Honda XR70R Скачать руководство пользователя страница 1 | Manualshive

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Содержание XR70R

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Страница 2: ...s and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel or could damage 8 vehicle or render it unsafe Please understand that those warnings could no...

Страница 3: ...erform service described in the following sections Sections 4 through 14 describe parts of the motorcycle grouped according to location Find the section you want on this page then turn to the table of...

Страница 4: ...bdenum disulfide grease containing more than 3 molybdenum disulfide NlGI t 2 or equivalent Example Molykote BR 2 plus manufactured by Dow Corning U S A Multi purpose M 2 manufactured by Mitsubishi Oil...

Страница 5: ...r W4 Ift Gasoline is extremely ffammable and s explosive under certain conditions KEEP OUT OF REACH OF CHILDREN TOOLS LUBRICATION SEAL POINTS CABLE HARNESS ROUTING EMISSION CONTROL SYSTEM EMISSION CO...

Страница 6: ...re not interchangeable with English fasteners 4 Install new gaskets O rings cotter pins and lock plates when reassembling 5 When tightening bolts or nuts begin with the larger diameter or inner bolt f...

Страница 7: ...side of the carburetor body as shown GENERAL INFORMATION 1 The frame serial number is stamped on the left side of the steering head 3 The Vehicle Identification Number VIN is located on right side of...

Страница 8: ...ystem Oil pump type Cooling system Air filtration Crankshaft type Engine dry weight Cvlinder arranoement 1 543 mm 60 7 in 1 565 mm 61 6 in 694 mm 27 3 in 877 mm 34 5 in 881 mm 34 7 in 1 055mm 41 5in 1...

Страница 9: ...et Clutch operation system Automatic centrifugal Transmission 3 speed Primary reduction 3 722 67 18 Final reduction 2 400 36 15 Gear ratio lSt 3 272 36 11 2nd 97 99 1 722 31 18 After 99 1 667 25 15 3...

Страница 10: ...learance 0 15 0 006 0 20 0 008 Bod clearance 0 10 0 21 0 004 0 008 0 27 0 011 Side clearance 0 03 0 08 0 001 0 003 0 12 0 005 FUEL SYSTEM ITEM SPECIFICATIONS Carburetor identification number PB12H Mai...

Страница 11: ...014 0 0001 0 0006 0 08 0 003 Piston ring to ring Top 0 Q15 0 050 0 0006 0 0020 0 12 0 005 groov8 clearance Second 0 015 0 05010 0006 0 0020 0 12 0 005 Piston ring end gap To 0 05 0 20 0 002 0 0081 0 5...

Страница 12: ...GENERAL INFORMATION CRANKSHAFT TRANSMISSION KICKSTARTER ITEM i I I 97 99 j i After 99 1 8 STANDARD SERVICE LIMIT...

Страница 13: ...o Honda Suspension Fluid 55 8 Fluid level 13515 3 Fluid capacity 74 eml 2 50 0 03 US OZ 2 60 O 041mo Ol r REAR WHEEL BRAKE SUSPENSION UnIt ITEM STANDARD SERVICE LIMIT i i ead depth 2 0 0 08 100 kPa 11...

Страница 14: ...MAINTENANCE Spark plug 0 1211 2 9 Oil drain bolt 12 25 2 5 lB Valve adjuster hole cap 2 30 12 1 2 9 Valve adjuster lock nut 2 5 9 0 9 6 5 Clutch adjuster lock nut B 12 1 2 9 LUBRICATION SYSTEM Oil pu...

Страница 15: ...r nut 2 10 45 4 6 33 NOTE 3 Fork bonom bridge pinch bolt 2 8 32 3 3 24 Brake lever pivot bolt 1 5 3 0 3 2 2 Brake lever pivot nut 1 5 3 0 3 2 2 Spoke 3 8C2 9 3 0 3 2 2 Front axle nut 1 12 59 6 0 43 NO...

Страница 16: ...0050300 NOTE 1 Fork seal driver 07747 0010100 NOTE 3 Fork seal driver attachment 07747 0010200 07947 1180001 Driver 07749 0010000 Valve spring compressor 07757 0010000 Valve seat cuner NOTE 1 Seat cut...

Страница 17: ...nshah sliding surface Countershaft sliding surface Transmission gear rotating surface Transmission gear teeth and shift fork groove Shift drum outer surface Shift drum lock plale sliding surface Kicks...

Страница 18: ...GENERAL INFORMATION CABLE HARNESS ROUTING FUEL TANK BAEATHERTUBE ENGINE STOP SWITCH WIRE BRAKE CABLE WIRE BANDS THROTTLE CABLE WIRE BANDS THROTILE CABLE IH iH ENGINE STOP SWITCH WIRE BRAKE CABLE 1 14...

Страница 19: ...TION COil CARBURETOR AIR VENT TUBE IGNlTION COil PRIMARYWlFlES THROTTLE CABLE SPARK PLUG WIRE CRANKCASE TUBE 97 99 IGNITION CONTROL MODULE FUEL TUBE THROTTLE CABLE ENGINE STOP SWITCH WIRE CARBURETOR D...

Страница 20: ...After 99 IGNITION COIL CARBURETOR AIR VENT TUBe SPARK PLUG WIRE CRANKCASE BREATHER TUBE After 99 IGNITION SWITCH WIRE IGNITION CONTROL MODULE THROTTLE CABLE ENGINE STOP SWITCH WIRE CARBURETOR TUBe AL...

Страница 21: ...t in the same way but it is toxic Honda Motor Co ltd utilizes lean carburetor settings as weI as other system to reduce carbon monoxide and hydorocarbons EXHAUST EMISSION CONTROL SYSTEM The exhaust em...

Страница 22: ...GENERAL INFORMATION EMISSION CONTROL INFORMATION LABEL AFTER 99 1 18 The Vehicle Emission Control Information label is attached on the rear fender VEHICLE EMISSION CONTROL INFORMATION LABEL h...

Страница 23: ...MEMO...

Страница 24: ...FRAME BODY PANELS EXHAUST SYSTEM BODY PANEL LOCATIONS NUMBER PLATE FRONT FENDER 2 0 TANK SHROUD After 2000 FUEL TANK SIDE COVER SEAT REAR FENDER...

