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.----- IMPORTANT SAFETY NOTICE --------.

Indicates a strong possibility of severe personal injury or death if instructions are not followed.
CAUTION: Indicates a possibility of eqiupment damage if instructions are not followed.
NOTE: Gives helpful information.

Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. It is
important to note that this manual contains some warnings and cautions against some specific service methods which
could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand
that those warnings could not cover all conceivable w ays in which service, whether or not recommended by Honda,
might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda investigate all
such ways. Anyone using service procedures or tools, whether or not recommended by Honda, must satisfy himself
thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected.
HOW TO USE TH IS MANUAL CONTENTS
Follow the Maintenance Schedule (Section 3)
recommendations to ensure that the vehicle is GENERAL INFORMATION
in peak operating condition and the emission
levels are within the standards set by the U.S. LUBRICATION
Environmental Protection Agency and Califor
nia Air Resources Board. Performing the first MAINTENANCE
scheduled maintenance is very important. It
compensates for the initial wear that occurs FUEL SYSTEM
during the break-in period.
COOLING SYSTEM
Sections 1 through 3 apply to the whole
motorcycle, while sections 4 through 1 9
ENGINE REMOVAL/INSTALLATION
describe parts of the motorcycle, grouped ac
w
cording to location.
CLUTCH/GEARSHIFT LINKAGE

Find the section you want on this page, then
turn to the table of contents on the first page
of that section.
orii ======
.
ALTERNATOR/STARTER CLUTCH

CYLINDER HEADIVALVE
Most sections start with an assembly or
system illustration, service l nformtion and CYLINDER/PISTON
troubleshooting for the section. The subse
quent pages give detailed procedures.
CRANKSHAFT/TRANSMISSION

If you don't know the source of the trouble,


FRONT WHEEL/SUSPENSION/STEERING
go to section 20, TROUBLESHOOTING. (I)
0 ======
en


REAR WHEEL/BRAKE/SUSPENSION
ALL INFORMATION, ILLUSTRATIONS, DI ======
0
RECTIONS AND SPECIFICATIONS INCLUDED IN HYDRAULIC DISC BRAKE
THIS PUBLICATION ARE BASED ON THE LATEST
PRODUCT INFORMATION AVAIL ABLE AT THE
BATTERY/CHARGING SYSTEM
TIME OF APPROVAL FOR PRINTING. HONDA
MOTOR CO., L TO. RESERVES THE RIGHT TO
MAKE CHANGES AT ANY TIME WITHOUT
NOTICE AND WITHOUT INCURRING ANY OBLI
GATION WHATEVER. NO PART OF THIS PUBLI ELECTRIC STARTER
CATION MAY BE REPRODUCED WITHOUT
WRITTEN PERMISSION.
LIGHTS/METER/SWITCHES

HONDA MOTOR CO., LTD. WIRING DIAGRAM


SERVICE PUBLICATIONS OFFICE
TROUBLESHOOTING

INDEX

Date of Issue: June, 19 9 4


HONDA MOTOR CO . , LTO.
1 . GEN E RAL INFORMATION
G E N ERAL SAFETY 1 -1 TOOLS 1 -8

S ERVI C E R U LES 1 -1 CABLE & HARNESS ROUTING 1-10

M O D E L I D EN T I F I CATI O N 1 -2 EMISSION CONTROL SYSTEMS 1 -21

SPECIFICATI O N S 1 -3 EMISSION CONTROL I N FORMATION


LABELS 1 - 22
T O RQ U E VAL U ES 1 -5

GENERAL SAFETY

If the engine must be running to do some work, make sure the Gasoline is extremely flammable and is explosive under certain
areals well-ventilated. Never run the engine in an enclosed conditions Work in a well ventilated area with the engine
area. The exhaust contains posisonous carbon monoxide gas stopped. Do not smoke or allow flames or sparks in the work
that may cause loss of consciousness and lead to death. area or where gasoline is stored.

The battery generates hydrogen gas which can be highly explo The battery electrolyte contains sulfuric acid. Protect your
sive. Do not smoke or allow flames or sparks near the battery, eyes, skin and clothing. In case of contact, flush thoroughly
especially while charging it. with water and call a doctor if electrolyte gets in your eyes.

CAUTION :
Inhaled asbestos fibers have been found to cause respiratory Used engine oil may cause skin cancer if repeatedly left in con
disease and cancer. Never use an air hose or dry brush to clean tact with the skin for prolonged periods. A lthough this is
brake assemblies. Use an OSHA-approved vacuum cleaner or unlikely unless you handle used oil on a daily basis, it is still
alternate method approved by OSHA designed to minimize adviseable to thoroughly wash your hands with soap and
the hazard caused by airborne asbestos fibers. water as soon as possible after handling used oil.

SERVICE RULES
1. Use genuine H O N DA or HON DA-recommended parts and lubricants or their equivalents . Parts that don ' t meet H O N DA ' s
design specifications may damage to the vehicle .
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the vehicle . Metric bolts, nuts, and screws are not i nterchangeable with English fas
teners.
4. I nstal l new gaskets, 0-rings, cott e r pins, and lock plates when reassembling .
5. When tightening bolts or nuts, beg i n with the larger-diameter or inner bolts first. Then tighten to the specified torque diag-
onally in 1-5 steps, u nless a particular sequence is specified .
6. Clean parts in non-flammable or h i gh flash point solvent upon disassembly.
7. Lubricate a ny sliding surfaces before reassembly.
8. After reassembly, check all parts for proper installation and operation .

1 -1
GENERAL I N F O RMATION

MODEL I DENTI FICATION

(1 ) VEHI CLE I DENTIFICATIO N N U M BE R

The vehicle identification number (VIN) is attached on the


left side of the steering head .

The frame serial number i s stamped o n the right side o f the The engine serial number is stamped on the right crank
steering head. case below the rear cylinder.

(5) COLOR LAB E L

The carburetor identification numbers are on the carbure The color label is attached on the frame under t h e seat.
tor body i ntake side. When ordering a color coded part, always specify its desig
nated color code.

1 -2
G E N ERAL I N FO R MATIO N

SPECIFICATIONS

ITEM S PECI F I CATIO N S


DIME N S I O N S Overall length 2 , 3 1 0m m (90 . 9 in)
Overall width '88 , '89 , ' 9 1 -'94: 7 60mm (29 . 9 in)
After' 94 : 890mm ( 3 5.0 i n )
Overall height 1 , 1 25 m m (44.3 i n )
Wheelbase 1 , 60 5 m m (63 . 2 i n )
Seat height 6 9 0 m m ( 2 7 . 2 in)
Footpeg height 28 5 m m ( 1 1 .2 in)
G ro u n d clearance 1 40mm ( 5.5 in)
Dry weight '88 , ' 89 , ' 9 1 -93 : 1 9 6 kg (432 1b)
'94 : 1 99 kg (439 lb)
After'94 (Standard type) : 1 99 kg (43 9 1b)
After' 94 ( Delux type) : 202kg (445 lb)
Curb weight ' 8 8 , '89 , ' 9 1 -93 : 207 kg (456 lb)
'94 : 2 1 3 kg (470 lb)
After' 94 ( Standard type) : 2 1 3 kg (470 lb)
After' 94 ( Deluxe type) : 2 1 6 kg (47 6 lb)
After'94 ( Standard/California type) : 2 1 4kg (472 lb)
After'94 ( Deluxe/California type) : 2 1 7 kg (478 1b)
FRAM E Type Double cradle
Front suspension , travel Telescopic fork, 1 46 . 5mm ( 5 . 7 7 in)
Rear suspension , travel Swingarm, 90mm (3. 5 in)
Front tire size 1 00/90- 1 9 5 7 S
Rear tire size 1 7 0/80- 1 5 M/C 7 7 S
Cold tire U p to maximum Front 200 kPa (2.00 kg/cm 2 , 29 psi)
pressu re vehicle capacity Rear 250 kPa (2.50 kg/cm2,36 psi)
U p to 90 kg Front 200 kPa (2 . 00 kg/cm2 , 29 psi)
(200 l bs) load Rear 200 kPa (2.00 kg/cm2,29 psi)
Front b ra ke Hydraulic single d isc
Swept a rea '88 , '89 , ' 9 1 -'93 : 448cm 2 ( 6 9 . 4 sq in)
After'93: 482 . 3cm 2 (74 . 8 sq in)
Rear brake M echanical leading & trailing
Swept a rea 20 1 cm 2 (3 1 .2 sq in)
Fuel capacity ' 8 8 , '89 , ' 9 1 -'93 : 9 . 0 liters (2 . 4 US gal , 2.0 Imp gal)
After' 9 3 : 1 1 .0 liters (2.9 U S gal ,2.4 Imp gal)
Fuel reserve capacity ' 88 , ' 89 , '9 1 -' 9 3 : 1 .9 liters (0.5 U S gai, 0.42 Imp gal)
After' 93 3.4 liters (0.9 U S gai , O. 74 I m p gal)
Caster angle 3 5'
Trail 1 64mm ( 6.5 in)
Fork leg o i l capacity '88 , ' 89 : 463cc ( 1 5.7 U S oz, 1 3 . 0 Imp oz)
' 9 1 -'93 : 468cc ( 1 5 . 8 US oz, 1 3 . 2 1 m p oz)
After' 93 : 449cc ( 1 6 . 9 US oz, 1 5 . 8 Imp oz)
ENGINE Type Water cooled 4-stroke SO H C
Cylinder a rrangement 52' V2 cylinders
Bore a n d stroke 7 5 . 0x6 6.0mm (2 . 9 5x2.60 in)
Displacement 583cc ( 3 5 . 5 cu-in)
Compressio n ratio 9 .2: 1
Valve train Silent, m u lti-link chain d rive and O H C with rocker arms
Oil capacity 2 . 8 lit (2 . 94 U S qt,2.46 I m p qt) after d isassem bly
2 . 1 lit (2.2 1 US qt, 1 .85 Imp qt) after d raining
Lu b ricatio n system Forced pressu re and wet su m p
Air filtratio n Paper filter
Cylinder compression 1 , 324 kPa ( 1 3. 5 kg/cm2 , 1 92 psi)

1 -3
G E N ERAL I N FO RMATIO N

ITEM S PECI F I CATI O N S


I ntake valve O pens 1 0" ( BTDC) at 1 mm lift
Closes 3 0" (AB DC)
Exhaust valve O pens 3 0" ( B B DC)
ENGINE Closes 1 0 (ATDC)
Valve clearance (cold) intake 0. 1 50.02m m (0.0060 . 0008 in)
exhaust 0.200.02mm (0.0080 . 0008 in)
Engine d ry weight '88 , '89 , ' 9 1 -'93 : 6 1 kg ( 1 34 1b)
After'9 3 : 62kg ( 1 3 6 . 7 lb)
After' 94 (standard type) : 6 1 kg ( 1 34 1b)
After' 94 ( Deluxe type) : 64kg ( 1 4 1 lb)
CAR B U R ETO R Type Piston valve,dual carbu retor
I . D. n u m ber See page 4- 1
Main jet F R O NT:# 1 1 5 R EAR:# 1 1 5
Pilot screw opening See page 4- 1 5
Float level 7 .0 m m ( 0.28 in)
Idle speed 1 ,200 1 00 rpm
D R IVE TRAI N Clutch Wet,mu lti-plate
Transmission 4-speed constant mesh
Primary redu ction 1 .8 8 8 ( 6 8/3 6 )
Final reductio n 2.7 50 (44/ 1 6 )
Gear ratio I 2. 5 7 1 ( 3 6/ 1 4)
Gear ratio II 1 . 700(34/20)
Gear ratio Ill 1 .227 (27 /22)
G ea r ratio IV 0.9 3 1 (27 /29 )
Gear shift pattern Left foot o perated return system, 1 -N -2-3-4
E LECT R I CAL Ignitio n Battery ignition ( Full transistor)
Ignition timing I n itial '88, ' 8 9 , ' 9 1 -' 9 3 : 6.2 BTDC at idle
After ' 9 3 : 6 . 5" BTDC at idle
Full advance 30" BTDC at 6,000 rpm
Alternator 345W/5,000 rpm

----
B attery capacity 1 2V BAH
S pa rk plug -----------------------------------,------------------- NGK N I P PO N D ENSO
Standard D PR B EA-9 X24 E P R - U 9
For cold climate D P R 7 EA-9 X22EPR-U9
( B elow 5" C,4 1 " F)
For extended high speed D P R 9 EA-9 X27 E P R-U 9
riding
Spark plug gap 0.8-0.9 m m ( 0.03 1 -0.03 5 i n )
Fuse Main 30 A
Sub 1 0 AX3, 1 5 AX 1
Starting system Electrical starter
H eadlight 1 2 v 60/ 5 5 w
Turn signal light Front 1 2 V 32/3 C P (23/8 W )X2 S A E No. 1 034
Rear 1 2 V 32 C P(23 W)X2 SAE N o. 1 0 7 3
B ra ke & taillight 1 2 V 32/3 C P (23/8 W)X2 S A E No. 1 034
M eter light 1 2 v 3.4 w
Indicator light Neutral 1 2 V 1 .7 W
High beam 1 2 V 1 .7 W
Tu rn signal 1 2 V 1 .7 W
Licence light 1 2 V 4 CP
Firing o rder Front(2)- R ear( 1 )308"

1 -4
G E N ERAL I N FO RMAT IO N

TORQU E VALU ES
ENG I N E

Thread dia . Torque


ITEM Q'ty Remark
(mm) m ( kg-m , ft-lb)
Cylinder head cover bolt 4 6 1 0 ( 1 . 0 , 7 . 2) Special bolt
Camshaft holder bolt 6 8 23 (2 . 3 , 1 7 )
nut 2 8 23 (2 . 3 , 1 7 )
bolt 4 6 1 0 ( 1 . 0 , 7 . 2)
Cylinder head n ut 8 10 48 (4 . 8 , 3 5 )
bolt 2 8 23 (2 . 3 , 1 7 )
nut 4 8 23 (2 . 3 , 1 7 )
bolt 2 6 1 0 ( 1 . 0 , 7 . 2)
Camshaft sprocket bolt 4 7 23 (2 . 3 , 1 7 ) Apply locking agent
Primary d rive gear bolt 1 12 90 ( 9 . 0 , 6 5 ) U BS bolt
Flywheel bolt 1 12 1 30 ( 1 3 . 0 , 94) U BS bolt left hand threads
Connecting rod bearing cap n ut 4 8 34 (3 . 4 , 25 ) Apply oil to t h e threads
Clutch lock n ut 1 18 1 30 ( 1 3 . 0 , 94)
Oil pressure switch 1 - 1 2 ( 1 . 2 , 9) Apply sealant
Spark plug 4 12 1 4 ( 1 . 5 , 1 0)
Oil d rain bolt 1 14 3 5 (3 . 5 , 25)
Starter clutch torx bolt 6 8 30 (3 . 0 , 22) Apply locking agent
1 6 1 5(1 .5, 1 1 ) Flange socket bolt . Apply lock-
Oli pump d riven sprocket
ing agent .
Oil pass pipe bolt 2 7 1 0 ( 1 . 0 , 7 . 2)
1 8 23 (2 . 3 , 1 7 )
Valve adjustin g screw lock n ut 6 7 23 (2 . 3 , 1 7 ) Apply oil
Gearshift retu rn spring pin 1 8 26 (2 . 6 , 1 9)
Starter motor cable nut 1 6 1 0 ( 1 . 0 , 7 . 2)
Clutch lifter plate bolt 4 6 1 0 ( 1 . 0 , 7 . 2) Flange bolt
Cam chain tensioner bolt 4 6 1 0 ( 1 . 0 , 7 . 2) Flange bolt
Oil filter 1 20 1 0 ( 1 . 0 , 7 . 2)
Drive sprocket bolt 2 6 1 0 ( 1 .0, 7 .2)
Timing hole cap 1 22 3 . 5 (0 . 3 5 , 2 . 5 ) Apply g rease t o the threads
Crankshaft h ole cap 1 30 1 5(1 .5, 1 1 ) Apply g rease to the threads
Cylinder stu d bolt ' 88 , ' 8 9 , ' 9 1 -' 9 5 : 8 10 30-50 (3 . 0-5 . 0 .
22-3 6 )
2 8 20-30 (2 . 0-3 . 0 ,
1 4-22)
Drum stopper plate bolt 1 - 1 2 ( 1 . 2 , 9) Apply locking agent .
Stator bolt 4 6 1 2 ( 1 . 2 , 9) Apply locking agent .
Stator wire clamp bolt 2 6 1 2 ( 1 . 2 , 9) Apply locking agent .
Right cra n kcase cover bolt 13 6 1 2 ( 1 . 2 , 9)
Left crankcase cover bolt 10 6 1 2 ( 1 . 2 , 9)

1 -5
G E N E RA L I N FO RMATIO N

FRAM E
Thread dia. Torque
ITEM O'ty Remark
(mm) N m ( Kg-m,ft-lb)
Steering stem nut 1 24 1 05 ( 1 0.5,7 6 )
Steeri ng bearing adjustment n ut 1 26 25 (2.5, 1 8 ) See page 1 2-23
Fork top pinch bolt 2 7 1 1 ( 1 . 1 ,8 )
Fork bottom pinch bolt 2 10 5 0 ( 5 .0,3 6 ) Apply o i l t o the threads
Front axle 1 18 7 5 ( 7 . 5,54)
Front axle pinch bolt 2 7 22(2.2, 1 6)
Rear axle nut 1 16 90(9.0, 6 5 )
B ra ke torque rod nut 8 27 (2.7,20)
'88, ' 8 9, ' 9 1 - ' 93, After '94: 2 8 22(2.2, 1 6)
'94.: 2 8 27 (2.7,20)
Middle brake a rm 1 8 27 (2.7,20)
M id d le rod joint n ut After ' 9 4 : 2 6 9 (0.9, 6 . 5 )
Caliper mounting bol '88,'89,' 9 1 -'93: 2 8 27 (2.7,20)
After '93: 2 8 3 1 (3. 1 ,22)
B ra ke hose oil bolt '88,'89,'9 1 -'93: 2 10 30(3.0,22)
After '93: 2 10 3 5 (3 . 5,25 )
B leed valve 1 8 5 . 5 (0. 5 5,4)
B ra ke master cylinder holder bolt 2 6 1 2( 1 .2,9)
B ra ke master cylinder cover screw 2 4 1 . 5 ( 0. 1 5, 1 . 1 )
B rake lever pivot bolt 1 6 1 (0. 1 ,0. 7 )
nut 1 6 6 ( 0. 6,43 )
B ra ke d isc mounting bolt 5 8 40(4.0,29) Apply locking agent
Caliper pin bolt 1 8 22(2.2, 1 6) Apply locking agent
Caliper bracket pin bolt 1 8 1 2( 1 .2, 9 ) Apply locking agent
Pad pin 1 10 1 8 ( 1 .8, 1 3 )
Pad pin plug 1 10 2.5 (0.25, 1 .8 )
Shock a bsorber u pper mounting bolt 1 10 4 5 (4.5,33 ) Socket bolt
Shock a bsorber lower mounting bolt 1 10 45 (4.5,33 )
Gearshift arm bolt 1 6 1 2( 1 .2, 9 )
Foot p e g bracket bolt 4 10 40(4.0,29 )
Swingarm pivot bolt 1 14 90(9.0, 6 5 )
Front u pper engine mounting bolt 1 10 5 5 ( 5. 5.40)
Front u pper engine bracket bolt 2 8 27 (2.7,20)
Front lower engine mounting bolt 1 10 5 5 ( 5. 5,40)
Rear u pper engine mounting bolt 1 10 5 5 ( 5. 5.40)
Rear u pper engine bracket bolt 2 8 27 (2.7,20)
Exhaust pipe joint n ut 4 8 25 (2.5, 1 8 ) Flange nut
Fuel tan k mounting bolt 1 8 1 9 ( 1 .9, 1 3 . 7 ) Flange bolt
Ignition switch mounting bolt 2 6 1 1 ( 1 . 1 ,8} Shear bolt
Exhaust pipe cover bolt 3 6 1 2( 1 .2,9)
Exhaust m uffler bracket bolt/nut
' 88 , ' 8 9 , ' 9 1 -' 93 : 1/1 8 27 (2.7,20)
After '93 1 /4 8 20(2.0, 1 4)
Helmet holder mounting bolt 2 6 1 3 ( 1 .3,9) Shear bolt
Side stan d pivot bolt 1 10 1 0( 1 .0,7.2) Socket bolt
nut 1 10 30(3.0,22)
Driven sprocket nut 5 10 6 5 ( 6.5,47 )
Fork tube cap 2 34 22(2.2, 1 6)
Front socket bolt 2 10 30(3.0,22) Apply locking agent
Damper rod lock nut '88,'89,'9 1 ,'92: 1 14 7 0 ( 7 .0,5 1 )
Spokes 1 08 4 4(0.4,2.9 )
Handlebar mounting nut 2 8 25 (2.5, 1 8)
Ha ndlebar upper holder bolt
After ' 9 4 : 2 8 3 0 ( 3 . 0, 22)
H a ndlebar lower holder n ut
After ' 9 4 : 2 8 23 (2. 3 , 1 6)
Fuel valve body 1 22 23 (2.3, 1 6 )
Throttle l i n k cover stay screw 2 4 2. 1 (0.2 1 ' 1 . 5 )
Rear ignitio n coil stay bolt 2 6 9 (0.9,6. 5 )
Battery cover mounting bolt 2 6 9 (0.9, 6 . 5 )
F u e l p u m p stay mou nting nut 1 6 9 (0.9,6 . 5 )

1 -6
GEN ERAL I N FORMATION

Torque specifications listed above are for specific tightening points. If a specification is not listed, follow the standard torque
values below .

STANDARD TORQUE VALUES

TYPE TORQU E Nm ( kg-m, ft-lbl TYPE TORQU E Nm (kg-m, ft-lbl


5 mm bolt, nut 5 (0.50, 3.6) 5 mm screw 4 (0.40, 2 . 9 )
6 mm bolt, nut 10 ( 1 .0, 7 . 2 ) 6 mm screw, 6 mm
8 mm bolt, nut 22 ( 2 . 2 , 1 6) bolt with 8 mm head 9 (0.9, 6.5)
10 mm bolt, nut 35 (3.5, 25) 6 mm flange bolt, nut 12 ( 1 .2, 9)
12 mm bolt, nut 55 (5 .5, 40) 8 mm flange bolt, nut 27 (2.7, 20)
1 0 mm flange bolt, nut 40 (4.0, 29)

1 -7
G E N ERAL I N FO RM ATIO N

TOOLS
SPECIAL

Description Tool number Alternate tool Tool number Refer to


section
Oil pressure gauge 07 506 - 3000000 tJ Equ ivalent 2
Oil pressure gauge attachment 07 5 1 0 - 4220 1 00 commercially
' 2
Oil filter wrench 07HAA - PJ 7 0 1 00 available 2
in U . S.A.
Vacuum gauge 07404 - 0030000 Vacuum gauge 07 LMJ -00 1 OOOA 3
Valve adjusting wrench 07908 - KE90000 N ot availa ble 07908 - KE90 1 00
in U . S . A . 4
L Pressure pump
Vacuum/Pressure pump A937X - 04 1 - XXXXX Vacuum pump ST - AH - 260 - MC 7 4
Snap ring pliers ST - AH - 2 55 - MC 7 2, 1 3,
079 1 4 - 323000 1 Equivalent 14
commercially
available
Steering stem socket 07 9 1 6 - 3 7 1 0 1 00 in U.S.A. 12
Clutch center holder 07923 - K E 1 0000 07 H G B -00 1 OOOA 7
Bottom holder pipe 07930 - KA 50000 1- N ot available 12
- holder attachment 07930 - KA50 1 00 I- i n U . S . A .
- holder handle 07930- KA40200 I-
Bearing remover set 07936 - 3 7 1 000 1 I- 11
- remover handle 07936 - 37 1 0 1 00
- bearing remover set 07936 - 37 1 0600
- remover weight 0774 1 - 00 1 020 1 Remover
weight 07936 - 3 7 1 0200
Valve guide driver attachment
(IN) 07943 - M F50 1 00 9
Valve guide driver attachment
( EX) 07943 - M F50200 9
Bearing race remover 07946 - 3 7 1 0500 12
Steering stem driver 07946 - M BOOOOO 12
D river shaft 07946 - MJ00 1 00 13

re Attachment
Fork seal driver , 3 9 m m 07947 - 4630 1 00 12
Ball race remover 07953 - MJ 1 0000 0 7 9 5 3 - MJ 1 OOOA , 12
- driver attachment 07953 - MJ 1 0 1 00 D river 0 7 9 5 3 - MJ 1 OOOB or
- driver handle 07953 - MJ 1 0200 D river handle 07 949- 3 7 1 000 1 and
Attachment,
32X35mm 07746- 00 1 0 1 00
Main bearing d river attachment 07H M F - M M 90400 11
Valve guide reamer, 5 . 5 1 0 mm
(IN) 07984 - 200000 1 9
Valve guide reamer, 6 . 6 1 2 mm 07 9 8 4 - 2 00000 D
(EX) 07984 -ZE2000 1 0 79 84 - ZE2 000 D 9
Attachment, 28 x 30 mm 07746 - 1 870 1 00
* Drive chain cutter 07 H M H - MR 1 01 03 N ot available 0 7 H M H- M R1010B
* Shock absorber compressor at- 07JM E - M R 1 0 1 00 in U . S .A. 13
tachment
* : New for this mode l .

1 -8
G E N ERAL I N FO RMATIO N

COMMON

Description Tool number Alternate tool Tool number Refer to


section
Float level gauge 0740 1 - 00 1 0000 4
Lock nut wrench , 1 7 x 2 7 m m 07 7 1 6 - 0020300 Equivalent 7
Gear holder 07724 - 00 1 0 1 00 commercially 7
Flywheel holder 07725 - 0040000 available 8
Torx bit 07 703 - 00 1 0 1 00 in U . S . A . 8
Rotor puller 07733 - 002000 1 0 7 933-32 9000 1 8
Valve guide remover, 5 . 5 m m 07742 - 00 1 0 1 00 9
Valve gu ide remover, 6 . 6 m m 07 742 - 00 1 0200 1-- N ot available 07942-657 0 1 00 9
in U . S . A.
Attachment, 32 x 35 m m 07 746 - 00 1 0 1 00 13
Attachment, 42 x 4 7 mm 07 746 - 00 1 0300 11' 1 2,
13
Attachment, 52 x 55 mm 07 746 - 00 1 0400 11' 12
Pilot, 1 5 mm 07 746 - 0040300 13
Pilot, 1 7 mm 077 46 - 0040400 13
Pilot, 20 mm 07 746 - 0040 500 11' 12
Pilot, 22 mm 07 746 - 004 1 000 11' 13
Pilot, 2 5 mm
Bearing remover head, 1 7 m m
Bearing remover shaft
07 746 - 0040600
07 746 - 0050 500
07746 - 0050 1 00
:quivalent
commercially
11
13
13
Bearing remover head, 20 m m 07 746 - 0050600 available 12
in U .S.A.
Driver 07 749 - 00 1 0000 1 1 ' 1 2,
13
Valve spring compressor 07757 - 00 1 0000 Valve spring 07957 - 32 9000 1 9
compressor
Shock absorber compressor 07G M E - 00 1 0000
- compressor screw 07G M E - 00 1 0 1 00 13
Spoke wrench 07JMA - M R601 00 I-- N ot available
in U . S . A .

VALVE SEAT CUTTERS (NOT AVAILABLE IN U. S. A. )

Description Tool number Remarks


Valve seat cutter, 2 7 . 5 m m 07780 - 00 1 0200 45 IN
Valve seat cutter, 35 mm 07780 - 00 1 0400 45 EX
Valve seat cutter, 28 mm 07780 - 00 1 2 1 00 32 I N
Valve seat cutter, 35 mm 07780 - 00 1 2300 32 EX
Valve seat cutter, 30 mm 07780 - 00 1 4000 60 IN
Valve seat cutter, 37.5 m m 07780.,-00 1 4 1 00 60 EX
Cutter holder, 5.5 mm 0778 1 - 00 1 0 1 0 1 Valve guide I N
Cutter holder, 6 . 6 m m 0778 1 - 00 1 020 1 Valve guide EX

1 -9
G E N ERAL I N FORMATI O N

CABLE & HARN ESS ROUTI N G


Note the following when routing cables and wire harnesses:

A loose wire, harness or cable can be a safety hazard . After


clamping, check each wire to be sure it is secure .
0 X

Do not squeeze wires against welds or clamps.

Secure wires and wire harnesses to the frame with their re


spective wire bands at the designated locations. Tighten
the bands so that only the insulated surfaces contact the
wires or wire harnesses.

Route harnesses so they are neither pulled taut nor have ex


cessive slack.

Protect wires and harnesses with electrical tape or a tube if


they contact a sharp edge or corner. Clean the attaching
surface thoroughly before applying tape.

Do not use a wire or harness with broken insulation. Repair


by wrapping them with protective tape or replace them.

Route wire harnesses to avoid sharp edges or corners. Also


avoid the projected ends of bolts and screws.

Keep wire harnesses away from the exhaust pipes and


other hot parts .

Be sure grommets are seated in their grooves properly.

After clamping, check each harness to be certain that it

X
does not interfere with any moving or sliding parts .

After routing, check that the wire harnesses are not twisted
or kinked.

Wire harnesses routed along the handlebars should not be


pulled taut, have excessive slack, be pinched by or interfere
with adjacent or surrounding parts in all steering positions.

Do not bend or twist the control cables.


Damaged control cables will not operate smoothly and may
stick or bind .

0: C O RRECT
x: INCORRECT

1 -1 0
GENERAL INFORMATION

'88- '89 ; '91 :


(2) CLUTCH CABLE

( 3) LEFT HANDLEBAR
SWITCH W I RE

(8) RIGHT HANDLEBAR


SWITCH W I RE

( 7 ) HORN
W I RE

'92-'93 : (2) CL UTCH CABLE

(3) LEFT HAN DLEBAR


SWITCH WI RE

(4) SPEEDOMETE R
CABLE

(9) F RONT B RAKE HOSE

(8) RIGHT HAN DLEBA R


SWITCH W I R E

1-11
GENERAL INFORMATION

' 94:
(1 ) THROTTLE CABLES

(3) LEFT HANDLEBAR


SWITCH WIRE

(4) SPEEDOMETER
CABLE

(9) FRONT BRAKE HOSE


(5) HEADLIGHT
CONNECTOR

(8) RIGHT HANDLEBAR


SWITCH WIRE

After '94:
( 1 ) TH ROTTLE CAB LES

(3) LEFT HAN D LE B A R


SWITC H WI R E

( 3 ) LEFT HAN D LE B A R
SWITC H WI R E

).::;1t::::
:i ::::=- ( 1 ) TH ROTTL E
, CAB LES

(9) R I G HT HAN D LE B A R
SWITCH WI R E
\-1-'7"'77T---t-- (4) SPE ED O M ETER
CAB LE

(2) CLUTCH CAB LE

(9) R I G HT HAN D LE B A R
SWITC H WI R E

( 8 ) H O R N WI R E
11@fo ,:....\-mTt-t--+----
,_
(6) H EA D Li G HT

-(7) H O R N
C O N N ECTO R

1-12
GENERAL INFORMATION

'88-'89 '9 1 :
'
(2 ) HANDLEBAR SWITCH
W I RE BANDS

(13) C RANKCASE BREATHER


TUBE
(12) WATER HOSE
(11 ) ENGINE BREATHER
T UBE

(9)

(6) I G N ITI O N P U LS E
GENERATOR
(7) CLUTCH CABLE W I RE

'92-'93: (1 ) HANDLEBA R SWITCH


WI RE BANDS

(2) C RANKCASE
(11 ) ENGINE B REATHER
B REATHER
TUBE
SE PA RATO R

(10 ) STARTER
M OTO R

(8) G RO U ND
CABLE ( 5 ) A I R CLEANE R
(7) CLUTCH CABLE
(6) I G N ITI O N P U LS E
GENE RATO R W I R E
HOUSING

1 - 13
G E N E R A L I N F O R MAT I O N

' 94 :
( 13) CRANKCASE BREATHER ( 1 ) HANDLEBAR SWITCH
TUBE WIRE BANDS

( 1 1 ) ENGINE B REATHE R
TUBE

(2) CRANKCASE
BREATHER
SEPARATO R

---l-1<:::.;..1--l-#-;.+---(3)
EVA PORATIVE
(9) STARTER EM ISSION
M OTOR PURGE CONTROL
CABLE VALVE (California
model only)

(4) SUB-AIR
CLEANER

(7) CLUTCH CABLE

After '94 (1) HANDLE BAR SWITCH


WIRE BANDS
(2) CRANKCASE
BREATHER
SE PA R ATO R

( 1) HANDLE BAR
SWITCH WIRE
BANDS
( 1 0) STA RTE R
MOTO R

( 9 ) STA RTE R
MOTO R
CA BLE

( 8 ) G ROUND (4) SUB-A I R


CLEANE R
CA BLE
r------------------------------------

:
0

'
'
'
:: ]
------- After' 9 5 : G
________

(6) IGNIT ION PULSE ( 5 ) A IR CLEANER


GENERATOR WIRE HOUSING

1 -1 4
GENERAL INFORMATION

( 1 ) THROTTLE
CABLES

(2) FRONT IGNITION COIL


(3) FUEL TANK BREATHER TUBE
(California model only)

(6) NE UTRAL SWITCH


W I RE
( 7 ) RIGHT CHOKE CABLE
( 1 0) PEEDOMETER (9) CLEANE R HOUSING ( THERMOSTATI C SWITCH
CABLE HOLDER BREATHE R TUBE

'88-'89, '91-'93:
( 1 1 ) I G N ITI O N PULSE GENERATOR
4P WHITE CONNECTOR

( 1 2) HORN/FAN MOTOR
2P BLA CK CONNECTOR

:JID

(13)
-(0
.- -----

T U RN SIGNAL
9P WHITE CONNECTOR
( 1 4) INDICATOR PANEL
6 P GREEN CONNECTOR
( 1 5) SPEEDOMETER
6P BLACK CONNECTOR
(16) RIGHT HANDLEBA R SWITCH
9P RED CONNECTOR

1-1 5
GEN ERAL I N F O RMATION

'94 :
( 2) FRONT B RA K E H O S E
(3) I G N ITI O N P U LS E G E N E RATO R
4 P WH ITE CO N N ECTO R
(4) H O R N/FAN M OTO R
2 P B LA C K C O N N ECTO R

TU9 P RWHN SITEI G NACOLN N ECTO R


(6) I N D I CATO R PAN EL
6 P G R EE N CO N N ECTO R
( 7 ) S P E E D O M ETER
6 P B LACK C O N N ECTO R
(8) R I G HT HAN D LEBAR SWITC H
9 P R E D C O N N ECTO R

After '94 :
( 9 ) C RAN K CASE B R EATH E R D RAI N TU B E
(10) MAI N WI R E HAR N ESS

( 11 ) FAN MOTO R WI R E

( 1 2 ) EVAPO RATIVE EM ISSION P U R G E


C O N T R O L VALVE (California model o n ly)

1-16
GENERAL INFORMATION

(1) T U RN SIGNAL RELAY


(2) FUEL
FILTER

(6) BATTERY (9) COOLANT RESERVE


(7)SUB-FUSE BOX TANK OVERFLOW TUBE
( 8 ) REAR BRAKE LIGHT
SWITCH
(23) S I DE STAND (1) T U RN SIGNAL RELAY
2P G REEN CONNECJOR 1 1 ) FUEL
(24) IGNITION SWITCH PU M P
2P BLACK COINNICl"OR
""'-
-.... '-

-----;of-41-_17) REGULATOR/
RECTIFIER

( 1 9 ) IGNITION SWITCH
OIL PRESSURE
SWITCH
(21 I S I DE STAND SWITCH

1 -17
GENERAL INFORMATION

( 9 1 GROUND ( 1 ) STATOR COIL ( 2 ) CLAMPS


PO INT

(3) GROM METS

(7) THERMOSTATI C
SWITCH W I RE
( 6 1 RIGHT
( 5 ) IGNITION P ULSE CRANKCASE
GENERATOR
( 1 1 I BRAKE/TA ILLIGHT
CASE

( 1 21 TU RN SIGNAL
LIGHT
W I RE

( 1 3) LI CENCE LIGHT
WIRE

1 -1 8
G E N E RA L I N F O R MATI O N

After '93 :
( 1 ) ALTE RNATO R WI RE

(4) SIDE STAND SWITCH

(3) OIL PRESSU RE SWITCH

1-19
GENERAL INFORMATION

EVAPORATIVE EMISSION CONTROL SYSTEM (California model only)

NOTE

The hoses shown below are n u mbered as they appear on the Vacu u m Hose Routing Diagram Labe l .

( 1 ) @TUBE

( 7 ) EVAPORAT IVE EMISSION


PU RGE CONTROL VALVE
,...::....r=="1 (5) @T UBE
JL\..-bi-\----
( 7 ) EVAPORATIVE EMISSION
PU RGE CONTROL
VALVE

( 1 5 ) ENGINE
BREATHER
TUBE
(FROM REAR
CYLINDER
HEAD )

(3) @T UBE (6) EVA PO RAT IVE EMISS ION CARBURETOR

@TUBE
AIR VENT CONTROL VALVE
(5)

( 1 4) COOLANT RESERVE TANK


DRAIN TUBE
( 1 0) TO EVAPORATIVE
EM ISS ION CANISTER
(9) AIR CHA MBER
DU CT

( 1 21 EVAPORATIVE
EMISSION
CANISTER ( 1 1 l EVAPORAT IVE EM ISS ION CANISTER
OPEN
AIR TUBE ( 1 31 REA R SHOCK ABSORBER TUBE

1 - 20
G E N ERAL I N FO RMATIO N

EMISSION CONTROL SYSTEMS


The U . S . Environmental Protection Agency and California Air Resources Board (CARB) requ ire manufacturers to certify that
their motorcycles comply with applicable exhaust emissions standards during their useful life, when operated and maintained
according to the instructions provided, and that motorcycles built after January 1 , 1 983 comply with applicable noise emis
sion standards for one year or 6,000 km (3, 7 30 miles) after the time of sale to the ultimate purchaser, when operated and
maintained according to the instructions provided . Compliance with the terms of the Distributor ' s Limited Warranty for Honda
Motorcycle Emission Control System is necessary i n order to keep the emissions system warranty in effect.

SOURCE OF E M I SS I O N S


The combustion process p roduces carbon monoxide and hydrocarbons. Control o f hydrocarbons i s very important because,
under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not
react in the same way, but it is toxic.

Honda Motor Co . , Ltd . utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydro
carbons.

EXHAUST E M I S S I O N C O N T R O L SYST E M

The exhaust emission control system is composed o f a l e a n carburetor setting, and no adjustments should be m a d e except
idle speed adjustment with the throttle stop screw. The exhaust emission control-system is separate from the crankcase
emission control syste m .

CRA N K C A S E E M I S S I O N C O N T R O L S Y S T E M

The engine is equipped with a closed crankcase system which routes crankcase emissions through the air cleaner into the
combustion chamber.

( 1 l CRAN KCASE BREATHER (2) AIR CLEANER HOUSING


SEPARATOR

c::::> FRESH A I R
-+ BLOW-BY GAS

1 -21
G E N ERA L I N FORMATION

EVAPORATIVE EMISSION CONTROL SYSTEM (California model only)

This model complies with California Air R eso u rces Board evaporative emissio n requirements.
Fuel vapor from the fuel tan k and carbureto r is d irected into the evaporative emission canister where it is adsorbed a n d sto red
while the engine is stopped.When the engine is running and the evaporative emissio n purge control diaphragm valve is o pen,
fuel vapor i n the evaporative emissio n canister is d rawn i nto the engine through the carbu retor.

TO
OPEN
AIR

I (3) DRAIN
(4) EVAPO RATIVE EMISSIO N


CAN I STER
-- ( 5 ) EVAPO RATIVE E M I S S I O N
CAR B U R ETO R
IT AI R VENT CONTRO L VALVE
'
( 7 ) TO OPEN ( 6 ) EVAPO RATIVE E M I S S I O N
AIR CAR B U R ETO R
AI R VENT CO NTROL
VALVE
( E N G I N E STO P)

NOISE EMISSION CONTROL SYSTEM

TAM PE R I N G WITH THE NOISE CONTROL SYSTEM IS PRO H I BITED : Federal law prohibits the fol lowing acts or the causing
thereof: ( 1 ) The removal or rendering inoperative by any person , other than for purposes of maintenance, repair, or replace
ment, of any device or element of design i ncorporated into any new vehicle for the purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is in use; or (2) the use of the vehicle after such device or element of design has
been removed or rendered inoperative by any person .

AMONG THOSE ACTS PRESU MED T O CONSTITUTE TAMPERING A R E T H E ACTS LISTED BELOW:

1 . Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust gases .

2 . Removal of, or puncturing of any part of the intake system .

3. Lack of proper maintenance .

4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified
by the manufacturer.

