERING STEM REMOVAL INSTALLATION 105 10 5 76 5 1 Is TOOL page 1 17 4 j 6 m 2 7 0_ g g 8 6125 2 5 18 3 page 1 17 9 17 11 12 6 16 page 1 17 Is o 1 page 1 17 15 V os cs 8 c SHORTER TABS Bend down L...

Страница 118: ...removed 1 Use race remover attachment 07953 MJ1000A with driver 07949 3710001 and attachment 37 x 40 mm 07746 0010200 for upper outer race removal Use race remover 07946 3710500 with driver 07949 3710...

Страница 119: ...ease and cancer Never use an air hose or dry brush to Clean brake assemblies Use an OSHA approved vacuum cleaner or alternate method approved by OSHA designed to minimize the hazard caused by airborne...

Страница 120: ...stos fibers NOTE Put the motorcycle on its center stand Do not depress the brake pedal when the caliper is removed or it will he difficult to refit the disc between the brake pads Support the removed...

Страница 121: ...CE Rear wheel removal installation page 12 2 PROCEDURE Q ty ASSEMBLY REMARKS DISASSEMBLY ORDER Right side collar Left side collar Right dust seal Left dust seal Assembly is in the reverse order of dis...

Страница 122: ...lightest loads before removing the shock absorber from the frame REQUISITE SERVICE Fuel tank removal installation page 2 4 PROCEDURE Q ty REMARKS REMOVAL ORDER Shock absorber mounting bolt upper Shock...

Страница 123: ...st the shock absorber to position I for lightest loads before removing the shock absorber from the frame For lower joint needle bearing replacement see next page REQUISITE SERVICE Shock absorber remov...

Страница 124: ...the lower joint securely onto the damper rod Hole the lower joint and torque the lock nut TORQUE 68 N m 6 8 kg m 49 ft lb 3 ALIGN Make sure the Lower Joint is aligned with the seat stopper pin and rem...

Страница 125: ...ith a piece of wire so that it does not hang from the brake hose Do not twist the brake hose If necessary loosen the rear engine mounting nut near the swingarm pivot to ease the swingarm removal insta...

Страница 126: ...tion page 12 2 ASSEMBLY REMARKS Q ty PROCEDURE Assembly is in the reverse order of disassembly Install them with the UP mark facing up and the index mark facing out DISASSEMBLY ORDER Drive chain adjus...

Страница 127: ...A DRIVER SHAFT r or BUSHING REMOVER M967X 038 XXXXX 07949 3710001 m DRIVER 3 NEEDLE BEARING REMOVER ATTACHMENT I Prose the noodle bearing into the swingarm with the marked side facing out 1 DRIVER 2 A...

Страница 128: ...ery careful whenever you remove the reservoir cap make sure the front reservoir is horizontal first Never allow contaminants dirt water etc to get into an open reservoir Once the hydraulic system has...

Страница 129: ...hazard caused by airborna asbestos fibers After replacement operate the brake lever to seat the caliper pistons against the pads NOTE Do not depress the brake lever when the caliper is removed or it...

Страница 130: ...e pedal to seat the caliper pistons against the pads NOTE Do not depress the brake pedal when the caliper is removed or it will be difficult to refit the disc between the brake pads Replace brake pads...

Страница 131: ...ize the hazard caused by airborne asbestos fibers NOTE If you remove the caliper pistons remove the caliper bracket bolts 4 before disconnecting The brake hose 3 and place a pan under the caliper to c...

Страница 132: ...OSHA designed to minimize the hazard caused by airborne asbestos fibers NOTE Before diooonnoGting the brake hose 1 place a pan under the raliper to catch the draining fluid and squeeze the brake leve...

Страница 133: ...moval installation page 13 2 Brake fluid replacement air bleeding section 17 of the Common Service Manual Front brake caliper removal installation page 13 4 PROCEDURE Q ty REMARKS DISASSEMBLY ORDER Pa...