Страница 25: ...tank and exhaust system Always replace the exhaust pipe gaskets after removing the exhaust pipe from the engine When installing the exhaust system loosely install all of the exhaust pipe fasteners Alw...

Страница 26: ...from the seat INSTALLATION Installation is in the reverse order of removaL NOTE For seat installation align the seat prongs with the frame clamps NOTE For seat installation align the seat hook with th...

Страница 27: ...k breather tube from the number plale Remove the fuel tank holder band Remove the fuel tank mounting bolts and fuel tank Installation is in the reverse order of removal TANK SHROUD AFTER 2000 REMOVAL...

Страница 28: ...ber plate Installation is in the reverse order of removal NOTE At installation align the lower grooves with the bracket tabs on the steering stem FRONT FENDER REMOVAL INSTALLATION Remove the bolt nuts...

Страница 29: ...right side cover lpage 2 2 Remove the exhaust pipe joint nuts Remove the muffler mounting bolt and exhaust pipe muffler assembly INSTALLATION Q fIIGASKET 26 N m 2 7 kgf m 20 Ibf tt 15 N m 1 5 kgf m 1...

Страница 30: ...porarily install the exhaust pipe joint nuts and mounting bolt First tighten the exhaust pipe joint nuts Tighten the exhaust pipe muffler mounting bolt to the specified torque TORQUE 26 N m 1 2 7 kgf...

Страница 31: ...e main fool peg brackeL Install the side stand pivot bolt and tighten it to the specified torque TORQUE 10 N m 1 0 kgf m 7 Ibf tt loosen the pivot bolt about 45 90 degrees Hold the pivot bolt and tigh...

Страница 32: ...MEMO...

Страница 33: ...plosive under certain conditions Work in a welf ventilared area Smoking or allowing flames or sparks in the work area or where the gasoline is stored can cause a fire or explosion When the engins must...

Страница 34: ...m t HONDA GN4 4 stroke oil or equivalent motor oil API service classification SF or SG Viscosil SAE lOW 30 1 700 100 rpm 2 0 6 0 mm 1 12 1 4 in 0 05 0 02 mm 10 002 0 001 in 0 05 0 02 rnm 0 002 0 001 i...

Страница 35: ...OTE m NANCEI REFER D F very 30 opera TO PAGE operat l on ing days about about 200 miles 1 000 miles 350 km 1 600 km I 3 5 I illfi lON NOTE 1 C 6 IG VALVE I Il P YEAR YEAR E ve _ 10 operating DRIVE CHA...

Страница 36: ...VE CLEARANCE I I I I I 3 8 m ENGINE OIL R R R R R 39 1 ENGINE OIL STRAINER SCREEN C C 3 11 0 ENGINE OIL CENTRIFUGAL FILTEA C C 3 11 1 ENGINE IDLE SPEED I I I I I I 3 12 DRIVE CHAIN NOTE 1 I l I L Ever...

Страница 37: ...completely remove the two bolts and remove the fuel valve and strainer screen Wash the fuel strainer screen in non flammable or high flash solvent Check the O ring is in good condition reinstall the...

Страница 38: ...ecessary AIR CLEANER 3 6 Remove the air cleaner housing cover mounting screws Remove air cleaner element holder and element from the housing Wash the element in non flammable or high flash point solve...

Страница 39: ...ber INSPECTION Check the following and replace if necessary rec ommended spark plug page 3 1 Insulator for damage Electrodes for wear Burning condition coloration dark to light brown indicates good co...

Страница 40: ...AUTION Do not overtighten the spark plug Install and hand lighten the new spark plug then tighten it about 1 2 of a turn after the seating washer contacts the seat of the plug hole Install the spark p...

Страница 41: ...0 U S A only TORQUE 9 N m 0 9 kgf m 6 5 Ibf ft Recheck the valve clearance Check the valve adjuster hole cap G ring is in good condition replace if necessary Coat the O rings wi th clean engine oil an...

Страница 42: ...arB8 The exhaust contains poisonous carbon monoxide gas that may cause loss ofconsciousness and lead to death Run the engine in 8n 0Plln area or with an exhaust evacuation system in an enclosed area...

Страница 43: ...recheck the oille lel Make sure there are no oil leaks ENGINE OIL STRAINER SCREEN OIL LEVEL INSPECTION Perform this Remove the right crankcase cover page 9 3 maintenance before filling the Remove the...

Страница 44: ...rk make sure the BrBS is well ventilated Never run the engine in 8n enclosed area The exhaust contains poisonous carbon monoKide gas that may cause loss of consciousness and lead to death Run the engi...

Страница 45: ...ake sure the index marks on the both adjusters are aligned with the index mark on the swingarm Tighten the rBar axle nut to the specified torque TORQUE 59 N m 6 0 kgf m 43Ibf ft Tighten the both adjus...

Страница 46: ...joint straightened SERVICE LIMIT 1 101 mm 43 3 in Installing a new chain on badly worn sprockets will cause the new chain to wear quickly Inspect the drive and driven sprocket teeth for wear or damag...

Страница 47: ...he 6 mark on the brake panel when the brake lever is applied Refer to page 12 12 for brake shoe replacement REAR BRAKE SHOES Check the brake shoes and brake drum if the arrow on the indicator plate al...

Страница 48: ...the brake cable guide bolt Loosen the lock nut and turning the adjusting nut After adjustment tighten the lock nut Tighten the brake cable guide bolt REAR BRAKE Check the brake pedal free play FREE PL...

Страница 49: ...Check the side stand spring for damage or loss of tension Check the side stand assembly for freedom of movement and lubricate the side stand pivot if necessary SUSPENSION Loose worn or damaged suspens...

Страница 50: ...ny are looseness is noted Check the action of the shock absorber by compres sing it several times Check the entire shock absorber assembly for signs of leaks damage or loose fasteners Replace damaged...

Страница 51: ...d properly secured WHEELS TIRES Tire pressure RECOMMENDED TIRE PRESSURE AND TIRE SIZE Should be checked when the tires are COLD FRONT REAR Tire pressure lOa 1 00 15 lOa 1 00 15 kPa kQf cm2 psi Tire si...