EM ISSION CONTROL I N FO RMATION LABELS


An Emission Control I nformation Label is located on the inside of the left side cover as show n . It contains basic tune-up speci
fications.

( 1 ) VEHICLE EMISSION CONTROL


I N FORMATION LABEL

1-22
G E N ERAL I N F O RMATI O N

VACUUM HOSE ROUTING DIAGRAM LABEL (California model only)

The Vacuu m Hose Routing Diagram label is on the inside of the left side cover. Route the vacuum hoses as shown on this
label.

1-23
L U B R I CATIO N

'88, '89:
(1) ROCKER A R M

( 2 ) O I L PIPE

( 1 2 ) PISTON

l MAIN SHAFT

( 5 ) O I L STRA I N E R
( 6 ) PRESSU R E
(7) OIL FILTER R E L I E F VALVE

2-0
2. LU B R I CATI O N
After '89:

(1) ROCK E R A R M

(12) CAMSH A FT

(11) PISTO N

(10) O I L JET

(9) C R A N KSH A FT
( 2) MA I NSH A FT

( 8) CO U NT E R S H A F T


(7) O I L P R ESSU R E
SW ITCH

(@n
( 3) O I L PUMP

(4) O I L ST R A I N E R

( 5) P R ESSU R E
R E L I E F VALVE

2- 1
L U BRICATI O N

S ERVIC E I N FO R M ATIO N 2-2 O I L P R ESS U R E C H ECK 2-5

TROUBLESHO OT I N G 2- 3 OIL P U MP 2-6

E N G I N E O I L LEVEL 2-4 CO NTROL CABLE L U BR I CATI O N 2- 1 2

ENGINE O I L C H AN G E 2-4 L U BRIC ATIO N P O I NTS 2- 1 2

O I L FILTER C H A N G E 2-5

SERVICE I N FO RMATION

If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.

CAUTION

Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. A lthough this is unlikely
unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possi
ble after handling used oil.

G E N ERAL
The o i l p u m p c a n be serviced a f t e r r e m o v i n g the e n g i n e from the fra m e .

S P E C I F I CATI O N S
Engine oil

O i l c a p a city 2 . 8 lit ( 2 . 94 U S qt, 2 . 4 6 I m p qt) after d i sasse m b l y .


2 . 2 5 lit ( 2 . 3 6 U S q t , 1 . 9 8 I m p q t ) at o i l filter a n d o i l c h a n g e .
2 . 1 lit ( 2 . 2 1 U S q t , 1 . 8 5 I m p qt) after d r a i n i n g .
Oil recomm e n d a t i o n H O N DA GN4 4-stroke o i l o r eq u ivalent API
O I L V I SCO S I T I E S
se rvice class ification: S F o r SG
V I SCOS ITY: SAE 1 0W - 40

Other viscosities s h o w n i n t h e c h a rt m a y
be u s e d w h e n the average tem perature
i n your riding area i s w i t h i n the i n d i cated
range .

0 20 40 60 80 100 F"

-20 -10 0 10 20 30 40 c

Oil pump

ITEM STA N DA R D S E R V I C E LI M I T

R o t o r tip c l e a r a n c e 0 . 1 5 m m ( 0 . 006 i n ) 0 . 20 m m ( 0 . 008 i n )


Pump body clearance 0 . 1 5 - 0 . 2 2 m m ( 0 . 006 - 0 . 009 i n ) 0.35 mm (0.0 1 4 in)
P u m p end c l e a r a n c e 0 . 0 2 - 0 . 0 7 m m ( 0 . 00 1 - 0 . 003 i n ) 0 . 1 0 m m ( 0 . 004 i n )
--
O i l pressure 44 1 kPa ( 4 . 5 kg/cm2, 64 psi) at 6,000 r p m

T O R Q U E VALU E S
O i l pressure s w itch 1 2 Nm ( 1 . 2 kg-m, 9 ft-lb)
Engine o i l d r a i n bolt 3 5 Nm ( 3 . 5 kg-m, 25 ft-l b )
Oil filter 1 0 N m ( 1 . 0 k g - m , 7 . 2 ft- l b )

2-2
L U BRICATIO N

T O O LS

Special
Oil filter wrench 07HAA - PJ 70 1 00

0 7 5 1 0- 4220 1 00 J
Oil pressure gauge 07 506 - 3000000 or equivalent commercially available in U . S . A .
Oil pressure gauge attachment
Snap ring pliers 079 1 4 - 323000 1 - or equivalent commercially available in U . S . A

TROUBLESHOOTI NG
Oil level too low

Normal oil consumption

External oil leaks

Worn piston rings

Oil contamination

Oil not changed often enough

Faulty head gasket

Worn piston rings

Low oil pressure

Faulty oil pump

Clogged oil strainer

Low oil level

Faulty pressure relief valve

Oil leaks

High oil pressure

Faulty pressure relief valve

Clogged oil filter or oil orifice

No oil pressure

Oil level too low

Broken oil pump drive or d riven sprockets

Broken oil pump drive chain

Faulty oil pump

Oil leaks

2-3
LUB R I CATIO N

ENGI N E OIL LEVEL


Support t h e motorcycle i n a n upright a n d level position using
a hoist or a jack under the engine.

Start the engine and let it idle for a few minutes.

Stop the engine, remove the oil fi ller cap/di pstick and wipe it
clean.
Check the oil level with the oil filler cap/d ipstick by inserting it
without screwing it in.

NOTE
Do not screw the cap in when making this check.

If the oil level is below the lower level mark on the di pstick, fill
to the upper level mark with the recommended oil .
Check the 0-ring for damage.

ENGI N E OIL CHANGE


NOTE

Change the engine oil with the engine warm and the motor
cycle on its side stand to assu re complete and rapid drain
ing .

( 1 ) DRA IN BOLT
R emove the o i l f i l ler cap/d ipst ick and d rain bo lt.
W ith the engine stop sw itch OFF, push the starter button for
a few seconds to drain any o i l which may be left in the eng ine.
( 1 ) D RA IN BOLT
NOTE
Do not operate the motor for more than few seconds.

After the oil has drained, check that the drain bolt sealing
washer is in good condition, and instal l the bolt.

TORQUE: 35 Nm (3.5 kg-m, 25 ft-lbl

Fill the crankcase with the correct quantity of the recommend


ed o i l .

OIL CAPACITY:
\
( 2 ) SEALING WASHER
2. 8 lit (2.94 US qt, 2.46 Imp qt) after disassembly
2.25 lit (2.36 US qt, 1 .98 Imp qt) at oil filter and oil change
2.1 lit (2.21 US qt, 1 . 85 Imp qtl after draining

RECOMMENDED OIL: Honda GN4 4-stroke oil or equivalent


API service classification: SF or SG
VISCOSITY: SAE 1 0W - 40

Install the oil filler cap/dipstick.


Start the engine and let it idle for 2 or 3 minutes.

Stop the engine and wait a few m inutes, then check that the
oil level is at the upper level mark with the motorcycle upright.

Check that there are no oil leaks .

2-4
LUB R I CATION

O I L FI LTER CHANGE
Drain the engine o i l ( page 2-4) .

CAUTION
Do not replace the oil filter when the exhaust system is hot.

Remove the oil filter with a filter wrench .

TOOL:
Oil filter wrench 07HAA - PJ70 1 00
(2) OIL FILTER WRENCH

Apply oil to the new oil filter 0-ring and install the new oil filter. (1 l OIL F I LTER
Tighten the oil filter with a filter wrench .

TORQUE: 1 0 N m ( 1 .0 kg-m, 7 . 2 ft-lb)

Fill the engine with recommended oil (page 2-4) .

O I L P RESSU R E CHECK
Remove the following:
- drive sprocket cover (page 1 3 - 1 4)
- drive sprocket cover bracket (2) 0-RING
- switch cover and switch screw

Disconnect the wire from the oil pressure switch, remove the
switch and connect an oil pressure gauge to the switch hole.

TOOLS :
Oil pressure gauge 07506 - 0 7 506 - 3000000
Attachment 07 5 1 0 - 4220 1 00 or
equivalent commercially
available in U . S . A .

Check the oil leve l .


Start the engine and allow it to warm-up to operating tempera
ture .
Check the oil pressure at 6,000 rpm.

STAN DARD OIL PRESSURE: 44 1 kPa (4. 5 kg/cm2, 64 psi)

Stop the engine.


Apply sealant to the pressure switch threads and install it.

TORQUE : 1 2 N m ( 1 . 2 kg-m, 8.7 ft-lb)

Connect the oil pressure switch wire and pull the dust cover
over the switch body securely.

Start the engine and check that the oil pressure warning light
goes out after one or two- seconds.

NOTE
Route the oil pressure switch wire properly ( page 1 - 1 5)

2-5
LU BRICATION

O I L PUM P ( 1 ) PRESSURE RELIEF VALVE COVER-



PRESS U R E R E L I E F VALVE R E M OV A L

Separate the crankcase (Section 1 1 ) .

Remove the bolt and pressure relief valve cover.


Remove the pressure relief valve from the oil pump.

PRES S U R E R E L I E F V A L V E D I SA S S E M B LY

Remove the snap ring and disassemble the relief valve .

TOOL:
Snap ring pliers 079 1 4 - 323000 1
or equivalent commercially
available in U . S.A.

I N S PECTI O N

Check the spring, 0-ring and valve for fatigue, wear or dam
( 1 ) 0-R I N G
( 2 1 BOOY

Q
age. ( 3 ) VALVE
Check the body for clogging or damage .
Replace the relief valve as an assembly.

Clean all the parts and assemble them i n the reverse order of
disassembly.


( 5 ) SNAP R I N G

OIL PU M P R E M OVAL/ D I SA S S E M BLY

Remove the oil pump by removing two mounting bolts .

Remove the dowel pins and 0-rings.

2-6
L UB R I CATIO N

Remove the oil strainer and oil pipe from the oil pump. (1 l O I L STRA I N ER

Check the 0-rings and oil seal for fatigue or damage. ( 1 l O I L SEAL (21 OIL STRA I N E R

Clean the oil strainer and oil pipe w ith non-flammable or high
flash point solvent.
/

0
(31 0-R I N G S

Remove the three cover bolts. ( 1 l C O V E R BOLTS


Disassem bled parts and clean them with non-flammable or
high flash point solvent.

O I L PUMP I N S P ECTI O N

I nstall t h e outer a n d inner rotors to the pump body.

Measure the outer rotor-to-pump body clearance .

SERVICE LIMIT: 0.35 mm (0.01 4 in)

2-7
LUBRICATI O N

Remove the oil pump shaft from the oil pump and measure the
pump end clearance.

SERVICE LIMIT: 0.1 0 mm (0.004 in)

Temporarily install the shaft i n the pump body.

Measure the inner rotor tip clearance.

SERVICE LIMIT: 0.20 mm (0.008 in)

Replace the oil pump, if necessary as a n assembly.

O I L PU M P A S S E M B LY
'88 , '89 , '91 -93:

(1 I PU M P BODY

( 1 0 1 0-RI N G

( 1 1 I O I L STRA I N E R

2-8
LUB R I CATI O N

After '93:

( 1 ) PU M P B O DY (4) P R ESS U R E R ELI EF VALVE B O DY

( 2 ) 0 UT E R R OTO R

(3 ) 1 N N E R R OTO R

(8)WASHER

(9)SPRING

I
( 1 4) D R IVE P I N

( 1 3 ) PU M P SHAFT

1 1 ) O I L STRAI N E R

I nstal l the outer rotor in the pump body with the punch mark
facing the cover, then i nstall the inner rotor.
I nstall the drive pin and spacer on the shaft.

I nstall the shaft i n the body, aligning the drive pin with the
inner rotor groove.

(6)
I N N E R ROTOR

'88 , '89 , '9 1 -'93: ( 1 ) O I L PU M P BODY


I nstall the dowel pin and a new gasket on the pump body, then
install the cover.

(2) OIL PU M P COVER

2-9
LABRICATION

After '93:
( 1 ) O I L P U M P B O DY
I nstall the dowel pins on the p u m p cover,then i nstall the pump
body.

( 3 ) 0 1 L P U M P COVER

Tighten the cover bolts securely . ( 1 ) COVER BOLTS

Install the 0-rings, oil seal, oil strainer and oil pipe on the oil
pump. (2) 0-R I NG (3) 0-R INGS

CAUTION

Install the 0-rings on the oil pipe with the tapered side facing
out as sho wn, or the engine will be damaged.

( 5) 0-R I NGS (4) O I L PIPE

After '93:
( 1 ) 01L S EAL ( 2 ) E DG E
Insta l l the oil seal on the oil pump.
Align the edge of oil strainer with the g roove of the pump
cover,then i nstall the oil strainer as shown.

(4) 0 1 L STRAI N E R

2-10
L UB R I CATI O N

O I L PU M P I N STALLAT I O N

I nstal l the dowel pins a n d n e w 0-rings.

I nstall the oil pump as an assembly .

( 2 ) DOWEL PIN

I nstall the pressure relief valve in the oil pump.

I nstall the pressu re relief valve cover with the bolt. (1 l PRESSU R E RELIEF VALVE COVER
Assemble the crankcase (Section 11 ).

2- 1 1
LUBRICATI O N

CONTROL CABLE LUBRICATION


Periodically disconnect the throttle and choke cable a t their
upper ends. Thoroughly lubricate the cables and their pivot
points with a commercially available cable lubricant or a light
weight oil .

LUBRICATION POI NTS


Use gen e ral purpose grease when not otherwise specified
here .
Apply oil or grease to the other sliding surfaces and cables not
shown here .

(1 l
,
CLUTCH AND BRAKE
LEVER
( 2 ) TH ROTTLE
GRIP

- ----
(11 l STE E R I N G
HEAD BEAR I N G

..

I
I
I
I
I

- ---- -
( 7 ) BRAKE PEDAL ( 5 ) SWI NGARM

-
PIVOT PIVOT BALL
AND N EEDLE
BEARINGS
,
(4) DRIVE CHAIN
- lijiVft
(8) ( PR O HO N DA CHA I N LU B E )
BRAKE & CHANGE
CALI PER PIVOTS (6) S I D E STAND
(SILICON G R EASE) PIVOT

2-12
3. MAI NTENANCE
S E R V I C E I N FORMAT I O N 3- 1 C Y LI N D E R CO MP RESS IO N 3- 1 2

M A I NTENANC E S C H E D U L E '88; 3-3 EVA PO RATIVE E M IS S IO N


CONTROL S YSTEM 3-1 3
MAI NT E NA N C E S C H E D U LE '8 9,'9 1 -'93; 3-4
After 93; 3-5 < C HASSIS>
MAI NT E N A N C E S CH E D U LE
D R I V E CHAIN 3-1 3

Ill
< EN G I N E>
BRAKE F L U I D 3-1 5
FUEL LINE 3-6
BRAKE S H O E/PAD WEAR 3-1 6
T H ROTTLE OP E RATIO N 3-6
BRAKE SYSTEM 3- 1 6
CA R B U R ETO R C HO K E 3- 7
BRAKE L I G HT SWITCH 3-1 7
A I R C LEAN E R 3- 7
H EADLIGHT AIM 3- 1 8
C RA N KCAS E B R EAT H E R 3-8
CLUTCH SYSTEM 3-1 8
S PA R K PLUGS 3-8
S I D E S TAND 3-1 9
VALV E CLEARANC E 3-8
S US PE N S IO N 3-1 9
CAR B U R ETO R S Y N C H RO N IZATIO N 3- 1 0
N UTS, BO LTS, FASTENERS 3 -20
CA R B U R ETO R I D L E SP E E D 3- 1 1
W H E E LS/TIRES 3 - 20
RADIATO R COO LA N T 3- 1 1
S T E E R I N G H EAD BEA R I N G S 3-21
C OO LI N G SYSTEM 3- 1 2

SERVICE I N FORMATION

If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.

Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area with the engine stopped.
Do not smoke or allow flames or sparks in the work area or where gasoline is stored.

G E N ERAL

Engine oil See page 2-4

Engine oil filter change See page 2-5

S P E C I F I CATI O N S

E N G I N E
Ignition timing Initial '88 . ' 8 9 ,'9 1 - ' 9 3; 6 . 2 BTDC at idle
After ' 93; 6 . 5 BTDC at idle
Full advance 30 BTDC at 6 , 000 rpm
Spark plug N I PPON DENSO
NGK
Standard DPR8EA-9 X24EPR-U9
For cold climate ( below 5 C/4 1 F) DPR7 EA-9 X22EPR-U9
For extended high speed driving DPR9EA-9 X27 EPR-U9
Spark plug gap 0 . 8 - 0 . 9 mm (0.03 1 - 0.035 in)
Valve clearance IN 0 . 1 5 0.02 mm (0.006 0 . 0008 in)
(COLD) EX 0 . 20 0.02 mm (0.008 0 . 0008 in)
Idle speed 1 , 200 1 00 rpm
Cylinder compression 1 , 324 98 kPa ( 1 3 . 5 1 .0 kg/cm2, 1 92 1 4 psi)
Throttle grip free play 2 - 6 mm ( 1 / 1 6 - 1 /4 in)

3- 1
MAINTENAN CE

C H A S S I S
Rear brake free play 20 - 30 mm (3/4 - 1 -3/1 6 in)
Brake pedal height 43 mm ( 1 . 7 in)
C l utch lever free play 1 0 - 20 mm ( 3/8 - 3/4 in)
D rive chain slack 20 - 30 mm ( 3/4 - 1 -3/ 1 6 in)
Tires
Front Rear
Tire size 1 00/90- 1 9 57S 1 70/80- 1 5 7 7 S
Cold tire pressures U p to vehicle capacity load 200 ( 2 . 00, 29) 2 50 ( 2 . 50, 3 6 )
kPa (kg/cm2, psi) Up to 90 kg ( 200 lbs) load 200 ( 2 . 00, 29) 2 0 0 ( 2 . 00, 2 9 )
M aximum weight capacity 1 6 1 kg ( 3 5 5 lbs)
Tire brand Bridgestone L309 G 546
Dunlop F24 K555

TO R Q U E VALU E S

Rear axle nut 90 N m ( 9 . 0 kg-m, 65 ft-lb)


Valve adjusting screw lock nut 23 Nm ( 2 . 3 kg-m, 1 7 ft-lb)
S pokes (front/rear) 4 Nm (0.4 kg-m, 2.9 ft-lb)
Timing hole cap 3 . 5 Nm (0. 3 5 kg-m, 2 . 5 ft-lb)
Crankshasft hole cap 1 5 N m ( 1 . 5 kg-m, 1 1 ft-lb)

T O O LS

Special
Valve adjusting wrench 07 908 - KE90000 N ot available in U . S . A .
07908 - KE90 1 00 U . S . A . Only
Vacuum gauge 07404-0030000 or N ot available in U . S . A .
07 LMJ - 00 1 000A U . S . A . Only
Drive chain cutter 07HMH- M R 1 0 1 00 or
07HMH- M R 1 0 1 0 B U . S . A . Only
Spoke wrench 07J MA- M R 6 0 1 00 N ot available in U . S . A .

3-2
MAINTENANCE

MAI NTENANCE SCHEDULE '88;


Perform the PRE-RI D E I N SPECTI O N in the Owner ' s Manual at each scheduled maintenance period .
1: I N SPECT AND C LEAN , ADJUST, LUBRICATE OR REPLAC E I F N ECESSARY .
C : CLEAN R : REPLAC E L : L U B R I CATE

WHICHEVER
FREQU E N CY
COMES ODOMETER READI N G ( N OTE 1 )
FI RST ..

x 1 ,000 mi 0.6 4 8 12 16 20 24 REFER TO


ITEM EVERY x 1 00 km 10 64 1 28 1 92 256 320 384 PAG E
* FUEL L I N E I I I 3-6
* THROTTLE OPERATI O N I I I 3-6
* CARBU RETOR CHO K E I I I 3-7
A I R CLEANER (NOTE 2 ) R R 3-7
CRANKCASE BREATHER (NOTE 3) c c c c c c 3-8
en
3-8
w SPARK PLUG R R R R R R
!:::: * 3-8
0
VALVE C LEARA N C E I I I I
I- 2 -4
w
ENGINE OIL R R R R
<{
...J
E N G I N E O I L F I LTER R R R R 2-5
a:
w

*
z CARBU RETOR-
I I I I 3- 1 0
0 SYNCHRO N IZAT I O N
U5
en * CARBURETOR-IDLE SPEED I I I I I I I 3- 1 1

w RADIATOR COOLANT 2 YEARS * R I I *R 3- 1 1
* COOLING SYSTEM I I I 3- 1 2
* EVAPO RATIVE E M I S S I O N
(NOTE 4) I I 3-1 3
CONTROL SYSTEM
DRIVE CHAIN EVERY 600 mi ( 1 ,000 km) I. L 3- 1 3
en BRAKE FLU I D 2 YEARS * R I I *R I I *R 3-1 5

w BRAKE SHOE/PAD WEAR I I I I I I 3- 1 6
!::::
0 BRAKE SYSTEM I I I I 3- 1 6
I-
w
* BRAKE LIGHT SWITCH I I I 3-1 7
<{
...J
* HEADLIGHT A I M I I I 3- 1 8
a:
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z CLUTCH SYSTEM I I I I I I I 3-1 8


0
U5 S I D E STAND I I I 3-1 9
en


w
* SUSPE N S I O N I I I 3-1 9
z * NUTS, BOLTS, FASTEN ERS I I I I 3-20
0
z ** WHEELS/TIRES I I I I I I I 3-2 0
** STE E R I N G HEAD BEA R I N G S I I I I 3-2 1
* Should be serviced by a n authorized Honda dealer, unless the owner has proper tools and service data and is mechanically
qualified .
** I n the interest of safety, we recommend these items be serviced only by an authorized Honda dealer.
NOTES : 1 . At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3 . Service more frequently when riding in rain or at full throttle.
4 . California model only.

3-3
MAINTENANCE

MAI NTENANCE SCHEDULE '89 , ' 9 1-' 9 3;


Perform the PRE-RIDE I N SPECTION in the Owner ' s Manual at each scheduled maintenance period .
1: I N SPECT AND C LEAN , ADJ U ST, LUBRICATE OR REPLACE I F NECESSARY .
C : CLEAN R : REPLACE L: LU BRICATE
The following items require some mechanical knowledge . Certain items ( particularly those m arked * and * * ) may requ i re
more tec h nical i nformation and tools . Consult their authorized Honda deale r .


O D O METER READ I N G ( N OTE 1 )
x 1 ,000 mi 0.6 4 8 12 16 20 24 REFER TO
M
NOTE x 1 ,000 km 1 6.4 1 2 . 8 1 9 . 2 2 5 . 6 32.0 38.4 PAG E
* FUEL LINE I I I 3-6
* THROTTLE OPERATION I I I 3-6
* CARBU RETOR CHOKE I I I 3-7
(/)
A I R CLEANER ( NOTE 2 ) R R 3-7
:2
w C RA N KCASE BREATHER ( N OTE 3 ) c c c c c c 3-8
!:::
c
SPARK PLUG R R R R R R 3-8
1- * VALVE CLEARANCE
w
I I I I 3-8
<(
....J
ENG I N E O I L R R R R 2-4
a:
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z ENG I N E O I L FILTER R R R R 2-5


Q * CARBURETOR SYNCHRON IZATION I I I I 3- 1 0
(/)
- * CARBURETOR IDLE SPEED
(/)
I I I I I I I 3- 11
:2
w
RAD IATOR COOLANT ( N OTE 5 ) I I * R 3- 1 1
* COOLING SYSTEM I I I 3- 1 2
* EVAPORATIVE EMISSION CON-
( NOTE 4) I I 3- 1 3
TROL SYSTEM
DRIVE CHA I N I , L EVERY 600 mi ( 1 ,000 km) 3- 1 3
(/) B R A K E FLU I D ( N OTE 5) I I * R I I * R 3- 1 5
:2
w BRAKE SHOES/PADS WEAR I I I I I I 3- 1 6
!:::
c BRAKE SYSTEM I I I I 3- 16
1- * BRAKE LIGHT SWITCH
w

<(
I I I 3- 1 7
w * HEADLIGHT AIM
....J

a:
I I I 3- 1 8
z CLUTCH SYSTEM I I I I I I I 3-1 8
0
U5 S I DE STAND I I I 3- 1 9
(/)


w
* SUSPENSION I I I 3- 1 9
z * N UTS, BOLTS, FASTENERS I I I I 3-20
0
z ** WHEELS/TI RES I I I I I I I 3-20
** STEERING HEAD BEARI N G I I I I 3-2 1
* SHOU L D BE SERVICED BY AN AUTHORIZED HONDA DEALER, U N LESS THE OWN ER HAS PROPER TOOLS A N D SER
VICE DATA AND IS M ECHANICALLY QUALI FIED.
** I N THE I NTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED O N LY BY AN AUTHORIZED HONDA
DEALE R .
NOTES : 1 . A t higher odometer readings, repeat a t the frequency interval established here .
2 . Service more frequently when riding in unusually wet or dusty areas.
3 . Service more frequently when riding in rain or at ful l throttle.
4 . California type only.
5 . Replace every 2 years, or at indicated odometer interval , whichever comes first . Replacement requires me
chanical skill.

3-4
MAI NTE N A N C E

MAI NTE NANCE SCHEDULE After '9 3;


Perfo rm t h e P R E - R I D E I N SPECTI O N i n the Ownera n u a l at each sched u led mai ntenance period .
! : I N S P E CT A N D C L E N A , ADJ U ST , LU B R I CATE O R R E PLACE I F N E C ESSARY .
C : C LEAN R : R E P LAC E L : LU B R I CAT E
The following items req u i re mech a n ical kn owle dge . Certa i n items (parti c u l a rly th o se ma rked and ) may req u i re more tec h n ical
i nformatio n and tools, Consu lt their a uth orized Honda dealer.

F R EQU E N CY O D O M ET E R R EAD I N G ( N OTE 1 )


x 1 , 000mi 0.6 4 8 12 1 6 20 24 R E F E R TO

ITEM N OTE x 1 00km 1 0 64 1 2 8 1 92 2 5 6 3 2 0 384 PAG E


* F U EL LI N E I I I 3-6
* TH R OTTLE O PE RATI O N I I I 3-6
* CAR B U R ETO R C H O K E I I I 3-7
(/) AI R C LEAN E R ( N OTE2) R R 3-7
:2:
w C RAN KCAS E B R EATH E R ( N OTE3) c c c c c c 3-8
!:::
c S PA R K PLU G R R R R R R 3-8

w
* VALVE C LEARAN CE I I I I 3-8
ENGINE OIL R R R R 2 -4
a:
w

z
E N G I N E O I L F I LTER R R R R 2-5
0 * CAR B U R ETO R SYN C H R O N IZATIO N I I I I 3- 1 0
en
(/) * CAR B U R ETO R I D LE S P E E D I I I I I I I 3- 1 1
:2:
w R A D I ATO R COOLANT ( N OTE5) I I R 3- 1 1
* C O O LI N G SYSTEM I I I 3- 1 2

* EVAPO RATIVE E M I SS I O N C O N -
( N OTE4) I I 3- 1 3
T R O L SYSTEM
D R IVE CHAI N I , L EVERY 500mi (80 0 km ) 3-1 3
(/) B RA K E F LU I D ( N OTE5) I I R I I R 3- 1 5
:2:
w
!:::
B RA K E S H O ES/ PADS WEAR I I I I I I 3- 1 6
c B RA K E SYSTEM I I I I 3- 1 6

w
* B RA K E LI G HT SWITC H I I I 3- 1 7
* H EA D L I G HT A I M I I I 3- 1 8
a:
w

z C LUTCH SYSTEM I I I I I I I 3- 1 8
0
en S I D E STA N D I I I 3- 1 9
* SUSPENSION I I I 3- 1 9
:2:
w * N UTS , B O LTS , FASTEN E R S I I I I 3-20
z
I

0 ** W H E E LS/TI R ES I I I I I I I 3-20
z
** STE E R I N G H EAD B EAR I N G I I I I 3-2 1
* S H O U LD B E S E RVICED BY YO U R AUTH O R IZ E D H O N DA D EALE R , U N LESS TH E OWN E R HAS P R O P E R TOO LS AN D
S E RV I C E DATA AN D IS M EC H AN I CALLY QUALI F I E D .
* * I N TH E I NT E R EST O F SAF ETY , W E R E CO M M E N D THESE ITEM S B E S E RVI C E D O N LY BY YO U R AUTH O R IZ E D
H O N DA D EALE R .
N OTES : 1 . At higher odometer readings, rep eat a t the frequency interval established here .
2 . Service more frequently when riding in u nusually wet or d u sty a reas .
3 . Service more frequently when rid i n g in rain or at fu ll throttle .
4 . California type only .
5 . Replace every 2 years , or at indicated odometer interva l , whichever comes first . Replacement requ i res me
chanical skill .

3-5
MAI NTENAN C E

FUEL LI N E
Remove the seat .

Check the fuel li nes for deterioration, damage or leakage .


Replace the fuel l ines if necessary .

F U E L F I LTER

Pul l the fuel filter out, clip the inlet line closed and remove the
filter.
Replace the fuel filter with new one, if necessary (page 4-3 ) .

TH ROTTLE O P E RATION
Check for smooth throttle grip full opening and automatic full
closing in all steering positions.
C heck the throttle cables and replace them if they are deterio
rated , kinked or damaged .

Lubricate the throttle cables, if throttle operation is not


smooth .

M easure the free play at the throttle grip flange .

FREE PLA Y : 2 - 6 mm ( 1 / 1 6 - 1 /4 in) t

Throttle grip free play can be adjusted at either end of the


throttle cable. Minor adjustments are made with the upper ad
juster.

Major adjustments are mode with the lower adjuster.

Adjust the free play by loosening the lock nut and turning the
adjusting nut. Tighten the lock nuts .

Recheck throttle operatio n . Replace any damaged parts, if


necessary.

3-6
M A I NTENANC E

CARBU RETOR CHOKE


NOTE

C hoke knob operating friction can be adjusted by turning


the adjuster.

Check for smooth operation of the choke knob.


Lubricate the choke cable and/or adjust the choke knob operat
ing friction if operation is not smooth.
To adjust the friction, pull the rubber cover away and turn the
adjuster.

Direction Friction
A Increase
B Decrease

Loosen the choke valve nut and remove the choke valve from
the carburetor.
Pull the choke knob all the way out to fully open position and
recheck for smooth operation of the choke knob.
There should be no free play.

Check the valve seat on the choke valve for damage. Reinstall
the choke valve in the reverse order of removal .

AI R CLEANER
Remove the a i r cleaner housing cover bolt and cover.

Remove the holder bolts and the air cleaner element.


Replace the element i n accordance with the maintenance
schedule.
Also, replace the element any time it is excessively dirty or
damaged .

3- 7
MAINTENANCE

CRAN KCASE BREATHE R


The crankcase breather drain tube i s behind the left frame pipe
and front cylinder head .

Pull the drain tube out of the frame clamp.

Remove the drain plug from the tube to empty any deposits .
Reinstal l the drain plug.

NOTE

Service more frequently when ridden in rain, at full throttle,


or after the motorcycle is washed or overturned . Service if
the deposit level can be seen i n the transparent section of
the drain tube.
(1 ) PLUG GAP (2) SIDE ELECTRODE
0 . 8 - 0 . 9 mm
SPARK PLUGS (0.03 1 - 0.035 in)

Disconnect the spark plug cap and remove the spark plugs.

RECOMMENDED SPARK PLUG : ( 3 ) CENTER


ELECTRODE
NGK NIPPON DENSO
Standard DPR8EA-9 X24EPR-U9
For cold climate
DPR7 EA-9 X22EPR-U 9
( below 5 C/4 1 F)
For extended high speed
DPR9EA-9 X27EPR-U 9
driving

Measure the spark plug gap with a wire-type feeler gauge .

S PARK PLUG GAP: 0 . 8 - 0 . 9 mm (0.03 1 - 0 . 035 in)

Adjust by bending the side electrode carefully. With the plug


washer attached, thread each spark plug i n by hand to prevent
c rossthreading . Continue tightening by hand until the spark
plug bottoms.
Then, tighten the spark plugs a nother 1 /2 turn with a spark
plug wrench to compress the plug washer.
Connect the spark plug caps.

VALVE CLEARANCE
NOTE

I nspect and adjust valve clearance while the engine is cold


( below 3 5 C/9 5 F) .

Remove the following parts :


- fuel tank ( page 4-3)
- air cleaner housing (page 4-4)
- air cleaner chamber and intake duct.

3 -8
MAINTENAN CE

Remove the crankshaft and timing hole caps.

Remove the valve adjusting covers from the cylinder head cov
ers.

NOTE

Adjust the front cylinder valves first.

F R O N T C Y L I N D E R H EA D

Rotate the flywheel counterclockwise to align the " FT" mark


with the index notch on the left crankcase cover. Make sure
the piston is at TDC (Top Dead Center) on the compression
stroke.

I nspect the clearance of all three valves by inserting a feeler


gauge between the adjusting screw and the valve .

VALVE CLEARANCES :
Intake : 0 . 1 5 0 . 02 mm (0.006 0 . 0008 in)
Exhaust : 0 . 20 0 . 02 mm (0.008 0 . 0008 in)

Adjust by loosening the lock nut and turning the adjusting


screw until there is a slight drag on the feeler gauge.

Hold the adjusting screw and tighten the lock nut.

TOOL:
Valve adjusting wrench 0790 8 - K E90000
N ot ava i lable i n U . S . A .
07908- K E 9 0 1 00

TORQUE : 23 N m ( 2 . 3 kg-m, 1 7 ft-lbl

Apply oil to the nut and bolt threads.

3- 9
MAINTENANCE

R E A R C Y L I N D E R H EA D

Rotate the flywheel counterclockwise to align the " RT" mark


with the index notch on the left crankcase cover. Make sure
the piston is at TDC on the compression stroke.

Check the 0-rings of the valve adjusting covers ( I N/EX) for


damage and replace if necessary .
I nsta l l the front and rear valve adjusting covers.

Apply g rease to the timing and crankcase hole caps, then


install and tighten them .

TORQUE
Timing hole cap:
3.5 Nm (0.35 kg-m, 2 . 5 ft-lbl
Crankshaft hole cap:
1 5 Nm ( 1 . 5 kg-m, 1 1 ft-lb)

CARBU RETOR SYNCH RON IZATION


N OTE

Perform this maintenance with the engine at normal operat


ing temperature .

Remove the fuel tank mounting bolt. Carefully raise the tank
and support it in the frame using a suitable base (see page 3-
9) . .

Remove the air cleaner case ( page 4-4) . Remove the plugs from
the cylinder intake ports and install the vacuum gauge
adaptors as shown .

Connect the vacuum gauge. 1l VAC U U M GAUGE

TOOL:
Vacuum gauge 07404 - 0030000
N ot ava i lable in U . S . A .
07 LMJ - 0 0 1 OOOA

Warm up the engine and adjust the idle speed with the throttle
stop screw.

I DLE SPEED: 1 , 200 1 0 0 rpm

3- 1 0
M A I NTENANC E

Check that the difference in vacuum readings is 40 mm ( 1 . 6


i n ) Hg or less.

NOTE
The rea r cylinder carburetor is the base carburetor .

If necessary, synchronize t o t h e specification b y turning the


synchronization adjusting screw.

Recheck the idle speed and synchronization.


Disconnect the gauge and adaptors and install the removed
parts .

CARBU RETOR I DLE SPEED


NOTE
Inspect and adjust idle speed after all other engine adjust
ments are within specifications .
The engine must be warm for accurate adjustment . Ten
m inutes of stop-and-go riding is sufficient.

Warm up the engine, shift to N EUTRAL, and place the motor


cycle on its side stand .
Turn the throttle stop screw as required to obtain the specified
idle speed .

IDLE SPEED: 1 , 200 1 00 rpm

RADIATOR COOLANT
Check the coolant level of the reserve tank with the engine
running at normal operating temperature .
The level should be between the " U P" and " LOW" level lines.

If necessary, remove the right side cover and then remove the
reserve tank cap.
Fill up to the upper level line with 50/ 50 mixture of distilled
water and antifreeze .

Reinstall the reserve tank cap and right sider cover .

3- 1 1
MAI NTENAN C E

COOLI NG SYSTEM
Remove the radiator shroud and check the radiator air pas
sages for clogging or damage . ..
llllf
Straighten bent fins or collapsed core tubes with a small flat
blade screwdriver as shown and remove insects, mud or any
-- --- -- -- . -
obstructions with compressed air or low pressure water.
Replace the radiator if the air flow is restricted over more than
20 % of the radiated surface .
For radiator replacement, refer to page 5-5.

Make sure the hoses are in good condition .


Replace any hose that shows any sign of deterioration.
Check that all hose clamps are tight.

(1 l RESERVE TAN K ( 2 ) RADIATOR

CYLI N DER COM P R ESSION


Warm up the engine.
Stop the engine and remove the spark plug.
Connect a compression gauge.
Turn the engine stop switch OFF.
O pen the throttle grip fully. Crank the engine with the starter
motor until the gauge stops rising.
Check the gauge reading .

NOTE
Check that there is no leakage at the gauge connection .
The maximum reading is usually reached within 4-7 sec
onds.

COMPRESSION :
1 ,324 98 kPa ( 1 3 . 5 1 . 0 kg/cm2, 1 92 1 4 psi)

Low compression can be caused by :


Improper valve clearance adjustment
Valve leakage

Leaking cylinder head gasket


Worn piston rings or cylinder

High compression can be caused by:


Carbon deposits in the combustion chamber or on the
piston head .

3- 1 2
MAINTENAN CE

EVAPORATIVE EM ISSION CONTROL


SYSTEM (California model only)
Check the hoses between the fuel tan k,evaporative emission
canister,evaporative emissio n purge control valve(EVAP
PU R G E CONTRO L VALVE),evaporative emission carburetor
air vent control valve(EVAP CAV C O NTRO L VALVE),and
carbu retor for deterioration,damage o r loose connections.

( 1 )EVAP CAN I STER

Also check the tubes for clogging due to bending or twisting.


Check the evaporative emissio n canister for cracks deterio VACUIII HOSE ROUTI NG DIAGRAM
ration,or other damage. ENGINE FAMILY-c=
EYAI'tiiA T IVE FAMILY-c=:_._ . .=::J
Refer to the vacuu m h ose routing diagram label for hose CALl FDRII I A VEHICLE
connections.

DRIVE CHAIN
CHAIN SLACK INSPECTION

Never inspect or adjust the drive chain while the engine is run
ning.

Turn the ignition switch off, su pport the motorcycle on its side
stand, and shift the transmission into n e utr a l .

Check slack in the d rive chain lower run midway between the
sprockets .

SLACK: 20 - 30 mm (3/4- 1 -3/ 1 6 in)

"'
CHAIN ADJ USTMENT

Loosen the axle nut .


Loosen both lock nuts and turn both adjusting bolts as neces
sary.
Make sure the index m arks on both the adjuster collars are
aligned with the corresponding scale grad uations on both
sides of the swingarm . Tighten both lock nuts, then tighten
the rear axle nut.

TORQUE: 90 Nm (9.0 kg-m, 65 ft-lb)

3- 1 3
MAINTENANCE

Recheck chain slack and free wheel rotation .


Lubricate the d rive chain with Pro Honda Chain Lube o r equiv
alent chain l ubrica nt designed specifically for use on 0-ring
chains .

Check the chain wear label. If the red zone on the label aligns
with the arrow mark of the chain adjuster after the chain has
been adjusted , the chain must be replaced .

REPLACEMENT CHAI N : R K525 S M 5


0 1 0525 VB

L U B R I CATI O N A N D C LE A N I N G
(1) W I PE D RY
When the drive chain becomes extremely dirty, i t should be
cleaned prior to lubrication.
Clean the drive chain with a non-flammable or high flash point
and wipe dry.

The d rive chain on this motorcycle is equipped with small 0-


rings between the link plates . The 0-rings can be damaged by
stea m cleaners, high pressure washers and certain solvents .

Lubricate the d rive chain with Pro Honda Chain Lube or equiv
alent chain l ubricant desig ned specifically for use on 0-ring
chains .

C H A I N R E PLAC E M E N T

The VT600C uses a drive chain ( 1 20 pins) with a staked


master link.
Loosen the drive chain (page 3- 1 3 ) .
Locate the crimped pin ends of the master link from the out
side of the chain and remove the link with the chain cutter.

TOOL:
Drive chain cutter 07HMH - M R 1 0 1 03
N ot ava i l a b l e i n U . S . A .
07 H M H - M R 1 0 1 0B

NOTE
When using the special tool, follow the manufacturer ' s op
erating instructions. (1) SWINGARM

CAUTION
Never reuse the old drive chain, master link, master link plate
and 0-rings.

REPLACEMENT CHAI N : RK525 SM 5


0 1 0 52 5 VB

I nstal l the new drive chain through the swingarm as shown.


(2) D RIVE CHA IN

3- 1 4
MAINTENANCE

Assemble the new master link, 0-rings and plate . (2) 0-RINGS

CAUTION
Insert the master link from the inside of the drive chain and in
stall the plate with the identification mark facing the outside.