Страница 134: ...e fluid replacement air bleeding section 17 of the Common Service Manual Rear brake caliper removal installation page 13 5 PROCEDURE Q ty REMARKS DISASSEMBLY ORDER Pad spring Pivot collar Pivot boot C...

Страница 135: ...rearview mirror Brake lever pivot bolt Brake lever Brake hose bolt Sealing washer Front brake light switch connector Master cylinder holder bolt Master cylinder holder Master cylinder assembly Install...

Страница 136: ...ty PROCEDURE REMARKS REMOVAL ORDER Brake hose bolt Sealing washer Brake hose Master cylinder mounting bolt Footpeg biaukul bull Reservoir hose joint Q ring Push rod joint Master cylinder assembly Ins...

Страница 137: ...eding section 17 of the Common Service Manual Front master cylinder removal installation page 13 8 PROCEDURE Q ty ASSEMBLY REMARKS DISASSEMBLY ORDER Reservoir cover Diaphragm plate Diaphragm Front bra...

Страница 138: ...bleeding section 17 of the Common Service Manual Rear master cylinder removal installation page 13 9 PROCEDURE Q ty ASSEMBLY REMARKS DISASSEMBLY ORDER Push rod joint Assembly is in the reverse order o...

Страница 139: ...ootpeg stay bolt Push rod joint Footpeg mounting bolt Wove washer Rear brakelight switch spring Brake pedal return spring Right footpeg Brake pedal Installation is in the reverse order of removal 1 2...

Страница 140: ...o remove the sealing caps from the cells may damage the bat tery Battery can be damaged if overcharged or undercharged or if left to discharge for long periods These same conditions contribute to shor...

Страница 141: ...RNATOR SYSTEM LOCATION 2 MAIN FUSE INTO STARTER RELAY SWITCH _ 1 ALTERNATOR fe9 m s 3 REGULATOR RECTIFIER i 4 BATTERY CIRCUIT DIAGRAM 2 MAIN FUSE 30 A 4 BATTERY Y Y Y G R W I I I I l 3 REGULATOR RECTI...

Страница 142: ...nda Battery Tester I CORRECT INCORRECT Electric system overloading NOT CHARGING i Faulty battery Check the voltages of the regulator rectifier bat tery charging line and ground line page 14 5 Open cir...

Страница 143: ...measuring current do not turn the ignition on A sudden surge nf r urrent may hlnw nut the fuse in the tester SPECIFIED CURRENT LEAKAGE 0 01 mA max If current leakage exceeds the specified value a sho...

Страница 144: ...the ignition off when conducting the test Disconnecting the ammeter or wires when current is flowing may damage the ammeter A I Start the engine and increase the engine speed gradually REGULATED VOLTA...

Страница 145: ...l type U S A only 07308 0020001 SANWA Analogue type TH 5H KOWA Analogue type Select the following range SANWA tester x kS2 KOWA tester x 100 0 0 5 10 30 500 30 500 10 200 10 200 0 5 10 30 500 30 500 0...

Страница 146: ...ing right crankcase cover page 9 2 flywheel bolt washer flywheel woodruff key I 4 FLYWHEEL TTOOL page 1 17 3 BOLT s TOOL page 1 17 I Remove the bolt and stator wire harness clamp Remove the bolts and...

Страница 147: ...gnition switch before servicing A faulty ignition system is often related to poorly connected connectors Check those connections before proceeding Make sure the battery is adequately charged Using the...

Страница 148: ...0 PULSE GENERATOR 8 SIDE STAND SWITCH CIRCUIT DIAGRAM 4 MAIN FUSE 30 A 12 IGNITION SWITCH r o R BI 2 ENGINE STOP SWITCH BI W o BI 5 FUSE 10 A Cu o Bl Br 1 SIDE STAND SWITCH INDICATOR down e 0 5 FUSE 1...