Страница 52: ...NG HEAD BEARINGS Check thaI the control cables do not interfere with handlebar o ation 3 20 Support the motorcycle securely and raise the front wheel off the ground Check that the handlebar moves free...

Страница 53: ...MEMO...

Страница 54: ...LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM AOCKEAAAM CAMSHAFT PISTON tJL f 2ii OIL PUMP THROUGH CRANKSHAFT MAINSHAFT Oil FILTEA AOTOR COUNTERSHAFT Oil STRAINER KICKSTARTEA 4 0...

Страница 55: ...or dirt to enter the engine If any portion of the oil pump is worn beyond the specified service limits replace the oil pump as an assembly After the oil pump has been installed check that there are no...

Страница 56: ...e inner and outer rotor from the oil pump body INSPECTION If any portion of Temporarily install the outer and inner rotors into the oil pump is the oil pump body worn beyond the Install the oil pump s...

Страница 57: ...0 005 in ASSEMBLY OUTER ROTOR Oil PUMP SHAFT 5 N m 10 5 kgf m 3 6Ibf ft INNER ROTOR Oil PUMP COVER Install the inner and outer rotors into the oil pump body Install the oil pump shaft aligning the fl...

Страница 58: ...ew gasket onto the oil pump body Install the oil pump into the crankcase while align ing the pump shaft groove with the cam chain guide spindle lug Install and tighten the three screws to the specifie...

Страница 59: ...MEMO...

Страница 60: ...FUEL SYSTEM 5 0 97 99 AFTER 99...

Страница 61: ...mbling fuel system parts note the location of the O rings Replace them with new ones on reassembly Before disassembling the carburetor place the suitable container under the carburetor drain tube loos...

Страница 62: ...er in CLOSE position Float valve faulty Float level too high Air jets clogged Air cleaner element contaminated Flooded carburetor 5 2 Engine stall hard to start rough idling Fuel line restricted Ignit...

Страница 63: ...r housing mounting boll After 99 Disconnect the crankcase breather tube from the air cleaner housing loosen the connecting tube band screw Remove the bolt and air cleaner housing assembly At installal...

Страница 64: ...ILDREN THROTILE VALVE Loosen the carburetor top Remove the carburetor top and throttle valve from the carburetor Remove the throttle cable from the throttle valve white compressing the throttle valve...

Страница 65: ...n screw and drain the fuel from float chamber into the approved gasoline container Disconnect the fuel tube air vent tube and drain tube from the carburetor body Loosen the carburetor connecting tube...

Страница 66: ...ir screw in and record the number of turns it takes before it seats lightly Remove the air screw and spring CAUTION Damage to the air screw seat wiff occur if the air screw is tightened agllinst the s...

Страница 67: ...rew adjustment procedure if a new air screw is installed page 5 11 12 Install the float and float valve in the carburetor body then inslall the float pin through the body and float FLOAT LEVEL INSPECT...

Страница 68: ...at chamber screws CARBURETOR INSTALLATION 5 8 CARBURETOR BODY Install the new O rings into the insulator and carbu retor body grooves Install the insulator and carburetor body to the intake manifold a...

Страница 69: ...clip on the jet needle STANDARD POSITION 3rd groove from top Install the jet needle into the throttle valve and secure it with a needle clip retainer Install the throttle valve spring onto the throttl...

Страница 70: ...pring Install the throttle valve into the carburetor body T RnTTI aligning its cut Qut with the throttle stop screw Tighten the carburetor top securely Ahar installing the carburetor check for the fol...

Страница 71: ...50 rpm or smaller that will accurately indicate 50 rpm change 1 Turn the air screw clockwise until it seats li ghtly and then back it out to the specification given CAUTION Damage to the sir screw sea...

Страница 72: ...ine until drain bolt to operating temperature 2 Turn the air screw clockwise until it seats lightly and then back it out to the specification given CAUTION Damage to the air screw seat will occur if t...

Страница 73: ...CRANKCASE BREATHER Remove the crankcase breather tube plug from the tube end and drain deposits into a suitable container then install the tube plug securely FUEL SYSTEM 5 13...

Страница 74: ...ENGINE REMOVAL INSTALLATION 12 N m 1 2 kgf m 9Ibf ft j 31 N m 3 2 kgf m 23 Ibf tt 26 N m 2 7 kgf m 20 Ibf tt 31 N m 3 2 kgf m 23Ibf ft 0 0 0 0 6 0...

Страница 75: ...ternator cam chain tensioner Section 10 Clutch Section 9 Cylinder piston Section 8 Cylinder head valves Section7 Gearshift linkage Section 9 Oil pump Section 4 The following components require engine...

Страница 76: ...e 2 2 Muffler page 2 4 Kickstarter pedal page 9 3 left crankcase cover page 10 2 Disconnect the spark plug cap Remove the intake manifold mounting bolts 97 99 Disconnect the alternator and ignition pu...

Страница 77: ...Push the rear wheel forward and fully slacken the drive chain Remove the fixing plate bolts fixing plate and drive sprocket Remove the bolts and footpeg bar Unhook the brake pedal return spring ENGIN...

Страница 78: ...mg hook 6 4 NOTE Note the direction of the hanger bolts Use a floor jack or other adjustable support to carefully maneuver the engine into place Place the engine into the frame and install the engine...

Страница 79: ...tighten the bolts to the specified torque TORQUE 12 N m 11 2 kgf m 9Ibf ft 97 99 Connect the alternator and ignition pulse generator connectors After 99 Connect the crankcase breather tube from the b...

Страница 80: ...ighten the intake manifold mounting bolts Install the spark plug cap to the spark plug Install the following left crankcase cover page 10 8 Kickstarter pedal page 9 18 Muffler page 2 5 Right side cove...

Страница 81: ...MEMO...

Страница 82: ...CYLINDER HEAD VALVES 12 N m 11 2 kgf m 9 11 N m 1 1 kgf m 8Ibf ft 12 N m 11 2 kgf m 9Ibf ft 9 N m 0 9 kgf m 6 5 Ibf ft 7 0...