Make sure that the master link pins are installed properly.

L
Measuring the master link pin length projected from the plate. MASTER (5) STAN DAR D
LI N K LEN GTH

1m
Standard length: R K: 1 .2-1 .4 m m (0.05 -0.06 i n )
D I D : 1 . 1 5-1 . 5 5 mm (0.05 -0.06 i n )

Stake the master link pins using the special tool. (4) D R IVE CHAI N CUTIER

Make sure that the pins a re staked properly by measuring the


diameter of the staked a rea using a slide calipers. ( 1 ) SLI DE CALI PER (2) GOOD

D I A M ET E R OF TH E STA K E D A R EA:
5.50-5.80 m m (0.2 1 7-0.228 i n )

After staking, check the staked area of the master link for
cracks.
If there is any cracking , replace the master link, 0-rings and (3) N O G O O D
plate . ( 4 ) CRACKED

CAUTION
Drive chain with clip-type master link must not be used.

D R I V E A N D D R I V E N SPRO C K ET

Inspect the sprocket teeth for excessive wear or damage . Re


place if necessary .

NOTE
Never install a new d rive chain on worn sprockets or a worn
chain on new sprockets . Both chain and sprockets must be
in good condition, or the new replacement chain or sprock
ets will wear repidly. (2) NORMAL
I

BRAKE FLU I D
Check the front brake fluid through the sight glass; if the level
is visible, remove the cover, set plate and diaphrag m . Fill the
reservoir to the upper level with DOT 4 fluid from a sealed con
tainer. Check the system for leaks.

CAUTION
Do not remo ve the reservoir cover until the handlebar has been
turned so that the reservoir is level.
Do not mix different types offluid, as they are not compatible
with each other.
Do not allo w foreign material to enter the system when filling
the reservoir.
A void spilling the fluid on painted, plastic or rubber parts.
Place a rag o ver these parts whenever the system is serviced.

Refer to section 14 for brake bleeding procedures .

3- 1 5
MAINTENAN C E

BRAKE SHOE/ PAD WEAR


BRAKE PAD W E A R
'88 , '89 , '9 1 -93 :
Check the brake pads for wear by looking through the slot indi
cated by the arrow cast on the caliper assembly.
Replace the brake pads if the wear grooves in the pads are visi
ble (page 1 4-5) .

CAUTION
A lways replace the brake pads as a set to assure even disc pres
sure.

After '93 :

I nspect the pads visually from under the caliper to determine


the pad wear.

Replace the brake pads if the wear grooves in the pads are visi
ble (page 1 4-5 ) .

CAUTION
A lways replace the brake pads as a set to assure even disc pres
sure.

B R A K E S H O E I N S P E CT I O N

Replace t h e brake shoes i f the arrow on t h e brake a r m aligns


with the reference mark " !::. " on full application of the rear
brake pedal.

BRAKE SYSTEM
I nspect the brake hoses and fittings for deterioration, cracks
and signs of leakage. Tighten any loose fittings.
Replace hoses and fittings as required .

BRAKE P E D A L H E I G H T

Adjust the brake pedal so that the pedal height is 43 mm ( 1 . 7


in) above the top of the footpeg .

3- 1 6
MAINTENANCE

To Adjust :
Loosen the stopper bolt lock nut and turn the stopper bolt .
Retighten the lock nut .

NOTE

After a djusting the brake pedal height, check the rear brake
light switch and brake pedal free play and adjust if neces
sary.

B R A K E P E D A L F R E E P LAY

NOTE

Perform brake pedal free play adjustment after adjusting


brake pedal height.

Check the brake pedal free play.


t
20 - 30 mm
( 3/4 - 1 - 1 /4 in)
FR EE PLAY : 20 - 30 mm (3/4 - 1 - 1 /4 in )

If adjustment is necessary. use the rear brake adjusting nut.

NOTE

After adjusting the brake pedal free play, check the rear
brake l ight switch operation and adjust if necessary.

B RAKE LIGHT SWITCH


N OTE

Perform rear brake light switch adjustment after adjusting


the brake pedal play and height.

The front brake light switch does not require adjustment.

Adjust the brake light switch so that the brake light will come
on when the brake pedal is depressed 20 mm (3/4 in). and
brake engagement begins. Hold the switch body and turn the
adjusting nut. Do not turn the switch body .

3- 1 7
MAINTENANCE

HEADLIGHT AI M ( 1 ) HORIZONTAL ADJUSTING


SCREW
Adjust vertically by turning the vertical adjustment screw .
Adjust horizontally by turning the horizontal adjusting screw .

NOTE
Adjust the headlight beam as specified by local laws and
regulations.

A n improperly adjusted headlight may blind oncoming drivers, (2) VERTICAL ADJUSTING
or it may fail to light the road for a safe distance. SCREW
----

CLUTCH SYSTEM
Measure the clutch lever free play at the lever end.

FREE PLAY : 1 0 - 20 mm (3/8 - 3/4 in)

i
( 1 ) 1 0 - 20 mm
( 3/8 - 3/4 in)

\
Minor adjustments are made with the upper adjuster. ( 1 ) U PPER ADJ U STER

Pul l the lever cover back, loosen the lock nut and turn the ad
juster to obtain the specified free play.

Tighten the lock nut and install the cover. "" L .


I
Check clutch operation .

After'9 5 :
M ajor adjustments are made with the lower adjuster.
Loosen the lock nut and turn the adjusting nut to obtain the
specified free play.

Tighten the lock nut and check the clutch operation .

( 1 ) LOWE R ADJ U ST E R

3- 1 8
MAI NTENANCE

SI DE STAND
Check the spring for damage o r loss of tension.
Check the side stand assembly for freedom of movement.
Lubricate the pivot bolt and the side stand pivot area if neces
sary.
Tighten the pivot bolt and nut.

TORQUE: BOLT: 10 Nm 1 1 . 0 kg-m, 7.2 ft-lbl


NUT: 30 Nm (3.0 kg-m, 22 ft-lbl

Check the side stand ignition cut-off system :


- Sit astride t h e motorcycle and raise t h e side stan d .
- Start t h e engine with t h e transmission in neutral , t h e n shift
the transmission into gear, with the clutch lever squeezed .
- Move the side stand full dow n .
- The engine should stop as t h e side stand is lowered .
If there is a problem with the system , check the side stand
switch (section 1 6 1 .

SUSPENSION
FRONT

Check the suspension action by compressing it several times .

Check the entire fork leg assembly for signs of leaks or dam
age .
Replace any components which are unrepairable.
Tighten a l l nuts and bolts to the specified torque value.

D o n o t ride a vehicle with faulty suspension. Loose, worn, or


damaged suspension parts may affect stability and rider con
trol.

!
REAR

Check the action of the rear suspension components by com


pressing them several times.
Check the entire suspension assembly, being sure it is securely
mounted and not damaged or distored .

Tighten a l l nuts and bolts to the specified torque value.

3- 1 9
MAI NTENAN C E

N UTS, BOLTS, FASTEN ERS


Tighten the bolts, nuts and fasteners at the i ntervals shown in
the Maintenance Schedule (page 3-3 ) .
Check that a l l chassis nuts and bolts are tightened t o their cor
rect torque values ( page 1 -5 , 6 and 7 ) .
Check a l l cotter pins and safety clips.

WHEELS/TI RES
TI R E P R E S S U R E

NOTE
Tire pressure should be checked when the tires are COLD .

Front Rear
Tire size 1 00/90- 1 9 5 7 S 1 70/80- 1 5 7 7 S
Up to
C o l d tire
pressures vehicle
200 ( 2 . 00, 29) 2 50 ( 2 . 50, 36)
kPa capacity
( kg/cm2, load
psi) U p to 90 kg ( 1 ) SPO K E
(200 lbs) 200 ( 2 .00, 29) 200 ( 2 .00, 29)
load
Maximum weight capacity 1 61 kg ( 3 5 5 lbs)
Tire Bridgestone L 3 09 G 546
brand Dunlop F24 K555

Check t h e tires for cuts, imbedded nails, or other sharp ob


jects .

Check the front and rear wheels for trueness ( Section 1 2 and
13).
Measure the tread depth at the center of the tires .
Replace the tires if the tread depth reaches the following limit:

MINIMUM TREAD DEPTH :


Front: 1 . 5 mm (0.06 in)
Rear: 2.0 mm (0.08 in)

Tighten the wheel spokes periodically.

TORQUE (front/rear) : 4 Nm ( 0 . 4 kg-m , 2 . 9 ft-lb)

TOOL:
Spoke wrench 07JMA - MR601 00
N ot ava i l a b l e in U . S . A .

3 -20
M AI N T E N A N C E

STE ER I N G H EAD BEAR I NGS


NOTE

Check that the control cables do not interfere with handle


bar rotatio n .

Raise t h e front w heel off the ground.


Check that the fork pivots freely from side to side. If the fork
pivots unevenly, binds, or has vertical movement, inspect the
steering head bearings ( Section 1 2 ) .

3-2 1
FUEL SYSTEM

1 9 N m ( 1 . 9 kg-m, 1 3 . 7 ft-lbl

4-0
4. FU EL SYSTEM
S ERV I C E I N FO RMATIO N 4- 1 CARBU R ETO R I NS TALLATIO N 4- 1 5

T RO U BLESHOO T I N G 4-2 PILO T S C R EW ADJ USTMENT 4- 1 5

F U EL TAN K 4-3 H I G H ALTIT U D E ADJ USTMENT


( U . S . A . ONL V) 4- 1 6
A I R CLEAN ER H O U S I N G 4-4
EVA P O R AT I V E E MI S S I O N
CARB U R ETO R REM OVAL 4-6
PU R G E CO NT RO L VALVE I N S PECTIO N
CAR B U R ETO R D I SASS E M BL V 4-6 ( California model only) 4- 1 6

CA R B U R ETO R ASS E M B L V 4- 1 0 EVA P O R ATIVE E M I S S IO N C A R B U R ETO R


A I R VENT CO NTRO L VALVE
Ill
CARB U R ETO R
I NS PECTIO N ( Californ ia model only) 4- 1 7
S E PA RATIO N / ASS E M B L V 4- 1 3

SERVICE I N FORMATIO N

Gasoline is extremely flammable and is explosive under certain conditions work in a well ventilated area a with the engine stopped.
Work in a well ventilated area.

If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.

G E N ERAL

Refer to Section 3 for carburetor synchronization, throttle cable and choke cable adjustments .
When d isassembling fuel system parts, note the locations of the 0-rings; replace them with new ones on reassembly .
The carburetor float chambers have d rain screws that can be loosened to drain residual gasol ine .
For fuel pump refer to section 1 8 .
All hoses used in the evaporative emission control system are numbered for identification . When connecti ng one of these
hoses, compare the hose number with the Vacuum Hose Routing Diagram Label on page 4- 1 6 (California model only) . for
its routing.

CAUTION
Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind.

N OTE

If vehicle is to be stored for more that one month , drain the float bowls. Fuel left in the float blowls will cause clogged jets
resulting in starting and drivability complaints .

S P E C I F I CATI O N S

Item 49 St. model California model


Type Constant Vacuum dual carburetor
Throttle bore 34 mm ( 1 .4in) 34 mm ( 1 .4 in)
Identification No. VDFDA VD FEA
Float level 7.0 mm ( 0 . 2 8 i n ) 7 . 0 mm ( 0 . 2 8 i n )
Main jet Front : # 1 1 5, Rear: #1 1 5 Front : # 1 1 5, Rear: # 1 15
Slow jet #40 #40
Idle speed 1 , 200 1 00 rpm 1 , 200 1 00 rpm
Throttle grip free play 2-6 mm ( 1 / 8 - 1 /4 in) 2-6 mm ( 1 /8 - 1 /4 in)
Pilot screw initial opening See page 4-15.

4- 1
F U E L SYSTEM

TO R Q U E VA LU E

Fuel tank mounting bolt 1 9 Nm ( 1 . 9 kg-m , 1 3 . 7 ft-lb)

TOOLS

Special
Vacuum/Pressure pump A937X - 04 1 - XXXXX or
Pressure pump ST - AH- 2 5 5 - M C 7 ( U S A . only)
. .

Vacuum pump ST - AH - 260 - M C 7 ( U . S A . only)


.

Valve guide driver, 7 mm 07942 - 8230000 ( U . S A. only)


.

Common
Float level gauge 0740 1 - 00 1 0000

TROU BLESHOOTI NG
Engine cranks but won't start Misfiring during acceleration
No fuel in tank Faulty ignition system
No fuel to carburetor
Engine flooded with fuel Backfiring
No spark at plug (ignition system faulty) Faulty ignition system
Clogged air cleaner faulty carburetor
Intake air leak
Improper choke operation Poor performance (driveability) and poor fuel economy
Improper throttle operation Clogged fuel system

Faulty ignition system
Hard starting or stalling after starting Dirty air cleaner
Improper choke operation (California model only : )
Ignition malfunction : Faulty evaporative emissio n carbu retor a i r vent
Faulty carburetor control valve

Fuel contaminated : Warn/damaged emission system hoses


Intake air leak
Incorrect idle speed Lean mixture

Incorrect valve clearance (Section 3 ) Clogged fuel jets


Incorrect carburetor synchronization (Section 3) Stuck vacuum piston
Improper choke valve operatio n . Faulty float valve
Low float level
Rough idle Clogged fuel tank breather
Faulty ignition system Clogged fuel strainer

Incorrect idle speed Restricted fuel line

Incorrect valve clearance (Section 3 1


I ntake air leak
Incorrect carburetor synchronization Restricted or faulty fuel pump
Faulty carburetor
Fuel contaminated Rich mixture
Faulty air cut off valve Clogged air jets
(California model only : ) Faulty float valve
: Fau lty evaporative em ission purge control valve Float level too high
: Fau lty evaporative em issio n carbu retor air vent Dirty air cleaner
control valve
: Worn/damaged emission system hoses

Afterburning during deceleration

Faulty ignition system

Faulty air cut off valve

Lean mixture
(California model only : )
: Worn/damaged emission system hoses

4- 2
F U EL SYSTEM

FUEL TAN K ( 2 ) FUEL TAN K


MOUNTING
REMOVAL BOLT

Gasoline is extremely flammable and is explosive under certain


conditions. Work in a well ventilated area with the engine
stopped. Do not smoke or allow flames or sparks in the work
area or where gasoline is stored.

Remove the seat and turn the fuel valve off.


Remove the fuel valve knob mounting bolt and fuel valve knob
from the fuel tank body.

Remove the fuel tank mounting bolt.

Disconnect the fuel tube from the fuel tank and fuel breather
tube (t o canister: California model only) .

Check that fuel flows out of the fuel valve freely.


If flow is restricted , clean the fuel strainer.

Remove the fuel tank from the frame.

I N STALLAT I O N

Install the fuel tank in the reverse order o f remova l .


Install t h e f u e l valve knob onto t h e fuel valve as shown a n d
tighten t h e bolt . .
Tighten the fuel tan k mounting bolt securely.

( 1 ) FUEL TAN K
(3) F U E L STRAINER SCREEN

(5) FUEL FILTER


N OTE



The fuel filter with its narrow
pointing toward the outside .
l1i< (8) TO FUEL
t.
($.,
PU MP
'
171 FUEL VALVE K N O B . i .

( 2 ) FUEL PIPE JOINT rt. ( 9 ) TO CARBU R ETOR


NOTE

The fuel pipe joint with its nar

_

row end toward outside .

4-3

FUEL S YSTEM

AI R C LEA N ER HOUSING ( 1 ) A I R CLEAN ER H O U S I N G "


MOUNTING BOLTS 1""'"'
REM OVAL

Remove the fuel tank mounting, and lift the tank and remove
the air cleaner housing mounting bolts .

'
Loosen the air cleaner housing -to-air cleaner chamber band .
Disconnect the crankcase breather tube from the air cleaner
housi ng.

I N STALLATI O N

Wipe clean the mating surfaces shown and apply a cemment


(or equivalent) .
I nstall the removed parts i n the reverse order of removal .

S U B-A I R C L E A N E R E L E M E N T

Remove t h e fol lowing :


- seat (page 1 3- 1 8) and fuel tank (page 4-3)
- air cleaner housing

Disconnect the air hoses (carburetors-to-sub-air cleaner cov


er) .
Remove the sub-air cleaner mounting bolt and cover and
remove the element.

4-4
F U E L SYSTEM

Wash the element in non-flammable or high flash point sol


vent, squeeze out the solvent thoroughly, and allow the ele
ment to dry.
Soak the element in gear oil (SAE #80 - 90) and squeeze out


the excess .
(3)

Reinstal l the element and cover, and tighten the bolt.
Reconnect the air tubes from the carburetors . DRY

! J
! t

(1 ) (2) (4) (5)


WASH I N S Q U E EZ E O U T GEAR O I L S Q U E EZ E OUT
SOLVENT SOLVENT (SAE #80 - 90 1 EXCESS O I L
T H O R O U G H LY

A I R C L EA N E R C H A M B E R
R E M OV A L/ I N STA LLAT I O N

Remove t h e air cleaner housing and sub-air cleaner element


( page 4-4 ) .

Loosen t h e intake duct hose b a n d s a t t h e carburetors and


unhook the air cleaner chamber drain tube from the frame .

Remove the air cleaner chamber from the frame .


To reinstal l the chamber: position it i n the frame, and connect
the i ntake ducts to the carburetors and tighten the band
screws .
I nstall the sub-element and cover ( page 4-4) .
I nstall the air cleaner housing (page 4-4) .

----- ( 8 ) PLUG

(3) A I R CLEA N E R H O U S I N G

(6) HOLDER

4- 5
FUEL SYSTEM

CARBURETOR REMOVAL

Gasoline is extremely flammable and is explosive under certain


conditions. Work in a well ventilated area with the engine
stopped. Do not smoke or allow flames or sparks in the work
area or where gasoline is stored.

Loosen the drain screws and drain the fuel into a container.

Remove the sub-air cleaner chamber ( page 4-4) .


Remove the throttle cable cover and disconnect the throttle
cables from the carburetor.

Remove the left choke valve from the carburetor and loosen
the carburetor insulator bands.

Disco n nect the evaporative emission p u rge control valve No.5


tubes and evaporative emission carburetor air vent control
valve No.6 and 1 0 tubes from the carburetor (California model
only) .
Pull the carbu retors the u pward and out of the engine.

.
CARBURETOR DISASSEM BLY (2) C H O K E
'
CABLE
NOTE LOCK

The carburetors can be disassembled without being sepa


rated .

Remove the air tubes (carburetors-to-sub-air cleaner) , and fuel


tube from the carburetor.

Remove the choke cable and right choke valve from the carbu
retor by loosening each lock nut.

VAC U U M C H A M B E R

Remove the four screws a n d vacuum chamber cover.

4-6
FUEL SYSTEM

Remove the spring, and diaphragm/vacumm piston. ( 1 I D IAPHRAG M/PISTON (2) SPRING
Inspect the vacuum piston for wear, nicks, scratches or other
damage.

Make sure the piston moves up and down freely in the cham
ber.

Push the needle jet holder in and turn it in 90 degrees counter


clockwise.

(1 I NEEDLE J ET HOLDER

Then remove the needle holder, spring, jet needle and washer (1 ( 2 ) J ET (3) HOLDER
from the piston . N EEDLE
Inspect the needle for excessive wear a t the tip, bending or
other damge .
Inspect the diaphragm for damage, fatigue or pin holes.
Inspect the vacuum piston for wear or damage.

I
(4) SPRING

FLOAT CHAMBER, FLOAT AND JETS

Remove the four screws and float chamber.

4- 7
F U E L SYSTEM

Remove the float pin, float and float valves.

Check the float valve and valve seat for scratches, clogging or
damage.

Inspect the operation of the float valve.

Remove the main jet, needle jet holder, slow jet and valve seat/
filter.
(2) MAIN
Check each part for wear or damage . J ET
Blow open all jets with compressed air.

Clean each jet with non-flammable or high flash point solvent.

Inspect the float valve seat and filter for grooves, nicks or de
posits .
/ lt. ow '
Clean the filter with low-pressure compressed air. ( 5 ) F I LTER
(4) VALVE SEAT
/''' ,..,
SLOW J ET
(3)

PILOT SCREW

NOTE

The pilot screws are factory pre-set and should not be re


moved u nless the carburetors are overhauled .

The pilot screw plugs are factory i nstalled to prevent pilot


screw misadjustment. Do not remove the plugs unless the
pilot screws are being removed.

Cover all openings with tape to keep metal particles out


when the plugs are drilled .

4-8
FUEL SYSTEM

Center punch the pilot screw plug to center the drill point.
Drill throug h the plug with a 4 mm ( 5/32 in) drill bit. Attach a
drill stop to the bit 3 m m (1/8 i n ) from the end to prevent
drilling into the pilot screw .

CAUTION
Be careful not to drill into the pilot screw.
Both pilot screws must be replaced even if only one requires it,
for proper pilot screw adjustment (page 4-15).

Force a self-tapping 4 mm screw, P/N 93903 - 3 5410) i nto


the drilled plug and continue turning the screwdriver until the
plug rotates with the screw.

Pull on the screw head with pliers to remove the plug.

Use compressed air to clean the p ilot screw area and remove
metal shavings.

Turn each pilot screw in and carefully count the n umber of


turns until it seats lightly. Make a note of this to use as a refer
ence when reinstalling the pilot screws .

CAUTION
Damage to the pilot screw seat will occur if the pilot screw is
tightened against the seat.

0
Remove the pilot screws and inspect them. Replace them if
they are worn or damaged . /
(4) WASHER

(3) PILOT SCREW /

A I R C U T O F F V A LV E

Remove t h e two screws, t h e set plate and t h e air cut off valve
cover.

NOTE
The air cut off valve cover is under spring pressure. Do not
loose the spring and screws.

4-9
FUEL SYSTEM

Visually check the following : 0-RING


- diaphragm for deterioration, pin hole or other damage.
- spring for deterioration or other damage.
- diaphragm needle for excessive wear at the tip or other
damage. (3) DIAPHRAG M
- orifice of air vent for clogging.

cl
- 0-ring for damage.

Replace the air cut off valve as an assembly, if necessary.

(4)
/
S PR I N G

Separate the carburetors ( page 4- 1 3 ) .


Blow open all passages with compressed air before i nstalling
jets and valves .

CARBU R ETOR ASSEMBLY

( 5 ) HOLDER

( 1 4) PISTON

( 1 5) FLOAT (9) A I R-CUT


VALVE
COVER
( 1 3) FLOAT
CHAMBER --:-i

( 1 2) VALVE ( 1 0) SLOW JET


SEAT

4- 1 0
F U E L SYSTEM

P I LOT S C R EW ER

I nstall the pilot screws and return them to their original posi
tion as noted during remova l .
Perform pilot screw adjustment if n e w pilot screws are in
stalled .

NOTE (4) PILO T SCREW

Do not install new plugs on new pilot screw holes until after

1 /
adjustment has been made.

If you replace the pilot screw i n one carburetor, you must


replace the pilot screw in the other carburetor for proper
pilot screw adjustment. (3) SPRING

FLOAT C H A M B E R , F LOAT A N D J ETS

I nstall the pilot screw and turn it i n until it seats lightly.


Turn the pilot screw out the number of turns recorded during
remova l .

CAUTION

Damage to the pilot screw seat will occur if the pilot screw is
tightened against the seat.

I nstall the valve seat, slow jet, needle jet holder and main jet.

Install the float with float valve i n the carburetor body, then in
stall the float arm pin through the body and the float.

FLOAT L E V E L GAUGE

Measure the float level with the float tang just contacting the
float valve.

TOOL:
Float level gauge 0740 1 - 00 1 0000

FLOAT LEVEL: 7 mm (0.28 in)

Adjust the float level by carefully bending the float tang .

4- 1 1
FUEL SYSTEM

I nstall the 0-ring on the float chamber groove.

I nstall the float chamber and tighten the screws securely .

NOTE

I nstall the fuel tube clamp.

VAC U U M CHAM B E R

I nstall t h e washer, jet needle, spring and needle holder t o the


vacuum piston.
Push the jet needle holder i n and turn it in 9 0 degrees cloc
kwise .

Hold vacuum piston u p to almost full open to avoid pinching


the diaphragm with the chamber cover.

(1 l J ET NEEDLE
HOLDER (4) F I N G E R

The vacuum piston with the tab of the diaphragm aligned with ( 2 ) CAVITY
the groove of the carburetor.

I nstall the chamber cover with the spring, aligning the cover
cavity with the hole i n the carburetor, and secure with at least
two screws before releasing the vacuum piston.

4- 1 2
FUEL SYSTEM

Install the right choke valve and choke knob.


(21 CHOKE KNOB

FUEL TUBE;:,p:s .
....--.......
Install the fuel and air tubes as shown. ( 1I
.lib

CARBU RETOR
SEPARATIO N / ASSEM BLY
SEPARATION

Loosen the synchronization adjusting screw.

NOTE

When separating the carburetors, be take careful not to lose


the thrust spring and synchronization adjusting spring.

Separate the carburetors by removing two attaching screws.

Remove the synchronization spring.

(2) SYNCHRON
. ..
IZATION SPRING

4- 1 3
FUEL SYSTEM

ASSEMBLY 111 THRUST


SPRING
loosen the synchronization adjusting screw until there is no
spring tension.

Install the thrust spring between the throttle links.

Secure the carburetors together with the two screws.

Install the synchronization spring and synchronization adjust 121 SYN C H RON IZATION
ing screw. ADJUSTING SCREW

Inspect throttle operation a s described below :

Open the throttle slightly by rotating the throttle valve, then


release the throttle. M ake sure that there is no drag when
opening and closing the throttle.

Turn the throttle stop screw to align the rear cyli nder carbure
tor throttle valve with the edge of the by-pass hole.

(2) THROTTLE STOP SCREW

Align the front cylinder carburetor throttle valve with the by (1 ) SYN C H RO N IZATION ADJUSTIN G
REW
pass hole edge by turning the synchronization adjusting
screw.

Make sure the throttle returns smoothly.

4- 1 4
FUEL SYSTEM

CARB U RETOR I NSTALLATION


I nstall t h e carburetors onto the cylinder heads a n d tighten the
insulator bands securely.

I nstal l the following parts


- air cleaner chamber
- air cleaner housing
- fuel tank
- throttle cables
Adjust as follows:
- pilot screw ( page 4- 1 51
- carburetor synchronization ( page 3- 1 0 ) .
- throttle grip free play ( page 3-6 ) 0

- carburetor idle speed ( page 3- 1 1 ) 0

- carburetor choke ( page 3-7 ) 0

P I LOT SCR EW ADJ USTM ENT


I D L E D R O P P R O C E D U R E ( U . S . A . O N LY l

NOTE

The pilot screws are factory p re-set and no adjustment is


necessary u nless the pilot screws are replaced .

Use a tachometer with graduations of 50 rpm or smaller


that will accurately indicate a 50 rpm change .

1. Remove the pilot screw plugs ( page 4-8) 0

2 o Turn each pilot screw clockwise until it seats lightly and


back it out to the specification give n .
CAUTION

Damage to the pilot screw seat will occur if the pilot screw is
tightened against the seat.

This is an initial setting prior to the final pilot screw adjust


ment.
I NITIAL OPENI N G : 1 - 1 /4 turns out
3 . Warm u p the engine to operating temperature .
Stop and go driving for 1 0 minutes is sufficient.
4 . Attach a tachometer according to the manufacturer ' s in
structions .
5 0 Adjust the idle speed to the specified rpm with the throttle
sto p screw .
I D LE S P E E D : 1 , 200 1 00rpm

6 Turn each pilot screw 1 /2 turn out from the initial setting .
0

7 . If the engine speed increase by 5 0 rpm o r more , turn each


pilot screw out by successive 1 /2 turn increments u ntil
engine speed does not increase 0
8 Adjust the idle speed with the throttle stop screw .
0

9 . Turn the rear cylinder carburetor pilot screw i n until the


engine speed drops 50 rpm .
1 0 . Turn the rear cylinder carburetor pilot screw 1 turn out
from the position obtained in step 9 0

1 1 Adjust the idle speed with the throttle stop screw.


0

1 2 Perform steps 9, 1 0 and 1 1 for the front cylinder carbu


o

retor pilot screw 0

1 3 0 Drive new pilot screw plugs i nto the pilot screw bores
with a 7 mm valve guide driver (P/N 07 942 - 8230000 ) .
W h e n fully seated the plug surfaces w i l l b e recessed 1 ( 1 I PLUG
mm.

4- 1 5
F U E L SYSTEM

H IGH ALTITUDE ADJ USTM ENT (U.S.A. only)


When the vehicle is to be operated continuously above 2 , 000
m (6, 500 feet) the carburetors must be readjusted as follows
to improve driveability and decrease exhaust emissions.
Remove each pilot screw plug ( page 4-8) .
Warm up the engine to operating temperature . Stop and go
d riving for 1 0 minutes is sufficient.
Turn each pilot screw to the specification below .
1/2 Turns in


H I G H ALTITU D E S ETTI N G :
Adjust the idle speed to 1 , 2 00 1 00 rpm , with the th rottle
stop screw . LE E M ISSION CONTROL
Drive new pilot screw plugs i nto the pilot screw bores ( page 4- I N FOR MATI O N UP DATE LAB E L
1 5) .
NOTE

This adjustment must be made at high altitude to ensure


proper high altitude operation .
Attach a Vehicle Emission Control I nformation u p date label
o nto the inside of the left side cover as shown.See S L# 1 3 2 for VEHICLE EMISSION CONTROL INFORMATION UPDATE
information on o btaining the label. HONDA MOTOR CO., LTD

NOTE
Do not attach the label to any part that can be easily re
THIS VEHICLE HAS BEEN ADJUSTED TO
IMPROVE EMISSION CONTROL PERFORMANCE
WHEN OPERATED AT HIGH ALmUDE.
.
moved from the vehicle. ALmuDE PERFORMANCE ADJUSTMENT INSTRUCTIONS
ARE AVAILABLE AT YOUR AUTHORIZED HONDA DEALER.

''51111d
Sustained operation at an altitude lower than 1, 500 m
(5, 000 feet) with the carburetors adjusted for high alti
tude may cause the engine to idle roughly and engine
may stall in traffic and may cause engine damage due to
overheating.
When the vehicle is to be operated continuously below
1 , 500m (5 , 000 feet), turn each pilot screw to the specificatio n
below, its o riginal position .
LOW A LTITU D E S ETTI N G : 1/2 turn out
Adjust the idle speed to 1 , 2 00 1 00 rpm with the th rottle
stop screw .
D rive new pilot screw plugs into the pilot screw bores ( page 4 VACUUM HOSE ROUTI NG DIAGRAM
- 1 5) .
ENGI NE FAMI LY- ';:;-;-;-; ==----
EVAPORAT I VE FAMILY;r: :: ------,:J
Be sure to make these adjustments at low altitude . Remove
L =:::
____
the Vehicle Emission Control U pdate Label that attached to
the inside of the left side cover after adjusti ng for the low CAL l FORNIA VEHI C L E
altitude .

EVAPORATIVE E M ISSION
P U RG E CONTROL VALVE INSPECTION
(Ca l iforn ia mod e l o n l y) "'
NOTE ..:
z
w
The evaporative em1ss1o n p u rge control valve should be
"-
0
inspected if hot restart is d ifficult.
Check all fuel tan k, Evaporative Emission Purge Control Valve
( EVAP P U R G E CONTROL VALVE),and evaporative emission
canister hoses to be su re they a re not kin ked and a re secu rely
connected. Replace any hose that shows signs of damage or EVAP CAN I ST E R
d eterioration. MZS -930

NOTE
The EVAP PU R G E CONTROL VALVE is located u nder the
fuel tan k.

4- 1 6
F U E L SYSTEM

Disconnect the EVAP P U R G E CONTROL VALVE hoses from ( 1 ) EVAPO RATIVE E M I S S I O N


their connections and rem ove the EVAP P U R G E CONTRO L P U R G E CONT R O L VALVE
VALVE from its mou nt. R efer t o the routin g label on the i nside
of the left side cover for hose connections.
Connect a vacuum p u m p to the 8 m m (0.3 1 in.) I . D.hose No.5
that goes to the 3-way joint.Apply the specified vacu u m to the
EVAP PU R G E CONTR O L VALVE.
SPECIFIED VACUUM: 250 mm (9.8 in) Hg
The specified vacuu m should be m aintained.
Replace the EVAP PU R G E CO NTRO L VALVE if vacuu m is not I
( 5 ) T VAPO RATIVE
E M I S S I O N CAN I STER
\'
\
maintained.
(4) TO CARBU RETOR ( 2 ) VACUUM PUMP
TOOL:
BODY
Vacuum/Pressure pump A937X - 041 - XXXXX or
Vacuum pump ST - AH - 260- MC7
( U .S.A. only)
Remove the vacu um p u m p a n d con n ect it to the vacuum hose
N o . 1 1 that goes to the left carbu retor body.
Apply the specified vac u u m to the EVAP P U R G E CONTRO L
VALVE.
( 1 ) VAC U U M PUMP

I
SPECIFIED VACUU M : 250 mm (9.8 in) Hg
The specified vacu u m should be maintained.
Replace the EVAP PU R G E CO NTRO L VALVE if vacuu m is not
maintained.
TOOL:
Vacuum/Pressure pump A937X - 041 - XXXXX or
Vacuum pump ST - AH - 260- MC7
( U . S.A. only)
Con nect a p ressu re p u m p to the 8 m m (0.3 1 in. ) I . D .hose N o.4
that goes to the evaporative emission canister.While a pplying
the specified vacu u m to the EVAP PU R G E CONTROL VALVE
hose that goes to the 3-way joint p u m p air through the
evaporative emission canister hose.Air shoud flow through the
EVAP PU R G E CONTR O L VALVE and out the hose that goes to
the 3-way joint.
R eplace the EVAP P U R G E CONTROL VALVE if air does not
flow out.
CAUTION
To preven t damage to the evaporative emission purge con trol valve,
do not use high air pressure sources. Use a hand operated air pump
only.

TOOL:
Vacuum/Pressure pump A937X - 041 - XXXXX or ( 2 ) VACUUM PU MP
Vacuum pump ST -AH - 260- MC7
Pressure pump ST -AH - 255 - MC7
( U . S.A. only)
R emove the p u m ps, i n stal l the EVAP P U R G E CONTR O L
VALVE on its mount, route and reconnect the house accord
ing to the routing label.

EVAPORATIVE EM ISSION CARBU R ETOR


AIR VENT CONTROL VALVE INSPECTION
(Ca l iforn i a mod e l o n l y)
D isconnect the Evaporative Emission Carburetor Air Vent
Control Valve( EVAP CAV CONTR O L VALVE)hoses from their
connections and remove the EVAP CAV CO NTRO L VALVE
from its mou nt. R efer to the routing label on left side cover for
hose connections.

4- 1 7
F U EL SYSTEM

Connect a vac u u m pump to the No. 1 0 hose that goes to the


rig ht carbu retor body. ( 1 1 TO A I R (21 TO OPEN A I R
Apply t h e specified vacuum t o t h e EVAP CAV CONTR O L J O I NT PIPE ( 3 ) EVAPO RATIVE E M I SS I O N
VALVE. N o . 6 HOSE CAR B U R ETO R AI R V E NT
CONTROL VALVE
SPECIFIED VACU U M : 250 mm (9.8 in) Hg
TOOL: (4) TO
Vacuum/Pressure pump A937X - 04 1 - XXXXX or EVAPO RATIVE
Vacuum pump ST - AH - 260 - MC7 EM ISSION
( U .S.A. only)
The specified vacuu m should be maintained.
CAN I STER
N o . 4 HOSE/
( 5 ) TO R I G HT
Replace the EVAP CAV CONTRO L VALVE if vacuum is not CARBU RETOR
maintained. BODY No. 1 0 HOSE ( 6 1 VAC U U M PU M P

CAUTION
To prevent damage to the evaporative emission carburetor air vent
con trol valve, do not use high air pressure sources. Use a hand
operated air pump only.

Connect the vacuum pump to the air vent port of the EVAP
CAV CONTROL VALVE.
Apply vacuum to the EVAP CAV CONTROL VALVE.The
vacuum should hold steady.
R eplace the EVAP CAV CONTRO L VALVE if vacuum leaks.
TOOL:
Vacuum/Pressure pump A937X - 04 1 - XXXXX or
Vacuum pump ST - AH - 260 - MC7
( U .S.A. only)

Connect the vacuum pump to the No. 1 0 hose that goes to the
right carb u retor body.
Connect the pressu re pump to the air vent port of the EVAP
CAV CONTROL VALVE.
While a pplying the vacuu m to the EVAP CAV CONTR O L
VALVE N o . 1 0 hose that goes t o t h e rig ht carburetor body,
pump air through the air vent port.
Air should flow through the EVAP CAV CONTROL VALVE and c..,_,'
out the hose that goes to the carb u retor air joint pipe.
TOOL:
Vacuum/Pressure pump A937X - 04 1 - XXXXX or
Vacuum pump ST - AH - 260 - MC7
Pressure pump ST - AH - 25 5 - MC7
( U .S.A. only)
Plug the hose that goes to the carburetor air joint pipe.
While applying vacuu m to the EVAP CAV CONTROL VALVE
No. 1 0 hose that goes to the rig ht carburetor body,apply air
pressure.
It should hold steady.
R eplace the EVAP CAV CONTR O L VALVE if pressure is not
retained.
Remove the p u m ps,install the EVAP CAV CONTROL VALVE
o n its mou nt,route and reconnect the hoses according to the
routing label.
TOOL:
Vacuum/Pressure pump A937 X - 04 1 - XXXXX or
Vacuum pump ST - AH - 260- MC7
Pressure pump ST - AH - 25 5 - MC7
( U .S.A. only)

4- 1 8
M EMO
COO L I N G SYSTEM

5-0
5. COOLI NG SYSTEM
S ER V IC E I N FO RMAT I O N 5- 1 THERMOSTAT 5-3

T R O U BL ES HOO T I N G 5- 1 RADIATOR/CO O LING FAN 5-5

S Y S T E M TESTING 5-2 WATER P U M P 5-7

C O O LA N T REPLAC E M E N T 5-3 COO LANT/RESERVE TAN K 5-9

SERVICE I N FORMATION
G E N ERAL

Do not remove the radiator cap when the engine is hot. The coolant is under pressure and severe scalding could result. The engine
m ust be cool before servicing the cooling system.
If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.

Use only distil led water and ethylene glycol in the cooling system. A 50 - 50 mixture is recommended for maximum corro
sion protection. Do not use alcohol-based antifreeze .
Add coolant at the reserve tank. Do not remove the radiator cap except to refi l l , coolant mixture testing or drain the sys-
tem, or to test the coolant mixture.
Avoid spilling coolant on painted surfaces .
After servicing the system , check for leaks with a cooling system tester.
For thermosensor and thermostatic switch removal and inspection, refer to section 1 8 .
To service the water pump, the engine must be removed from the frame.

S P E C I F I CAT I O N S

ITEM SPEC I F I CATIONS


Radiator cap relief pressu re 88 - 1 27 kPa (0. 9 - 1 . 3 kg/cm2, 1 3 - 1 8 psi)
Freezing point (Hydrometer test ) : 55 % Distilled water + 45 % ethylene glycol: -32 C (-2 5 F)
50 % Distilled water + 50 % ethylene glycol: -37 C (-34 F)
45% Distilled water + 5 5 % ethylene glycol : -44. 5 C (-48 F)
Coolant capacity: Coolant change : 1 .45 lit ( 1 . 3 7 U S qt, 1 . 28 Imp qt)
Total system: 1 . 6 lit ( 1 . 5 1 US qt, 1 .4 1 Imp qt)
Thermostat Begins to open: 80 to 84 C ( 1 7 6 to 1 83 F)
Valve lift: Minimum of 8 m m at 9 5 C (0.3 in at 203 F)
Boiling point (with 50 - 50 mixture ) : Unpressurized : 1 07 . 7 C (226 F)
Cap on, pressurized : 1 2 5 . 6 C ( 2 58 F)

TROUBLESHOOTI NG
Engine temperature too high Engine temperature too low
Faulty thermosensor bulb or sensor
Faulty thermosensor bulb or sensor
Thermostat stuck closed
Thermostat stuck open
Faulty radiator cap
I nsufficient coolant or coolant l evel too low Coolant leaks
Passages blocked in radiator, h oses or water jacket
Faulty pump mechanical seal
Cooling fan motor does not turn Deteriorated 0-rings
- Burned or loose sub fuse
- Faulty fan motor
- Faulty thermostatic switch
- Poor connector contact or open circuit in harness
Faulty water pump

5- 1
COO LING SYSTEM

SYSTEM TESTI NG
C O O LANT M I XT U R E

Remove the fuel tank (page 4-3) .


Remove the steering covers by removing the bolt.

Remove the radiator cap.

Be sure the engine is cool before removing the cap or you may
be severely scalded.

Test the coolant mixture with an antifreeze tester.