Страница 149: ...it in wire harness Loose or poor contact of related circuit con nectors I BATTERY VOLTAGE MEASURED I Measure the pulse generator resistance at the unit connector page 15 6 ABNORMAL Check the pulse gen...

Страница 150: ...nce of the ignition primary coil at spark unit connector page 15 6 Poor or loose contact of ignition coil 4P mini connector Open circuit between the unit and ignition coil GOOD Faulty spark unit No sp...

Страница 151: ...h When the side stand is up the side stand switch line b of the spark unit passes to ground via the side stand switch The spark unit monitors lines a and b and provides spark only when one or both of...

Страница 152: ...primary coil No 1 4 Black White and Yellow Blue No 2 3 Black White and Blue Yellow 2 4 Q 200C 68 F Neutral switch line Light Green Red and ground Continuity into neutral No continuity in any gear exc...

Страница 153: ...20 C 68 F y Q 2 PRIMARY COIL I REMOVAL INSTALLATION 1 BOLT COLLAR 2 IGNITION COIL ASSEMBLY Disconnect the ignition coil 4P mini connector under the fuel tank Remove the bolts and collars 3 Y Bu l Dis...

Страница 154: ...8 Remove the bolts and pulse generator 2 GROMMET Install the pulse generator and wire clomp and tighten the bolts securely Set the wire harness grommet into the cover groove O r o Install the left cr...

Страница 155: ...n T I IGNITION TIMING Warm up the engine Stop the engine and connect a timing light to the No 3 cylin der 3pork plug wire I NOTE Read the instructions for timing light for operating O 0 o Remove the f...

Страница 156: ...e starter motor to turn it while the engine is not cranking over the starter motor may he damaged For the following component inspections refer to the following pages for the parts locations see page...

Страница 157: ...WITCH j 10 STARTER MOTOR 9 NEUTRAL SWITCH s 8 SIDE STAND SWITCH CIRCUIT DIAGRAM 11 IGNITION SWITCH 4 STARTER RELAY SWITCH 6 BATTERY f e R BI R M 10 STARTER ivy MOTOR 5 FUSE P 5 P 10 A SFUSES yio Aj Bl...

Страница 158: ...turn NO CLICK Faulty starter motor i Loose or disconnected starter motor cable Faulty starter relay switch Disconnect starter relay switch connector and check the lelay uuil ground wire lines as below...

Страница 159: ...15 8 ABNORMAL Faulty side stand switch NORMAL Open circuit in wire harness Loose or poor contact of connector I Starter motor turns slowly Low specific gravity in battery or Dead battery Poorly connec...

Страница 160: ...Turn the ignition switch OFF REQUISITE SERVICE Fuel tank removal installation page 2 4 REMARKS PROCEDURE Q ty Installation is in the reverse order of removal REMOVAL ORDER Starter motor cable Starter...

Страница 161: ...ELECTRIC STARTER STARTER CLUTCH STARTER MOTOR DISASSEMBLY ASSEMBLY 8 t 10 OJ 11 13 14 15 12 s 16 1 2 3 m 17 19 18 0 W cT 7 4 O O o 0 5 6 I A ALIGN t 1 ft ft...

Страница 162: ...tall with the groove side facing to the brushes Align the index marks on the rear cover and case 1 7 O iiny Lock washer Insulated washer Washer Armature Shims 1 8 1 9 1 10 1 11 1 12 Record and store t...

Страница 163: ...CLUTCH STARTER CLUTCH REMOVAL INSTALLATION 3 to oj CLAMP p o Jff 4 w 2 u 14 c O J ti 1 1 13 I T B a Q HD 12 7 o 5 6 0 o I o 5 l s T 01 1 page 16 9 Q 85 8 5 61 t ALIGN THE WIDE GROOVE AMONG THE CRANKS...