Страница 83: ...and dry them by blowing them off with compressed air before inspection Camshaft lubricating oil is fed through oil passages in the cylinder head Clean the oil passages before assembling cylinder head...

Страница 84: ...scope If the performance is poor at low speeds check for white smoke in the crankcase breather tube If the tube is smoky check for a seized piston ring Section 8 Compression too low hard starting or p...

Страница 85: ...ion can be caused by Blown cylinder head gasket Improper valve adjustment Valve leakage Worn piston ring or cyfinder High compression can be caused by Carbon deposits in combustion chamber or on pisto...

Страница 86: ...The outer race should turn smoothly and quietly Also check that the bearing inner race fits tightly on the camshaft Replace the camshaft assembly if the outer race does not turn smoothly and quietly...

Страница 87: ...r head mounting bolt and cylin der head Remove the following Gasket Dowel pins Collar 14 8 mm O ring 14 5 mm DISASSEMBLY Remove the bolts and cylinder right side cover Temporarily install a 8 mm bolt...

Страница 88: ...he following during Spring retainer disassembly so Outer and inner valve springs they can be placed Valve back in their Stem seal original locations Valve spring seat INSPECTION CVLlNDER HEAD Remove c...

Страница 89: ...arm shafts for wear or damage Measure the a D of the rocker arm shaft SERVICE LIMIT 9 91 mm 0 390 in VALVE SPRING Measure the free length of the inner and outer valve springs SERVICE LIMITS Inner 31...

Страница 90: ...r detemermine if a new guide with standard dimen the valve guides sians would bring the clearance within tolerance If are replaced so replace any guides as necessary and ream to fit page 7 9 If the st...

Страница 91: ...ctes Aefaee the valve seat see below VALVE SEAT INSPECTION REFACING Clean the intake and exhaust valves thoroughly to remove carbon deposits Apply a light coating of Prussian Blue to the valve seats l...

Страница 92: ...ree cutter to remove any roughness or with a 45 degree irregularities from the seat cutler whenever 8 valve guide is rep aced 7 10 Use a 32 degree IN 30 cutter to remove the top 114 of the existing va...

Страница 93: ...hrough the valve guide and Onto the seat to make a clear pattern NOTE The location of the valve seat in relation 10 the valve face is very important for good sealing If the contact area is too high on...

Страница 94: ...SPRING SEAT STEM SEAL 2 OUTER VALVE SPRING INNER VALVE SPRING y V A L V E SPRING RETAINER VALVE COnERS Clean the cylinder head assembly with solvent and blow through all oil passages with compressed...

Страница 95: ...tic hammers as shown to seat the cotters firmly CAUTION Support the cylinder head above the work bench surlace to prevent possible valve damage Instalilhe rocker Install the rocker arms and rocker arm...

Страница 96: ...Clean off the gasket material from the cylinder sur face Install the following New O ring 14 5 mm Collar 14 8 mm Dowel pins New gasket Install the cylinder head Install the cylinder Install a new gask...

Страница 97: ...and tighten the cylinder head mounting bott Install a new O ring into the groove of the intake manifold Install and tighten the intake manifold mounting bolts Install the following MuHler exhaust pip...

Страница 98: ...onto the cylinder head Align the lab on the side cover with the stopper on the cylinder head as shown Install the 6 mm bolt with a new sealing washer onto the cylinder head and lighten it Adjust the v...

Страница 99: ...MEMO...

Страница 100: ...CYLINDER PISTON 10 N m 1 0 kgf m 7 Ibf ft 8 0...

Страница 101: ...e with the engine installed in the frame Camshaft lubrication oil is fed to the cylinder head through an orifice in the cylinder head cylinder and crankcase Be sure that this orifice is not clogged an...

Страница 102: ...engine is hard to start Blown cylinder head gasket Worn stuck or broken piston ring Worn or damaged cylinder or piston Cylinder compression is too high or engine overheats or knocks Carbon deposites o...

Страница 103: ...bolt and cylinder Remove the following Rubber packing Gasket Dowel pins PISTON REMOVAL Do nollel the Remove the piston pin clip with pliers pis on pin clips fa l Inlo the crankcas8 Press the piston pi...

Страница 104: ...ut of round at three levels in X and Y axis Take the maximum reading to determine them SERVICE LIMITS Taper 0 10 mm 0 004 in Out of round 0 10 mm 0 004 in The cylinder must be raborad and an oversize...

Страница 105: ...d 0 12 mm 0 005 in Inspect the piston for wear or damage Measure the diameter of the piston at 10 mm 0 4 in from the bonom and 90 degrees to the piston pin hole SERVICE LIMIT 46 90 mm 1 846 in Measure...

Страница 106: ...mm 10 04 in PISTON RING INSTALLATION Clean the piston ring grooves thoroughly and install the piston rings NOTE Apply oil to the piston rings Avoid piston and piston ring damage during installation I...

Страница 107: ...o not let the piston pin clips fall into the crankcase CYLINDER INSTALLATION Clean off any gasket materials from the crankcase surface Install the dowel pins new gasket and new rubber packing Coat the...

Страница 108: ...ain guide roller pin bolt to the sr specified torque AL TORQUE 10 N m 1 0 kgf m 7 Ibf ft Install the cylinder mounting bolt but do not tighten it yet Install the cylinder head and tighten the bolt and...

Страница 109: ...MEMO...

Страница 110: ...CLUTCH GEARSHIFT LINKAGE Ibf tt 13 N m 1 3 9 Ibf ft 42 N m 14 3 k gf m 31Ibf ft 3Ibf tt 4 N m 0 45 kgf m 3 9 0...

Страница 111: ...h does not disengage or the motorcycle creeps with clutch disengaged inspect the transmission oille el before servicing the dutch system SPECIFICATIONS center TORQUE VALUES Clutch outer cover screw Cl...

Страница 112: ...rect clutch adjustment Clutch plate warped Faulty clutch lifter Faulty clutch weight Incorrect engine oil weight 9 2 Hard to shift Incorrect clutch adjustment Loose stopper plate bolt Damaged stopper...