For maximum corrosion protection, a 50- 50% solution of
ethylene glycol and distilled water is recommended.

RAD I ATOR CAP

i
Wet the radiator cap sealing surface, install the cap on the
tester, and apply pressure.
Replace the radiator cap if it does not hold pressure, or if it ' s

relief pressure is too high or too low. It must hold specified


pressure for at least six seconds.

I
t
-

RADIATOR CAP RELIEF PRESSURE:


88 - 1 27 kPa (0. 9 - 1 . 3 kg/cm2, 1 3 - 1 8 psi)

( 1 I RAD IATO R
CAP

SYSTEM PRES S U R E TEST

Remove the steering covers and radiator cap.

Attach the tester to the radiator and apply enough pressure to


test the radiator, engine and hoses.
Check for leaks.

CAUTION
Excessive pressure can damage the radiator. Do not exceed 125
kPa (1 . 25 kg!cm2, 18 psi)

Repair or replace components if the system will not hold speci


fied pressure for at least six seconds .

5-2
COOLING SYSTEM

COOLANT R E P LACE M ENT (2) REAR CYLINDER


DRAIN BOLT

The engine must be cool before replacing the coolant or severe


scalding may result.

Remove the radiator cap ( page 5-2 ) .

Drain the coolant from the system by removing the drain bolt
on the water pump cover.
Remove the rea r cylinder coolant drain bolt and drain the
collant using a vinyl as shown .
Reinstal l the drain bolt. ( 1 ) DRAIN BOLT (3) VINYL

Fill the system with 50 - 50 mixture of distilled water and eth


ylene glyco l .
Bleed a i r from t h e cooling system .

Lower the side stand and shift the transmission into neutra l .

Start the engine and snap the throttle grip, 3 - 4 times at


4,000 - 5,000 rpm . Then add coolant up to the radiator
filler neck.

Reinstall the radiator cap.

Check the level of coolant in the reserve tank and fill to the
correct level if the level is low.

THERMOSTAT
R E M O VAL

Remove the following :


- fuel tank ( page 4-3)
- air cleaner housing ( page 4-4)
- steering covers ( page 5-2)
- radiator cap

Drain the coolant.


Remove the thermostat housing and radiator filler mounting
bolts .

Disconnect the siphon tube from the radiator filler.


Disconnect the u pper radiator hose at the radiator and remove
filler and the radiator hose from the frame.

Remove the thermostat housing cover.

5-3
COOLI N G SYSTEM

Remove the thermostat from the housing .

I N S P E CT I O N
( 1 ) THERMOSTAT
I nspect t h e thermostat visually for damage .
Suspend the thermostat in heated water to check its opera
tion.

NOTE

If the thermostat or thermometer touches the pan, you ' l l


get a false reading.

Replace thermostat if valve stays open at room temperature,


or if it responds at temperatures other than those specified.

Data :
Start to open 80 to 84 C ( 1 7 6 - 1 8 3 F)
Valve lift 8 mm (0.3 in) minimum when
heated to 9 5 C (203 F) for five
minutes .

I N STALLAT I O N

I nstall t h e thermostat into the housing .

I nstall a new 0-ring on the housing cover and i nstall the hous
ing cover onto the housing.

5-4
COOLING SYSTEM

Tighten the thermostat housing cover mounting bolts .

NOTE
Be sure to secure the thermostat ground wire with the
cover mounting bolt shown.

I nstall a new 0-ring on the radiator filler, and connect the


u pper radiator hose to the radiator.

I nstall the radiator filler onto the thermostat housing.


Tighten the filler and thermostat housing mounting bolts .

Install the remaining removed parts in the reverse order of re


mova l .

F i l l t h e system with coolant.

RADIATOR/COOLI NG FAN
REM OVAL

NOTE
For fan motor i nspection, refer to section 1 8 .

Remove the steering cover and disconnect the fan motor con
nector ( 2 P BLACK)
Remove the horn mounting bolt and horn, then disconnect the
horn wires.

Remove the radiator mounting bolt and disconnect the lower


radiator hose from the radiator by loosening the hose band.

5- 5
COOLI N G SYSTE M

U nhock the radiator mounts from the grommets from in frame.


Unclamp the upper radiator hose and disconnect the hose from
the radiator.

D I SAS S E M B LY ( 1 ) G R O U N D "-..
TERM INAL /""'
Disconnect the thermostatic switch wire connector from the
switch and remove the wire from the clamp.
Remove the ground wire terminal bolt.

Remove the fan motor shroud mounting bolts, and remove the
fan motor shroud and fan motor as an assembly.

( 2 ) WIRE CONN ECTO R

Remove the nut to separate the fan from the shroud . ( 1 ) NUT

( 2 ) FAN

Remove the fan motor mounting nuts and fan motor from the
shroud.

5-6
COOLING SYSTEM

A S S EM B LY

Inspect the radiator soldered joints and seams for leaks.

Blow dirt out from between core fins with compressed air. If
insects, etc . , are clogging the radiator, wash them off with
low pressure water.

Carefully straighten any bent fins.


I nstal l the motor on the shroud and tighten the nuts .

Install the fan to the fan motor shaft, aligning the boss of the
shaft with the groove of the fan .

Assemble the remained components in the reverse order of the


disassembly.

If removed the thermostatic switch from the radiator, refer to


page 1 8-8.

NOTE
Do not overtighten the thermostatic switch, when reinstall
it.
TORQU E : 1 8 N m ( 1 . 8 kg-m , 1 3 ft-lb) .

WATE R P U M P
ME C H A N I CA L S E A L I N S P E C T I O N

NOTE
The w ater pump cover and 0-ring can be removed with
engine i n the frame .

Inspect the telltale hole for signs of mechanical seal coolant


leakage .
Replace the water pump as an assembly if the mechanical seal
is leaking.

REMOVAL

Remove the engine from the frame (section 6).

Remove the water pump cover mounting bolts and cover.

Remove the 0-ring and dowel pins from the water pump as
sembly and disconnect the water hose .

Remove the water pump from the crankcase.

( 3 ) WATER HOSE

5- 7
COOLING SYSTEM

I N S P E CTI O N ( 1 ) 0-RING ( 2 ) WATER P U M P ASSEM BLY

Check t h e water pump f o r mechanical seal leakage a n d bear


ing deterioration. Replace the water pump as an assembly if
necessary .

(4) 0-RING

I N STA L LAT I O N

Apply a coat of clean engine oil to a new 0-ring and install it i n


t h e water p u m p shaft housing groove .

Align the water pump shaft g roove with the oil pump shaft and
insert the water pump into the crankcase.

Apply a coat of engine oil to a new 0-ring and install it around


the impeller housing .

I nstal l the two dowel pins.

Connect the water hose with the clamp.

I nstall the water pump cover and tighten the cover mounting
bolts .
Connect the water hose with the clamp.

I nstall the engine in the frame (section 6 ) .

Fill the system with coolant ( page 5-3 ) .


Fill the engine with the recommended engine o i l (page 2-4) .

Check the cooling system for leakage.

5-8
COOLI N G SYSTEM

COOLANT / R ESERVE TANK (1 I G R O M M ET (21 TAB

REMOVAL/INSTALLATION

Raise and support the motorcycle rear frame using a hoist or


jack u nder the engine.

Remove the evaporative emission canister(California model


only) .

Place a clean container u nder the reserve tank.

Disconnect the radiator siphon tube at the reserve tank.


Remove the reserve tank mounting bolt, filler mounting nut
and the reserve tank.

Hold the overflow tube u pright and remove the reserve tank
from the frame.
Empty the tank, if necessary.
I nstall the reserve tank i n the reverse order of removal .
Fill the tank with coolant, i f necessary.

CAUTION

The tab of the reserve tank should be aligned with the grommet
in the frame.

5-9
EN G I N E REM OVAL/INSTALLAT I O N


2 5 Nm, ( 2 . 5 kg-m, 1 8 ft-lb)

2 7 Nm, ( 2 . 7 kg-m, 20 ft-lb)

6-0
6. ENG INE REMOVAL/ I NSTALLATION
S ERVI C E I N F O RMAT I O N 6-2 EN G I N E I N STALLATION 6- 5

E N G I N E R E M OVAL 6-3

Ill

5 5 N m ( 5 . 5 kg-m,
40 ft-lb)

27 Nm (2. 7 kg-m,
20ft-lb)

6- 1
E N G I N E REM OVAL/ I N STALLATION

SERVICE I N FO RMATION
G E N E RAL

Support the motorcycle using a hoist, a floor jack or other adjustable support.
The following parts can be serviced with the engine i nstalled in the frame:
Clutch Alternator
Gearshift linkage Starter motor
Camshafts Carburetors
Front cylinder head/cylinder
To service the water pump body, oil pump, and rear cylinder head/cylinder the engine m ust be removed from the frame.

S P E C I F I CATI O N S

Engine dry weight 6 1 kg ( 1 34 lb)


Oil capacity 2 . 8 l it ( 2 . 94 U S qt, 2.46 Imp qt) at disassembly
Coolant capacity 1 . 6 1it ( 1 . 5 1 U S qt, 1 .4 1 Imp qt) total

TO R Q U E VALU E S

Rear axle 90 Nm (9.0 kg-m , 65 ft-lb)


Shock absorber lower mounting bolt 45 Nm (4. 5 kg-m , 33 ft-lb)
Gearshift arm bolt 12 Nm ( 1 .2 kg-m , 9 ft-lb)
Foot peg bracket bolt 40 Nm (4.0 kg-m , 29 ft-lb)
Swingarm pivot bolt 90 Nm (9.0 kg-m , 65 ft-lb)
Front upper engine mounting bolt 55 Nm (5.5 kg-m , 40 ft-lb)
Front upper engine bracket bolt 27 Nm (2. 7 kg-m, 20 ft-lb)
Front lower engine mounting bolt 55 Nm (5.5 kg-m, 40 ft-lb)
Rear upper engine mounting bolt 55 Nm (5.5 kg-m, 40 ft-lb)
Rear upper engine bracket bolt 27 Nm (2. 7 kg-m , 20 ft-lb)
Exhaust pipe joint nut 25 Nm (2.5 kg-m, 1 8 ft-lb)
Fuel tank mounting bolt 19 Nm ( 1 .9 kg-m , 1 3 . 7 ft-lb)
Exhaust muffler bracket bolt 27 Nm (2. 7 kg-m , 20 ft-lb)

6-2
E N G I N E REM OVAL/ I N STALLATION

ENG I N E REMOVAL
Support the motorcycle using a hoist or a jack.

CAUTION
Do not jack up the engine at the oil filter.

Drain the engine oil (page 2-4) and the radiator coolant (page
5-3 ) .
Disconnect the battery negative cable from the battery termi
nal .

Remove the following:


- fuel tank (page 4-3)
- air cleaner housing (page 4-4)
- air cleaner chamber ( page 4-4)
- carburetor (page 4-6)
- exhaust pipe protectors
- exhaust pipe and muffle rs

Loosen the drive chain ( page 3 - 1 3 ) .


Remove the drive sprocket cover ( page 1 3- 1 4 ) . then remove
the sprocket from the drive chain by removing the two sprock
et bolts.

Disconnect the oil pressu re and neutral switch wires from the
switch terminals and free the switch wire harness from the
engine and frame.
Remove the gearshift arm from the gearshift spindle.

Disconnect the starter motor cable and ground cable from the
starter motor.

Disconnect the clutch cable from the clutch lifter arm by re


moving the holder bolt.

Remove the right foot peg and rear brake pedal by removing
the two bracket mounting bolts.

6-3
EN G I N E REMOVAL/ I N STALLATIO N

Disco n ncet the ignition pulse generator wire connector(4P


WH ITE) .

Remove t h e lower radiator hose ( radiator-to-water pump) .


Disconnect the water hoses (thermostat housing-to-cylinder
heads) from the cylinder heads ( page 9-3 ) .

Place a floor jack o r other adjustable support under the engi ne.

NOTE
The jack height must be continually adjusted to relieve
stress for ease of bolt removal .

Remove the following :


41
- rear wheel (page 1 3-3)
- swingarm (page 1 3- 1 4)
- front upper engine bracket (two 8 mm bolts, 1 0 mm bolt
and collar)
., , ( 3 ) FRONT LOWER BOLT
- front lower engine bracket ( 8 mm bolts and 1 0 mm bolt) SWI N ARM PIVOT
- rear engine bracket (two 8 mm bolts and 1 0 mm bolt) BOLT

N OTE
Do not damage the radiator fin .

6-4
E N G I N E R E MO VAL/IN STALLATIO N

ENG I N E I N STALLATION
Engine insta l l ation is essentially the reverse order o f removal .
Use a floor jack or other adjustable support t o carefu lly
manuever the engine into place.

CAUTION

Carefully align mounting points with the jack to prevent


damage to m ounting bolt threads and wire harness and cables.

NOTE

Be sure to i nstall the mounting collars and swingarm dust


seals i n their correct positions.

( 1 ) SWI NGARM LEFT S I D E COLLAR


Tighten all the fasteners to the specified torque given on page I --
5-0, 1 and 2.

NOTE

Route the w i res and cables properly (section 1 ) .

Fill the cran kcase to the proper level with the recommended
oil (page 2 - 4 ) .

Fill the cooling system (page 5-3) .

Perform the following inspection and adjustments :


Throttle operation ( page 3-6) .
/
Clutch ( page 3- 1 8 ) . ( 2 ) SWI NGARM RIGHT SIDE CO LLARS

6-5
CLUTCH/GEARS H I FT L I N KAGE

1 2 N m ( 1 . 2 kg-m ,
9ft-lb)

- - - - - - - - - - - - - - - - - - - - - ,
'

After' 8 9 : ,
,
'
'
'
'
'
'
2 3 N m (2 . 3 kg-m , 1 7ft-lb)
'
'
'
'
'
'
'
'
'
'
After' 9 5 :
'
'

'I
'

7 -0
7. CLUTCH/G EARSH I FT LI N KAG E
S ER V I C E I N FO RMAT I O N 7-1 P RI MARY DRIVE G EAR 7- 1 1

T R O U B L ESHOOTI N G 7-2 CLUTCH I N STALLATION 7- 1 2

R I G H T C RANKCASE C O V ER R E MOVAL 7-3 RIGHT CRANKCASE COVER


I N STALLATION 7- 1 4
C L U T C H REMOVAL 7-4

G EA RS H I FT L I N KA G E 7-8

S E RV I CE I N FORMATION
G E N ERAL

This section covers the removal and installation of the clutch, oil pump drive chain, gearshift linkage and primary drive
gear. All these operations can be done with the engine installed in the frame.

If the shift fork, drum and transmission require servicing, remove the engine and separate the crankcase (section 1 1 ).
C oat the new clutch discs w ith clean engine oil before reassembly.

S P E C I F I CAT I O N S
U nit: mm (in)
ITEM STANDARD SERVICE LIMIT
C l utch Spring free length 88; 39.0 ( 1 . 54) 3 7 . 4 ( 1 .47)
After 88; 43 . 2 ( 1 . 70) 4 1 . 6 ( 1 . 64)
Spring preload/length 25. 2 5 - 27 . 2 5/2 6 . 2 kg/mm --

Disc thickness A 2 . 62 - 2 . 7 8 (0. 1 03 - 0 . 1 07 ) 2 . 30 (0. 090)


8 2 . 92 - 3 .08 (0. 1 1 5 - 0. 1 2 1 ) 2 . 60 (0. 1 02)
Plate warpage --
0.30 ( 0 . 0 1 2 )
Outer guide I. D. 2 1 . 9 9 1 - 22 . 0 1 6 (0.8658 - 0 . 8668) 2 2 . 09 (0. 870)
O.D. 3 1 . 9 59 - 3 1 .025 ( 1 . 2 582 - 1 . 2 589) 3 1 . 98 ( 1 . 2 59)
Outer I . D . 32.000 - 32.025 ( 1 . 2 598 - 1 . 2608) 3 2 . 1 0 ( 1 . 264)
O i l pump d rive sprocket I . D . 32.000 - 32.025 ( 1 . 2 598 - 1 . 2608) 3 2 . 1 0 ( 1 . 2 64)
M ainshaft O . D . at clutch outer guide 2 1 . 967 - 2 1 . 980 (0. 8648 - 0 . 8654) 2 1 . 9 2 ( 0 . 863)

T O R Q U E VALU ES

Drum stopper plate bolt 1 2 Nm ( 1 . 2 kg-m, 9 ft-lb) Apply locking agent


Primary d rive gear bolt 90 Nm (9.0 kg-m, 65 ft-lb)
Oil pump d riven sprocket bolt 1 5 Nm ( 1 . 5 kg-m, 1 1 ft-lb) Apply locking agent
C lutch lock nut 1 30 N m ( 1 3.0 kg-m, 94 ft-lb)
Oil pass pipe bolt (8 mm) 23 Nm ( 2 . 3 kg-m, 1 7 ft-lb)
( 7 mm) 1 0 Nm ( 1 .0 kg-m, 7.2 ft-lb)

T O O LS

Special
Clutch center holder 07923 - KE 1 0000 o r 07 H G B -00 1 000A( U . S . A . only)
Gear holder 07724 - 00 1 0 1 00

Common
Luck nut wrench, 1 7 x 27 mm 077 1 6 - 0020300 Equ ivalent com mercially available i n U . S . A .

7- 1
CLUTCH/GEARS H I FT LI N KAGE

TROU BLESHOOTI NG
Faulty clutch operation can usually b e corrected b y adjusting the clutch lever free play .

Clutch slips when accelerating


No free play
Discs worn
Springs weak

Clutch will not disengage


Too much free play
Plates warped

Motorcycle creeps with clutch disengaged


Too much free play
Plates warped

Excessive lever pressure


Clutch cable kinked, damaged or dirty
Lifter mechanism damaged

Clutch operation feels rough


Clutch outer slots rough
Dirty clutch cable

7-2
CLUTCH/GEARS H I FT L I N KAGE

R IGHT CRAN KCASE COVER REMOVAL


'88, '89:
Drain the engine oil ( page 2 - 4 ) .
Remove the clutch cable holder and disconnect the clutch
cable from the clutch lifter arm .
Loosen the oil pipe holder and remove the oil pipe bolt and seal
ing washers from the right crankcase cover.

Remove the right crankcase cover bolts and cover.

After '89:
Drain the engine oil ( page 2 - 4 ) .
Remove the clutch cable holder and disconnect the clutch
cable from the clutch l ifter arm .
Remove the right crankcase cover bolts and cover.

Remove the dowel pins and gasket.

'88, '89 :
Remove the oil orifice.

C L U T C H L I FT E R S H A FT

Remove the clutch lifter piece, and remove the snap ring and
return spring from the right crankcase cover.

Remove the clutch lifter shaft.

Check the clutch lifter piece and shaft for damage or excessive
scratching .
Check the return spring for fatigue or damage.

7 -3
CLUTCH/GEARS H I FT L I N KAGE

Check the needle bearing for wear or damage or a loose fit in


the cover.
Check the dust seal for fatigue or damage.

Apply grease to the dust seal and needle bearing .

(1 l D U ST SEAL

I nstall the clutch lifter shaft, snap ring and return spring.
Hook the spring end in the cover tab securely, and turn the
shaft.

Install the clutch lifter piece, aligning the piece end with the
groove i n the clutch lifter shaft.

CLUTCH REMOVAL
Remove the following:
- clutch bolts
- clutch lifter plate
- springs

Unstake the clutch lock nut with a drill or grinder.

NOTE
Be careful not to damage the shaft threads .

7 -4
CLUTCH/G EARS H I FT L I N KAGE

Hold the clutch center with the special tool and loosen the
clutch lock nut. Remove the tools and the lock nut.

TOOLS :
Clutch center holder 07923- K E 1 0 0 00 or
07 H G B-00 1 000A
( U . S.A. only)
Lock nut wrench, 1 7 x 27 mm 077 1 6-0020300
Equivalent com mercially
avai lable in U . S .A.

Remove the following :


- spring washer (After' 9 5 o nly)
- washer
- clutch center. judder spring and sprin g seat
- discs a n d plates
- pressu re plate

Remove the thrust washer and clutch outer.

- -
Remove the oil pump d riven sprocket mounting bolt, driven (1 l O I L PU MP DRIVEN
sprocket and oil pump drive cha i n . SPROCKET

7-5
CLUTCH/GEA R S H I FT L I N KAGE

Remove the drive sprocket and clutch outer guide from the
mainshaft.

I N SPECT I O N (1 1 BEARI N G

Check the lifter plate bearing for damage.


Turn the bearing inner race with your finger.
The bearing should turn smoothly and quietly .
Also check that t h e bearing outer race fits tightly in t h e clutch
lifter plate .
Replace the bearing if necessary .

."--
-..
..._
___ /
( 2 ) CLUTCH L I FTER PLATE

Measure the spring free length .

SERVICE LIMIT: 88; 88; 37.4 mm ( 1 .47 in)


After 89; 4 1 , 6 mm ( 1 . 6 5 in)

Replace the lutch discs if they show signs of s coring or dis


-

coloration.
-

Measure the thickness of discs A and B.

SERVICE LIMIT: ( A I 2 . 30 m m (0.090 in)


(8) 2 . 60 mm (0. 1 02 in)

N OTE

Replace the discs and plates as a set if any one is beyond


the service limit.

7 -6
CLUTCH/GEARS H I FT L I N KAGE

Check the plate warpage on a su rface plate using a thickness


gauge.

SERVICE LIMIT: 0 . 30 mm (0.0 1 2 in)

Check the cl utch center for nicks or indentations made by the 111 CLUTCH
clutch plates. C ENTER

,!

(1 I J U DDER SPRING
. _......... ..
Check the spring seat and judder spring for distortion, wear or
damage.
Replace them it necessary .

Check the slots in the clutch outer for nicks or indentations


made by the clutch discs.

Measure the I. D. of the clutch outer and the O . D . of the clutch


outer guide.

SERVICE LIMITS:
Clutch outer I . D. 32. 1 0 mm ( 1 . 264 in)
Clutch outer guide O.D. 3 1 .98 mm ( 1 . 259 in)

7- 7
CLUTCH/GEARS H I FT LI N KAGE

Check the oil pump drive sprocket for damage.

Measure I . D of the d rive sprocket and the O . D . of the outer


guide.

SERVICE LIMITS:
Oil pump drive sprocket 1.0. 32. 1 0 mm ( 1 .264 in)
Clutch outer guide 0 . 0 . 3 1 .98 mm ( 1 .259 in)

Measure the mainshaft O . D . at the clutch outer guide.

SERVICE LIMIT: 2 1 .92 mm (0.863 in)

GEARSH I FT LI N KAGE
R E M OVAL

Remove the following :


- drive sprocket cover ( page 1 3- 1 4)
- gearshift pedal arm from the gearshift spindle
- right crankcase cover ( page 7-3)
- clutch assembly ( page 7-4)
- oil pump drive chain ( page 7-5)

Loosen the two oil pipe stay mounting bolts and remove the oil
pipe mounting bolt.

Pull the oil pipe out of the stay and oil pump.

7 -8
CLUTCH/GEARS H I FT L I N KAGE

Remove the following :


- gearshift spindle
- drum stopper arm bolt, stopper arm, collar and spring
- drum stopper plate bolt and stopper plate/drum

I N S PECTI O N

Check the gearshift spindle for bending o r damage.


Check the return spring for fatigue or damage.

r
(2) RETU RN SPRING

I nspect the gearshift pedal shaft for damage or loose lock ( 1 ) GEARSH PEDAL SHAFT
nuts.
Replace the shaft if necessary.

,_
l
_ ,_

I nspect the dust seals and pivot collar for wear or damage.

Replace if necessary .

Apply grease to the dust seal lips and pivot collar and install
them into the pedal shaft.

7-9
CLUTCH/GEARS H I FT L I N KA G E

I N STA L LATI O N

I nstall the collar, spring, stopper arm, washer a n d stopper arm


bolt and tighten the bolt.

I nstall the dowel pins into the holes of the gearshift dru m .

Lift up t h e d r u m stopper a r m and install t h e d r u m stopper


plate.

Apply locking agent to the threads of the stopper plate bolt


and tighten the bolt.

TORQUE : 1 2 Nm ( 1 . 2 kg-m, 9 ft-lbl

., "

I nstall the gearshift spindle, aligning the return spring ends (1 l G EARSH I FT SPI N O
with the pin in the case. !

Install the oil pipe with a new 0-ring onto the oil pipe stay and
oil pump.

Tighten the bolts securely.

I nstall the removed parts in the reverse order of removal.

I nstall the gearshift arm to the gearshift spindle.


Align the punch mark on the arm with the punch mark on the
spindle .
Tighten the gearshift arm mounting bolt.

7- 1 0
C LUTCH/G EARS H I FT L I N KA G E

I nstal l the gearshift pedal mounting bolt and tighten the bolt
securely.
I nstal l the d rive sprocket cover (page 1 3- 1 7 ) .

(1 ) 1 FT PEDAL
MOUNTING BOLT

P R I MARY DRIVE GEAR


REMOVAL

Remove the followin g :


- right crankcase cover (page 7-3)
- clutch assembly ( page 7-4)

Remove the ignition pulse generator mounting bolts and


ig nition pu lse generators.

Temporarily install the clutch outer, (page 7- 1 3 ) then install


the gear holder as shown.

TOOL:
Gear holder 07724 - 00 1 0 1 00

Remove the fol lowing:


- ignition p ulse generator rotor bolt and rotor
- clutch outer and gear holder
- primary d rive gear

_,

I N STALLAT I O N ( 1 ) PRIMARY
- DRIVE
Instal l the primary drive gear with the " O UT" mark facing out. ,_, GEAR

NOTE

The p ri m a ry d rive gear and ignition p u lse generator rotor


will only g o on i n one position becau se of the extra wide
aligning spline.

Instal l the ignition pulse generator rotor .


(4) I G N ITI O N P U LS
G E N E RATO R R OTO R

7- 1 1
CLUTCH/GEARS H I FT LI N KAGE

Temporarily install the clutch outer and install the gear holder
as shown .

TOOL:
Gear holder 07724 - 00 1 0 1 00

Install the washer and bolt and tighten the bolt.

TORQUE: 90 N m (9.0 kg-m, 65 ft-lbl

Remove the gear holder and clutch outer.

Install the following:


- ignition pulse generators
- clutch ( page 7 - 1 2 )

NOTE
If removed the ignition pulse generator wire grommets were
removed from the case g roove,reinstall them securely.

CLUTCH I NSTALLATION
Apply MoS2 paste grease t o t h e outside o f the clutch outer
guide and install the oil pump d rive sprocket over the outer
guide.

I nstall the oil pump d rive chain on the drive sprocket. 'iiToiL PU MP D R I VEN
SPROCKET
I nstall the oil pump driven sprocket with the " I N " mark facing
inside.
Guide the drive chain over the sprocket.
Apply locking agent to the threads of the driven sprocket
mounting bolt and tighten it with the washer to the specified
torque.

TORQUE: 1 5 Nm ( 1 . 5 kg-m, 1 1 ft-lbl

7- 1 2
CLUTCH/G EARS H I FT L I N KAGE

Align the grooves in the clutch outer with the bosses on the oil
pump drive sprocket while turning the sprocket with the chain
and pushing the clutch outer onto the shaft.

Install the thrust washer onto the m a i nshaft.

I nstall the spring seat, judder sprin g and clutch disc 8 on the
c l utch center.

N OTE
N ote the positions of the seat, spring and disc B.

I nstal l clutch discs, clutch plates, clutch disc A, the plates,


d i scs, and pressure plate on the clutch center and install them
in the clutch outer as an assembly.

Align the tabs in the disc 8 w ith the slots on the clutch outer. (2) J U DDER SPRING
(3) DISC B
( 1 ) SPR I N G SEAT
N OTE
Stack the discs and plates alternately as shown.

Coat the new clutch discs with clean engine oil.

I n stall the washer on the mainshaft .


After' 9 5 :
I n stall the spring washer o n the mainshaft with the
" O U T S I D E" mark facing o utside .

7- 1 3
CLUTCH/G EARS H I FT LI N KA G E

Hold the clutch center with the clutch center holder, and tight
en the lock nut to the specified torque .

TO RQU E : 1 30 Nm ( 1 3.0 kg-m , 94 ft-l b)

TOOLS :
Clutch center holder 07923 - K E 1 0000 or
07 H G B-001 000A
( U . S .A. only)
Lock nut wrench, 1 7 x 27 mm 077 1 6-0020300
Equivalent com mercially
available in U .S .A.

Stake the lock nut with the center punch .

Install the clutch springs, lifter plate and bolts .


Tighten the bolts in a crisscross pattern in 2 or 3 steps.

NOTE

Make sure the pressure plate firmly pushes the discs and
plates.

I nstall the bearing into the l ifter plate .

R IGHT CRAN KCASE COVE R I NSTALLATION


'88, '89 :
I nstall a new 0-ring on the oil orifice .
I nstall the oil orifice with its smaller hole facing in.

7- 1 4
CLUTCH/G EARS H I FT LI N KA G E

Install the dowel pins and new gasket.

'88, '89 :
Tighten t h e right c r a n kcase cover mounting bolts in a
crisscross pattern in 2 or 3 steps and install the clutch cable
holder and oil pipe holder at the same time.
Connect the clutch cable to the clutch lifter arm.

Tighten the oil pipe bolt with the sealing washers .

TORQU E : 23 N m ( 2 . 3 kg-m, 1 7 ft-lbl

Fill the crankcase with engine oil (page 2 -4 )


Adjust the clutch lever free play (page 3- 1 8 )

After '89:
Tighten t h e right c r a n kcase cover m o u nti n g bolts i n a
crisscross pattern in 2 or 3 steps and i nstall the clutch cable
holder and oil pipe holder at the same time.
Connect the clutch cable to the clutch lifter arm .

Fill the crankcase with engine oil (page 2 - 4 )


Adjust the c l utch lever free play (page 3- 1 8 )

7- 1 5
ALTERNATO R/STARTER CLUTCH

8-0
8. ALTERNATOR/STARTE R CLUTCH
S E R V I C E I N FORMATI O N 8- 1 F LYW H E E L I N STALLATION 8- 5

L E F T C R A N KCASE C O V E R R E M OVAL 8-2 LEFT CRANKCASE COVER


I N STALLAT I O N 8-6
F LYW H E E L REMOVAL 8-3

S TA R T E R CLUTCH 8-4

SERV I CE I N FORMATION
GENERAL

This section covers the removal and i nstallation of the alternator, starter clutch and starter gears.
These o pe ration can be done with the engine installed in the frame.
Refer to section 1 5 for troubleshooti ng and inspection of the alternator.

S P EC I F I CATI O N S
mm (in) .
ITEM STANDARD SERVICE L I M IT
Starter d riven gear O . D . 5 7 . 749 - 5 7 . 768 ( 2 . 2 7 36 - 2 . 2743) 5 7 . 60 ( 2 . 268)

TORQU E VALUES

Flywheel bolt 1 30 Nm ( 1 3 . 0 kg-m, 94 ft-lb) Left-hand thread


Starter clutch torx bolts 30 Nm ( 3 . 0 kg-m , 22 ft-lb) Apply locking agent

TOOLS

Common
Rotor puller 07733- 002000 1 or 0 7 9 3 3 - 3 2 9000 1 ( U . S . A . only)
Flywheel holder 0 7 7 2 5 - 0040000 Equivalent commercially available in U . S . A .
Torx bit 07 703 - 00 1 0 1 00 Equivalent commercially available in U . S . A .

8- 1
ALTE RNATO R/S TARTER CLUTCH

LEFT CRAN KCASE COVE R REMOVAL


Remove the left side cover and disconnect the alternator wire
3P connector (WHITE ) .

Remove the drive sprocket cover (page 1 3- 1 4) .

Place a container under the left crankcase cover to catch the


engine oil .

Remove the eleven left crankcase cover bolts and the cover.

Remove the dowel pins and gasket.

STATOR R E P LAC E M E N T

Remove the wire clamp bolts and the clamps.


Remove the stator mounting bolts and stator.

Position the new stator and the grommets in the cover.


Apply a locking agent to the th reads of the stator
mou nting bolts and wire cla m p bolts .
Tighten the stato r mounting bolts and the clamp bolts .

( 1 ) BOLTS

8-2
ALTERNATO R/STARTER CLUTCH

FLYWH EEL REMOVAL


Remove the starter d rive and i d l e/reduction gears by removing
the s h afts .

H o l d the flywheel with the f l y w h e e l h o l d e r and remove the fly


wheel bolt a n d w a s h e r .

TOOL:
Flyw heel holder 0 7 7 2 5 - 0040000
Equivalent commerc i a l l y
ava i lable i n U . S . A .

NOTE

The flywheel bolt h a s l eft- h a n d thre a d s .

Remove t h e flywheel w ith the rot o r p u l l e r .

TOO L :
Rotor puller 07733 - 002000 1 or
07933-329000 1
( U . S . A . only)

Remove the starter d r i v e n gear, washer and needle bearing


from the c r a n kshaft .

Remove t h e wood ruff key .

8-3
ALTERNATOR/STARTER CLUTCH

STARTER CLUTCH ( 1 l STARTER DRIVEN GEAR

D I SA S S E M B LY

Reinstall the starter driven gear i nto the flywheel .

I nspect the starter clutch by turning the starter driven gear.


The gear should turn counterclockwise freely and should not
turn clockwise: if it turns i ncorrectly, replace the starter
clutch.

Hold the flywheel with the flywheel holder and remove the
torx bolts using a torx bit.

Remove the starter clutch outer and oneway clutch.

TOOLS :
Flywheel holder 07725-0040000
Equivalent commercia l ly
ava i l a ble in U .S.A.
Torx bit 07703-001 0 1 00
Equivalent commercially
available in U .S.A.

I N S PECTI O N ( 1 l STARTER DRIVEN GEAR

Measure the O . D . of the starter driven gear.

SERVICE LIMIT: 57.6 0 mm (2.268 in)

I nspect the oneway clutch for wear or damage and replace if ( 1 l ON EWAY CLUTCH
necessary .

8-4
ALTERNATOR/STARTER CLUTCH

ASS E M B LY

Install the oneway clutch i nto the clutch outer with the flange
side facing inside.

(3) ON EWA Y CLUTCH

Hold the flywheel with the flywheel holder. Apply locking


agent to the trox bolt threads and tighten the bolts .

TORQUE : 30 N m ( 3 . 0 kg-m, 22 ft-lb)

TOOLS :
Flywheel holder 07725-0040000
Equivalent commercially
available i n U . S.A.
Torx bit 07703-00 1 0 1 0 0
Equivalent commercially
avai lable i n U . S.A.

FLYWHEEL I NSTALLATION
Clean the crankshaft and install the woodruff key.

Install the needle bearing onto the crankshaft.

Instal l the starter d riven gear and washer onto the crankshaft .

8- 5
ALTERNATO R/STARTER CLUTCH

Instal l the flywheel, aligning the woodruff key on the crank


shaft with the flywheel keyway.

Hold the flywheel with the flywheel holder, install the washer
and flywheel bolt and tighten the bolt.

TORQUE: 1 30 Nm ( 1 3 . 0 kg-m, 94 ft-lbl

TOOL:
Flywheel holder 07725-0040000
Equivalent comm ercially
available i n U . S.A.
NOTE
The flywheel bolt has left hand threads.

Install the starter idle/reduction gear with the longer shaft .

Install the starter d rive gear with the " O UT" mark facing out
and the shorter shaft .

Install t h e dowel p i n s a n d n e w gasket .

LEFT CRAN KCASE COVER I NSTALLATION


Install the left crankcase cover a n d tighten t h e cover bolts with
the neutral and oil pressure switch wire harness clamps as
shown.

Route the alternator wire and connect the alternator 3P con


nector.

Install the drive sprocket cover and the left side cover.

Check the oil level and add oil if necessary .

8-6
M E MO
CYLI NDER H EAD/VALV E

10 Nm ( 1 .0 kg-m, 7.2 ft- l b l

23 Nm (2.3 kg-m, 1 7 ft- l b)

After '89 :

' '
I
e
'

1 7 ft- l b )
2 3 N m ( 2 . 3 kg-m '
-
I
- "0
48 N m ( 4 . 8 k g - m, " 2 3 Nm ( 2 . 3 k g - m,


35 ft- l b ) 23 Nm ( 2 . 3 kg-m '
() 1 7 ft- l b )
1 0 Nm ( 1 .0 kg-m,
7 . 2 ft- l b )

/ @
10 Nm ( 1
ft-l b )
.0 kg-m '

'88, '89 :

1 0 Nm ( 1 .0 kg-m,
2 3 Nm ( 2 . 3 k g - m ,
7 . 2 ft- l b )
1 7 ft- l b )

9-0
9. CYLI N DE R H EAD/VALVE
SERVICE I N FORMATI O N 9-1 VALVE SEAT I N S PECT I O N / REFAC I N G 9- 1 2

TROUBLES H OOTI N G 9-2 CYLIN DER H EAD ASSEM BLY 9- 1 5

CYL I N D E R H EAD COVER REMOVAL 9-3 CYL I N DER H EAD I N STALLATION 9- 1 6

CAM S HAFT R E M OVAL 9-4 CAMS HAFT I N STALLATION 9- 1 8

CYL I N D E R H EAD 9-8 CYL I N DER H EAD COVER


I N STALLATION 9-21
VALVE G U I D E REPLAC E M ENT 9-1 1

SERVICE I N FORMATION
G E N ERAL

The front cylinder head can be removed without removing the engine.
To service the rear cylinder head, the engine must be removed from the frame. (See section 6 for engine removal and in
stal lation . ) However, the rear cylinder head cover can be removed to service the camshaft, rocker arms, cam chain and
cam chain tensioner.
Camshaft l ubricating oil is fed through an oil pass pipe. Be sure the holes in the oil pass bolts are not clogged .
D u ring assembly a p ply molybd e n u m disu lfide oil (a 50/50 m ixtu re of engine oil a nd molybde n u m disulfide g rease) to
the camshaft h olders , camshaft journals of the cylinder head , rocker a rm shafts, rocker a rm slipper faces and valve
g
stems to p rovide initial l u b rication .

S P E C I F I CATI O N S
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Compression pressure 1 , 324 kPa --

(1 3.5 1 .0 kg/cm2, 1 92 1 4 psi)


Camshaft Cam lobe height IN 3 7 . 930 ( 1 .4933) 3 7 . 730 ( 1 .48 54)
EX 3 7 . 9 50 ( 1 .494 1 ) 37 . 7 50 ( 1 .4862)
Journaf O . D . 2 1 . 9 59 - 2 1 . 980 (0. 8645 - 0 . 8 6 54) 2 1 . 90 (0.862)
Runout 0. 030 (0.00 1 2) 0.05 (0.002)
Oil clearance 0.050 - 0. 1 1 1 (0.0020 - 0 . 0044) 0. 1 30 (0.005 1 )
Rocker arm Rocker arm I. D . IN/EX 1 2 . 000 - 1 2 . 0 1 8 (0.4724 - 0 . 47 3 1 ) 1 2 .05 (0.474)
Rocker arm shaft IN/EX 1 1 . 966 - 1 1 . 984 (0.47 1 1 - 0 . 47 1 8) 1 1 . 83 (0.466)
O.D.
Valves and Valve stem O . D . IN 5 . 47 5 - 5. 490 (0. 2 1 56 - 0 . 2 1 6 1 ) 5.45 (0.2 1 5)
valve guides EX 6 . 5 5 5 - 6 . 570 (0.2580 - 0 . 2 5 8 7 ) 6 . 5 5 (0.258)
Valve guide I . D . IN 5 . 500 - 5 . 5 1 2 (0.2 1 6 5 - 0 . 2 1 70) 5 . 56 (0.2 1 9)
EX 6 . 600- 6 . 6 1 5 (0.2598 - 0 . 2604) 6 . 6 5 (0.262)
Stem-to-guide IN 0 . 0 1 0 - 0.037 (0.0004 - 0 . 00 1 5) 0. 1 0 (0.004)
clearance EX 0 . 030 - 0 .060 (0.00 1 4 - 0 . 0024) 0. 1 1 (0.004)
Valve seat width 0.9- 1 . 1 (0.03 5 - 0.043) 1 . 5 (0.06)
Valve guide pro- IN 1 9.4- 1 9.6 (0.76 - 0 . 7 7 ) --

jection height EX 1 7.9- 1 8. 1 (0. 7 0 - 0. 7 1 ) --

Valve springs Free length OUTER IN 42. 1 4 ( 1 .659) 40 . 58 ( 1 . 598)


EX 42.83 ( 1 . 686) 41 .25 ( 1 . 624)
INNER IN 38 . 1 1 ( 1 . 500) 36.47 ( 1 .436)
EX 38. 8 1 ( 1 . 765) 37. 5 1 ( 1 .47 7 )
Cylinder head warpage --
0. 1 0 (0.004)

9- 1
CYL I N D E R H EAD/VALVE

TORQU E VALU E S

Cylinder head cover bolt 1 0 Nm ( 1 .0 kg-m, 7 . 2 ft-lb)


Camshaft holder 8 mm bolt 23 N m (2.3 kg-m, 1 7 ft-lb)
8 mm nut 23 N m ( 2 . 3 kg-m, 1 7 ft-lb)
6 mm bolt 1 0 Nm ( 1 .0 kg-m , 7 . 2 ft-lb)
Cylinder head 1 0 mm nut 48 N m (4.8 kg-m , 3 5 ft-lb)
8 mm bolt 23 N m (2.3 kg-m, 1 7 ft-lb)
8 mm nut 23 N m ( 2 . 3 kg-m, 1 7 ft-lb)
6 mm bolt 1 0 Nm ( 1 .0 kg-m , 7 . 2 ft-lb)
Camshaft sprocket bolt 23 N m ( 2 . 3 kg-m, 1 7 ft-lb)
Cam chain tensioner bolt 1 0 Nm ( 1 .0 kg-m, 7.2 ft-lb)
Oil pass pipe 7 mm bolt 1 0 Nm ( 1 .0 kg-m, 7 . 2 ft-lb)
8 mm bolt 23 N m (2.3 kg-m, 1 7 ft-lb)

TO O L S

Special
Valve guide reamer ( I N ) 07984 - 200000 1 o r 0 7 9 8 4 - 2 00000D
Valve guide reamer ( E X ) 07984 -ZE2000 1 o r 0 7 9 8 4-ZE2000D
Valve guide driver attachment ( I N ) 07943 - M F50 1 00
Valve guide driver attachment (EX) 07943 - MF50200

Common
Valve guide driver, 5 . 5 mm ( I N ) 07742 - 00 1 0 1 00
Valve guide driver, 6 . 6 mm (EX) 07742 - 00 1 0200 N ot available i n U . S . A . 07942 - 6 5 7 0 1 00
Valve spring compressor 0 7 7 5 7 - 00 1 0000 or 07957 - 329000 1

Valve seat cutter (Not available in U . S . A . )


Cutter holder I N 5 . 5 mm 0778 1 - 00 1 0 1 0 1
EX 6 . 6 mm 0778 1 - 00 1 020 1
Flat cutter I N 28 mm (32 ) 07780 - 00 1 2 1 00
E X 3 5 m m ( 32 ) 07780 - 00 1 2300
Interior cutter I N 3 0 m m (60 ) 07780 - 00 1 4000
E X 3 7 . 5 m m (60 ) 07780 - 00 1 4 1 00
Seat cutter I N 2 7 . 5 mm (45 ) 07780 - 00 1 0200
E X 3 5 m m (45 ) 07780 - 00 1 0400

TROUBLESHOOTI NG
Engine top-end problems are usually performance-related and can usually be diagonosed by a compressio n test.
Engine noises can usually be traced to the top-end with a sounding rod or stethoscope .