Страница 164: ...tch 9 1 I 10 1 11 1 At installation make sure the starter clutch roller is in stalled properly into the clutch housing 12 Spline washer Starter drive gear shaft Starter drive gear 1 13 1 14 1 I STARTE...

Страница 165: ...A continuity test can be made with the switches installed on the motorcycle For the following component locations see page 17 2 of this manual SYSTEM LOCATION for inspections refer to the applicable...

Страница 166: ...AUGE 3 FRONT BRAKELIGHT SWITCH 4 OIL PRESSURE SWITCH 6 BATTERY 1 IGNITION SWITCH 5 FUSE BOX I 15 CLUTCH SWITCH 14 HOR1 13 THERMO SENSOR I 12 FAN MOTOR SWITCH 11 NEUfRAL SWITCH 9 FUEL CUT 17 REAR RRAKF...

Страница 167: ...as they may create hot spots on the bulb and cause it to break If you touch the bulb with your bare hands clean it with a cloth moistened with alcohol to prevent its early failure Be sure to install t...

Страница 168: ...wise and remove it Turn the bulb counterclockwise and remove it o o J Install a new bulb in the reverse order of removal 5s i J 1Lis j 4 SOCKET 3 SCREW TAILLIGHT 1 BULB BULB REPLACEMENT Remove the scr...

Страница 169: ...ffi 1 IT ro c I 3 REQUISITE SERVICE Headlight assembly removal page 17 3 PROCEDURE Q ty REMARKS REMOVAL ORDER Meter mounting bolt Speedometer cable Meter connector Meter oasembley Installation is in t...

Страница 170: ...wire har ness 3 5 STAY 2 TERMINALS 3 WIRE HARNESS 4 NUTS Remove the screw and meter front cover 1 FRONT COVER V a i o K30 Ct 2 SCREW Remove the following two screws and tachometer trip meter reset kno...

Страница 171: ...connector and spark unit connec ik4 tor Continuity exists at all times If there is no continuity replace the main wire harness If all checks are O K replace the tachometer SC 1 SPARK UNIT CONNECTOR SI...

Страница 172: ...0 ET a f 3 S I 3zt 3se Rft3K i i 5 5 I f f j f ii 8 l i hi sEl 1 i IN fc l 9 u O o 1 s I lies 11565 I m u u tt tt s 5 J CW III CH 11 o 111 111 o s 1 1 _i r h i Q s 3 o j 5r o i 1 f nil ill 1 w ft sjiF...

Страница 173: ...engine stop switch WEAK OR NO SPARK 2 Perform spark test GOOD SPARK Mixture too rich Carburetor flooded Carburetor choke excessively closed Cylinder flooded Air cleaner dirty Faulty Purge Control Valv...

Страница 174: ...vent hole Faulty fuel pump Faulty fuel pump relay Loose broken or shorted wire or connection of pump relay 4 Accelerate lightly ENGINE SPEED INCREASES S Check ignition timing INCORRECT Faulty spark un...

Страница 175: ...l Excessive carbon build up in com bustion chamber Ignition timing too advanced Faulty spark unit Lean fuel mixture ENGINE DOES NOT KNOCK POOR PERFORMANCE AT LOW AND IDLE SPEEDS POSSIBLE CAUSE t Check...

Страница 176: ...jets CLOGGED Clogged jets t NO COLGGED JETS I 4 Check valve timing INCORRECT Camshaft not installed properly CORRECT 1 5 Check valve spring tension WEAK Faulty valve spring POOR HANDLING Check tiie a...

Страница 177: ...ft Removal lnstallation Carburetor Combination Disassembly assembly Removal lnstallation Separation Synchronization Charging System Alternator Circuit Diagram Inspection Location Clutch Installation R...

Страница 178: ...ging System Alternator Clutch Geaishift Linkage Cooling System Crankshaft Transmission Cylinder Head Cylinder Piston Electric Starter Starter Clutch Frame Body Panels Exhaust system Front Wheel Suspen...

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