Страница 113: ...Unhook the brake pedal return spring Loosen the rear brake pedal adjusting nUl and lowar the brake pedal Remove the bolts and right crankcase cover Remove the gasket and dowel pins Remove the clutch a...

Страница 114: ...the kickstarter oil seal for damage replace if necessary REMOVAL Remove the clutch liher lever ball retainer and spring Remove the oil through and spring Remove the clutch lifter cam plate Remove the...

Страница 115: ...ls as shown TOOLS Flvwheel holder 07725 0040000 Equivalent com mercially available in U S A lock nut wrench 20 X 24 mm 07716 0020100 Extension bar 07716 0020500 Equivalent com mercially available in U...

Страница 116: ...g and primary driven gear from the mainshaft Remove the collar from the crankshaft DISASSEMBLY Remove the following Set ring Clutch plate B Clutch disc A Clutch disc B Clutch disc A Free springs Clutc...

Страница 117: ...ights and center ring INSPECTION Clutch lifter bearing Turn the inner race of the lifter bearing with your finger The bearing should turn smoothly and freely without excessive play Also check thai the...

Страница 118: ...3 mm 0 09 in Clutch disc B 3 0 mm 0 12 in Clutch plate Check each disc plate for warpage on a surface plate using a feeler gauge SERVICE LIMIT 0 20 mm 0 008 in Primary drive gear clutch center guide...

Страница 119: ...er Check the drive gear outer and clutch center for excessive wear or damage ASSEMBLY 6 N m 0 6 kgf m 4 3 Ibf ft CLUTCH OUTER DRIVE PLATE DRIVE GEAR OUTER CLUTCH PLATE A CLUTCH GEARSHIFT LINKAGE DRIVE...

Страница 120: ...ch springs onto the clutch outer bosses Install the drive plate assembly into the clutch outer aligning its bosses with the clutch springs Install the plain washers and screws Tighten the screws in a...

Страница 121: ...Clutch plate B NOTE Install the clutch disc A with its flat surface facing the clutch disc B Install the clutch plate B with its chamfered side facing the dutch disc A Install the clutch set ring wit...

Страница 122: ...e primary driven gear onto the mainshaft and secure it with the snap ring Install the clutch center guide onto the crankshaft Install the primary drive gear Install the clutch assembly onto the cranks...

Страница 123: ...n U S A lock nut wrench 20 X 24 mm 07716 0020100 Extension bar 07716 0020500 Equivalent com mercially available in U S A TORQUE 42 N m 4 3 kgf m 31 Ibf tt If the lock nut groove does not align with th...

Страница 124: ...te Install the oil through spring and oil through Install the cam plate side spring Install the ball retainer and clutch lifter lever Install the right crankcase cover page 9 17 GEARSHIFT LINKAGE REMO...

Страница 125: ...per arm and return spring Pull down the gearshift arm then pull out the gearshift spindle from the crankcase Remove the bolt and shift cam plate Remove the dowel pins and gearshift drum pins CLUTCH GE...

Страница 126: ...STALLATION InstaU the four gearshift drum pins and two dowel pins Install the stopper plale and tighten the bolt to the specified torque TOROUE 17 N m 1 7 kgf m 12Ibf ft Install the gearshift spindle...

Страница 127: ...Install the following Clutch page 9 12 Right crankcase cover see below RIGHT CRANKCASE COVER INSTALLA TION Install the clutch lifter plate adjusting bolt into the right crankcase cover while aligning...

Страница 128: ...crankcase cover SH bolts Install the kickstarter pedal and tighten the bolt Hook the return spring to the brake pedal and lower engine hanger bolt Adjust the brake pedal free plav page 3 16 Install t...

Страница 129: ...MEMO...

Страница 130: ...ALTERNATOR CAM CHAIN TENSIONER 16 N m 1 6 kgf m 12Ibf ft 23 N m 1 2 3 kgf m 17 bf ft 41 N m 4 2 kgf m 30 Ibf ft 10 0...

Страница 131: ...chain tensioner sealing bolt Cam chain tensioner pivot bolt TOOLS Universal holder Flywheel puller Flywheel puller S rin free len th TROUBLESHOOTING Excessive engine noise Worn or damaged cam chain t...

Страница 132: ...alternator and ignition pulse genera tor connectors Remove the bolt and gearshift pedal Remove the SH bolts and eft crankcase cover Hold the flywheel using the universal holder then remove the flywhe...

Страница 133: ...woodruff key 07933 GEOOOOO Not available in U S A 07933 0010000 U S A only Remove the bolt and wire damp Release the wire grommet from the crankcase groove Remove the ignition pulse generator mountin...

Страница 134: ...age 3 10 Remove the screws and stator base Remove the O rings CAM CHAIN TENSIONER REMOVAL 10 4 Remove the stator base page 10 21 Remove the sealing bolt tensioner spring and push rod Remove the pivot...

Страница 135: ...mm 0 470 in INSTALLATION Install the cam chain tensioner rolier tensioner arm and pivot bolt Tighten the pivot bolt to the specified torque TORQUE 16 N m 1 6 kgf m 12Ibf ft Install the push rod and te...

Страница 136: ...washer and bolt Tighten the bolt securely_ STATOR FLYWHEEL INSTALLATION 10 6 Check the stator base oil seal for damage replace if necessary Apply grease to the lip of the oil seal Apply engine oil to...

Страница 137: ...ely Set the wire grommet into the crankcase groove Inslall the wire clamp and tighten the bolt Clean any oil from the crankshaft taper Install the woodruff key on the crankshaft Install the flywheel b...

Страница 138: ...ghten the nut to the specified torque TOOL Universal holder 07725 0030000 TORQUE 41 N m 4 2 kgf m 30 Ibf ft Install the left crankcase cover and tighten the SH bolts Install the gearshift pedal and ti...

Страница 139: ...MEMO...

Страница 140: ...CRANKSHAFTITRANSMISSION KICKSTARTER 97 99 11 0 AFTER 99 97 99 AFTER 99...

Страница 141: ...ted to service the crankshaft transmission and kickstarter The following parts must be removed before separating the crankcase Alternator cam ch ain tensioner Seclion 10 Clutch gearshift linkage Secti...