Uneven or low compression Excessive noise

Valves
Incorrect valve adjustment
- Incorrect valve adjustment
Sticking valve or broken valve spring
- Burned or bent valves
Damaged or worn rocker arm or camshaft
- I ncorrect valve timing
Loose or worn cam chain
- Broken valve spring
Worn or damaged cam chain tensioner

Cylinder head
Worn cam sprocket teeth
- Leaking or damaged head gasket
- Warped or cracked cylinder head Poor idling

Cylinder and piston ( Refer to Section 1 0)


Compression too low

High compression

Excessive carbon build-up on piston crown or combus


tion chamber

9-2
CYL I N D E R H EAD/VALVE

CYLI N DE R H EAD COVE R REMOVAL


Remove the following parts:
- steering covers
- fuel tank ( page 4-3 )
- air cleaner housing (page 4-4)
- carburetors (page 4-6 )

Drain t h e coolant (page 5-3 ) .

Front:

Disconnect the spark plug caps and the water hose.


Remove the water pipe mounting bolt, front water pipe and 0-
ring.

NOTE
If coolant drips on the engine, wipe it off immediately .

Remove the cylinder head cover bolts and cover.

Rear:

'88-'89 , ' 9 1 -'94 :


Disconnect the spark plug caps, crankcase breather tube and
water hose .
Remove the water pipe mounting bolt, rear water pipe and 0-
ring .
Remove the cylinder head cover bolts and cover.
Unclamp the wire harness from the frame.

After '94 :
D iscon nect the spark plug caps, c ra nkcase b reather tube and
water hose .
Remove the water p i pe mounting bolt, rea r water pipe and
0-ri n g .

Remove the socket bolt and valve adjusti ng cover.

( 2 ) VALVE ADJ U STI N G COV E R

9-3
C Y L I N D E R H EA D IV ALVE

Remove the cylinder head cover bolts, washers and rubber.

(3) RUBBER

Alig n the wire harness with the valve adjusting hole, then re
move the rear cylinder head cover forward . ( 1 ) R EA R CYLI N D E R H EA D COVER

CAUTI O N
B e careful not t o damage the the wire harness .

CAMSHAFT R EMOVAL
Remove the cylinder head covers.
Remove the timing hole cap and crankshaft hole cap from the
left crankcase cover.
Align the FT mark ( rear: RT mark) on the flywheel with the
index mark on the left crankcase cover timing hole by turning
the crankshaft counterclockwise . Make sure the piston is at
TDC (TOP DEAD CENTER) on the compression stroke .
If the piston is not at TDC, turn the crankshaft 360 counter
clockwise, and re-align the mark and index mark.

Measure the amount of the cam chain tensioner projection as ( 1 ) WEDGE B


shown. Replace the cam chain with the new one if the projec 6.0 mm
tion exceeds 6 .0 mm (0. 24 i n ) . (0.24 in)
T o replace the c a m chain, drain the o i l from t h e engine and
remove the following parts :

FRONT CYLI NDER HEAD REAR CYLINDER H EA D


Left crankcase cover Right crankcase cover
Front camshaft Rear camshaft
Flywheel Primary drive gear

( 2 ) CAM C H A I N TEN SIONER

9-4
CYLI N D E R H EAD IVALVE

Pull wedge A straight up while holding wedge 8 down.


Secure wedge A with a 2 m m pin as shown.

Remove the camshaft holder on the cam sprocket side by re


moving the two mounting bolts .

Remove the cam sprocket bolt, rotate the crankshaft counter


clockwise one turn (360 ) and remove the other cam sprocket
bolt.

NOTE

Be careful not to let the cam sprocket bolts fall into the
crankcase .

'88, '89:
Remove the three camshaft holder mounting bolts and the nut,
the oil plate and the holder.

After '89:
Remove the three camshaft ho ld er mou nting bo lts, nuts,
o i l p late and the ho lder.

Remove the dowel pins.


Hang the cam chain on the camshaft behind the camshaft
flange and remove the cam sprocket while lifting the camshaft
out.

Attach a piece of wire to the cam chain to prevent it from


being d ropped into the crankcase.

9-5
CYLI N D E R H EAD IVALVE

I N S PE CT I O N

Cylinder head
Inspect the camshaft holder and cylinder head journal surfaces
for scoring or evidence of i nsufficient lubrication.

Camshaft runout
Support both ends of the camshaft with V-blocks and check
the camshaft runout with a dial indicator.

SERVICE LIMIT: 0.05 mm (0 .002 in)

Using a micrometer, measure the height of each cam lobe.

SERVICE LIMIT:
IN: 37. 730 mm ( 1 .4854 in)
EX: 3 7 . 7 50 mm ( 1 .4862 in)

Check the camshaft journals for wear or damage .


Measure the O . D . of each journ a l .

SERVICE LIMIT: 2 1 .90 mm (0.862 in)

Camshaft bearing oil clearance


Wipe any oil from the journals. Lay a strip of plastigauge
lengthwise on top of each camshaft journa l .

NOTE

Avoid placing plastigauge over the oil hole .

9-6
CYLI N D E R H EAD/VALVE

2
I nstall the camshaft holders and tighten the mounting bolts in ' 88 '89 :
,

a crisscross pattern i n or 3 steps .

NOTE
Do not rotate the camshaft when using plastigauge.

TORQUE:
6 mm flange bolt: 1 2 Nm ( 1 . 2 kg-m, 9 ft-lb)
8 mm flange bolt: 23 Nm ( 2 . 3 kg-m, 1 7 ft-lb)

/(2) 6 mm FLANGE
8 mm flange nut: 23 Nm (2.3 kg-m, 1 7 ft-lb) i

BOLTS

After '89 :

Remove the camshaft holder and measure the width of each


plastigauge. The widest thickness determines the oil clear
ance.

SERVICE LIMIT: 0.23 mm (0.009 in)

When the service limit exceeded, replace the camshaft and re


check the oil clearance .

Replace the cylinder head and camshaft holder if the clearance


still exceeds the service limit.

Camshaft holder/Rocker arm shaft/Rocker arm ( 1 ) ROCKER ARM SHAFTS


Remove the rocker arm shafts by tapping the holder with a
soft hammer.

9- 7
CYLI N D E R H EAD/VALVE

Remove the rocker arms and wave washers from the shafts .

(2)

WAVE WASHERS

Inspect the rocker arm shafts and rocker arms for wear or
damage.

Check the rocker arms for clogged oil holes.

Measure the O . D . of each rocker arm shaft.

SERVICE LIMIT:
IN/EX : 1 1 .83 mm (0.466 in)

Measure the I . D . of each rocker arm.

SERVICE LIMIT: 1 2 .05 mm (0.474 in)

CYLI N DE R H EAD
REMOVAL

NOTE
The front cylinder head can be removed with the engine
installed . The engine must be removed to service the rear
cylinder head .

Drain the coolant (page 5-31 and remove the following:


- front camshaft (page 9-31
- the cam chain tensioner mounting bolts and washers from
the cylinder head and cylinder
- cam chain tensioner

Remove the exhaust pipes as an assembly ( Section 6 ) by re


moving the heat protector and exhaust pipe joint nuts.
Disconnect the clutch cable from the clutch lifter arm by re
moving the clutch cable holder bolt.
Remove the oil pipe from the engine.

NOTE

Do not bend the oil pipe during removal .

Loosen the 6 mm bolt, 8 mm bolts, 8 mm nut a n d 1 0 mm nuts/


washers in a criss-cross pattern in 2 or 3 steps.
Remove the bolts and nuts.

9-8
CYLI N D ER H EAD/VALVE

Remove the upper radiator hose and the radiator mounting


bolts (page 5-5 ) .
Release the radiator from t h e frame grommets a n d suspend it
with a piece of rope or something suitable.

Remove the front cylinder head .

Remove the gasket, dowel pins and cam chain guide from the
cylinder.

Rear cylinder head :


Remove the following :
- engine (section 6 )

NOTE
Make sure the piston is at TDC on the rear cylinder com
pression stroke .

- o i l pass pipe ( '88, ' 89) , cy linder head cover, and cam chain
tensio ner
- head bolts and nuts, as described for front cylinder head re
moval
- cylinder head , head gasket, dowel pins, and cam chain
guide

D I SAS S E M BLY/ I N S P E CT I O N

Cylinder head
Clean the cylinder head surfaces of any gasket materia l .

CAUTION
A void damaging the gasket surfaces.

Gaskets will come off easier if soaked in solvent.

Check the spark plug hole and valve areas for cracks .
Check the cylinder head for warpage with the straight edge
and thickness gauge.

SERVICE LIMIT: 0 . 1 0 mm (0.004 in)

Remove the valve spring cotters, retainers, springs, and valves


using a Valve Spring Compressor.

TOOL:
Valve spring compressor 07757 -001 0000 or
07957 - 329000 1

CAUTION
To prevent loss of tension, do not compress the valve springs
more than necessary to remove the cotters.

NOTE
Mark all parts during disassembly so they can be placed
back in their original locations.

9-9
CYLI N D ER H EAD/VALVE

Remove the valve stem seals and valve spring seats.

Remove carbon deposits from the combustion chamber.

Valve springs
Measure the free length of the inner and outer valve springs.

SERVICE LIMITS :
INNER (IN) : 36.47 mm ( 1 .436 in)
(EX) : 37 . 5 1 mm ( 1 .477 in)
OUTER (IN ) : 40 . 58 mm ( 1 . 598 in)
(EX) : 41 . 2 5 mm ( 1 .624 in)

Replace the springs as a set if they a re shorter than the service


limit.

Valve stem-to-guide clearance (1 ) V VE STEM


Inspect each valve for bending, burning, scratches or
abn o rmal stem wear.

Check valve movement i n the guide and measure and record


each valve stem O . D .

SERVICE LIMITS: I N : 5.45 m m (0. 2 1 5 in)


EX: 6.55 mm (0.258 in)

Measure and record each valve guide I . D .

NOTE
Ream the guides to remove any carbon deposits before
checking clearances.

SERVICE LIMIT: IN: 5 . 56 mm (0.2 1 9 in)


EX: 6.65 mm (0. 262 in)

Subtract each valve stem O . D . from the corresponding guide


I . D . to obtai n the stem to guide clearance.
SERVICE LIMIT: IN: 0. 1 0 mm (0.004 in)
EX: 0. 1 1 mm (0.004 in)

9- 1 0
CYLI N D ER H EAD/VALVE

If the stem-to-guide clearance exceeds the service limits, de


termine if a new guide with standard dimensions would
bring the clearance within tolerance. If so, replace any guides
as necessary and ream to fit.
TOOLS :
Valve guide reamer
IN: 07984-2000001 or
07984-2000000
EX: 07984-Z E2000 1 or
07984-Z E2000D
NOTE
It is important that the reamer always be rotated in the
same direction when it is inserted or removed .

If the stem-to-guide clearance exceeds the service limits with


new guides, also, replace the valves.

NOTE
Reface the valve seats whenever the valve guides are re
placed .

VALVE G U I DE REPLACEM ENT


Chill the valve guides in the freezer section of a refrigerator for
about an hour.
Heat the cylinder head to 2 1 2 F ( 1 00 C ) with a hot plate or
ove n . Maximum allowable temperature is 300 F ( 1 50 C ) .

To avoid burns, wear heavy gloves when handling he heated


cylinder head.

CAUTION
Do not use a torch to heat the cylinder head; it may cause
warping.
Support the cylinder head and drive out the old guides from the
combustion chamber side of the cylinder head .
TOOL:
Valve guide driver ( I N ) : 07742-00 1 0 1 00
(EX) : 07742-00 1 0200 N ot
ava i l a ble i n U .S.A.
07942-65701 00
NOTE
( 1 ) VALVE G U I D E
Avoid damaging the cylinder head . DRIVER
MENT
Make note of the valve guide projection specifications (follow
ing ) , then drive i n new guides from camshaft side of the cylin
der head .
TOOLS:
Valve guide driver
5 . 5 mm (IN) : 07742 - 00 1 0 1 00
6 . 6 mm (EX) : 07742 - 00 1 0200
Attachment
5 . 5 mm (IN): 07943 - MF50 1 00
6 . 6 mm (EX) : 07943 - MF50200

9- 1 1
CYLI NDER H EAD/VALVE

VALVE GUIDE PROJECTION HEIGHT:


IN: 1 9.4- 1 9 .6 mm (0.76 - 0 . 77 in)
EX: 1 7 . 9 - 1 8 . 1 mm (0.70 - 0 . 7 1 in)

Ream the new valve guides after installation .

NOTE

Use cutting oil on the reamer during this operation .

It is important that the reamer always be rotated i n the


same directio n when it is inserted or removed.

Clean the head thoroughly after reaming the valve guides.


TOOLS :
Valve guide reamer I N : 07984-2000001 o r
07984-200000 D
EX: 07984-Z E200 0 1 or
07984-Z E2000D

VALVE SEAT I NSPECTION/ REFACI NG


Clean a l l intake a n d exhaust valves thoroughly t o remove
carbon deposits .

Apply a light coating of Prussian Blue to each valve seat. Lap


each valve and seat using a rubber hose or other hand-lapping
tool .

Remove and inspect each valve .

CAUTION

The valve cannot be ground. I/ the valve face is burned or badly
worn or if it contacts the seat unevenly, replace the valve.

Inspect the width of each valve seat.

STANDARD: 0 . 9 - 1 . 1 mm (0.035 - 0 . 043 in)


SERVICE LIMIT: 1 . 5 mm (0.06 in)

If the seat is too wide, too narrow or has low spots, the seat
must be ground .

9- 1 2
CYLI N D E R H EAD/VALVE

\--- 16
l'--- l }\
VALV E S EAT C U TT E R S
60
Honda Valve Seat Cutters, grinder or equivalent valve seat ------ 32 '
refacing equipment are reco m m ended to correct a worn valve ___._ _
I N : 07780 - 00 1 4000 I N : 07780 - 00 1 2 1 00 (28 c/>)
seat. EX: 07780 - 00 1 2300 (35 c/>)
(30 c/>)
EX: 07780 - 00 1 4 1 00
NOTE
(37 . 5 c/>)
Follow the refacer manufacturer's operating instructions.

I N : 07780 - 00 1 0200 (27 .5 </> )


EX: 07780 - 00 1 0400 ( 3 5 </> )

VALV E S EAT R E FAC I N G


( 1 ) R O U G H N ESS/I RREGULARITI ES
Use a 4 5 degree cutter t o remove any roughness o r irregulari
ties from the seat.

NOTE
Reface the seat with a 45 degree cutter when a valve guide
is replaced .

Use a 32 degree cutter to remove the top 1 /4 of the existing


valve seat material .

Use a 60 degree cutter to remove the bottom 1 /4 of the old


seat. Remove the cutter and i nspect the area you have
ref aced .

9- 1 3
CYLI N DER H EAD IVALVE

Install a 45 degree finish cutter and cut the seat to the proper
width . Make sure that all pitting and irregularities are removed .
Refinish if necessary .

Apply a thin coating of Prussia n Blue to the valve seat. Press


the valve through the valve guide and onto the seat to make a ( 1 ) CONTACT TOO H I G H
clear pattern.

NOTE

The location of the valve seat i n relation to the valve face is


very important for good sealing .

If the contact area is too high on the valve, the seat must be
lowered using a 32 degree flat cutter.

If the contact area is too low on the valve, the seat must be
raised using a 60 degree inner cutter. ( 1 ) CONTACT T O O LOW

Refinish the seat to specifications, using a 45 degree finish


cutter.

After cutting the seat, apply lapping compound to the valve


face, and lap the valve using light pressure.
After lapping, wash all residual compound off the cylinder
head and valve .

NOTE

Do not a llow lapping compound to enter the guides.

9- 1 4
CYLINDER H EAD/VALVE

CYLI N DE R H EAD ASSEM BLY ( 1 ) VALVE (4) RETAINER

I nstall the valve spring seats and new stem seals.


Lubricate each valve stem with m olybdenum disulfide oil and
i nsert the valve i nto the valve guide. Turn the valve slowly SPRING

j/_ 11(.
while i nserting to avoid damaging the seals .

1"
( 5 ) COTTERS ?
171 SPR I N G ( 6 ) I N N E R
S EAT SPR I N G

Move the valves u p and down to check for smooth operation.

Install the valve springs with the tightly wound coils facing the
combustion chamber.

I nstall the spring retainers.

Compress the springs and i nstall the valve cotters.

CAUTION

To prevent loss of tension, do not compress the valve springs


more than necessary to install the valve cotters.

TOOL:
Valve spring compressor 07757 - 00 1 0000 or
07957 - 329000 1

9- 1 5
CYLI N D E R H EAD/VALVE

Tap the valve stems gently with a soft hammer to firmly seat
the cotters .

NOTE

Support the cylinder head above the work bench surface to


prevent possible valve damage.

Apply locking agent to the threads of the sealing bolts and


tighten them, if removed.

CYLI N DER HEAD I NSTALLATION


I nstall the cam c h a i n g u i d e into the cylinder.

Make sure that the cam chain guide bosses are i n the grooves
of cylinder.

Clean the cylinder head surface of any gasket material .

I nstall the dowel pins and a new head gasket.

9- 1 6
CYLI N D E R H EA D IV ALVE

I nstall the carburetor insulator o n the cylinder head, aligning


the boss on the cylinder head with the slot in the insulator.

( 1 ) BOSS (2) SLOT

After '9 1 (Cal ifornia model only) :

I nstall the insulator bands align i n g the pins o n the insulator


bands with the slots o n the insulato rs as shown .

Tighten the band screws secu rely .

I nstall the cylinder head .


I nstall the 1 0 m m nut/washer, 8 m m nut/washer, 8 mm bolt/
washer and 6 mm bolt and tighten them in a crisscross pattern
i n 2 or 3 steps.

TORQUE :
1 0 mm nut: 48 Nm (4.8 kg-m, 35 ft-lb)
8 mm bolt: 23 Nm (2.3 kg-m, 1 7 ft-lbl
8 mm nut: 23 Nm (2.3 kg-m, 1 7 ft-lbl
6 mm bolt: 10 Nm ( 1 .0 kg-m, 7.2 ft-lbl

41

RS!
. ..
( 3 ) 8 m m BOLTS/WASHE

'88, '89: ( 1 ) SEALING WASH ERS


Check the oil pass pipe bolts and oil pass pipe for clogging or
bending.
.--

I nstall the oil pass pipe, new sealing washers, oil pass pipe
bolts and the pipe holder bolt.
Tighten the bolts .

r
TORQU E :
O i l pass pipe bolt:
7 mm: 1 0 Nm ( 1 .0 kg-m, 7 . 2 ft-lb)
8 mm: 23 N m (2.3 kg-m, 1 7 ft-lb)
( 3 ) O I L PIPE (2) HOLDER

9- 1 7
CYLI N D ER H EAD/VALVE

I nstal l the following :


- cam chain tensioner with washers and bolts .

TORQUE: 1 0 Nm ( 1 . 0 kg-m , 7 . 2 ft-lbl

- camshaft ( page 9- 1 8 )
- camshaft holders ( page 9 - 1 9 )
- cylinder head cover (page 9-2 1 )

( 1 l CHAIN TEN SIONER


WASH ERS/SOLTS
------- .,_, 'il!lltW' """"'

CAMSHAFT I NSTALLATION ( 1 ) WAVE WASHERS

Apply m ol ybdenum disulfide oil to t h e rocker arm shafts .


I nstal l the ocker arms, rocker arm shafts and wave washers i n
t h e camshaft holders .

NOTE

I nstal l the wave washers in the proper position as show n .

Position the grooves in the rocker a r m shafts vertically, align


ing the bolt holes of the holder with the holes of the shafts .
, MoS2
Apply molybdenum disulfid e oil to the rocker a rm slipper faces .

F R O N T CYLI N D E R ( 1 ) G ROOVES

NOTE

If the rear cylinder head has not been serviced, remove the
rear cylinder head cover and check the camshaft position as
follows:
Turn the crankshaft counterclockwise and align the " RT"
mark on the flywheel with the index mark on the timing
hole, then look for the identification mark on the camshaft
flange .
If the notch mark is facing up, turn the crankshaft counter
clockwise approximately 1 - 1 /8 turn (41 2 ) and begi n
instal l ation of t h e front camshaft.
If the notch mark faces down ( cannot be seen) , turn the
cra nkshaft cou nterclockwise approxi matel y 1 /8 turn

( 52 ) and beg i n insta l lation.

9- 1 8
CYLI N D ER H EAD IV ALVE

Align the " FT" mark on the flywheel with the index mark on
the timing hol e .

N OTE

If the front and rear cylinder c a mshafts were removed, do


not confuse the m . Check the i dentification mark on the
neck of the camshaft flange.

I nstall the camshaft i n the cylinder h ead through the cam chain
and install the cam sprocket on the camshaft with the I N mark
facing inside .

With the notch mark on the camshaft flange facing up, align
the timing marks ( i ndex lines) on the cam sprocket with the top ( 1 ) N OTCH
of the cylinder head.

Place the cam chain on the sprocket.

Install the cam sprocket on the camshaft flange and recheck


that the timing marks (index lines) a l ign with the top of the cyl ( 1 ) CAM SPROCKET BOLT (2) HOLDER
inder head .
Align the cam sprocket bolt holes in the cam sprocket and
camshaft, install and tighten the cam sprocket bolt.

TORQUE: 23 N m (2.3 kg-m, 1 7 ft-lbl

T u rn the crankshaft cou nterclockwise one fu l l t u rn (360 )


. and insta l l the other sprocket b o lt .


T u rn the crankshaft counterclockwise one fu l l t u rn (360 ) .
a l i gning the "FT" mark with the i ndex mark, then check that
the tim ing marks on the cam sprocket a l ign with the to p of
the cy l ind er head .

9-19
CYLI NDER H EAD/VALVE

'88, '89:
I nstal l the dowel pins into the cylinder head .
I nstal l the holders, oil plate, 8 mm bolts, 8 m m nut and 6 mm
bolts .

After '89:
I nsta l l the dowel p ins into the cy linder head .
1 11sta l l the ho lders, o i l pipe 8 m m bo lts, 8 m m nuts and 6 mm
bo lts.

TORQU E :
'8 mm bolt: 23 N m (2.3 kg-m, 1 7 ft-lb)
8 mm nut: 23 Nm (2.3 kg-m, 1 7 ft-lbl
6 mm bolt: 10 N m ( 1 .0 kg-m, 7.2 ft-lb)

CAUTION

Note the direction of the camshaft end holder, install the flat After '89 :
surface on the holder facing in.

After insta l l ing the front cy l inder camshaft, t u rn the crank



shaft counterclockw ise approximate ly 7 /8 t u rn ( 308 ) and
a l i gn the RT mark with the index on the t i m ing ho le, then
insta l l the rear cylinder camshaft.

Lubricate the cam lobes with fresh engine o i l .

If the cylinder head w a s removed from t h e engine in t h e frame,


instal l the following :
- radiator with upper radiator hose
- exhaust pipe

R E A R CYLI N D E R

NOTE

If. the front cylinder head was not serviced, remove the
front cylinder head cover and check the camshaft position
as follows:
Turn the crankshaft counterclockwise and align the "FT"
mark on the flywheel with the index mark on the timing
hole, then look for the identification mark on the camshaft
flange. If the notch mark is facing up, turn the crankshaft
countercl ockwise approx i mate l y 7/8 tu rn (308 ) a n d
begin insta l lat ion of the rear camshaft.
I f the camshaff notch mark faces down (cannot be seen) ,
t u rn the crankshaft co unterclockw i se appro x i mately
1 -7 /8 t u rn (668 ) and begin insta l lation.

9-20
C Y L I N D E R H EADNA L V E

Make sure that the " RT" mak on the flywheel aligns with the
index mark on the timing hole .

Place the camshaft into the correct position with the notch
mark on the camshaft flange facing up and install the cam
sprocket and camshaft holders using the same procedu re as
for the front cylinder.

Remove the 2 m m pin holding cam chain tensioner wedge A.

NOTE

Be careful not to let the 2 mm pin fal l i nto the crankcase .

Do not forget to remove the 2 m m pin before installing the


cylinder head cover.

CYLI N DE R H EAD COVE R I NSTALLATION ( 1 ) APPLY C ONTACT CEMENT

Clean the gasket and apply contact cement to the gasket


groove .
Apply sealant around the gasket.

Install the cylinder head cover, rubber washer, washer cover


and cylinder head cover bolts .
Tighten the cover bolts.

'\\
TORQUE: 1 0 N m ( 1 .0 kg-m, 7 . 2 ft-lb)

( 1 ) R U BB ER


WASH E R
( 2 ) WASH E R

"\ (3) BOLT COVER


CYLI NDER H EAD IV ALVE

I nstall the 0-ring on the water pipe with the tapered side facing
out and install the water pipe i nto the cylinder head .

Connect the water hose to the water pipe and i nstall the spark
plug caps.
I nstall the following parts :
- carburetors (page 4- 1 5)
- air cleaner housing (page 4-4)
- fuel tank ( page 4-3)
- steering covers

Fill the cooling system (page 5-3)

' 2
9- 2
MEMO
CYLI N D ER/P IS TO N

1 0-0
10. CYLI N DE R/ P I STO N
S E RVIC E I N FO R M ATIO N 1 0- 1 P IS TO N R I N G I NS TALLATIO N 1 0- 5

TRO U BLES HOO T I N G 1 0- 1 PISTO N I NS TALLATIO N 1 0- 5

C Y LI N D E R 1 0- 2 C Y L I N D E R I NS TALLATIO N 1 0- 6

PIS TO N 1 0- 3

SERVICE I N FORMATION
GEN ERAL

This section covers service of the cylinder and pisto n .


The front cyl inder/piston c a n b e serviced with t h e engine installed in the frame.
The engine must be removed to service to rear cylinder/piston.
To service the crankcase stud bolts, refer to page 1 1 - 1 5 .

S P E C I F I CATI O N S Unit: mm ( i n )
ITEM STANDARD SERVICE LIMIT
Cylinder I. D . 7 5 . 000 - 7 5 . 0 1 5 ( 2 . 9 5 2 8 - 2 . 9 5 3 3 ) 75. 1 0 (2.957)
Warpage across top --
0 . 1 0 ( 0 . 004)
Taper --
0 . 06 ( 0 . 00 2 )
O ut-of-round --
0 . 0 6 ( 0 . 00 2 )
Piston, Piston ring-to-ring TOP 0 . 0 1 5 - 0 . 0 4 5 ( 0 . 0006 - 0 . 00 1 8 ) 0 . 1 0 ( 0 . 004)
piston g roove clearance SECO N D 0 . 0 1 5 - 0 . 0 4 5 ( 0 . 0006 - 0 . 00 1 8 ) 0 . 1 0 ( 0 . 004)
rings
and piston Ring end gap TOP 0 . 1 0 - 0 . 30 ( 0 . 004 - 0 . 0 1 2 ) 0 . 50 ( 0 . 020)
pin SECOND 0 . 1 0 - 0 . 30 ( 0 . 004 - 0 . 0 1 2 ) 0 . 50 ( 0 . 020)
OIL 0 . 20 - 0 . 7 0 ( 0 . 00 8 - 0 . 0 2 8 ) 0 . 90 ( 0 . 0 3 5 )
Piston O . D . 7 4 . 9 6 5 - 7 4 . 9 90 ( 2 . 9 5 1 4 - 2 . 9 5 2 4 ) 7 4 . 90 ( 2 . 94 9 )
Piston pin bore 1 8 . 0 0 2 - 1 8 . 008 ( 0 . 7 08 7 - 0 . 7 0 9 0 ) 1 8 .05 (0. 7 1 1 )
Connecting rod smal l end I . D . 1 8 . 0 1 6 - 1 8 . 034 ( 0 . 7 0 9 3 - 0 . 7 1 0 0 ) 1 8.07 (0. 7 1 1 )
Piston pin O . D . 1 7 . 9 94 - 1 8 . 000 ( 0 . 7084 - 0 . 70 8 7 ) 1 7 . 98 (0.708)
Piston-to-piston pin clearance 0 . 00 2 - 0 . 0 1 4 ( 0 . 000 1 - 0 . 00 0 6 ) 0 . 040 ( 0 . 00 1 6 )
Cylinder-to-piston clearance 0 . 0 1 0 - 0 . 0 5 0 ( 0 . 0004 - 0 . 00 2 0 ) 0 . 1 0 ( 0 . 004)
Piston pin-to-connecting rod
0 . 0 1 6 - 0 . 040 ( 0 . 0006 - 0 . 00 1 6 ) 0 . 060 ( 0 . 00 2 4 )
small end clearance

TROUBLESHOOTI NG
Low o r uneven compression Piston noise
Worn cylinder or piston rings. Worn cylinder and piston.
Leaking head gasket . Excessive carbon deposits .
Incorrect valve timing.

Excessive smoke
Worn cylinder and piston rings.
Improperly insta lled piston rings.
Damaged piston or cylinder.

Overheating
Excessive carbon deposits on piston or combustion
chamber.
Faulty water p u m p .

1 0- 1
CYLI N D E R/PI STO N

CYLI N DER
R E M OVAL

NOTE

To service the rear cylinder/piston , first remove the engine


and then proceed with the common removal steps below.

Remove the following :


- cylinder head cover (page 9 - 3 )
- cylinder head (page 9-8)
- gaskets, dowel pins, and cam chain guides.
Disconnect the water hose from the coolant connector.

Remove the clip and slide the cylinder joint collar toward
eigther the front or rear cylinder.

Remove the cylinder to be serviced .


Remove the cylinder gasket and dowel pins from the crank
case .

I N S PE CT I O N

Clean the top o f each cylinder thoroughly.

I nspect the cylinder walls for scratches and wear .

Measure and record t h e cylinder I . D . a t three levels in both an


X and Y axis . Take the maximum reading to determine the cyl
inder wear.

SERVICE LIMIT: 7 5 . 1 0 mm ( 2 . 9 5 7 in)

Calculate the piston-to-cylinder clearance . Take the maximum


reading to determine the clearance.

SERVICE LIMIT: 0. 1 0 mm (0.004 in)

Calculate the cylinder for taper at three levels i n an X and Y


axis. Take the maximum reading to determine the taper.

SERVICE LIMIT: 0.06 mm (0.002 in)

Calculate the cylinder for out-of-round at three levels in an X


and Y axis . Take the maximum reading to determine the out
o
of-roun d .
(1) IN ( 2 ) EX
SERVICE LIMIT: 0.06 mm (0.002 in) (3) TOP F""-....,.;;1;;;; X

The cylinder must be rebored and an oversize piston fitted if


the service limits are exceeded.

The following oversize piston are available:


0.25 mm (0.01 0 in) and 0 . 50 mm (0. 020 in)

The cylinder must be rebored so that the clearance to a n over


size piston is 0. 0 1 0 - 0.050 mm (0. 0004 - 0 . 0020 in) .

1 0- 2
CYLI N D E R/PISTON

Inspect the cylinders for transverse warpage across the top.

NOTE

Measure warpage using a straight edge and feeler gauge as


shown .

SERVICE LIMIT: 0 . 1 0 mm (0.004 in)

P I STON
R E M OVAL

Place a shop towel i nto the crankcase and remove the piston
pin clips.

NOTE
Do not let the clips fall into the crankcase .

Push the piston pin out and remove the piston .

I N SPECTI O N

Clean the piston domes, ring lands and skirts .

Measure the piston ring-to-groove clearance .

SERVICE LIMIT:
Top : 0 . 1 0 mm (0.004 in)
Second : 0 . 1 0 mm (0.004 in)

If clearance is excessive, replace the piston ring.

Remove the piston rings and mark them to indicate the correct
cylinder and piston position for reassembly.

NOTE

Do not damage the piston rings when removing them.

1 0-3
CYLI N D ER/PISTON

I nsert the old piston ring into the proper ring groove and clean
the groove by rol l i n g the ring around the pistons
circumference .

Inspect the piston for cracks or other damage.

Measure the piston O . D .

NOTE

Take measurements 1 0 mm (0.4 in) from the bottom , and


9 0 to the piston pin hole.

SERVICE LIMIT: 74.90 mm ( 2 . 949 in)

Calculate the piston-to-cylinder clearance by subtracting the


piston O . D . from the cylinder I . D . (page 1 0- 2 ) .

SERVICE LIMIT: 0.32 mm (0.0 1 3 in)

Measure the top and second piston ring end gaps : using a pis
ton , push the ring into the cyl inder squarely and make the mea
surement.

SERVICE LIMIT:
Top/Second : 0 . 50 mm (0.020 in)
Oil: 0 . 90 mm (0.035 in)

Measure each piston pin bore .

SERVICE LIMIT: 1 8 .05 mm (0. 7 1 1 in)

Measure each piston pin O . D .

SERVICE LIMIT: 1 7 . 98 mm (0. 708 in)

Calculate the piston pin-to-piston clearance .

SERVICE LIMIT: 0.40 mm (0.00 1 6 in)

1 0-4
CYLI N D E R/P ISTON

Measure the I . D . of the connectin g rod small end .

SERVICE LIMIT: 1 8 .07 mm (0. 7 1 1 in)

Calculate the piston pin-to-con n e cting rod clearance .

SERVICE LIMIT: 0.060 mm ( 0 . 0024 in)

Refer to section 1 1 for connecting rod replacement.

P I STON R I N G I NSTALLATION
NOTE

Insert the outside surface of the ring into the proper ring
groove and rol l around in the g roove to make sure that the
ring has a free fit around the p i ston ' s circumference.

Carefully install the piston rings o nto the piston with the mark
ings facing u p .

NOTE

Be careful not to damage the p i ston and piston rings during


assembly.

Stagger the ring end gaps 1 20 apart from each other as


show n . (7) (7)
20mm OR 20 mm OR
NOTE MORE MORE

To install the oil ring, instal l t h e spacer first, then instal l the
side rails.

After installing the rings, check that they rotate freely without
sticking.

P I STON I N STALLATION
Place a shop towel into the cra n k case .
Coat the rod small end with molybdenum disulfide grease . As
semble the piston and connecting rod with the piston and
piston pin clips as shown .

NOTE

I nstall the pistons with the m a rk " I N " facing towards the
intake side .

After installing the piston pin c l ips, make sure that they are
seated properly and the end gaps are not aligned with the
cut-out in the piston.

Do not let the piston pin clips fall into the crankcase .

1 0- 5
CYLI N D E R/PISTON

CYLI N DER I NSTALLATION


Clean the cylinder gasket surface being careful not t o drop any
gasket material into the crankcase .

I nstall the dowel pins and new gasket.

Coat the cylinders piston rings/grooves and piston with oil .

Install the piston assembly into the cylinder from the top of the
crankcase while compressing the piston rings with your fin
gers.
Be sure each assembly is returned to its original position as
noted during remova l .

N OTE

Be careful not to damage the piston rings during assembly.

When the cylinder is halfway over the piston , route the cam
chain through the cylinder.

I nstal l a new 0-ring onto the cylinder joint and install the cylin
der joint collar by sliding the collar toward eigther cylinder.
I nstal l the clip securely.

Clean the cylinder gasket surface being careful not to drop any
gasket material .

NOTE

Avoid damaging the gasket surface .

Install the cam chain guide.

NOTE

Align the guide boss with the groove in the cylinder.

Make sure that the end of the guide is inserted into place in
the crankcase .

1 0- 6
CYLI N D ER/PISTON

I nstal l a new 0-ring into the connecting pipe and install and
tighten the connecting pipe mounting bolts, if the connecting
pipe was removed .

If only the water hose was removed , connect the hose with
clamp.

I nstal l the dowel pins and a new gasket . , (1) DOWEL PINS

\
I nstal l the cylinder heads and covers (Section 9 ) .

1 0- 7
CRAN KSHAFT/TRANSM ISSION

'88 -'89 , ' 9 1 -' 9 5 :


20 - 30 N m ( 2 . 0 - 3 . 0 kg-m, 1 4 - 22 ft-lb)

34 Nm (3.4 kg- m 2 5 ft-lb)


'

'88 -' 8 9 . ' 9 1 -' 9 5 :


30-50N m (3 . 0-5 . Okg - m , 2 2 - 3 6ft- lb)
1 1 . CRAN KSHAFT/TRANSM I SSION
S E RVIC E I N FO R MATIO N 1 1 -1 C RA N KC A S E 1 1 -1 3

T RO U BLESHOOT I N G 1 1 -3 TRAN S M I S S IO N ASS EMBLY I


I N STALLATIO N 1 1 -1 7
C RA N KCASE SEPARAT I O N 1 1 -4
C RA N KC A S E ASSEM BLY 1 1 -1 9
C RA N KS H AFT/CO N N EC T I N G RO D 1 1 -5

T RA N S M I SSIO N 1 1 -1 1

SERVICE I N FORMATION
G E N ERAL

To service the connecting rods, crankshaft, transmission and oil pump, the engine must be removed from the frame ( Sec
tion 6 ) .
A l l bearing i nserts are select fitted a n d are identified b y color code. Select replacement bearings from the code tables.
After instal l ing new bearings, recheck them with plastigauge to verify clearance.
Apply molybdenum disulfide g rease to the main journals and crankpins during assembly.
Before separating the crankcase, the following parts must be removed .

Section 9 NOTE
Section 9
Cylinder head cover
. The front cylinder camshaft and cylinder head
Water pipe - Camshaft service c an be performed without removing
the engin e from the frame.
Ill
Camshaft holder

l
Cam chain and drive sproket

Section 1 0 Section 9
O i l pass pipe
Cylinder joint collar - Cylinder head
Water hose connecting pipe
Cam chain tensioner

Section 9, 10 Section 1 0

Cylinder
C a m chain guide ------
Piston

+
Crankshaft - C R A N KCASE _ Starter motor ( Section 1 7 )
Connecting rod SEPA RATIO N
R ight crankcase cover ( Section 7 )
Transmission - Clutch
O i l pump - Gearshift linkage
- Primary drive gear
- Oil pipe
Left crankcase cover ( Section 8 )
- Flywheel
- Starter gears

1 1 -1
C RA N KS HAFT/TRAN S M I S S I O N

S P E C I F I CATI O N S
mm (in)
ITEM STAN DAR D S E RV I C E LI M IT
Cra n kshaft/ Con nectin g rod big end side clearance 0 . 05-0 . 2 0 (0 . 002-0 . 008) 0 . 30(0 . 00 1 )
connecting rod Crankpin o i l clearance 0 . 02 8 -0 . 05 2 (0 . 00 1 1 -0 . 0020) 0 . 07 ( 0 . 003)
Main journal oil clearance 0 . 02 5-0 . 04 1 (0 . 00 1 0-0 . 00 1 6 ) 0 . 06 (0 . 002)
Crankshaft ru nout -
0 . 05 ( 0 . 002)
Transmission Gear I . D . C1 2 4 . 000-24 . 02 1 ( 0 . 9449-0 . 94 5 7 ) 2 3 . 94 (0 . 943)
M 4 , M 2 , C3 2 8 . 000-2 8 . 02 1 ( 1 . 1 02 4- 1 . 1 03 2 ) 2 8 . 04 (0 . 1 04)
Gear bushing O . D . C 1 2 3 . 9 59-23 . 980 ( 0 . 9433-0 . 944 1 ) 2 4 . 94 (0 . 982)
M 4 , M 2 , C3 2 7 . 9 59-2 7 . 980( 1 . 1 007- 1 . 1 0 1 6) 2 7 . 94 ( 1 . 1 00)
Gear bushing I . D . C1 2 0 . 0 1 6-2 0 . 03 7 ( 0 . 7 880-0 ._7889) 2 0 . 06 ( 0 . 790)
M2 2 5 . 000-2 5 . 02 1 ( 0 . 9843-0 . 9 8 5 1 ) 2 5 . 04 (0 . 986)
B ushing-to- C1 0 . 02 3 -0 . 05 7 (0 . 0009-0 . 02 2 ) 0. 1 0 (0 . 004)
shaft clearance M2 0 . 020-0 . 062 ( 0 . 0008-0 . 0024) 0. 1 0 (0 . 004)
Gear-to- M4, M2 0 . 002-0 . 062 ( 0 . 0008-0 . 0024) 0. 1 0 (0 . 004)
bushing clearance C 1 , C3
Cou ntershaft 0 . D . C 1 bushing 1 9 . 980- 1 9 . 99 3 ( 0 . 7 8 6 6-0 . 7 8 7 1 ) 1 9 . 9 6 (0 . 786)
Mainshaft 0 . D . M 2 bushing 2 4 . 9 59-24 . 980(0 . 98 3 5 -0 . 9 8 2 6 ) 2 4 . 94 (0 . 982)
Backlash 1 st, 2 n d , 3rd 1 . 02 1 -0 . 1 1 0 ( 0 . 0008-0 . 0043)
4th 1 . 02 3 -0 . 1 1 7 ( 0 . 0009-0 . 0046)
S hift fork/ Claw thickness 5 . 93-6 . 00(0 . 2 3 3 -0 . 2 3 6 ) 5 . 63 ( 0 . 2 2 2 )
fork-shaft Right and left shift '88 , ' 89 , ' 9 1 -' 9 5 : 1 3 . 000- 1 3 . 0 1 8 ( 0 . 5 1 1 8-0 . 5 1 2 5 ) 1 3 . 04 (0 . 5 1 3)
fork I . D . After'9 5 : 1 3 . 000- 1 3 . 02 1 ( 0 . 5 1 1 8-0 . 5 1 2 6 ) 1 3 . 04 (0 . 5 1 3)
' 88 , ' 89 , ' 9 1 -' 9 5 : 1 2 . 9 6 6 - 1 2 . 984(0 . 5 1 05-0 . 5 1 1 2 ) 1 2 . 9 0 (0 . 508)
Shaft O . D .
After'9 5 : 1 2 . 9 6 6- 1 2 . 984(0 , 5 1 05-0 . 5 1 1 2 ) 1 2 . 9 5 (0 . 509)
Shift drum 0 . D . (at the left side journal) 1 1 . 9 6 6 - 1 1 . 984 ( 0 . 47 1 1 -0 . 47 1 8) 1 1 . 94 (0 . 47 0)

T O R Q U E VALU ES

Connecting rod bearing cap nut 34 N m ( 3 . 4 kg- m , 2 5 ft-lb)


Crankcase 8 mm stud bolt 20 - 30 N m ( 2 . 0 - 3 . 0 kg-m, 1 4 - 2 2 ft-lb)
1 0 mm stud bolt 30 - 50 N m ( 3 . 0 - 5 . 0 kg-m, 2 2 - 36 ft-lb)

TOOLS

Special
Main bearing driver attachment 0 7 H M F - M M 90400
Bearing remover set 07936 - 3 7 1 000 1 N ot available in U . S . A .
- remover handle 07936 - 3 7 1 0 1 00
- bearing remover set 07936 - 3 7 1 0600
- remover weight 07741 - 00 1 020 1 or
07936 - 3 7 1 0200 U . S . A . Only

Common
Driver 07749 - 00 1 0000
Attachment, 42 x 4 7 mm 07 746 - 00 1 0300
Pilot, 20 mm 077 46 - 0040 500
Attachment, 52 x 55 mm 07746 - 00 1 0400
Pilot, 22 mm 07 746 - 004 1 000
Pilot, 2 5 mm 07746 - 0040600

1 1 -2
CRA N K S HA FT/TRANSMISS I O N

TROU BLESHOOTI N G
Excessive noise
Crankshaft
- Worn main bearing
- Worn crankpin bearing
connecting rod
- Worn rod small end
- Worn crankpin bearing

Hard to shift
Shift forks bent
Shift fork shaft bent
Shift spindle claw bent
Shift drum cam grooves damaged
Shift fork guide pin damaged

Transmission jumps out of gear


Gear dogs worn
Shift shaft bent
Shift forks bent

1 1 -3
CRANKS HAFT/TRANSMISSION

CRAN KCASE SEPARATION


Remove the engine from the frame ( Sectio n 6).

Refer to the service i nformation ( page 1 1 - 1 ) for the parts that


must be removed before the separating the crankcase .

Remove the oil pipe stay and cam chain tensioner set plate by
removing the bolts .

Remove the rear cam chain and cam chain drive sprocket.

Remove the bolt and cam chain tensioner set plate .


Remove the front cam chain from the crankshaft.

Remove the 8 mm bolts and 6 mm bolts from the left crank


case .

NOTE

2
Remove the bolts in a crisscross pattern in or 3 steps.

Loosen the 6 mm bolts first, then loosen the 8 mm bolts .

Remove the 8 m m bolts and 6 mm bolts from the right crank


case .

NOTE
2
Remove the bolts in a crisscross pattern in or 3 steps.

Loosen the 6 mm bolts first, then loosen the 8 mm bolts .

1 1 -4
CRANKS HAFT/TRA N S M I S S I O N

Place the left crankcase side down and separate the right
crankcase from the left crankcase while prying where indicat
ed at the point shown and tapping the cases at several loca
tions w ith a soft hammer.

Remove the dowel pins and clean the cran kcase halves of any
sealant materia l .

(1) DOWEL PINS .__

CRAN KSHAFT/CON N ECTI NG ROD


C RA N K S H A FT R E M OVAL

Remove the crankshaft from the left crankcase .

C RA N K S H A FT S I D E C L EARA N C E I N S PECTI O N (1 l FEELER GAUGE

Check t h e connecting rod side clearance with feeler gauge.

SERVICE LIMIT: 0 . 30 mm (0.001 in)

If either side clearance exceeds the service limit, replace the


connecting rod and recheck.
If still beyond the limit, replace the crankshaft.
I nspect the crankshaft for rough spots or damage.

1 1 -5
CRANKSHAFT/TRA N S M I S S I O N

C O N N ECTI N G R O D D I SA S S E M B LY ( 1 ) BEA R I N G CAPS

Remove the connecting rod bearing caps noting their loca


tions .

NOTE
Tap the side of the cap lightly if it is hard to remove .

CAUTION
Do not interchange the crankpin bearings. They must be in
stalled in their original positions or the correct bearing oil clear
ance may not be obtained resulting in engine damage.

C RA N K S H A FT R U N O U T I N S P ECTI O N

Place the crankshaft on a stand or V blocks .


Set a dial indicator on the main journals. Rotate the crankshaft
two revolutions and read the runout.
Actual runont is 1 /2 the tota l indicator read ing .

SERVICE LIMIT: 0.05 mm (0.002 in)

NOTE

The crankshaft cannot be repaired . Replace it if the journals


or crankpins are burnt, cracked, or if the runout is beyond
limits .

C O N N E CTI N G R O D B E A R I N G I N S P E CT I O N

Inspect the bearing insert for damage or separation .


Clean all oil from the bearing inserts and crankpins.

( 2 1 SEPARATION ( 1 1 DAMA G E

O I L C LEARA N C E I N S P ECTI O N ( 1 ) PLASTI GAU G E

Put a piece o f plastigauge o n each crankpin avoiding the oil


hole .

I nstal l the bearing caps and rods on the correct crankpins, and
tighten them evenly.

TORQUE: 34 N m (3.4 kg-m, 25 ft-lbl

NOTE

Do not rotate the crankshaft during inspectio n .

1 1 -6
CRAN KS HAFT/TRA N S M ISSION

Remove the caps and measure the compressed plastigauge at


its widest point on each crankpin to determine the oil clear
ance.

SERVICE LIMIT: 0.07 mm (0.003 i n )

I f the rod bearing clearance is beyond tolerance, select re


placement bearings.

C O N N E C T I N G ROD B EA R I N G S E LECT I O N ( 1 ) I . D . CODE N U M BER

Determine t h e connecting rod I . D . code number.


The code will be either a number 1 or 2 located on the rod in
the area shown.

Determine the corresponding crankpin O.D. code (or measure


the crankpin O . D . ) . The code will be either a letter A or B on
the crank weight.

C ross reference the crankpin and connecting rod codes to de


termine the replacement bearing color. ( 1 l O . D . CODE LETTERS

1\ C RANKPIN O . D . CODE
A
3 9 . 982 - 39.974-
B
( 1 ) CRANKPIN BEAR I N G S
3 9 . 990 mm 39.98 1 mm
/
\
C O N N ECTI NG ( 1 . 5 741 - ( 1 . 5738-
R O D I.D. CODE 1 . 5 744 in) 1 . 5741 in)
43.000 - 43 . 007 mm c B
1
( 1 . 6 9 29 - 1 . 6932 i n ) ( BROWN ) (BLACK)
43.008 - 43 .0 1 6 m m B A
2
( 1 . 6932 - 1 .6935 i n ) ( B LACK) ( BLUE)

BEARING I NSERT THICKN ESS


A ( B L U E ) : 1 . 49 5 - 1 .499 mm (0.0589 - 0 .0590 i n )
B ( B LACK) : 1 .49 1 - 1 .495 mm (0.0587 - 0 . 0589 i n )
C ( BROWN ) : 1 .487 - 1 .49 1 mm (0.058 5 - 0. 0587 in)

1 1 -7
CRANKS HAFT/TRA N S M ISSION

M A I N BEAR I N G I N S PECTI O N

Measure the main journal O . D . and record it.

Measure the main journal bearing I . D . and record it.

Calculate the clearance between the main journal and the main
bearing .

SERVICE LIMIT: 0.06 mm (0.002 in)

If the oil clearance is beyond the service limit, select a replace


ment bearings as follows:

M A I N BEAR I N G S E LECTI O N

2
Determine the crankshaft main journal O . D . code. The code
will be either a number 1 or on the crank weight.

Determine the replacement main bearing.

Determine the corresponding main bearing I . D . code . The code


will be either a letter A or 8 on the crankcase .

1 1 -8
C RAN KSHAFT/TRAN S M ISSION

Choss replacement main bearings i n accordance with the table


below .

M A I N J O U RNAL 1 2
O . D . CODE 44. 992- 44. 984 -
4 5 . 000 mm 44 . 9 9 1 mm

\
( 1 . 7 7 1 3- ( 1 . 77 1 0-
CASE I . D . C O D E 1 . 77 1 7 i n ) 1 . 7 7 1 3 in)
48 . 9 90 - 49 . 000 mm c B
A
( 1 . 9 2 8 7 - 1 . 9 2 9 1 in) ( B ROWN ) ( BLACK)
49.000 - 49 .0 1 0 mm B A
B
( 1 . 9 2 9 1 - 1 . 92 9 5 i n ) ( B LACK) ( BLU E)

BEARING I NSERT THICKNESS


A (BLU E ) : 2 . 003 - 2 . 0 1 3 mm ( 0 . 0789 - 0.0793 in)
B (BLACK) : 1 . 998 - 2 . 008 mm ( 0 . 0787 - 0 . 0 7 9 1 in)
C ( BROWN ) : 1 . 9 93 - 2 . 003 mm ( 0 . 0785 - 0.0789 in)

MAI N B EA R I N G R E P LA C E M E N T

Press the main bearing out of the crankcase using a hydraulic


press and special tools.

NOTE
Always use a press to remove the main bearing.

TOOLS :
Driver 07749 - 0 0 1 0000
Main bearing remover attachment 07HM F - MM90400

Mark a vertical line below each side of the bearing tab.

Apply molybdenum disulfide grease to the outer surface of the


main bearing.

(2) MARKS
(3) G ROOVE

Align the marks on the bearing w ith the groove in the bearing
hole, and press the main bearing i nto the crankcase .

CAUTION
Be careful not to damage the bearings.

TOOLS : (3) MAIN


Driver 07749 - 00 1 0000
BEARING
Main bearing driver attachment 07HMF - MM90400

1 1 -9
CRAN KS HAFT/TRANSMISSION

C O N N ECTI N G R O D/ C RA N K S H A FT
S E L E CT I O N

If a connecting rod requires replacement, y o u should select a


rod with the same weight code as the original. But if that is
unavailable, you may use one of the others specified in the fol
lowing chart.

NOTE

The " 0 " mark in the table indicates that the matching is
possible in the crossed codes. ( 2 ) CRANKSHAFT
WEIGHT CODE
SELECTIO N TABLE ( " L" or "H" or no mark)

Front rod code


A B c
Rear rod code ( 1 ) Apply molybdenum disulfide g rease
A * 0 0

B 0 0 0

c 0 0 * *

CAUTION
For selecting crankshaft weight:

Select "L " crankshaft weight, if the front rod and rear road
have code A ( ) .

Select "H" crankshaft weight, if the front rod and rear rod
have code C ( * *) .

Select crankshaft weight with no code, other than the above


two cases.

C O N N ECTI N G R O D A S S E M B LY

Install the bearing inserts on the rods and caps .

NOTE

Align the boss on the bearing with the groove in the rod or
cap.
Apply molbdenum disulfide grease to the bearing.

Install the connecting rods and caps on the crankpin. Be sure


each part is i nstalled i n its original position, as noted during re
mova l .

Tighten t h e bearing c a p nuts.

NOTE
Align the I . D . code on the cap and rod .

Tighten the nuts in two or more steps. After tightening,


check that the rods move freely without binding.

TORQUE : 34 N m (3.4 kg-m, 25 ft-lbl

CRA N K S H A FT I N STALLAT I O N

Install t h e crankshaft in the left crankcase .


Install the dowel pins and assemble the crankcase .

1 1-10
C RAN KSHAFT/TRAN S M ISSION

TRANSM ISSION ( 1 ) MAI N


SHAFT
R EMO V A L

' 8 8 . '89 . ' 9 1 -'9 5 :


Remove the mainshaft, cou ntershaft, shift fork shaft and shift
drum as a n assembly.

After'9 5 :
Remove the shift fork shaft then remove the shift drum and
shift forks .
Remove the mainshaft and countershaft as a n assembly.

' 8 8 , '89 , ' 9 1 -' 9 5 : ( 2 .) S H I FT FORK/


Separate the shift fork/shaft, mainshaft a n d cou ntershaft AFT
assemblies from each other:

After'9 5 :
Separate the mainshaft and countershaft assemblies from
each other.

(3) COUNTERSHAFT
ASSEM BLY

D I SASS EMBLY/ I N SPECT I O N

Temporarily i nstall t h e mainshaft and countershaft t o the left


crankcase .
Measure the backlash of each gear.

STANDARD : 1 st, 2nd, 3rd


1 .02 1 - 0. 1 1 0 mm (0.0008 - 0.0043 in)
4th
1 .023 - 0. 1 1 7 mm (0.0009 - 0 . 0046 in)

' 8 8 , '89 , ' 9 1 -'9 5 :


Bend down the lock washer tabs and remove the bolt and lock ( 1 ) LOCK WASHER ( 2 ) BOLT
washer from the left shift fork.
Remove the shift fork shaft.

Disassemble the mainshaft and countershaft.

Remove the C4 gear by removing the stop rin g .

1 1 -1 1
C RAN KSHAFT/TRA N S M I S S I O N

I nspect the shift drum end for scoring, scratches, or evidence


of insufficient l ubrication . Check the shift drum grooves for
damage.
Measure the shift drum shaft O . D . at the left side journal.

I
SERVICE LIMIT: 1 1 . 94 m m (0.470 in)

Check the bearing inner and outer races for damage .


The bearing should turn smoothly and quietly.

1 2 1 S H I FT DRUM

Check the shift fork shaft for scratches, scoring or evidence of


insufficient lubrication .
Measure the shift fork shaft O . D .

S E RV I C E LI M I T : '88 , '89 , '91 -'95 : 1 2 . 90mm (0 . 508 in)


After'95 : 1 2 . 95mm (0 . 509 in)

M easure the shift fork I. D. ( right and left) and the shift fork
claw thickness .

SERVICE LIMIT:
I.D.: 1 3 .04 m m (0 . 5 1 3 in)
CLAW THICKNESS: 5.63 mm (0. 222 in)

I nspect the shift drum and shift fork shaft journals for exessive
wear or damage .

Check the gear dogs, holes and teeth for excessive or


abnormal wear, or evidence of insufficient l ubrication .
Measure the I . D . of the following mainshaft countershaft at
C3, C 1 gears.

SERVICE LIMITS : C 1 gear: 24.04 mm (0. 947 in)


M2, M4, C3 gear: 28.04 mm ( 1 . 1 04 in)

1 1 -1 2
CRANKSHAFT/TRANSMISSION

Measure the O . D . of the mainshaft following bushings:

SERVICE LIMITS :
M4 gear bushing : 27 . 94 mm ( 1 . 1 00 in)
C3 gear bushing : 2 7 . 94 mm ( 1 . 1 00 in)
M 2 gear bushing : 2 7 . 94 mm ( 1 . 1 00 in)
C1 gear bushing : 24. 94 mm ( 0 .982 in)

Calculate the clearance between each bushing and gear.

SERVICE LIMIT: 0. 1 0 mm (0.004 in)

Measure the I . D . of the M2 and C 1 bushings:


or C3 BUSH I N G ( 2 ) M 2 or C 1 BUSHING
SERVICE LIMITS :
M2 gear bushing : I . D . 2 5 . 04 mm (0.986 in)
C1 gear bushing : I . D . 24.06 mm (0. 790 in)

Measure the O . D . of the mainshaft and countershaft at the M 2


a n d C 1 bushings.

SERVICE LIMITS :
Mainshaft (at M2 gear bushing) (1) 2
24. 90 mm (0.980 in)
Countershaft (at C 1 gear bushing)
1 9 .92 mm (0. 784 in)

Calculate the clearance between each bushing and shaft.


(2) C 1
SERVICE LIMIT: 0.06 mm (0.0024 in)

Check the each shaft grooves for damage. ( 1 ) SNAP R I N G GROOVES


I

Replace if necessary .

( 2 ) LOCK A N D STOP
WASHER G ROOVES
+ +

t t
( 3 ) SNAP RING (4) STOP
G ROOVE R I N G GROOVE

CRAN KCASE
BEA R I N G R E P LA C E M E N T

Turn the inner race of each bearin g with your finger. The bear
ings should turn smoothly and q uietly . Also check that the
bearing outer race fits tightly i n the crankcase.

Remove and discard the bearin g s if the races do not turn


smoothly, quietly, or if they fit l oosely i n the crankcase.

1 1 -1 3
CRAN KSHAFT/TRAN S M I S S I O N

Left crankcase
Remove the left mainshaft bearing using the special tools.

TOOLS:
Bearing remover set 07936 - 37 1 000 1 N ot
ava i lable i n U . S . A .
- remover handle 07936 - 37 1 0 1 00
- bearing remover set 07936 - 37 1 0600
- remover weight 0774 1 - 00 1 020 1 or
07936-37 1 0200

Drive the countershaft bearing and oil seal out of the crank
case .

I nstal l the new mainshaft bearing set plate on the left crank (1 ) BEARING
case. S ET
PLATE

NOTE

Apply fresh engine oil to the new crankcase bearings before


installation .

I nstall t h e n e w bearings with t h e following tools.

TOOLS :
Left mainshaft bearing
Driver 07749 - 00 1 0000
Attachment, 42 x 47 mm 07746 - 00 1 0300
Left countershaft bearing
Driver 07749 - 00 1 0000
Attachment, 52 x 55 mm 07746 - 00 1 0400
Pilot, 25 mm 07746 - 0040600

I nstall a new countershaft oil sea l .


Check the gearshift spindle oil seal for wear or damage, re
place if necessary.

1 1-14
CRANKSHAFT/TRANSMISSION

Right crankcase
Remove the mainshaft bearing set plate and drive the counter
shaft bearing, mainshaft bearing and shift drum bearing out of
the crankcase .

TOOLS :
Right mainshaft bearing
Driver 07749 - 00 1 0000
Attachment, 52 x 55 mm 07746 - 00 1 0400
Pilot, 22 mm 07746 - 0041 000
Right countershaft bearing
Driver 07749 - 00 1 0000
Attachment, 42 x 47 mm 07746 - 00 1 0300
Pilot, 20 mm 07746 - 0040500

Apply a locking agent to the threads of the mainshaft bearing


set plate attaching bolt.

I nstall the set plate and tighten the bolt securely.

I N SPECTI O N ( 1 ) 1 0 mm STU D BOLT HOLES

Crankcase studs
'88 ' ' 8 9 ' ' 9 1 -'9 5 :
Check that the studs a re tight. I f any are loose, remove them ,
clean their threads with c ontact cleaner, then reinstall them
using Honda Anaerobic Thread Lock , o r equivalent.

(2) 8 mm STU D BOLT HOLE

After i nstalling, be sure to measure the distance from the top ( 1 ) 8 mm STU D BOLT ( 2 ) 1 0 mm STUD BOLT
of each stud to the crankcase surface .

Tighten the stud bolts to the specified torque.

TORQUE: 8 mm stud bolt:


20 - 30 N m ( 2 . 0 - 3.0 kg-m, 1 4 - 22 ft-lb) 1 78 - 1 80 mm 1 68 - 1 70 mm
1 0 mm stud bolt: ( 7 .008 - 7 .087 in) ( 6 . 6 1 4 - 6 . 693 i n )
3 0 - 50 Nm (3.0 - 5 .0 kg-m, 22- 36 ft-lb)

1 1 -1 5
C RAN KS H A FT /TRAN S M ISSI O N

After'9 5 :
Check that the studs a re tight, I f any a re loose, remove them ,
clean their threads with contact cleaner, then reinstall them
apply engine oil to the threads . (1 ) FLAT SI DE

NOTE
Install the studs with the flat side into the crankcase .
\I=-=;1..1 %,...
.--- .. 1 11,
(2 ) B OSS S I DE

After installing , be sure to measure the distance from the top


of each stud to the crankcase surface as shown . (1) 8 mm STU D BOLT (2) 1 0 mm STU D BOLT

1 8 5- 1 8 7 mm 1 68 - 1 70 mm
( 7 . 2 83-7 . 3 62 in) (6.6 1 4 - 6.693 in)

O I L J ET

Remove the oil jets from the front cylinder bore of the right and
left crankcase .

Check the 0-ring for fatique and damage .

1 1 -1 6
CRAN KSHAFT/TRA N S M ISSION

TRANSM I SSION ASSEM BLY I


I NSTALLATION
Apply molybdenum disulfide grease to the fol lowing.
- shift fork grooves
- inside and outside of the bushings
- outside of the spline bushings
( 51 C1 ( 36TI

(4) C2 (34T)

( 3 ) C3 ( 2 7TI

(6) MAINSHAFT

( 1 I COUNTERSHAFT

M4

( 1 0) M4 (29TI

(2) C4 C3 C 2 C1
C O U NTERSHAFT

I nstal l the stopper ring and C4 gear onto the countershasft.

1 1 -1 7
C RAN KSHAFT/TRANSMISSION

I nstall the lock washer and stop washer, aligning bigger tabs of
the lock washer with bigger grooves of the stop washer in the
countershaft groove .

Turn the washers as shown to lock them on the nearest spline.

I nstall the stop washer first, and then the lock washer for the ( 1 ) STOP
C3 gear. WASHER

I
Align and lock the washers using the procedure above.

Assemble the countershaft and mainshaft.

Check the gears for freedom of movement or rotation on the


shaft .
Check that the snap rings are seated in the grooves and align

I
their end gaps with the lands of the splines.

( 2 ) LOCK WASHER

' 8 8 , ' 89 , ' 9 1 -' 9 5 :


I nstall the left shift fork on t h e shaft with M R 1 mark facing the ( 1 ) MR1 MARK
groove on the shaft end and the bolt hole aligned with the
shaft hole.

( 2 ) G ROOVE
' 8 8 , ' 89 , ' 9 1 -' 9 5 :
Tighten the bolt with the lock washer a n d bend up the tabs of ( 1 ) BOLT
the lock washer.

( 2 ) TABS

1 1 -1 8
CRANKSHAFT/TRANSMISSION

'88 . '89 . ' 9 1 -' 9 5 :


I nstall the right shift fork with the " R " mark o n the fork facing
up.

Assemble the mainshaft, countershaft, shift fork shaft and


shift drum.
I nstall them into the l eft crankcase as an assembly.

After'9 5 :
Assemble the mainshaft a n d countershaft .
STE P P E D
I nstall them into the left cankcase as an assembly . EN D
I nstall the shift forks into the shifter gear g rooves with the
markings facing up ( right crankcase side) .
I nstall the shift drum by aligning the shift fork guide pins wiht
the shift drum guide g rooves .
I nsert the shift fork shaft throug h the shift forks into the left
crankcase with the stepped end facing u p .

CRAN KCASE ASSE M BLY


Apply sealant to the crankcase mating surfaces.
I nstall the dowel pins.

( 1 I DOW EL PINS
,

Assemble the right and left crankcases being careful to align


the dowel pins and shafts .

CAUTION
Do not force the crankcase halves together; if there is exessive
force required, something is wrong. Remove the right crank
case and check for misaligned parts.

1 1 -1 9
C RAN KSHAFT/TRANSMISSION

Apply oil to all crankcase bolts .

2
Instal l and tighten the right crankcase bolts i n a crisscross pat
tern in or 3 steps.

NOTE

Tighten the 8 mm bolts first, then tighten the 6 mm bolts.

2
I nstall and tighten the left crankcase bolts in a crisscross pat
tern in or 3 steps.

NOTE

Tighten the 8 mm bolts first, then tighten the 6 mm bolts .

I nstall the rear cam chain drive sprocket over the crankshaft,
aligning the extra-wide splines i n the sprocket and crankshaft.

Instal l the rear cam chain over the drive sprocket.

Install the oil pipe stay and cam chain tensioner set plate .
Tighten the bolt sercurely.

1 1 - 20
C RAN KS HAFT/TRA N S M ISSION

I nstal l the front cam chain over the front cam chain d rive
sprocket.
I nstall the cam chain tensioner set p l ate and tighten the bolt
securely.

I nstal l the rema1mng parts in the reverse order of removal


(page 1 1 - 1 ) .

1 1 -2 1
F R O NT W H E E L/ S U S P E N S I O N / STE E R I N G

3 0 N m (3 . 0 K g-m , 2 2 ft-lb )
After g4 .

1 05 N m ( 1 0 . 5 Kg -m, 76 ft-lb)

2 3 N m (2 . 3 K g-m , 1 7 ft-lb)

2 2 N m (2 . 2 K g-m , 1 6 ft-lb)

'88 , ' 8 9 ' ' 9 1 - . 93 2 7 N m (2 . 7 K g-m , 2 0 ft-lb)


After ' 9 3 :. 3 1 N m (3 . 1 K g-m , 22 ft-lb)

12-0
1 2. FRONT WH EEL/SUSP ENSION/STEER I NG
SERVICE I N F O RMATION 1 2- 1 FRONT W H EEL 1 2-6
TROU BLES H O O T I N G 1 2-2 FORK 1 2- 1 2
HAN D LEBAR 1 2-3 STEERING STEM 1 2- 1 9

SERV I CE I N FORMATION

A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high
quality brake degreasing agent.

Inhaled asbestos fibers have been found to cause respiratory disease 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 air borne asbestos fibers.

This section covers maintenance of the front wheel, fork and steering ste m . Refer to section 1 4 for front (hydraulic) brake
service .
Support the motorcycle using a hoist or a jack under the engine.
The VT600C uses leaf valve to the left .

S P E C I F I CATI O N S

ITE M STAN DAR D S E RVICE LI M IT


Axle ru nout -
0.2 m m (0.008 in)
Front wheel rim runout Radial -
2 . 0 m m ( 0.08 in)
Axial -
2 . 0 mm (0.08 in)
' 8 8 , ' 8 9 ' ' 9 1 -' 9 3 : 3 0 5 m m ( 1 2 . 0 in) 299 mm ( 1 1 .8 in)
Fork spring free length
After' 93: 333.9 m m ( 1 3. 1 in) 3 2 7 . 2 m m ( 1 2.9 i n )
Fork tu be runout -
0.2 m m ( 0.008 in)
'88.' 8 9 : 463 cc( 1 5.7 U S oz, 1 3.0 Imp oz) -

Fork flu id capacity ' 9 1 -' 9 3 : 468 cc( 1 5.8 US oz, 1 3.2 Imp oz) -

After'93 : 449 cc( 1 6. 9 US oz, 1 5.8 Imp oz) -

R ight 9 5.0 m m ( 3 .74 in) -

'88.'89
Left 93.0 mm(3.66 i n ) -

Fork fluid level R ight 89.0 m m ( 3 . 5 0 in) -

' 9 1 -'93
Left 87.0 m m ( 3 .43 i n ) -

After'9 3 : 1 1 1 m m (4.4 in) -

T O R Q U E VALU E S

H andlebar mounting bolt 23 Nm (2.3 kgm, 17 ft-lb)


H andlebar upper holder bolt After ' 94 : 3 0 N m ( 3 . 0 kg-m, 2 2 ft-lb)
Clutch lever holder bolt 1 2 Nm ( 1 . 2 kg-m, 9 ft-lb)
Brake m astercylinder holder bolt 1 2 Nm ( 1 .2 kg-m, 9 ft-lb)
Spokes 4 Nm (0.4 kg-m, 2.9 ft-lb)
Brake disc mounting bolt 40 Nm (4.0 kg-m, 29 ft-lb)
Front axle 75 Nm ( 7 . 5 kg-m, 54 ft-lb)
Fork axle pinch bolt 22 Nm ( 2 . 2 kg-m, 1 6 ft-lb)
Fork socket bolt 30 Nm ( 3 . 0 kg-m, 22 ft-lb)
Fork top pinch bolt 1 1 N m ( 1 . 1 kg-m, 8 ft-lb)
Fork bottom pinch bolt 50 N m ( 5 . 0 kg-m, 36 ft-lb)
B ra ke caliper mounting bolt ' 8 8 , ' 8 9 , ' 9 1 -' 9 3 : 2 7 Nm ( 2 . 7 kg-m, 20 ft-lb)
After ' 9 3 : 3 1 N m ( 3 . 1 kg-m,2 2 ft-lb)
Steering bearing adjustment nut 2 5 N m ( 2 . 5 kg-m, 1 8 ft-lb)
Steering stem nut 1 05 Nm ( 1 0. 5 kg-m, 76 ft-lb)

1 2- 1
FRONT WHEEL/S U S P E N S I O N/STE E R I N G

T O O LS

Special

Spoke wrench
Bottom holder pipe
- holder attachment
07930- KA50000
07930- KA50 1 00
j
07JMA - M R60 1 00 o r equivalent commercially available in U . S . A .
N ot available i n U . S . A .

- holder handle 07930 - KA40200

07953 - MJ 1 0 1 00 T
Ball race remover 07953 - MJ 1 0000 N ot available in U . S . A .

07953 - MJ 1 0200 J
- driver attachment 0 7 9 5 3- MJ 1 000A . 0 7 9 5 3- M J 1 000B o r
- driver handle 0 7 949 -37 1 000 1 a n d 0 7 7 4 6-00 1 0 1 00

Fork seal driver , 39mm 07 947 - 4630 1 00


Steering stem socket 079 1 6 - 37 1 0 1 00
Steering stem driver 07 946 - M BOOOOO
Bearing race remover 07946 - 37 1 0500

Common
Driver 07 749 - 00 1 0000
Attachment, 42 x 47 mm 07 746 - 00 1 0300
Pilot, 20 mm 07 746 - 0040500
Bearing remover shaft 07 746 - 0050 1 00 -r-- Equivalent commercially available i n U . S . A .
Bearing remover head , 20 m m 07 746 - 0050600 _j
Attachment, 52 x 55 m m 07 746 - 00 1 0400

TROUBLESHOOTI N G
Hard Steering Soft Suspension

Steering bearing adjustment nut too tight


Weak fork springs
Faulty steering stem bearings
I nsufficient fluid in fork legs

Insufficient air in front tire


Hard Suspension
Steers to One Side or Does Not Track Straight
Fork oil level too high
Bent fork legs
Fork tube(s) bent or fork slider(s) damaged

Bent front axle, wheel installed incorrectly


Unequal oil quantity i n each fork tube Front Suspension Noise
Slider binding
Front Wheel Wobbling
Insufficient fluid in fork legs
Distorted rim
Loose fork leg fasteners

Worn front wheel bearings

Loose or broken spokes

Faulty tire

Axle or axle holder not tightened properly

1 2- 2
FRONT WH EEL/SUSPENSION/STEERING

HAN DLEBAR
G R I P R E PLAC E M E N T

Remove t h e right handlebar switch screws a n d disconnect the


throttle cables from the throttle pipe.

Remove the grip end cap and right handlebar grip. ( 1 ) CEMMENT
Remove the grip from the throttle pipe.

Apply Honda Bond A or Honda Grip Cemment ( U . S . A . only) to


the inside surface of the throttle grip to the clean surface of
the throttle pipe. Wait 3 - 5 minutes and install the grip. Rotate
the grip for even application of the adhesive .

Connect the throttle cables to the throttle pipe and i nstall the

"()
right handlebar switch.

I nstall the grip end cap.


(3) ROTTLE PIPE ( 2 ) G R I P END CAP

Remove the grip end cap and pull the grip off of the left handle ( 1 ) C E M M ENT
bar.

Apply Honda Bond A or Honda Grip Cemment ( U . S . A . only) to


inside surface of the left grip to the clean surface of the
handlebar. Wait 3 - 5 minutes and install the grip. Rotate 1:he
grip for even application of the adhesive.

NOTE

Allow the adhesive to d ry for a n hour before using . Check


for smooth throttle operation after the right grip is installed .

I nstall the grip end cap.

REMOVAL

Disconnect the clutch switch wires from the switch terminals.


Remove the following:
- rear view mirror from the clutch lever holder
- clutch lever holder mounting bolts and holder
- left handlebar switch wire bands.
- left handlebar switch screws and switch

1 2-3
FRONT W H EEL/S USPENSION/STEERING

Disconnect the front brake light switch wires from the switch. ( 1 l BARKE LIGHT SWITCH
Remove the following : WIRE
- rear view mirror from the master cylinder
- master cylinder holder mounting bolts and holder
- right handlebar switch wire bands
- right handlebar switch screws and switch

Loosen the throttle cable lower adjusting nuts at the carbure


tors and disconnect the throttle cables from the throttle pipe.

Remove the handlebar mounting nuts, handlebar and rubber


seat from the fork bridge .

After '94 :
Remove the ha ndlebar upper holder bolts caps .
Remove the socket bolts , upper holders and handleba r .

Remove t h e n uts and handlebar lower holders .


R>/"1------, ( 2 ) LOW E R
H O LD E R S

1 2-4
F R O N T WHEEL/SUSPENSIO N/STEERING

I N STA LLAT I O N

'88 , '89 , '9 1 -'94 :


I n stall the rubber seat into the fork bridge .

I n stall the washers and handlebar mounting n uts.


Tighten the nuts .

TO RQU E : 23 N m ( 2.3 kg-m, 1 7 ft-lb )

After '94 :
I nstall the handlebar lower holders a n d tem porarily tighten
the n uts .
I nstal l the handlebar and upper holders with their pu nch marks
facing forward .
Tem porarily tighten the socket bolts .

Tig hten the lower holder nuts to the specified torque .

TO RQU E : 23 N m ( 2 . 3 kg-m, 1 6 ft-lb)

( 1 ) LOWER H O L D E R N UTS

Loosen the u pper holder socket bolts a nd align the punch


m arks o n the handlebar with the splits of the handlebar
holders .
Tighten the forward bolts first, then tig hten the rear bolts .

T O R QU E : 3 0 N m ( 3 . 0 kg-m , 22 ft-lb)

I nstal l the u pper holder bolt caps .

Install the left handlebar switch set collar on the upper switch
housing . Align the locating pin in the lower switch housing
w ith the hole in the handlebar.

Install the left handlebar switch attaching screws, and tighten


the forward screw first, then tighten the rear screw.

1 2- 5
FRONT WH EEL/S U S PE N S I O N/STE E R I N G

Install the clutch holder/lever and with the " U P" mark facing
up.
Align the end of the holder with the punch mark on the handle
. bar and tighten the upper bolt first then tighten the lower bolt.

TORQUE: 12 Nm ( 1 . 2 kg-m, 9 ft-lbl

Connect the clutch switch wires.


I nstall the right rea r view mirror in the holder.
Secure the wires with wire bands.

Apply grease to the throttle cable ends and connect the cables
to the throttle pipe.
I nstal l the right handlebar switch onto the handlebar, aligning
the locating pin with the hole in the handlebar.

I nstall the right handlebar switch screws and tighten the for
ward screw first, then tighten the rear screw.

I nstall the front brake master cylinder/holder with the " U P"
mark facing up.
Align the end of the holder with the punch mark on the handle
bar and tighten the upper bolt first, then tighten the lower bolt.

TORQU E : 12 N m ( 1 . 2 kg-m, 9 ft-lbl

Connect the front brake light switch wires.


I nstal l the right rear-view mirror into the master cylinder/
holder.
Secure the wire with wire bands.
Adjust the following:
- throttle operation and free play (page 3 - 6 ) .
- clutch lever free play (page 3 - 1 8 ) .

1 2-6
FRONT WHEEL/S U S PE N S I O N /STEERING

FRONT WHEEL
R E M OVA L

Raise and support the motorcycle using a hoist or a jack u nder


the engine . t-
Remove the set screw and pull the speedometer cable out of (
..

the speedometer gearbox .

( 2 ) SET SCREW

Remove the axle pinch bolt caps, a n d bolts from the right front
fork leg .

Remove the axle and the front wheel.

NOTE
Do not operate the front brake lever after removing the
front wheel. To do so will cause difficulty in fitting the
brake disc between the brake pads.

Remove the side collar.

Remove the speedometer gearbox .

1 2- 7
FRONT W H E E L/SUSPEN S I O N/STEE R I N G

I N S P E CT I O N (1 ) FRONT AXLE

e AXLE
Set the axle in V blocks and measure the runout .
Actual ru nout is 1 /2 the tota l i n dicator reading .

SERVICE LIMIT: 0 . 2 mm (0 . 0 1 in) -


I

e WHEEL
Check the spokes and tighten any that are loose .

TORQU E : 4 N m (0.4 kg-m, 2 . 9 ft-lbl

Check the rim runout by placing the wheel on a truing stand .


Then spin the wheel with hand, and read the runout using a
dial indicator.

SERVICE LIMITS :
RADIAL: 2 . 0 mm (0.08 in)
AXIAL: 2.0 mm (0.08 in)

CAUTION (1) VALVE

Wheel balance directly affects the stability, handling and over

\
all safety of the motorcycle. A lways check balance when the
tire has been removed from the rim .

\a
NOTE

For optimum balance, the tire balance mark (a paint dot on


the sidewall) must be located next to the valve stem.

Remount the tire if necessary .

(2) BALANCE MARK

Mount the front wheel in a inspection stand .


Spin the wheel, allow it to stop, and mark the lowest
(heaviest) part of the wheel with chalk. Do this two or three
times to verify the heaviest area.
If the wheel is balanced, it will not stop consistently i n the
same position.

1 2- 8
F R O N T W H EEL/S USPENSION/STEERING

To balance the wheel, i nstall wheel weights on the highest


side of the rim, the side opposite to the chalk marks. Add just
enough weight so the wheel will no longer stop i n the same po
sition when it is spun .
D o not a d d more than 70 grams.

"'( 1 ) WHEEL WEIGHT


e WHEEL BEARING
Turn the inner race of each bearing with your finger.
The bearings should turn smoothly and quietly.
Also check that the bearing outer race fits tightly i n the hub.
Remove and discard the bearings if the races do not turn
smoothly, quietly, o r if they loosely in the hub.