Страница 142: ...adjustment Bent shift fork Bent fork claw Damaged shih drum cam groove Incorrect transmission oil weight Transmission jumps out of gear Worn gear dogs and slots Bent fork shaft Broken shift drum stopp...

Страница 143: ...arating the crankcase Remove the snap ring from the kickstarter spindle Unhook the return spring and remove the retainer and return spring Remove the rubber cap Hold the shift drum and remove the shif...

Страница 144: ...e the left crankcase down Separate the right and left crankcase halves Remove the gasket and dowel pins CRANKSHAFT REMOVAL 11 4 Remove the crankshaft from the left crankcase If necessary remove the ca...

Страница 145: ...ical points as shown SERVICE LIMIT 0 05 mm 0 002 in Turn the outer race of the crankshaft bearing with your finger The bearing should turn smoothly and quietly Also check that the inner race of the be...

Страница 146: ...measuring locations are shown in the illustra tion SERVICE LIMIT 0 10 mm 0 004 in INSTALLATION Install the guide sprocket and guide spindle Install the crankshaft into the left crankcase TRANSMISSION...

Страница 147: ...20 10 mm 0 791 in Af sr 99 M 2 17 10mm O 673inj Cl 23 10 rnm lO 909 in C3 20 10 mm 0 791 in Measure the I D and 0 0 of Cl gear bushing SERVICE LIMITS 97 99 0 0 19 93 mm 0 785 in 1 0 11 08 mm 0 672 in...

Страница 148: ...f the mains haft and countershaft SERVICE LIMITS At M2 gear 16 950 mm 0 6673 in At Cl gear 19 94 mm 0 785 in TRANSMISSION ASSEMBLV Assembly is in the reverse order of removal 97 99 C3 25T C2 GEAR 31T...

Страница 149: ...NTERSHAFT M3 GEAR 21T M2 GEAR 15T MAINSHAFT M1 GEAR 1lT GEARSHIFT DRUM DISASSEMBLY PIN Remove the guide pin clips Remove the guide pins then remove the shift forks Inspect the shift drum grooves for w...

Страница 150: ...ARTER 11 10 Measure the shih fork I D SERVICE LIMIT 34 14 mm 1 344 in Measure the shift fork claw thickness SERVICE LIMIT 4 60 mm 0 181 in SHIFT DRUM ASSEMBLY 97 99 SHIFT DRUM RIGHT SHIFT FORK WASHER...

Страница 151: ...HIFT FORK SHIFT DRUM LEFT SHIFT FORK GUIDE PIN Install the shift forks onto the gearshift drum Install the guide pins and secure them with clips If the washer has been removed install the new washer a...

Страница 152: ...and quietly Also check that the bearing outer race fits tightly in the crankcase Remove and discard the bearing if the race does not turn smoothly quietly or fits loosely in the crankcase Remove the c...

Страница 153: ...40400 Apply grease to the new countershaft oil seal lip Install the counterhsaft oil seal TRANSMISSION INSTALLATION Apply clean engine oil to the transmission gears and shift drum Assemble the mainsha...

Страница 154: ...LV Remove the washer Remove the snap ring and remove the starter ratchet and ratchet spring Remove the snap ring washer and starter pinion gear INSPECTION Check the kickstarter spindle for bem Check t...

Страница 155: ...ng with the groove in the left crankcase as shown CRANKCASE ASSEMBLY Clean the crankcase mating surfaces before assem bling NOTE Dress the surfaces with an oil stone if necessary to correct any minor...

Страница 156: ...se gasket slays m place 11 16 Install and tighten the crankcase bolts in a criss cross pattern in 2 3 steps Install the crankcase breather tube and cam chain Install the washer and bolt to the shift d...

Страница 157: ...ICKSTARTER Install the rslainer Install the return spring and retainer onto the with Its tab with kickstarter spindle Ihe groove in lhe crankcase Install the snap ring into the groove on the kickstart...

Страница 158: ...FRONT WHEEL BRAKE SUSPENSION STEERING 32 N m 3 3 kgf m 24 Ibf ft 12 0 o l I I I 74 N m 7 5 kgf m 54Ibf ft 10 N m 1 0 kgf m 7 Ibf ft 23 N m 2 3 kgf m 17lbf ft I 59 N m 6 0 kgf m 43Ibf h...

Страница 159: ...er bolt Handlebar lower holder nul Fork bottom bridge pinch bolt Brake lever pivot boh Brake lever pivot nut Spoke nipple Front axle nut Front brake arm pinch bolVnut Fork bolt Fork cap Fork socket bo...

Страница 160: ...Worn swingarm pivot components Front wheel wobbling Bent rim Worn front wheel bearings Faulty tire Unbalanced tire and wheel 12 2 07701 0020200 Commercially available in U S A 07746 0050100 T Commerc...

Страница 161: ...onnect the thronle cable end from the throttle pipe and remove the housing Remove the throttle pipe from the handlebar Slide the dust cover off from the brake lever pivot Disconnect the brake cable fr...

Страница 162: ...bar lower holders INSTALLATION Install the lower holders onto the top bridge Temporarily install the nuts but do not tighten them yet Place the handlebar onto the lower holders align ing the punch mar...

Страница 163: ...lodry for an hour before usmg Place the brake lever bracket onto the handlebar Install the holder with its punch mark facing up Align the mating surface of the bracket with the punch mark on the hand...

Страница 164: ...le cable to the throttle pipe Install the throttle housing by aligning its locating pin with the hole in the handlebar Align the hooks between the housing and cover in stall the housing cover Tighten...

Страница 165: ...ping power Discard contaminated shoes Bnd clean B contaminated drum with a high quality brake degreasing agent Support the motorcycle securely using a safety stand or a hoist Disconnect the brake cabl...

Страница 166: ...ce fits tightly in the hub Always replace the Remove and discard the bearings if they do not bearings in pairs turn smoothly quietly or if they fit loosely in the hub 12 8 Install the new bearings int...

Страница 167: ...t commercially available in U S A 07746 0050100 Equivalent commercially available in U S A RIGHT WHEEL BEARING 6201 U DUST SEAL CAUTION Never install the old bearings Once the bearings have been remov...

Страница 168: ...ace to the side of rim is 12 0 1 mm 10 47 0 04 in as shown TOOL Spoke wrench 4 5 X 5 1 mm 07701 0020200 Equivalent com mercially available in U S A TORQUE 3 N m 0 3 kgf m 2 2 Ibf ft Check the rim runo...

Страница 169: ...nt axle from the right side Hold the axle and temporarily tighten the axle nut Install the brake cable to the brake panel Install the spring and connect the cable end to the brake arm Adjust the front...

Страница 170: ...t wheel page 12 7 INSPECTION Measure the front brake drum I D SERVICE LIMIT 96 0 mm 3 78 in Measure the brake lining thickness SERVICE LIMIT 2 0 mm 0 08 in DISASSEMBLY Remove the brake shoes and sprin...

Страница 171: ...AAKEARM 10 N m 1 0 kgf m 7Ibf ft Apply grease to the anchor pin and brake cam Install the brake cam into the brake panel Apply oil to the dust seal and install it onto the brake panel Install the wear...

Страница 172: ...he brake arm pinch bolt and tighten the nut to the specified torque TORQUE 10 N m 11 0 kgf m 7 Ibf ft Install the brake shoes and springs INSTALLATION Install the brake panel into the left wheel hub p...

Страница 173: ...ottom pinch bolt Loosen the fork bolt but do not remove it yet loosen the fork bottom pinch bolt and remove the fork leg OISASSEMBLY Remove the fork bolt The fork bolt is under spring pressure Use caf...

Страница 174: ...lider in a vice with soft jaws or a shop towel If the fork piston Remove the fork socket bolt with a hex wrench tt rns with the socket bolt tempo rarily install the fork spring and for bolt 12 16 Pull...

Страница 175: ...e length SERVICE LIMIT 396 4 mm 15 61 in Fork tube slider piston Check the fork tube fork slider and fork piston for score marks and excessive or abnormal wear Check the fork piston ring for wear or d...

Страница 176: ...IMIT 0 20 mm 0 008 in ASSEMBLY FORK TUBE DUST SEAL STOPPER RING OIL LOCK PIECE Before assembly wash all parts with a high flash or non flammable solvent and wipe them dry Install the rebound spring an...

Страница 177: ...a new sealing washer into the fork piston rarify install the fork spring ana TORQUE 20 N m 2 0 kgf m 14 Ibf ft fork bolt Apply fork fluid to the oil seal lips then install it into the fork slider with...

Страница 178: ...tube several times to remove trapped air from the lower portion of the fork tube Compress the fork leg fully and measure the oil level from the top of the fork tube FORK OIL LEVEl 135 mm 5 3 in Pull...

Страница 179: ...op bolt tighten the bolt to the specified torque TORQUE 23 N m 2 3 kgf m 17 Ibf h Tighten the fork bottom pinch bolt to the specified torque TORQUE 32 N m 3 3 kgf m 24Ibf ft Install the front wheel pa...

Страница 180: ...stem Lower bearing 07702 0020001 BEARING RACE REPLACEMENT Always rep ace the Drive out the upper and lower bearing outer races bearings and using the special tool faces 8S a set 12 22 TOOL 8all race r...

Страница 181: ...pply grease to new dust seal lips and install it over the steering stem Install a new lower bearing inner race using a spe cial tool and a hydraulic press TOOL Steering stem driver 07946 GC40000 Steer...

Страница 182: ...steering stem right and left lock la lock fiv8 times to seat the bearings Make sure the steering stem moves smoothly without play or binding then loosen the top thread Retighten the top thread to the...

Страница 183: ...MEMO...

Страница 184: ...REAR WHEEL BRAKE SUSPENSION 34 N m 3 5 kgf m 25Ibf h 39 N m 4 0 kgf m 29 Ibf tt 59 N m 6 0 kgf m 43 Ibf tt 34 N m 3 5 kgf m 25 Ibf ft 10 N m 1 0 kgf m 7 Ibf tt 13 0...

Страница 185: ...r brake arm pinch bolt nut Swingarm pivot bolt nut Ii i Shock absorber upper mounting bolt nut Shock absorber lower mounting bolt nut TOOLS Spoke wrench 4 5 x 5 1 mm Bearing remover shaft Bearing remo...

Страница 186: ...heel bearings Tire pressure too low Faulty lire Unbalanced tire and wheel Hard suspension Tire pressure too low Bent damper rod Faulty swingarm pivot bushings Damaged swingarm pivot bushings Bent swin...

Страница 187: ...scon necllhe rear brake rod from the brake arm Remove the axle nut Push the rear wheel forward Derail the drive chain from the driven sprocket Remove the axle from the left side and remove the feaf wh...

Страница 188: ...bearings into the hub using the special tools page 13 6 Wheel rim runcut Check the rim runcut by placing the wheel in a turn ing stand Spin the wheel slowly and read the runcut using a dial indicator...

Страница 189: ...e bearing out of the wheel hub Remove the distance collar and drive out the other bearing TOOLS Bearing remover head 12 mm 07746 0050300 Bearing remover shaft ASSEMBLY Equivalent commercially avail ab...

Страница 190: ...46 0040200 Place the rim on the work bench Place the hub with the left side down and begin lacing with new spokes Adjust the hub poSition so that the distance from the hub left end surface to the side...

Страница 191: ...arm boss Install the drive chain over the driven sprocket Apply thin layer of grease to the a le Install the axle and right drive chain adjuster from the right side Install the left drive chain adjust...

Страница 192: ...adjusting nut Adjust the brake pedal free play page 3 16 REAR BRAKE REMOVAL 13 8 Remove the brake panel from the rear wheel page 13 3 INSPECTION Measure the rear brake drum 1 0 SERVICE LIMIT 96 0 mm...

Страница 193: ...ate dust seal and brake cam ASSEMBLY BRAKE PANEL SPRINGS BRAKE SHOES Apply grease to the anchor pin and brake cam Install the brake cam into the brake panel REAR WHEEL BRAKE SUSPENSION N m 1 0 k m 7 I...