( 1 ) WHEEL BEARING

B EA R I N G R E P LA C E M E N T
-
( 1 ) DUST SEALS

Remove the front wheel ( page 1 2-7) .


Remove the dust seal and retainer from the left side of the
wheel hub.
Remove the dust seal from the right side of the hub.

Remove the brake disc mounting bolts and disc.

1 2-9
FRONT WH E E L/S USPENSION/STE E R I N G

Drive out the wheel bearings and distance collar.

CAUTION

Never reuse old bearings.

TOOLS :
Bearing remover shaft 07746-005 0 1 0 0
Equivalent commercially
available in U .S.A.
Bearing remover head, 20 mm 07746-0050600
Equivalent commercially
available i n U .S.A.

Drive in the new left bearing first until it seats. ( 1 ) DRIVER


I nstall the distance collar and drive in the right bearing.

N OTE

Install the bearings with the vendor markings facing the


outside. Be sure to drive the bearings i n squarely.

Always replace wheel bearings in pairs .

TOOLS :
Driver 07749 - 00 1 0000
Attachment, 42 x 47 mm 07746 - 00 1 0300
Pilot, 20 mm 07746 - 0040500

A S S E M B LY

Do not get get grease on the brake disc or stopping power will
be reduced.

- (1 l DISTAN C E COLLAR

(1 1 l
'__:::..c:o .
SIDE .
CO LLAR

(9) BEARI NG

(4) SPEEDOMETER
GEARBOX

(6) SPEEDO f?
M ETER (5) WASHERS
G EAR

1 2- 1 0
FRONT WH EEL/S U S PEN S I O N /STEERING

To replace the wheel;


Remove the tire and tube from the rim .
Place the rim and hub on the work bench and begin lacing with
new spokes from inside the hub.
Install the spokes with a space of six holes in between.
Measure the d istance ( B ) , and make a calculatio n .
(A) = 7 0 . 8 mm ( 2 . 787 in) ( 8 ) + 2
-

Adjust the hub position so that the d ista n ce from the hub sur
face where the brake disc mounts to the side of rim is (A) .
Tighten the spokes in 2 or 3 progreassive steps.

TOOLS :
Spoke wrench : 07JMA - MR60 1 00 or
equivalent commercially
available in U . S .A.

TORQU E : 4 Nm (0.4 kg-m, 2 . 9 ft-lb)

Check the wheel runout (page 1 2-8) .


I nstall the tube and tire .

Coat the speedometer gear retainer with grease and install the
retainer i nto the wheel hub, aligning the tangs with the slots in
the hub.
Apply grease to the oil seal lip and instal l the oil seal over the
gear retainer.

Install the brake disc onto the wheel hub.


Apply a thread locking agent to the bolt threads and install and
tighten the bolts .

N OTE

Tighten the bolts in a crisscross pattern in 2 or 3 steps .

TORQUE : 40 N m 14.0 kg-m, 29 ft-lb)

Do not get grease on the brake disc or stopping power will be


reduced.

Apply grease to the dust seal lips and install the seal on the ( 1 ) DUST SEAL
right side of the hub.

1 2- 1 1
FRONT WHEEL/SUSPENSIO N/STEERING

Apply grease to the speedometer gearbox and gear. (1 I G EAR BOX


I nstall the speedometer gear and washers into the gearbox.

I nstall the speedometer gearbox into the wheel hub, aligning


the tangs with the slots .

Clean the brake discs with a high quality degreasing agent.

I nstall the right side collar.

INSTALLATION

Place the front wheel between the front fork legs.


Fit the caliper over the brake disc, taking care not to damage
the brake pads.

Clean the axle and holder.


I nstall the axle through fork leg, the side collar, wheel hub and
speedometer gear box .

Set the speedometer gearbox tab under the tang on the left
fork slider.
t2 1 ST SCREW

Tighten the front axle.

TORQUE: 75 Nm (7 . 5 kg-m, 54 ft-lbl

Tighten the fork pinch bolts .

TORQUE: 22 Nm (2.2 kg-m, 1 6 ft-lb)

I nstall the speedometer cable and set screw securely.

1 2- 1 2
FRONT W H EEL/S U S PENSION/STEERING

FORK
R E MOVAL

Remove the front wheel ( page 1 2 - 7 ) .


Remove the brake caliper mounting bolts and brake caliper.
Unhook the brake hose from the hook on the fender.
Tie the caliper to the handlebar so its weight does not pull on
the brake hose .

Pull the speedometer cable out of the cable holder on the fend
er.

Remove the front fender mounting bolts from the fork legs.

If the fork legs will be disassembled, loosen the fork cap bolts,
but do not remove them yet.

Loosen the following bolts : Q l il FO R KT O P P IN C H


- turn signal mounting bolt . BOLT
- fork top pinch bolt
- fork bottom pinch bolt

Pull the fork tubes out of the top bridge and steering stem.

/ ( 2 ) TURN SIGNAL LIGHT


(3) FORK BOTTO M PINCH BOLT . MOUNTING BOLT

1 2- 1 3
FRONT W H E E L/S U SPENSION/STE E R I N G

D I SA S S E M BLY ( 1 ) FORK CAP

Remove the fork cap bolt .

The cap bolts are under spring pressure. Take care when re
moving, and wear eye and face protection.

Remove the fork spring, seat washer and spacer.


Pour out the fork fluid by pumping the fork up and down sever

'\
al times .

Hold the fork slider in a vise with soft jaws or a shop towe l . ( 1 ) HOLDER HANDLE

CAUTION

Do not distort the fork slider in the vise.

I nstall the special tool i nto the fork tube and hold the piston,
then remove the socket bolt.
TOOLS :
Bottom holder pipe 07930-KA50000
N ot available i n U . S .A.
- holder attachment 07930- KA5 0 1 00
N ot available i n U . S .A.
- bottom holder handle 07930- KA40200
N ot available i n U . S .A.
Remove the dust seal and stop ring . ( 1 ) D U ST SEAL

CAUTION

Be careful not to damage the fork tube.

1 2- 1 4
FRONT W H E EL/S USPENS I O N/ST E E R I N G

I n quick successive motions, pull the fork tube out of the slid
er.

NOTE

The slider bushing that is pressed into the slider, and the
fork tube bushing on the end of the fork tube, must be
forced out.

Remove -th e oil lock piece from the fork slider.


Remove the piston and rebound spring from the fork tube.

Remove the oil seal, back-up ring and slider bushing from the
fork tube.
Do not remove the fork tube bushing until inspection
determines it is necessary ( page 1 2- 1 5 ) .

\
(4) BACK-U P RING (3) TUBE BUS H I NG

I N S PE CT I O N ( 1 ) FO SPRI NG

Fork spring
Measure the fork spring free lengt h .

S E RV I C E L I M IT: '88,'89 .' 9 1 -'93: 2 9 9 mm ( 1 1 .8 i n )


After'93: 333 . 9 mm ( 1 3 . 1 i n )
Replace the spring if it is shorter than the service limit. J\/"""fJ\J 'v'\I/lJJIIIIIIlf/1

.
Fork tube/slider/piston ( 1 I FORK S L I D E R ( 2 ) FORK TUBE

\
Check the fork tube, fork slider and piston for score marks, ex
cessive or abnormal wear.
Replace any components which are worn or damaged .

Check the rebound spring for fatigue or damage. . ,

(5)

REBO U N D
SPRING ! '\(3) OIL LOCK PIECE
(4) PISTON

1 2- 1 5
FRONT W H E E L/SUSPEN S I O N/STEERING

Set the fork tube i n V blocks and read the ru nout.


Actual runout is 1 /2 the total indicator reading.

SERVICE LIMIT: 0 . 20 mm (0. 008 in)

Bushings
Visually inspect the slider and fork tube bushings. (11 BUSH I N G (21 BACK-UP RING
Replace the bushings if there is excessive scoring or scratch
ing, or if the teflon is worn so that the copper surface a ppears
on more than 3/4 of the entire surface.

~
Check the back-up ring; replace it if there is any distortion at
the points shown.
.. ... ... (31 CHECK
PO INTS
(41 COPPER
SU RFACES

A S S E M BLY


(1 I FORK TUBE CAP
'88 . '89 . ' 9 1 -'93 O N LY
0-RING LEFT FORK TUBE (21 RIGHT FO RK TUBE
--_JJ
( 1 91 (1 I

( 1 81 SPAC ER >+---r l 5 1 BACK-UP RING .


( 1 71 SPR I N G SEAT -----1/ (61
(71
SLIDER BUSHING
FORK SLIDER
( 3) LEAF ""'==
-
( 1 61 FORK SPRING VALVE

;:!
( 1 51 PISTON RING ( 9 1 DRAIN BOLT

( 1 41 PISTO N
J.-- ( 1 01
@>
( Except after'9 5)

SOCKET BOLT
FORK TUBE

(1 1 I
( 1 31 REBOU N D BUSH I N G CAUTION
SPRING
( 1 21 O I L LOCK PIECE
The fork tube cannot be disassembled.

Do not interchange the right and left fork tube when in
stalling the fork tu be in th e fork slider.

1 2- 1 6
FRONT WHEEL/S U S P E N S I O N /STEERING

I nstall the rebound spring i nto the fork tube. ( 1 I OIL SEAL
(21 BACK-U P R I N G
/
I nstall a new postion ring i nto the piston groove .
Place the oil lock piece on the end of the piston and insert the
fork tube i nto the slider. PISTON

(61 SLIDER I
BUSH I N G ( 5 ) TUBE BUSH I N G ( 4 ) LOCK PIECE

I nstal l the special tools i nto the fork tube to hold the pis (1 I HOLDER ATTACH MENT ( 2 1 BOTTO M HOLDER
HANDLE

ton,and i nstall and tighten the socket bolt.

TOOLS :
Bottom holder pipe 07930- KA50000
N ot ava i l a ble i n U . S.A.
- holder attachment 07930- KA50 1 00
N ot ava i lable i n U . S.A.
- bottom holder handle 07930- KA40200
N ot ava i l able i n U . S.A.

Place the fork slider i n a vise with soft jaws or use a shop ( 1 l SOCKET
-
BOLT
,
towel. Apply a locking agent to the socket bolt and thread it .....
'
i nto the piston . Tighten w ith a 6 mm hex wrench . .....
'
'

NOTE

Temporarily install the fork sprin g and fork cap bolt to tight
en the socket bolt.

TORQU E : 30 Nm (3.0 kg-m, 22 ft-lbl

Place the sl ider bushing over the fork tube until it rests on the
slider.

N OTE

Tape the upper edge of the fork tube to avoid damaging the
( 2 ) D U ST SEAL
oil seal lip, while i nstalling the o i l sea l . V
d Iv ( 3 ) STOP
(4) O I L SEAL
RING
U s i n g a fork seal driver , drive t h e bushing into place .

-
I nstal l the back-up ring with the c hamfered side facing the
slider bushing.
Coat the oil seal lip with the recom mended fork oil.
D rive the oil seal i nto place using a fork seal driver.
l ( 5 ) BACK-U P
RING

I nstall the oil seal stop ring and the dust sea l .

TOOL:
Fork seal driver, 39mm 07947 - 4630 1 00

1 2- 1 7
FRONT WHEEL/S U S P E N S I O N/STEERING

Com press the fork leg and pour Honda Su spensio n F luid
SS-8 o r equ iva lent i nto the fork tube.

SPECI F I E D L E V E L :
'88, 89:
'

Right fork : 95.0 mm (3.74 in )


(1 )
O I L LEVEL
r
U
LR
Left for k : 93.0 mm (3.36 i n )
'91 -'93 : .
R ight fork : 89.0 m m (3.50 in)
Left fork: 87.0 mm (3.43 i n)
After '93:
R i g ht and l eft forks : 1 1 1 m m (4 . 4 i n )
CAPAC I TY :
'88, '89: 463 cc ( 1 5.7 US oz , 1 3.0 I mp oz)


' 9 1 -'93 : 468 cc ( 1 5.8 U S oz, 1 3. 2 Imp oz )
After '93: 449 cc( 1 6 . 9 U S oz , 1 5.8 1 m p oz)

I nstal l the fork spring, washer and spacer into the fork tube. ( 1 )TI G HTLY WO U N D
C O I LS
'88 . '89 . ' 9 1 - '93 :
r t'
NOTE

Note the direction: the tightly wound coils should be at bot


l\Jt
. t
' ' '' \I v
r r , t r .
J 11 V 'iJ 'v J J111/(({(r
: . . . . , ,

tom .
A Fter '93 :
N OT E

N ote the directio n :the tightly wound coils should be at top.

Loosely install the fork tube cap with a new 0-ring. ( 1 l 0-RING (2) FORK TUBE CAP

I N STA LLAT I O N

I nstall t h e fork tube, aligining its top e n d with the upper sur
face of the top bridge as show n .

Temporarily install a n d tighten the fork top pinch bolts and


turn signal mounting bolts . :
; .:

1 2- 1 8
FRONT WHEE L/S U S P E N S I O N/STEERING

I nstall and tighten the bottom pinch bolt.

TORQU E : 50 N m (5.0 kg-m, 36 ft-lbl

Tighten the top pinch bolt.

TORQU E : 1 1 Nm ( 1 . 1 kg-m, 8 ft-lb)

I nstall the front fender and tighten the mounting bolts secure
ly.

,1
"
(2) M O U N T I N G BOLTS

Hook the brake hose onto the hose clip.

I nstal l the brake caliper with the mounting bolts .


Tighten the bolts to the Specified torque.

TORQU E : '88 . '89 . ' 9 1 - ' 9 3 ;


27 Nm ( 2 . 7 kg-m, 20 ft-lb)
After '93 :
3 1 N m ( 3 . 1 kg-m , 22 ft-l b )

I nsert the speedometer cable through the fender holder.

1 2- 1 9
FRONT W H EEL/S U S P E N S I O N /STEER I N G

STEER I NG STEM (2) SPEEDO


M ETER
R E M OVAL

Remove the fork legs and handlebar.


Disconnect the speedometer cable from the speedometer, and
the 6P black connector (see page 1 - 1 3 ) .
Remove the following :
- speedometer from the fork bridge
- headlight from the headlight case
- headlight stay and mounting nuts, headlight stay and case

(4) STAY

Remove the steering stem nut and washer. (1 l STE E R I N G


STEM
NUT

Remove the top bridge .


Remove the indicator panel and lights by removing the two
screws.

Straighten the lock washer tabs and remove the lock nut and (1 ) LOCK NUT (2) LOCK WAS H E R
lock washer. TABS

1 2-20
FRONT WHEEL/S U S P E N S I O N/STEERING

Loosen the steering head bearing adjustment nut. ( 1 ) STEE R I N G


STEM
S O C K ET
TOOL: Steering stem socket 079 1 6 - 37 1 0 1 00

Hold the steering stem by hand and remove the adjustment


nut, dust sea l , upper bearing inner race and upper bearing.

Remove the steering stem from the steering head .

Check the bearings and outer race for wear or damage .


Replace if necessary.

B EA R I N G R E PLAC E M E N T

( 9 ) LOWER B E A R I N G

( 1 0 ) L O W E R B EA R I N G I N N E R RACE

( 1 1 ) D U ST S E A L

1 2- 2 1
FRONT WH EEL/S U S P E N S I O N /STEERING

NOTE ( 2 ) STEM
NUT

Always replace the bearing and race as a set.

I nstal l the steering stem nut o n the top end of the steering
stem to protect the threads from damage.
Remove the lower i n ner race and dust seal using a punch or
d river.
Replace the dust seal with a new one whenever it is removed .

(3) LOWER I N N E R R A C E

Remove the lower outer race using the special tools and a suit
able shaft.

TOOLS : Bearing race remover: 07946 - 37 1 0500

Remove the upper bearing outer race using the special tools.

TOOLS :
Ball race remover 07953 - MJ 1 0000 N ot ava i l a b l e
- attachment
- driver handle
07953 - MJ 1 0 1 00
07953 - MJ 1 0200 J in U . S . A .

or
Attachment 0 7 9 5 3 - MJ 1 OOOA ,
07953 - MJ 1 0008 or
D river 0 7 949-3 7 1 000 1 and
Attachment, 32 X 35 m m 0 7746-00 1 0 1 00

Install a new dust seal over the steering stem.


Press a new lower bearing inner race onto the stem.

TOOL: Steering stem driver 07946 - MBOOOOO

Drive new upper and lower bearing outer races into the steer
ing head pipe .

TOOLS :
U pper bearing outer race :
Drive 07749 - 00 1 0000
Attachment, 42 x 47 mm 07746 - 00 1 0300

Lower bearing outer race :


Driver 07749 - 00 1 0000
Attachment, 52 x 55 mm 07746 - 00 1 0400

1 2-22
FRONT WH EEL/S USPEN S I O N /STE E R I N G

,,
I N STALLAT I O N

Pack t h e bearing cavities w i t h grease.


I nstall the lower bearing onto the stem.
Insert the stem i nto the steering head pipe and i nstall the upper
bearing, inner race, dust seal and steering bearing adjustment
n ut.

E R I N G B EA R I N G A DJ U ST M E N T t
... .
NUT
( 1 ) 1NNER RACE

Apply e n g i n e o i l to the a d j u st m e n t n ut t h reads . (1 I STE E R I N G


STEM
Tighten the steering bearing adjustment nut to the specified SOCKET
torque.

TOOL: Steering stem socket 0 79 1 6 - 37 1 0 1 00

TORQUE: 2 5 Nm ( 2 . 5 kg-m, 1 8 ft-lbl

Turn the steering stem back and forth five times to seat the
bearings.
Retighten the adjustment nut to the same torque.
Turn the steering stem to seat the bearings.

I nstall a new lock washer and bend the two opposite tabs ( 1 I LOCK WA S H E R (2) LOCK NUT
down into the grooves i n the adjustment nut.

Install and finger tighten the lock n ut all the way.


Hold the bearing adjustment nut and further tighten the lock
nut, within 90 degrees, to align its g rooves with the tabs of the
lock washer.
Bend up the lock washer tabs i nto the grooves of the lock nut.

1 2-23
FRONT WH EEL/S U S PENS I O N /ST E E R I N G

I nstall the indicator panel with two screws.

I nstall the fork bridge then temporarily i nstal l the fork legs.
Tighten the steering stem nut.

TORQUE : 1 05 N m ( 1 0 . 5 kg-m, 76 ft-lb)

Instal l the following parts:


- fork legs (page 1 2 - 1 8 ) .
- front wheel (page 1 2 - 1 2 ) .
Check the steering head bearing preload .

ST E E R I N G H EA D B EA R I N G P R E L O A D

Place a stand under the engine and raise the front wheel off
the groun d .
Position t h e steering stem t o the straight ahead position.
Hook a spring balance to the fork tube and measure the steer
ing head bearing preload .

NOTE

Make sure that there is no cable and wire harness interfer


ence.

The preload should be within 1 .0 - 1 . 5 kg ( 2 . 20 - 3 . 3 1 lb) for


right and left turns.
If the readings do not fall within the limits, lower the front
wheel on the ground and adjust the bearing adjustment nut.
After making sure the bearing preload , instal l the removed
parts in the reverse order of removal .

1 2 - 24
MEMO
REAR WHEEL/BRAKE/S U S PENSION

1 3-0
1 3. REAR WH EEL/ B RAK E/SUSP E NSION
SERVICE I N FO R M AT I O N 1 3- 1 BRAKE PEDAL 1 3- 1 0

T R O U BLESHOOTI N G 1 3-2 S H O C K ABSORBER 1 3- 1 1

REAR WH EEL 1 3- 3 SWINGARM 1 3- 1 4

R EAR BRAKE 1 3- 7 S EAT /REAR FENDER/S U B-FRA M E 1 3- 1 8

SERVICE I N FORMATION
G E N ERAL

Support the motorcycle using a hoist or a jack under the engine.

CAUTION
Do not jack up the motorcycle using the oil filter.

Use only genuine Honda replacement fasteners for the rear suspension.
Note the i nstallation direction of the bolts.

A ny attempt to mount automobile tires on a motorcycle rim may cause the tire bead to separate from the rim with
enough explosive force to cause serious injury or death.

The rear shock absorber contains nitrogen under high pressure. Do not allow fire or heat near the shock absorber. Use only nitro
gen to pressurize the shock absorber. The use of an unstable gas can cause a tire or explosion resulting in serious energy.

Before disposal of the shock absorber, release the nitrogen by pressing the valve core. Then remove the valve from the shock ab
sorber.

IIEI:f:l

Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to clean brake
assemblies. Use an OSHA -approved vacuum cleaner or alternate mothod approved by OSHA, designed to minimize the hazard
coused by airborne asbestos fibers. ..:I
S P E C I F I C AT I O N
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Rear wheel runout Radial --
2 . 0 mm (0.08 in)
Axial --
2 . 0 mm (0.08 in)
Rear axle runout --
0 . 2 mm (0.01 in)
Rear brake drum I . D . 1 60 mm ( 6 . 3 in) 1 6 1 mm ( 6 . 3 in)
Rear brake lining thickness 5 mm (0. 2 in) 2 mm (0.08 in)
Shock absorber spring free length 1 37 . 5 m m ( 5 . 4 1 in) 1 3 5 . 0 mm ( 5 . 3 1 in)
Rear suspension damper compression 1 3 . 4 - 1 7 . 4 kg ( 2 9 . 5 4 - 3 8 . 36 lb) 1 3 . 3 kg ( 2 9 . 3 2 lb)

T O R Q U E VALU E S

Spokes 4 Nm (0.4 kg-m, 2.9 ft-lb)


Sprocket nut 65 Nm ( 6 . 5 kg-m, 4 7 ft-lb)
Shock absorber mounting bolt 45 Nm (4. 5 kg-m, 33 ft-lb)
Swingarm pivot bolt 90 Nm ( 9 . 0 kg-m , 6 5 ft-lb)
Rear axle 90 Nm ( 9 . 0 kg-m, 6 5 ft-lb)
Damper rod lock nut 70 Nm (7.0 kg-m , 51 ft-lb)
Brake torque rod nut 27 Nm (2. 7 kg-m , 20 ft-lb)

1 3- 1
REAR WHEEL/BRAKE/S USPEN S I O N

T O O LS

Special
Driver shaft 07 946 - MJ00 1 00
Attachment, 28 x 30 mm 07746 - 1 870 1 00
Spoke wrench 07JMA - M R60 1 00 or equivalent commercially
available i n U . S .A.
Shock absorber compressor 07G M E - 00 1 0000
Attachment 07 J ME - M R 1 0 1 00
Compressor screw 07G M E - 00 1 0 1 00
Snap ring pliers 079 1 4 - 323000 1

Common
Bearing remover shaft 07 746 - 0050 1 OO or equivalent commercially

Bearing remover head , 1 7 mm 07 746 - 0050500 J available in U . S . A .

D river 07749 - 00 1 0000


Attachment, 42 x 47 mm 07 746 - 00 1 0300
Pilot, 1 7 mm 077 46 - 0040400
Attachment, 32 x 35 mm 07 746 - 00 1 0 1 00
Pilot, 1 5 mm 07 746 - 0040300
Pilot, 22 mm 07 746 - 004 1 000

TROUBLESHOOTI NG
Wobble o r vibration i n motorcycle
Bent rim
Loose wheel bearing(s)
Loose or bent spokes
Damaged tire
Axle not tightened properly
Swingarm pivot bearing worn
Chain adjusters not adjusted equally
Bent frame or swingarm

Soft suspension

Weak spring

I mproper shock absorber spring preload

Hard suspension

I mproper shock absorber spring preload

Bent shock absorber rod

Swingarm pivot bearings damaged

Bent frame or swingarm

Suspension noise

Faulty rear damper

Loose fasteners

Poor brake performance

Improper brake adjustment

Worn brake shoes

Brake linings oily, greasy or dirty

Worn brake cam

Worn brake drum

Brake arm serrations improperly engaged

Brake shoes worn at cam contact area

:,,1 3-2
R E A R W H EEL/BRAKE/S U S P E N S I O N

REAR WHEEL
REM OVAL
Support the motorcycle using a hoist or a jack under the en
gine.

CAUTION
Do not jack up the oil filter.

Loosen the drive chain adjusters on both sides of the swing


arm .
Remove the following parts :
- brake rod
- cotter pin, nut, seat washers and bolt from the torque rod
on the brake panel.
- Axle nut, adjuster collars, side collar and rear axle.
- drive chain from the drive sprocket
- rear wheel
- brake panel from the brake drum

I N S PE CT I O N

e AXLE
Set the axle on V blocks and measure the runout.

SERVICE LIMIT: 0.2 mm (0.01 in)

e WHEEL
Check the spokes and tighten any that are loose .

TORQUE : 4 N m (0.4 kg-m, 2.9 ft-lbl


TOOL: Spoke wrench 07JMA - MR60 1 00 or
equivalent commercially
available in U .S.A.
Check the rim runout by placing the wheel on a truing stan d .
S p i n t h e w h e e l h a n d and read t h e runout using a d i a l indicator.

SERVICE LIMITS:
RADIAL: 2.0 m m (0.08 in)
AXIAL: 2.0 mm (0.08 in)

e WHEEL BEARING
Turn the i n ner race of each bearing with your finger.
The bearings should turn smoothly and quietly .
Also c h e c k that t h e bearing outer race fits tightly in t h e hub.
Remove a n d discard the bearings if the races do not turn
smoothly, q uietly, or if they fit loosely i n the hub.

NOTE
Replace wheel bearings i n pairs .

For bearin g replacement, see page 1 3-4.

e WHEEL BALANCING
Refer to page 1 2- 7 .

NOTE
Do not add more than 70 grams of balancing weight to the
11 l WHEEL BEA RING
rear wheel

1 3- 3
REAR W H EEL/BRAKE/S USPENSION

S P R O C K ET/D R I V E N FLAN G E
D I SA S S E M B LY / I N S PECTI O N
( 1 1 GOOD ( 2 1 REPLACE

Remove the wheel ( page 1 3-31 .


Remove the mounting nuts and separate the sprocket from the
flange .
Check the condition of the sprocket teeth .
Replace a worn or damaged sprocket.

NOTE
The d rive chain and d rive sprocket must also be inspected if
the driven sprocket is worn or damaged . Never instal l a new
drive chain on worn sprockets or a worn chain on new
sprockets . Both chain and sprocket must be i n good condi
tion or the new replacement chain or sprockets will wear
rapidly.

If driven flange the hub, drive it out by tapping it at several lo


cations with wood block.

Remove the dampers from the flange in the hub.


Remove the collar and dust seal from the flange .
D rive out the driven flange bearing, if necessary .

I nspect the dampers for deterioration.

Turn the inner race of the bearing with your finger.


The bearing should turn smoothly and quietly.
Also check that the outer race fits tightly in the flange .
Remove and discard the bearing if it does not turn smoothly
and quietly, or if the outer race fits loosely in the flange .

BEA R I N G R E PLAC E M E N T

Wheel bearing
Drive out the wheel bearings and the distance collar.

NOTE
If the bearings are removed , they must replaced .

TOOLS :
Bearing remover shaft 07746 - 0050 1 00
Bearing remover head, 1 7 mm 07746 - 0050500
or equivalent commercially
available in U . S . A .

1 3-4
REAR WH EEL/BRAK E/S U S PENSION

First, drive in a new left wheel bearing until it is fully seated, in


stall the distance collar, then drive in a new right bearing.

TOOLS :
Driver 07749 - 00 1 0000
Attachment, 42 x 47 mm 07746 - 00 1 0300
Pilot, 1 7 mm 07746 - 0040400

NOTE

Drive the wheel bearings i n w ith the vendor mark facing


out.

Flange bearing
Drive out the bearing using a suitable tool.
Drive the new bearing in with its vendor mark facing out.

TOOLS :
Driver 07749 - 00 1 0000
Attachment, 42 x 47 mm 07746 - 00 1 0300
Pilot, 1 7 mm 07746 - 0040400

( 3 ) ATTACHM ENT

A S S E M B LY

- -
(3) 0-RING

j
A
/1
( 1 1 1 BEARING (4) DRIVEN SPROCKET

1 1 01 DAMPER RUBBER

( 9 ) COLLAR

(8) FLANGE

( 7 ) NOISE ARRESTER

1 3- 5
REAR WH EEL/BRAKE/S U S P E N S I O N

Place the rim and hub on the work bench and begin lacing with
a new spoke from the hole of inside i n the hub.
Install the spoke with a space of two holes in between .
Measure the distance ( B ) , a n d make a calculation.
(A) = 79 mm ( 3 . 1 1 0 in) ( B ) + 2
-

Adjust the hub position so that the distance from the hub right
end surface to the side of rim is (A) .
Tighten the spokes i n 2 or 3 progressive steps.

TOOL:
Spoke wrench 07JMA - MR60 1 00
or equivalent commercially
available in U . S .A.

TORQUE : 4 Nm (0.4 kg-m, 2 . 9 ft-lb)

Check the wheel runout ( page 1 3-3) .


Install the tube and tire.

I nstall the collar in the driven flange bearing.

I nstall the damper rubbers on the flange and place flange i n the
hub.
Apply grease to a new 0-ring and i nstall it onto the flange
groove .

(2) 0-RING

Apply grease to the dust seal lip and install it.

I nstall the driven sprocket, if removed, and a new seal .

Tighten t h e driven sprocket mounting nuts.

TORQU E : 65 Nm ( 6 . 5 kg-m, 47 ft-lb)

1 3-6
REAR WH EEL/BRAKE/S USPENSION

I nstal l the axle collar.

--=

I N STALLAT I O N

I nstall the brake panel on the wheel hub.


Position the rear wheel between i n swingarm and install the
drive chain over the driven sprocket.

Install the left side adjuster collar onto the rear axle and insert
the axle (from the left side) through the swingarm, wheel hub
and right side collar.
I nstall the adjuster collar and axle nut.
Tighten the axle nut lightly.
Adjust the drive chain ( page 3 - 1 3 ) .
Tighten the axle nut.

TORQUE: 90 N m (9.0 kg-m, 65 ft-lbl

Connect the brake torque rod to the brake panel with bolt, seat
washer, washer and nut. (page 1 3-8 ) .
Tighten the nut.

TORQUE: 27 N m (2. 7 kg-m, 20 ft-lbl

I nstall the cotter pin and bend back it securely.


Connect the brake rod to the brake arm and adjust the rear
brake pedal free play (page 3 - 1 6 ) .

R EAR BRAK E
I N S PECT I O N

Remove t h e rear w heel (page 1 3-3)

Remove the brake panel and measure the rear brake drum I . D.

SERVICE LIMIT: 1 6 1 mm ( 6 . 3 in)

Measure the rear brake lining thickness.

SERVICE LIMIT: 2 m m (0.08 in)

Replace the brake shoes if either one is thinner than the service
limit.

1 3- 7
REAR WHEEL/BRAKE/S USPENSION

D I SASS E M B LY

Remove the cotter pins and set plate .

(2) COTTER PINS

Remove the brake shoes and springs from the brake panel .

NOTE

Mark the shoes to indicate their original positions before re


moving them.

Remove the following parts form the brake panel :


- bolt and brake arm
- indicator plate
- brake cam
- felt seal

A S S E M BLY
( 1 ) BOLT
(2) I N D I CATOR
PLATE
(3) FELT SEAL
(4) BRAKE SHOES

( 1 0) BRAKE
ARM

(9) BRAKE (8) SPRINGS


7(6) COTTER PINS

PANEL (7) SET PLATE

1 3-8
REAR W H E E L/BRAKE/S USPENSION

Apply grease to the brake anchor pins and brake cam. I nstall ( 1 ) BRAKE CAM
the brake cam into the brake panel .

I nstall the felt seal.

Install the indicator plate on the brake cam aligning its tab with
cut-out on the brake cam .

Install the brake arm by aligning the punch marks on the arm
and cam.
I nstall and tighten the bolt.

(3)

Position the brake shoes in their original locations and install


the springs .

Grease on the brake linings will reduce stopping power.


Keep grease off of the brake linings. Wipe excess grease off the
cam and anchor pin.

I nstall the set plate and cotter pins, then bend back the pins.
I nstall the brake panel onto the wheel hub and install the rear
wheel (page 1 3-7 ) .
( 3 ) COTTER PI N ( 2 ) SPRINGS
....
(4) SET PLATE

1 3-9
REAR WHE EL/BRAKE/S U S PE N S I O N

BRAKE PEDAL
R E M OVAL

Remove the foot peg bracket mounting bolts and washers .


Remove t h e brake pedal b y removing t h e cotter p i n , washer
and bolt.

I N STA LLAT I O N

Install the brake pedal in the reverse order o f removal .

NOTE
Note the locations of the washers .

(4) BRAKE SHAFT ARM

( 1 ) BRAKE PEDAL ADJ U STER BOLT

( 2 ) DUST SEALS
-

(5) PUNCH M A R K

(8) PIVOT CO LLAR (7)M I DDLE BRAKE ARM


- ljiii@ NOTE

Align the punch mark on the brake shaft arm end with
the punch mark on the middle brake arm.

1 3- 1 0
R EAR W H EEL/BRAK E/S USPEN S I O N

REAR SHOCK ABSORBER


REM OVAL

The rear shock absorber contains nitrogen under high pressure.


Do not allow fire or heat near the shock absorber.

Support the motorcycle using a hoist, or a jack under the en


gine.

Remove the follow i n g :


- seat, right and left s i d e cover
- rear ignition coil mounting bolts (page 1 6- 5 )
- rear ignition coil stay mounting bolt

Disconnect the fuel pump, fuel pump relay and turn signal
relay from the fuel pump stay .

Remove the fuel pump stay mounting bolt, nut and fuel pump
stay .

Remove t h e upper and lower shock absorber mounting bolts


and nuts then remove the shock absorber.

D I SA S S E M BLY ( 2 ) ATTACH M ENT

Set the spring preload adjuster to No. 1 position .


Compress the shock absorber with the compressor a n d attach

.;:f;:.':
ment.

CAUTION 'I
,

Be sure the base is adjusted correctly for the shock spring seat
and the clevis pin is all the way in.

:::
TOOLS :
Shock absorber compressor 07GME - 00 1 0000
Attachment 07J ME - MR 1 0 1 00
(1 ) No. 1 POSITION
Compressor screw 07GME - 00 1 0 1 00

11 1 INT

J
Loosen the lock nut and remove the lower joint and nut.

Remove the com pressor and disassemble the shock absorber.

. -

LOCK NUT

1 3- 1 1
REAR WHEEL/BRA K E/S U S PENSION

SPRING FREE LEN GTH

Measure the shock absorber spring free length .

SERVICE LIMIT: 1 35 . 0 mm ( 5 . 3 1 in)

Mark the damper rod at 1 0 mm below the case as show n .


Place the damper rod on a scale a n d measure t h e force re
quired to compress the damper to the 1 0 mm (0.4 i n ) mark.

COMPRESSION FORCE: 1 3 . 4 - 1 7 . 4 kg (29 . 54 - 38 . 36 1bl

If the force required is less than 1 3 . 3 kg ( 2 9 . 3 2 l b ) , gas is leak


ing. 1 0 mm (0.4 i n )
Examine the damper rod and replace the damper unit if it is
bent or scored .

Check the damper unit for oil leaks or other damage and the
damper rod for trueness .
Check the upper mount bushing for wear or damage .

S H O C K A B S O R B E R D I S POSAL PR O C E D U R E

Center punch the damper case t o mark a drilling point, a pproxi


mately 45 mm ( 1 . 8 in) from the mount top surface .
Wrap the damper unit inside a plastic bag and support the
damper unit upright i n a vise as shown.

Through the open end of the bag, insert a power drill with a
sharp 2 or 3 mm ( 5/64 - 1 /8 in) drill bit.

Do not use a dull drill bit which could cause a build-up of exces
sive heat and pressure inside the damper, leading to explosion (3) D A M P E R U N I T
and severe personal injury.
The shock absorber contains nitrogen gas and oil under high
pressure. Do not drill any farther down the damper case than
the measurement given above, or you may drill into the oil
chamber; oil escaping under high pressure may cause serious
personal injury.
Always wear eye protection to avoid getting metal shavings in
your eyes when the gas pressure is released. The plastic bag is
only intended to shield you from the escaping gas.

Hold the bag around the drill motor and briefly run the drill
motor inside the bag; this will inflate the bag with air from the
motor and help keep the bag from getting caught in the bit
when you start.

1 3- 1 2
R EAR W H EEL/BRAKE/S U S PENSION


A S S E M B LY
( 1 ) DAMPER
( 2 ) SPRING
( 1 2 ) ADJU STER ADJUSTER
SEAT (4) SPRING
( 5 1 LOWER
SPRING
SEAT

p
(3) U PPER SPRING
SEAT

lQ

Install the following:


( 1 01 STOPPER RUBBER
(B) PLUG

( 9 ) LOCK N UT
:\'
(7) LOWER JO I NT ( S) DRAI TU BE
N
- stop rubber onto the damper rod
- spring a djuster seat and spring a djuster onto the damper so
that it rests in the softest position LOCK NUT
- upper spring seat, spring (with the tightly wound end
upward and lower spring seat ) ,
- lock nut

Compress the spring with the compressor (07GME -


00 1 0000)
and attachment (07 J M E - M R 1 0 1 00) .

Screw the lower joint onto the d a m per rod fully, hold it, and
tighten the lock nut.

TORQUE : 70 Nm (7 .0 kg-m, 51 ft-lb)

I N STA L LAT I O N
( 1 ) UPPER MOUNTING BOLT
Install the rear shock absorber w ith the drain tube pointing
dow n .
Install a n d tighten the upper and lower mounting bolts and
nuts.

TORQUE : 45 Nm (4. 5 kg-m, 33 ft-lb)

Route the drain tube into the tube guide in the swingarm .
Install the removed parts in the reverse order of removal .
Adjust t h e shock absorber spring preload b y turning the spring
adjuster, if necessary .

1 3- 1 3
REAR WH EEL/BRAKE/S U S P E N S I O N

SWI NGARM
R E M OVAL

Remove the rear wheel (page 1 3-3)


Remove the gearshift pedal mounting bolt from the foot peg .

( 1 I PEDAL
BOLT

(i') DRIVE S 2 )

Remove the drive sprocket cover. BO LTS
Remove the drive sprocket bolts, set plate and drive sprocket. COVER
Disconnect the gearshift arm from the gearshift spindle.
!?W, .

Remove the reserve tank from the frame ( page 5-9)


Remove the shock absorber lower mounting bolt and nut.
Remove the swingarm pivot bolt caps, pivot bolt and nut then
remove the swingarm from the frame .

D I SA S S E M B LY ( 1 I CHAIN COVER

Inspect the drive chain slider for wear or damage.


Replace it if necessary.
Inspect the drive chain for dirt or damage .
Clean or replace it if necessary ( page 3 - 1 4 )

Remove the following :


- drive chain slider and chain cover
- dust seals and pivot collars

1 3- 1 4
REAR W H E E L/BRAKE/S U S PE N S I O N

I N S PECT I O N

I nspect the swingarm f o r deformation o r cracks.


Check the pivot bearings, collars and dust seals for wear or
damage.

\
'

\
'

(3) DUST '

SEALS (4) BEARINGS

Disassemble the drive chain cover and inspect the chain pro ( 1 ) CHAIN COVER
tector for wear or damage, Replace if necessary .

(2) PROTECTOR

P I VOT B E A R I N G R E PLAC E M E N T

Remove the dust seals from t h e right a n d left swingarm pivots .


Remove the snap ring from the right pivot.

TOOL: Snap ring pliers 079 1 4 - 323000 1

Drive the right pivot ball bearing out of the swingarm using a
hydraulic press and driver shaft.

TOOL: Driver shaft: 07946 - MJ00 1 00

1 3- 1 5
REAR WHEEL/ BRAKE/SUSPENSION

Drive the left needle bearing out of the swingarm .

TOOL: Driver shaft 07946 - MJ00 1 00

Carefully press new bearings into the swingarm pivots .

NOTE

I nstall the bearings with the marks facing out.

Right side ball bearing:

TOOLS :
Driver 07749 - 00 1 0000
Attachment, 32 x 35 mm 07746 - 00 1 0 1 00
Pilot, 1 5 mm 07746 - 0040300

Left side needle bearing:

TOOLS :
Driver 07749 - 00 1 0000
Attachment, 28 x 30 mm 07746 - 1 870 1 00
Pilot, 22 mm 07746 - 0041 000
Snap ring pliers 079 1 4 - 323000 1

I nstall the snap ring into the right pivot.

Apply grease to the new dust seal lips and install them , and
the collars i n the correct positions .

( 2 ) PIVOT COLLARS

1 3- 1 6
REAR WH EEL/BRAKE/S USPENSION

A S S E M B LY / I N STA L LAT I O N ( 1 ) CHAIN COVER

I nstall the chain slider a n d chain cover with protector .

(2) CHAIN SLIDER

I nstall t h e swingarm in t h e frame.


I nstall the swingarm pivot bolt and nut, and tighten the nut to
the specified torque.

TORQU E : 90 N m ( 9 . 0 kg-m, 6 5 ft-lb)

I nstall the lih ock absorber lower mounting bolt and nut.