Страница 194: ...een the arm and the brake cam Install the brake arm pinch bolt and tighten the nut to the specified torque TORQUE 10 N m l a kgf m 7Ibf h Install the brake shoes and springs INSTALLATION Install the b...

Страница 195: ...ushings for damage Inspect all the other parts for wear or damage INSTALLATION Instali lhe shock absorber into the frame Install the upper and lower mounting bolts and nuts Tighten the upper mounting...

Страница 196: ...olts nuts and drive chain guard Remove the shock absorber lower mounting baltl nut Remove the swingarm pivot nut bolt and swing arm Remove the bolt nut and drive chain slider INSPECTION Inspect the sw...

Страница 197: ...hten the nut to the specified torque TORQUE 34 N m 3 5 kgf m 25 Ibf ft Install the drive chain guard bolts and washers and tighten the bolts Install the drive chain case and tighten the bolts Install...

Страница 198: ...sher and brake pedal rod Remove the coner pin and joint pin then separate the brake rod from the brake pedal ASSEMBLY INSTALLATION Nore he Install the brake rod to the brake pedal IOs sllallon directi...

Страница 199: ...a new cotter pin Hook the return spring to the lower engine hanger bolt Install the spring OniO the brake rod Installthe joint pin onto the brake arm Push down the brake pedal and install the brake r...

Страница 200: ...NUITY ENGINE STOPSW IG E RUN OFF COLOR B N G 81 Slack W te Y Yelow R lied IIu Bt G G n 14 0 ALTERNATOR l n O W G O Y G Pi IGNITION IGNITION CONTROL I COIL MODULE U SPARK PLUG G IGNITION CmlTRC LMODUlE...

Страница 201: ...COIL After 99 14 0 14 2 14 4 14 5 14 8 ENGINE STOP SWITCH IGNITION SWITCH SPARK PLUG ALTERNATOR _ 0 allWG IGNITION CONTROL MODULE ENGINE STOP SWITCH IGNITION SWITCH AFTER 99 IGNITION TIMING IGNITION C...

Страница 202: ...en servicing the ignition system always follow the steps in the troubleshooting sequence on page 14 4 The ignition timing does not normally need to be adjusted since the Ignition Control Module lCM is...

Страница 203: ...TOOLS Peak voltage tester U S A only or Peak tollage adaptor IGNITION SYSTEM 07HGJ 0020100 not available in U S A with commercially available digital multimeter impedance 10 M Q DCV minimum 14 3...

Страница 204: ...peak voltage adaptor or peak voltage tester 1 Faulty exciter coil measure the peak voltage 8 Faulty ignition pulse generator measure the peak vol tage 9 Faulty ICM when above No 1 8 are normal Peak vo...

Страница 205: ...11 11 or Peak voltage adaptor 07HGJ OO20100 Inot available in U S A with commercially availa ble digital multimeter limpedance 10 MQ IDCV minimum IGNITION COIL PRIMARY PEAK VOL TAGE f jiW l ij Avoid t...

Страница 206: ...ooting chart on page 14 4 IGNITION PULSE GENERATOR PEAK VOLTAGE NOTE Check cylinder compression and check that the spark plug is installed correctly Remove the seat and side covers page 2 2 3 Disconne...

Страница 207: ...ems are normal the ignition pulse generator is faulty See section 10 for igni tion pulse generator replacement ALTERNATOR EXCITER COIL PEAK VOLTAGE NOTE Check cylinder compression and check that the s...

Страница 208: ...n circuit or loose connection If both peak voltages measure are abnormal check each item in the troubleshooting chart page 14 4 If all items are normal the alternator exciter coil is faulty See sectio...

Страница 209: ...ION SWITCH AFTER 99 INSPECTION Disconnect the ignition switch connectors Check for continuity at the connectors on the ignition switch side There should be no continuity when the ignilion switch is in...

Страница 210: ...usness and lead to death Run the engine in an open area or with an exhaust evacuation system in an enclosed area Warm up the engine Stop the engine and remove the left crankcase cover page 10 2 Read t...

Страница 211: ...GINE STOP SW IG E RUN OFF C COLOR BIW G 81 Black W White Y Yellow R Red B u Blue G Greell BIJW G B IN BIIY G G BI R SulY IGNITION IGNITION CONTROL COIL MODULE SPARK PLUG o B u Y SIIA B ulY SIIR IGNITI...

Страница 212: ...OP IGNITION SW SW I IG E IG RUN ON OFF10 ro OFF 10 ctlL OR BLI I G COL OR IBlI I 81 Black R Red Y Yellow W White Bu Blue G Green E ro G BIIW G BVY BVY G BIIA T IGNITION CONTROL MODULE SPARK PLUG IGNIT...

Страница 213: ...le 16 4 16 4 Broken or shorted spark plug wire J Remove and inspect spark plug I Good j Faulty ignition pulse generator Faulty engine stop switch Loose or disconnected ignition sys tem wires Wet plug...

Страница 214: ...air cleaner Erne speed in oase ____ _____ __ _______ _ i Z reathertube 5 Check ignition timing Incorrect Faulty ignition control module I Faulty ignition pulse generator Correct j 6 Test cylinder com...

Страница 215: ...odule Lean fuel mixture POOR PERFORMANCE AT LOW AND IDLE SPEED 1 Check carburetor air screw adjustment I Correct I Possible cause Incorrect See section 5 2 Check for leaking intake pipe Leaking Loose...

Страница 216: ...rly I Correct j 4 Check ignition timing Incorrect Faulty ignition control module I Faulty ignition pulse generator Correct j 5 Check valve spring Weak Faulty spring j Not weak POOR HANDLING Possible c...

Страница 217: ...ARRESTER 3 18 EMISSION CONTROL SYSTEM AFTER 99 1 17 SPARK PLUG 3 7 ENGINE IDLE SPEED 3 12 SPECiFiCATIONS 4 ENGINE INSTALLATION 6 4 STATOR FLYWHEElINSTAlLATION 10 6 ENGINE OIL 3 9 STEERING HEAD BEARIN...

Страница 218: ...INDEX VALVE CLEARANCE 3 8 WHEELSfTIRES 3 19 WIRING DIAGRAM 15 1 17 2...

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