TUr1\:.. E : 45 Nm (4. 5 kg-m , 33 ft-lb)


I
I
I
I
( 1 ) PIVOT NUT

I nstall the following :


- swingarm pivot caps
- reserve tank (page 5-9)
- evapo rative e m iss i o n canister (California model only)
- drive sprocket with the drive chain
- gearshift arm

I nstall the drive sprocket cover and tighten the mounting bolt.

I nstall the gearshift pedal mounting bolt.

Apply grease to the gearshift pedal pivot collar refer to page


7-9.

Adjust the drive chain (page 3 - 1 3 ) and rear brake pedal free
play ( page 3 - 1 6 )

- rear wheel (page 1 3-7)

1 3- 1 7
REAR W H E E L/BRAKE/S U S P E N S I O N

SEAT/ R EAR FEN DER/SUB-FRAM E


R E M OVAL/ I N STA L LAT I O N

Remove the seat mounting socket bolts a n d unhook the seat


hooks from the frame, then remove the seat.

Remove the right and left side covers, pull out the prongs then
pull the cover down slowly to the release tabs .

Remove the fuel tank (page 4-3) and the rear fender mounting
bolts and Remove the tallight case mounting nuts .
Disconnect the right and left turn signal wire connectors, and
the rear brake light and licence light connectors.
Remove the rear fender from the main frame and sub-frame.

Remove the two sub-frame mounting bolts and two nuts, then
remove the sub-frame.

I nstall the removed parts i n the reverse order of remova l .

- - - . .
( 2 ) SEAT

(3) RIGHT
SIDE
COVER

( 9 ) REAR
FENDER -----

(6) TAILLIGHT CASE


MOUNTING N UTS

( 7 ) SUB-FRA M E
MOUNTING
N UTS

1 3- 1 8
M E MO
HYDRA U LI C D I S C BRAKE

'88 , '89 , '9 1 -'93 :

1 . 5 N m (0 . 1 5 kg-m , 1 . 1 ft-lb)

12 Nm ( 1 .2 kg-m , 9 ft- l b )

2 7 N m ( 2 . 7 kg-m, 20 ft-lb)

1 4-0
14. HYDRAU LIC DISC BRAK E
After '93 :

1 2 N m ( 1 .2 Kg-m,9 ft-lb )


7
3 5 N m ( 3 . 5 Kg-m,2 5 ft-l b )

0 /:0
2 2 N m (2 . 2 Kg-m, 1 6 ft-lb)


co go
5 . 5 N m(0.5 4 ft-lb )

1 2 N m ( 1 .2 Kg-m,9 ft-lb)()
3 1 N m ( 3 . 1 Kg-m,22 ft-lb)

2.5 N m (0.2 5 Kg-m, 1 .8 ft-lb)

1 4- 1
H Y D RA U LI C D I S K B R A K E

S ERVICE I N FORMATION 1 4- 2 BRAKE PAD/DISC 1 4- 5

TROU BLES H O OTI N G 1 4- 3 MASTER CYL I N D E R 1 4- 8

BRAKE F L U I D R EPLACEM ENT/ BRAKE CALIPER 1 4-1 1


AIR BLEED I N G 1 4- 4

SERVICE I N FORMATION
G E N E RAL

A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high
quality brake degreasing agent.

Use only DOT 4 brake fluid.

The brake caliper can be removed without disconnecting the hydraulic system.

Once the hydraulic system has been disassembled, or if the brakes feel spongy, the system must be bled.

Do not allow foreign material to enter the system when filling the reservoir.

Brake fluid will damage painted, plastic, and rubber parts. Whenever handling brake fluid, protect the painted, plastic and rubber
parts by covering them with a shop towel. If fluid does get on these parts, wipe it off immediately with a clean cloth.

A lways check brake operation before riding the motorcycle.

Inhaled asbestos fibers have been found to cause respiratory disease 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 asbestos fibers.

S P E C I F I CAT I O N S
U n it: m m ( i n )
ITEM STAN DA R D E R V I C E LI M IT
Disc thickness 5.0(0.2 ) 4.0(0. 1 6)
Disc runout -
0.30(0.0 1 2 )
' 8 8,'89, I. D. 1 2. 7 00- 1 2 .743 (0.5000-0. 50 1 7 ) 1 2 . 7 6 (0.502 )
Master '9 1 -'93: piston O.D. 1 2 . 6 5 7 - 1 2 .684(0.4983-0.4994) 1 2 . 6 5 (0.498 )
cylinder I . D. 1 1 .0- 1 1 .043 (0.433 1 -0.4348) 1 1 .05(0.43 5 )
After ' 9 3:
piston O.D. 1 0.9 5 7-1 0.984(0.43 1 4-0.4324) 1 0.94 5 ( 0.4309)
' 88,'89, cylinder I . D . 30.2 3 0-30.280( 1 . 1 902 - 1 . 1 92 1 ) 30.2 9 ( 1 . 1 93 )
B rake ' 9 1 -'93 : piston O.D. 30. 1 6 5-30. 1 9 8 ( 1 . 1 8 7 6- 1 . 1 8 8 9 ) 3 0. 1 6 ( 1 . 1 87 )
caliper cylinder I . D. 2 7 .000-2 7 .050( 1 .0630- 1 .06 50) 2 7 .06 ( 1 .065 )
After ' 9 3:
piston O.D. 2 6.93 5-2 6 . 9 6 8 ( 1 .604- 1 .06 1 7 ) 2 6.93 ( 1 .060)

T O R Q U E VA L U E S

Caliper mounting bolt 27 N m ( 2 . 7 kg-m , 20 ft-lb)


Brake hose oil bolt 30 Nm (3.0 kg-m, 22 ft-lb)
Bleed valve 5 . 5 N m (0. 5 5 kg-m, 4 ft-lb)
M aster cylinder holder bolt 1 2 Nm ( 1 . 2 kg-m, 9 ft-lb)
Master cylinder cover screw 1 . 5 Nm (0 . 1 5 kg-m, 1 . 1 ft-lb)

TOOL

Special
Snap ring pliers 07 9 1 4 - 32 3000 1 or equivalent commercia lly
available in U . S . A .

1 4- 2
H Y D RA U L I C D I S C BRAKE

TROUBLESHOOTI N G
Brake lever soft o r spongy

A i r bubbles in hydra u l i c syste m .

Low f l u i d leve l .

H y d r a u l i c system l e a k i n g .

F a u lty dust s e a l or piston s e a l .

Brake lever too hard

Sticking pisto n ( s ) .

C logged hyd ra u l i c syste m .

Pads g l a zed or w o r n e x c e s s i ve l y .

Brake drag

H y d r a u l i c system stic k i n g .

Sti c k i n g piston ( s ) .

Brake grab o r pull t o one side

Pads conta m i n ated .

D i s c or wheel m i sa l ig n e d .

Brake chatter or squeal

Pad conta m i n ated .


Excessive d i s c r u n o u t .

C a l i p e r insta l l e d i n correct l y .

D i s c or w h e e l m i s a l i g n e d .

1 4-3
HYDRAULIC DISC BRAKE

BRAKE FLU I D REPLACE M ENT/


AI R BLEEDI NG
CAUTION
Be careful not to allo w dust or water to enter the brake system
when filling the reservoir.
USE ONL Y D O T 4 BRAKE FL UID
Do not mix different types of fluid since they are not
compatible.
A void spilling fluid on painted surfaces. Place a rag over the
fuel tank whenever the system is serviced.

Check the fluid level with the fluid reservoir parallel to the
ground.
Remove the reservoir cover, set plate and diaphragm.

BRAKE F LU I D D RA I N I N G

Connect a bleed hose to the bleed valve.

Loosen the caliper bleed valve and pump the brake lever. Stop
operating the lever when fluid stops flowing out of the bleed
valve.

BRAKE FLU I D F I L L I N G /A I R B L E E D I N G

Close the bleed valve, fill the master cylinder with DOT 4 brake
fluid to the casting ledge level ( brake fluid upper level ) .

CAUTION
Do not mix different types of fluid since they are not
compatible.

Connect the commercially available brake bleeder to the


bleeder valve.

Pump the brake bleeder and loosen the bleed valve.


Add fluid when the fluid level in the reservoir is low.
Repeat above procedures until no air bubbles appear in the
plastic hose .

NOTE
If air is entering the bleeder from around the bleed valve
threads, seal the threads with teflon tape .

If a brake bleeder is not available, fill the system as follows:

Pump up the system pressure with the lever or pedal until


there are no air bubbles in the fluid flowing out of the reservoi r
hole a n d lever or pedal resistance is felt.

1 4-4
H Y D RAU LIC D I SC BRAKE

1 ) Squeeze the brake lever, then open the bleed valve 1 /2 turn
and close the valve.

NOTE

Do not release the brake lever (or pedal) u ntil the bleed
valve has been closed .

2) Release the brake lever slowly and wait several seconds


after it reaches the end of its travel.

Repeat steps 1 and 2 until bubbles cease to appear i n the fluid


at the end of the hose.

Tighten the bleed valve .

TORQUE : 5 . 5 N m ( 0 . 5 5 kg-m, 4 ft-lbl

Close the bleed valve, fill the reservoir with the specified brake
fluid to the casting ledge leve l .

Reinstal l t h e diaphragm, set plate and cover.

A contaminated brake disc or pad reduces stopping po wer. Dis


..
card contaminated pads and clean a contaminated disc with a
high quality brake degreasing agent.

BRAKE PAD/DISC
F R O N T B RA K E PAD R E PLAC E M E N T

A contaminated brake disc or pad reduces stopping po wer. Dis


card contaminated pads and clean a contaminated disc with a
high quality brake degreasing agent.

NOTE

Always replace the brake pads i n pairs to assure even disc


pressure .

'88 , '89 , '9 1 -'93 :


Remove the pad pin plugs and loosen the pad pins.
Remove the caliper mounting bolts, then remove the brake cal
iper and bracket.

Pry one old pad agai nst the caliper with a screwdriver to push
the pistons i nto the caliper.

1 4- 5
HYDRA U L I C D IS C BRAKE

Pull the pad pins out of the caliper and remove the brake pads.

Position the pad spring in the caliper as show n .

I nstall new pads in the caliper.

NOTE

Always replace the brake pads in pairs to assure even disc


pressure .

I nstall the pad pins, first one pin, then the other, by pushing
the pads against the caliper to depress the pad spring .

Position the retainer spring i n the bracket .


Apply silicone grease to the caliper and bracket pin bolts .
I nstall the bracket .

1 4- 6
H Y D R A U LI C D I S C B RA K E

I nstal l the brake caliper over the disc, being careful not to

( 1 ) CALIPER MOUTING
- '

damage the pads, then tighten the caliper mounting bolt. BOLTS

TORQUE : 27 Nm (2. 7 kg-m, 20 ft-lbl

Tighten the pad pins and tighten the pad pin plugs securely.

NOTE

Operate the brake lever to seat the caliper pistons against


the pads.

-
After '93 :
Remove the pad pin plug and loosen the pad pin.

(
.
. " -l
f .
f /, ( 1 ) PAD PI N

Pull the pad pin out of the caliper.

Remove the bra ke pads.

I nsert new outsid e pad and push the caliper piston in allow
clearance for installation of the new inside pad .

Instal l new inside pad.

Install the pad pin by pushing the pads against the caliper to
depress the pad spring.

Tighten the pad pin to the specified torque.


TO R Q U E : 1 8 N m ( 1 . 8 Kg-m, 1 3 ft-lb)
I nstall a n d tig hten the pad pin plug to the specified torque.
TO R Q U E : 2 . 5 N m(0.25 Kg-m, 1 .8 ft-l b)

1 4- 7
HYDRAULIC DISC BRAKE

D I S C TH I C K N E S S

Measure the thickness of the d isc .

SERVICE LIMIT: 4.0 mm (0. 1 6 in)

BRA K E D I S C WA R PA G E

Measure the brake disc for warpage with a dial indicator as


shown.

SERVICE LIMIT: 0.30 m m (0.0 1 2 in)

MASTER CYLI N DER


R E M OVAL

Drain brake fluid from the hydraulic system .


Remove the rear view mirror from the master cylinder a n d dis
connect the brake light switch wires.
Disconnect the brake hose by removing the oil bolt and sealing
washers .

CAUTION
A void-spilling brake fluid on painted surfaces. Place a rag over
the fuel tank whenever the brake system is serviced.

N OTE
When removing the oil hose bolt, cover the end of the hose
to prevent contamination . Secure the hose to prevent fluid
from leaking out.

Remove the master cylinder holder bolts and holder, then


remove the master cylinder from the handlebar.

D I SA S S E M B LY (1 ) BRAKE LEVER

Remove the brake lever and brake light switch. '

( 2 ) BRAKE LIGHT SWITCH

1 4-8
H Y D RA U LIC DISC BRAKE

Remove the boot . ( 1 ) SNAP R I N G

Remove the piston and spring by removing the snap ring .

TOOL:
Snap ring pliers 079 1 4 - 323000 1
or equivalent commercially ( 2 ) BOOT


available in U . S . A.

Clean the inside of the master cylinder, reservoir, spring and ( 1 )SPRING
piston with clean brake fluid .

, .,.._ ( 2 ) PISTON

I N SPECT I O N

Measure the master cylinder I . D .


S E RV I C E L I M IT: '88,'89,'9 1 -' 9 3 : 1 2. 7 6 m m (0. 502 in)
After'93: 1 1 .05 m m (0.435 i n )
Check the master cylinder for scores, scratches or nicks.

Measure the master piston O . D . at the shown position.


S E RV I C E L I M IT: '88,'89,'9 1 -'93: 1 2.65 m m (0.498 i n )
After'93: 1 0. 945 m m (0.4309 in)
Check the primary and secondary cups for damage before as
sembly.

AS S E M B LY
CAUTION

Handle the master cylinder piston, cylinder and spring as a set.

Coat all parts with clean brake fluid before assembly.


If the spring and seat were disassembled, assemble the wide
end of the spring on the seat .
Install the spring in the master cylinder with its seat facing in
side.
Instal l the piston.
CAUTION

When installing the piston, do not allo w the cup lips to turn
iside out.

1 4-9
HYDRA U L I C DISC BRAKE

I nstal l the snap ring using a snap ring pliers.


(1 ) SNAP RING
Install the boot .

CAUTION
Be certain that the snap ring is seated firmly in the groove.

TOOL:
Snap ring pliers 079 1 4 - 323000 1
or equivalent commercially


available in U . S A .
.

( 2 ) BOOT

Install t h e brake lever a n d brake light switch. I1 ) BRAKE LEVER


/

I N STALLAT I O N

Set the master cylinder onto the handlebar with the holder
" U P" mark facing up.
Temporarily install the holder bolts. Align the slit of the master
cylinder with the punch mark on the handlebar.
Tighten the upper bolt first, then the lower bolt.
Connect the brake light switch wires to the switch terminals.
I nstall the rear view mirror.
Connect the brake hose with the oil bolt and two sealing wash
ers and tighten the oil bolt.

TORQU E : 30 Nm (3.0 kg m. 22 ft-lb)

Fill the reservoir with DOT 4 brake fluid to the casting ledge
and bleed the brake system (page 1 4- 4) .

1 4- 1 0
HYDRAULIC DISC BRAKE

BRAKE CALl P E R
R E M OVAL

Place a clean container under the caliper and disconnect the


brake hose from the caliper by removing the oil bolt and sealing
washers.

CAUTION
A void spilling brake fluid on painted surfaces.

Remove the brake pads ( page 1 4- 5 ) .

D I SA S S E M BLY

Remove the following:


- pad spring and pin bolt boot from the caliper
- retainer spring and pin bolt boot from the bracket

If necessary, apply compressed air to the caliper fluid inlet to


get the piston out. Place a shop rag under the caliper to cush
ion the piston when it is expelled . Use the air i n short spurts.

CAUTION
Do not bring the nozzle too close to th inlet.

Push the dust seals and piston seals in, lift them out and dis ( 1 ) PISTON SEAL
card the m .

NOTE
The seals must be replaced whenever they are removed.

Clean the seal grooves with clean brake fluid .

CAUTION
Be careful not to damage the piston sliding surfaces.

(2) DUST SEAL

I N S P ECTI O N

Check the pistons for scoring, scratches o r other faults.


Measure the piston O . D .
S E RV I C E LI M IT: '88,'89.'9 1 -'93: 30. 1 6 m m ( 1 . 1 87 i n )
After'93: 26.93 m m ( 1 .060 in)
Check the caliper cylinder for scoring, scratches or other
faults .
Measure the caliper cylinder I . D .
S E RV I C E L I M IT: '88.'89.'9 1 -'93: 30.29 m m ( 1 . 1 93 in)
After'93: 27.06 m m ( 1 .065 in)

1 4- 1 1
HYDRAULIC D I S C BRAKE

A S S E M BLY

Coat new piston seals and dust seals with clean brake fluid
and install them in the caliper.
I nstall the pistons anrJ i nstall them with the open ends toward
the pads.

( 2 ) D U ST SEALS

Instal l the pad spring on the caliper as show n .


Apply silicone grease t o t h e inside o f t h e boot, and instal l it.

(3) SILICONE
-

I nstall the retainer spring as shown. ( 1 ) RETAINE R


Apply silicone grease to the inside of the boot and install it. SPRING

I nstall the following:


- pads and pad pins to the caliper
- bracket to the caliper

I nstall the caliper assembly over the brake disc so that the disc
is positioned between the pads.

CAUTION
(2) SILICONE
-
Be careful not to damage the pads.
( 2 ) BOOT

I nstall and tighten the caliper mounting bolts .


TO R Q U E : '88,'89,'9 1 -'93: 27 N m (2.7 Kg- m,20 ft-lb)
After'93: 3 1 N m (3. 1 Kg- m,22 ft-lb)
Tighten the pad pins and i nstall and tighten the pad pin plugs.

Connect the brake hose to the caliper with the hose bolt and
two new sealing washers.

TORQU E: 30 Nm (3.0 kg-m, 22 ft-lb)

Bleed the air from the brake system (page 1 4-4) .

1 4- 1 2
MEMO
BATTERY CHARG I N G SYSTEM

( 3 ) ST
SWITCH
MAIN FUSE
30A

1 5-0
1 5. BATTERY /CHARG I NG SYSTEM

' 8 8- ' 8 9 , ' 9 1 :

y
y
( 3 ) MAIN F U S E 30A
y
R/W
G

8 1 /G
81 81 81

Y : Yellow
(4) ALTER NATO R ( 1 ) R E G U LATO R/R E CTI F I E R
8 1 : Black
G : G reen
R : Red
W : White

After '9 1 :

y
y
( 3 ) M A I N F U S E 3 0A
y
G R/W

Y : Yellow
(4) ALTER NATO R ( 1 ) R E G U LATO R/R ECTI F I E R G : G reen
R : Red
W : white

1 5- 1
B ATTERY/ C H A R GING SYSTEM

S E RVI C E I N F O R M ATION 1 5-2 CHARG I N G SYSTEM 1 5- 7

TROUBLESHOOTING 1 5-3 REGU LATO R/RECT I F I E R 1 5- 8

BATTERY 1 5-4 ALTERNATOR 1 5-9

SERVICE I N FORMATION
G E N E RA L

The battery generates hydorogen gas which can be highly explosive. Do not smoke or allow flames or sparks near the battery,
expecially while charging it.

If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed. The ex
haust contains posisonous carbon monoxide gas that may cause loss of consciousness and, lead to death.

The following color codes are used throughout the electrical sections .
Bu = Blue G = Green Lg = Light Green R = Red
Bl Black Gr = Gray 0 = Orange W = White
Br = Brown Lb = Light Blue P = Pink Y = Yellow

Slow charge the battery whenever possible, quick charging should be an emergency procedure only.
Remove the battery from the motorcycle for charging.
The battery on this motorcycle is a sealed type . Do not remove the filler hole caps even during charging. Do not use a non
maintenance free battery as a replacement.
All charging system components can be checked on the motorcycle.
When i nspecting the charging system , check the system components and circuits step-by-step according to the trouble
shooting chart on the next page.
Alternator removal is described in Section 8.

S P E C I F I CATI O N S

ITEM STANDARD
Battery Capacity 1 2 V - 8 AH
Voltage at 20 C ( 68 F) Fully cahrged 1 3.0- 1 3.2 v
Needs charging 1 2.3 v
Charging current 0.8 amperes
Charging time 1 0 Hr
Regulator/rectifier Type Three-phase/ful l-wave
Regulated voltage 1 4 - 1 5 V/4, 000 rpm
Alternator Charging coil resistance at 20 C (68 F) 0. 1 - 1 . 0 0
Output 0 . 345 kw/5,000 rpm
Charging start rpm 1 ,000 1 00 rpm

TO O LS

Digital multitester ( KOWAl 0 7 4 1 1 - 0020000 or KS-AHM-32-003 ( U . S . A . only)


or
Circuit tester ( SANWA) 07 308 - 002000 1
or
Circuit tester ( K OWAl TH-5H

1 5-2
BATTERYI CHARG I N G SYSTEM

TROU BLESHOOTI NG

I
ABNORMAL
Measure the battery leakage (page 1 5- 7 ) . Check the regulator/rectifier resistances be-
tween each regulator/rectifier terminals (page
1 5- 8 )

NORMAL
NORMAL . Short circuit in wire
harness
ABNORMAL ----+ Faulty ignition

L.
switch

I
ABNORMAL
Check for an overcharged battery (page 1 5-8 ) . I Faulty regulator/

J I
rectifier
NOT OVE CHARG E D REG U LATED . Fault y battery

Measure the voltage between the R/W (+) and G NO VOLTAGE


with terminals (-) of the regu lator/rectifier 4P t-------_. Open or short circuit in wire harness
Black connector. (wire harness side) (page 1 5-8 ) Loose connecotor

BATTERY VOLT AGE C O M ES


+
Disconnect the 3P connector of the regulator/
rectifier, check the alternator stator coil
resitances ( page 1 5-8)
STA N DARD
1..._ _______ _. . Loose 3P connector

ABNORMAL
...___________.,. Faulty stator coil

Check the regulator/recrifier resistan ces be ABNORMAL


tween each regulator/rectifier terminal ( page t-------.... Faulty regulator/
1 5- 8 ) . rectifier

NORMAL
'"------- Faulty battery

1 5-3
BATTE RY/CHARG I N G SYSTEM

BATTERY
R E M OVAL

CAUTIO N
D o not remove the battery while exhaust pipe is hot.

Remove the right side cove r .


U n hook t h e fuse box from t h e battery case cove r . ( 1 ) BATTE RY
Remove t h e battery case cover by removi ng t h e bolts . CASE
COVER
-......:..).:t:::;;;.::::...u-1 21 s o LT s -

Remove the left side cove r . ( 1 ) N EGATIVE


TERMINAL
Disconnect t h e battery negative terminal lead from t h e battery
fi rst , then disconnect the positive terminal lead .
Pull the battery out of the battery case .

--- \ ',
2:,L.) - - "

v v< r\\ -- -
\ \\
(2) POSITIVE "'-
_.._ _ TER M I NAL \

I N STALLATION

P l a c e the battery i nto the case and connect the battery posi
tive cable to the battery fi rst from the rig ht side, then connect
the negative cable from the left side .
Coat the battery term i n a l with clean g rease .
I nsta ll the battery case cover by hooking the tab on the cover
to the hook on the case .
I nsta ll and tighten the cover m o u nting bolts .
I nstall the fuse box onto the battery case cover .

I nstall the ru bber covers in the seq uence as shown .


I nstal l the right and left side covers .

R oute the battery cables as shown on the battery caution


la bel .

CAUTI O N
WIRING AS SHOWN BELOW

1 5-4
BAlTERY/CHARG I N G SYSTEM

VO LTAGE I N S PECTI O N

R emove the right a n d left side covers . I


Remove the battery case cove r .

M easu re the battery voltage using a digital multimete r .

VO LTAG E : Fully charged : 1 3 . 0- 1 3 . 2V


U nder charged : Below 1 2 . 3V

TOO L :
Digital multimeter 0741 1 -0020000 ( KOWA)
(1\ BATTERY
KS-A H M -32-003 ( U . S. A. only)

BATTERY TESTI N G
N OTE

Always clear the work a rea of flammable materials such as


gasoline, brake flu i d , electrolyte , or cloth towels when
operating the tester , the heat generated by the tester may
cause a fire .

R emove the battery (page 15-4) .

Secu rely con nect the tester's p ositive ( + ) cable first, then
connect the negative ( - ) cable .

N OTE

For accu rate test result, be s u re the tester's cables and


clamps a re in good working condition and that a secu re
connection can be made at the battery .

Set the tem pe ratu re switch to " H I G H" o r " LOW" depending
o n the ambient tem pe ratu re .

~
HIGH:
6 0 F ( 1 5 C ) o r higher
LOW:
00@ @ 0
M-
6 0 F ( 1 5. C ) or lower
LIM
LJ LJ

Push in the appropriate test b utton for th ree secon d and read
the condition of the battery on the mete r .

N OTE


Be sure you 've selected the test butto n of 5 . 5 Ah-9Ah .
For the first check, DO N OT charge the battery before
testing-test it is an "as is" condition .
Test B utton s
lQoOOOO@ @ O

1 5- 5
BATTERY/CHARG I N G SYSTEM

CAUTIO N
To avoid damaging the tester, only test betteries with an
amperage rating of less than 30A .
YELLOW
Tester damage can result from overheating when : RED (- 1 ) G RE E N
- The test button in pushed in for more than three seconds. (-3, -2) (+ 1 ' +2, +3)
- The tester is used without being allowed to cool for at
least one minute when testing more than one battery.
- Move than ten consecutive tests are performed without
allowing at least a 30- minute cool-down period.

N OTE

The result of a test on the meter scale is relative to the amp .


hour rating of the battery . Any BATTERY R EA D I N G I N
T H E G R EE N ZO N E I S O K . B atteries should only b e char
ged if they register in the YELLOW o r R E D zone .

BATTERY C H AR G I N G
N OTE

B e sure the a rea a round the charger is well ventilated , clear


of flammable materials, and free from heat, humidity,
water and dust .

Clean the battery terminals and position the battery as far


away from the charger as the leads will permit .

D o not place batteries below the charger-gases from the


battery may corrode and damage the charger.

D o not place batteries on top of the charger. B e sure the air


vents a re not blocked .

1 . Tu rn the Power Switch to the O F F position .


2 . Set the battery Amp . H r . Selector Switch for the size of
the battery being charged .
3 . Set the Timer to theposition indicated by the Honda
Battery Tester ; R E D-3 , R E D-2 or YELLOW- 1 . If you a re
charging a new battery , set the switch to the N EW BATT BATTERY A M P H R .
position . SELECTOR SWITCH

. ... .
5.5 10 1.0
4 . Attach the clam ps to the battery terminals-R E D to Posi
tive, B LACK to N egative .

\11)
3 . .. .

Connect the battery cables only when the Power Switch is


OFF. .

Set the a ppropriate a m p . hour ratin g .


Connect the battery cables only when the Power Switch is O F F .

Connecting the cables with the Power Switch can pro


duce a spark which could ignite or explode the battery.

1 5- 6
BATTE RY/CHARG I N G SYSTEM

5. Turn the Power Switch to the O N position .


6 . When the timer reaches the "Trickle" position , the charg
ing cycle is complete . Turn the Power Switch OFF a n d
disc o n n ect t h e cla m ps .

N OTE

The c h a rger will automatically switch to the Trickle mode


after the set charging time has elapsed .

7. Retest the battery using the Honda Battery Tester a n d


rech a rg e i f necessary using t h e above steps .

N OTE

For accurate test results, let the battery cool for at least ten
m i nutes o r u ntil gassing subsid es after charging .

CHARG I NG SYSTEM
N OTE

When i nspectin g the charging system , check the system


components and lines step-by-step according to the
tro ubleshootin g o n page 1 5-2 .

Measurin g circuits with a large capacity that exceeds the


capacity of the tester may cause damage to the tester .
Before starting each test, set t h e tester a t the high capacity
range first, then g radually down to low capacity ranges i n
order that y o u have t h e correct range a n d d o not damage
the tester .

When measuri n g small capacity circuits, keep the ignition


switch off . If the switch is suddenly turned on d u ring a
test, the tester fuse may blow . (1 ) BATTERY
NEGATIVE TERM INAL
LEAKAG E I N S PECTIO N

Check the battery a mpere leakage before making the regulat


ed ampere inspection .
Turn the ignition switch off and d i sco n n ect the battery nega
tive cable from the battery .
Connect the tester between the negative cable and the nega
tive battery terminal .
( 2 1 BATTERY
The voltag e should i n dicate less than 0 . 1 rnA with the ignition N EGATIVE
switch off. CABLE

LEAKAG E AM P E R ES : 0 . 1 mA max.

1 5- 7
BATTERY/ C HA R GING SYSTEM

R E G U LATED V O LTAG E I N S P E CT I O N

N OTE

Be sure the battery is i n good condition before performing


this test .

Warm up the engine to normal operating temperature .


Stop the engine, a n d connect the voltmeter a s shown .

Start the engine a n d allow i t to idle, then increase the engine


speed gradually.
The voltage should be controlled to 1 4. 3 - 1 5 . 1 V at 5,000
rpm .

CAUTION

Be careful not to let the battery positive cable contact the frame
while testing.

REGULATOR/ RECTI Fl ER
I N S PECT I O N

Remove the left side cover.


Disconnect the 3P (WHITE) and 4P ( BLACK) regulator/rectifier
connectors .

Check the connectors for loose or corroded terminals.

If the regulated voltage reading was out of specification,


check the circuits between the connector terminals (wire
harness side and alternator side) following the chart below .

ITEM TER M I NALS STANDARDS


Battery charging line Red/White (+) and Green (-) Battery voltage should come
Alternator coil line Yellow and Yellow 0 . 1 - 1 . 0 0 (20 C/68 F)

Check the resistances between the leads with an ohmmeter. If '88-'89 , '9 1 U n it : KO
the resistance is out of the specifications, replace the regulator
rectifier.

NOTE

Red/White
e
Red/White


G reen

00
Yellow

00
Yellow

00
Yellow

00

Use a SANWA [SP- 1 0Dl or [TH-5Hl tester or KOWA D I G I G reen 5 "' 30 ------ 1 "' 20 1 "' 20 1 "' 20

TAL VOLTO M ETER (074 1 1 - 0020000 ) . Yellow 4.2 00


00 00

The reg ulator/rectifier has a semi-co nducto r . If a d ifferent Yellow 4.2 00 00


------ 00

tester is used , the results will be out of specification . Yellow 4.2 00 00 00


------

You ' ll get a false reading if your finger touches the tester
probe . After '9 1 : U n it: KO
If the pointer of the tester fails to swing to zero when the

adjusting knob is turned fully clockwise or counter Red/White Yellow Yellow Yellow G reen
e
clockwise, replace the battery in the tester.
Red/White ------ 00 00 00 00

Yellow 0.5- 1 0 00 00 00

Tester Range 0.5- 1 0


Yellow 00
------ 00 00

SP- 1 0D KO Yellow 0.5- 1 0 00 00


00

G reen 0. 7 - 1 5 0.5- 1 0 0.5- 1 0 0.5- 1 0 ----


TH-5H RX 1 00

15- 8
B ATT E R Y/ C HA R GIN G SYST E M

ALTERNATOR
I N S P ECTI O N

NOTE

It is not necessary to remove the stator coil to make this


test.

Remove the left side cover.

Disconnect the alternator 3P (WHITE) connector.

M easure the resistance between the yellow wire terminals and


check for no continuity between each terminal and ground.

STANDARD: 0 . 1 - 1 . 0 0

Replace the stator if the resistance is out of specification or if


there is continuity between each yellow wire terminal and
ground ( page 1 5 - 8 ) .

1 5- 9
I G N I T I O N SYST E M

ENGINE STOP SWITCH

(4) MAIN
FUSE

( 5 ) IGN ITION
SWITCH

( 1 1 ) NEUTRAL (6) REAR I G N ITION


SWITCH COIL ( 1 2 ) I G N ITI O N
CONTR O L M O D U LE

A FTE R '93 ;

( 1 4) S I D E STAN D SWITCH

1 6-0
1 6 . I G N I T I O N SYST EM
'88 , '89

r---- B I/W ---B I R/BI -o


( 1 ) ENGINE (2) SUB (5) I G N I T I O N ( 4 ) M A I N
STOP FUSE SWITCH FUSE
SWITCH 10 A 30 A
e
( 1 3 ) S I D E STA N D
SWITCH
( 3 ) BATT E RY
1 2 V BAH
G/W

B l : Black
Y : Yellow
B u : Blue
G : G reen
( 1 2 ) TO
R : Red
FUEL CUT
R E LAY W : White
Lg : Light G re e n

>-


( 9 ) FRONT

11 - -
( 1 0) REAR

11 - -
( 1 2 ) I G N ITION
CONTRO L
M O D U LE

( 9 ) FRONT ( 1 0) REAR
( 1 4 ) I G N ITION P U L S E G E N E R A T O R

( 7 ) I G N IT I O N C O I L

AFTER '89 :

.---- B I/W ---B I R/BI-o


( 1 ) ENGINE (2) SUB ( 5 ) I G N I T I O N (4) M A I N
STOP FUSE SWITCH FUSE
SWITCH 10 A 30 A
e
( 1 3 ) S I D E STA N D
SWITCH
( 3 ) BATT E R Y
1 2 V BAH
G /W

B l : Black
Y : Yellow
Bu : B l u e
G -:: G : G reen
( 1 2 ) TO R : Red
FUEL C U T W : White
R E LAY Lg : Light G reen

Bl
a:

::J > >-


:J
aJ

Bu
aJ -
>: G/W G Y


( 9 ) FRONT

11
- -
( 1 0) REAR

11- -
( 1 2 ) I G N ITI ON
CONTROL
M O D U LE

( 7 ) I G N ITION COIL

1 6- 1
I G N I TIO N S Y ST E M

S E RVIC E I N FO R MATIO N 1 6- 2 I G N I T IO N P U LS E G E N E R ATO R 1 6- 6

TRO U BLES HOO T I N G 1 6- 3 S I D E STAND SWITCH 1 6- 7


I G N I T IO N CO N T RO L MO D U LE
1 6_ 4 I G N ITIO N T I M I N G 1 6- 8
I N S P E CT IO N
I G N ITIO N CO I L 1 6- 5

SERVICE I N FORMATION

If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in on enclosed area.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.

G E N ERAL

Ignition timing cannot be adjusted since the ignition control module is non-adjustable.lf ignition timing is incorrect.check
the system inspectio n and replace any faulty parts.
For spark plug gap inspectio n and adjustment procedu re,see page 3-8.
For alternator removal and i nstallation,see sectio n 8.
For ignition pulse generator removal and installation,see page 7 - 1 1 .
When i nspecti n g the i g n ition system,check the system components a n d li nes step-by-step according to the tro u ble
shooting on next page.
Each pair of the spark plugs( Front and Rear) has its own ignition circu it.
To test the neutral switch,refer to section 1 8.

S P E C I F I CAT I O N S

ITEM STAN DARDS (20 C/68 F)


S p a r k plug NGK N I PP O N D E N SO

DPR8EA-9 X24EPR-U9
S p a r k plug 0.8-0.9 mm (0.03 - 0.04 in)
I g nition t i m i n g I n it i a l ( F m a r k ) 6.2 BTDC/i d l e
I g n ition c o i l Pri m a ry 1 .89- 2.32 n
resistance 2 3 . 5 5 - 30 . 4 5 kO
Secondary With p l u g w i re
Without p l u g w i re 1 9 . 8 - 24 . 2 kO
Ignition pulse g e n e rator C o i l resistance 4 50 - 550 n

Firing order F ( 2 ) - R ( 1 ) 308

TOOLS

Tester
D i g it a l m u ltitester ( KOWAl 074 1 1 - 0020000 or KS-AH M-32-003 ( U . S . A . only)
or
C i rc u i t tester (SANWA) 07 308 - 0020000 N ot available in U .S.A.
or
C i rc u it tester (KOWAl TH-5H J

1 6-2
I G N ITI O N SYSTEM

TROU BLESHOOTI N G

When performing a spark test, keep open flames or sparks away from the work area.

No spark at one spark plug


Faulty spark plug
Faulty spark plug wire

No spark at all plugs

1 . Check the i g n ition contro l m od u le connec- ABNORMAL


loose connectors .
tors for loose contact.
Faulty
NORMAL
Fuel cut relay (page 1 8-9)
,.-
2 . Measure voltage betWeen the B l ( + )and G (-)/ Fuel pump (page 1 8- 1 0)

between the B u/Y( + )a n d G (-)/between Y Open circuit in wire harness


( + )and G (-)of the ignition control module 6 P ABNORMAL
NORMAL (page 20- 1 )
connector. B attery voltag e should appear
with the ignition switch ON and engine stop Faulty
switch at R U N . Side stand switch ( page 1 6-6)

Neutral switch ( page 1 8- 1 1 )

Short circuit in wire harness


NORMAL

3- 1 . C h e c k the i g n it i o n p u lse g e n e rato r resist- ABNORMAL 3-2. Check the ignition pulse generator( page

l
ances at the ignition control module 4P 1 6- 6 ) .
connector( page 1 6-4). NORMAL ABNORMAL

Open or short circuit Faulty pulse gener


in wire harness ator
loose connectors

No spark at either spark group ( Front or Rear) - (CHECK WRONG SPARK GROUP)

1 . Check the ignition secondary coil resistance 1--- A


_ B_N_O_R_M
_ A_L_--1 Faulty ignition coil
( page 1 6-4) . - Faulty spark plug wire

NORMAL
r
\
O_R_M_A_L
2- 1 . Check the ignition primary coil resistance at 1---A_B_N_

l
__

2-2. Check the ignition coil (page 1 6-4) .


the ignition control module 6 P connector
( page 1 6-4) . NORMAL ABNORMAL

1
loose connectors Faulty ignition coil
NORMAL Open or short circuit Open circuit in wire
in wire harness harness

}
I
3- 1 . C h e c k the i g n it i o n p u lse g e n erator resist- I -ABNORMAL 3-2. Check the ignition pu lse generator( page

l
- -.! 6 -_6)
1_
ances at the ignition control module 4P con - - --- -- L____ ,.:-. ________....-________
nector(page 1 6- 4). NORMAL ABNORMAL

Open or short circuit Faulty ignition pulse


NORMAL in wire harness generator
loose connectors.

4. Exchange the ignition coil and try the spark GOOD JUMP
r------t ' Faulty ignition coil
test.

1 6-3
I G N ITION SYSTEM

I G N ITION CONTROL MODULE


I N S P ECTION
Remove the left side cover and connector plate .

N OTE

Check the system components and lines step-by-step ac


cording to the troubleshooting chart on page 1 6-3.

Disconnect the ignition control module connectors and check


them for loose o r corroded termi nals.

Measure the resistance between connector terminals using


the following chart.

<6P CONN ECTOR>


ITEM TERMI NALS STANDARD ( 2 0 C/68 F)
Ignition primary coil Y and 81 ( Rear) Bu!Y and 81 ( Front) 1 . 89 - 2 . 3 2 (}

D C power supply circuit line 81 (+) and G (- ) , Bu/Y (+) and G ( - ) , Y (+) and G Battery voltage should come.
(-) with the ignition switch " O N " and engine stop
switch " R U N "

< 4 P C O N N ECTOR>
ITEM TERMINALS STANDARD ( 2 0 C/68 F)
I g n ition pulse generator coil W/Y and Y ( Front) W/Bu and Bu ( Rear) 450 - 550 (}
Each terminal and body ground NO CONTI N U ITY

I G N ITION COI L
I N S PECTI O N

Remove the fuel tank ( page 4-3) a n d crankcase breather tank.


Measure the primary coil resistance of the front ignition coil in
the frame.
Remove the right side cover and rear ignition coil and measure
the primary coil resistance.

Checking for continuity between the primary terminals.

STANDARD : 1 .89 - 2 .32 0 (20 C/68 F)

Disconnect the spark plug caps from the plugs and measure
the secondary coil resistance with the spark plug caps in place.

STANDARD : 23 . 5 5 - 30.45 kO (20 C/68 F)

1 6 -4
I G N ITION SYSTEM

If the resistance is out of range, remove the spark plug wires


and measure the resistance between the secondary coil termi
nals.

STAN DARD : 1 9 . 8 - 24 . 2 kO (20 C/68 F)

R E PLAC E M E N T

Rear ignition coil


Remove the right side cover.
Disconnect the fuse connectors and starter relay switch from
the case .

Front ignition coil 1) CRAN KCASE


BR EATH E R
Remove the fuel tank ( page 4-3 ) .
TA N K
Remove the crankcase breather tank from the frame.

Remove the ignition coil mounting bolts and disconnect the


primary terminals from the coils.
Remove the spark plug caps from the spark plugs.

Install the new ignition coil in the reverse order of the removal .

NOTE

Connect the primary wire terminals properly.


Front coi l : black terminal - black/white wire
green terminal - yellow/blue wire
Rear coi l : black terminal - black/white wire
green termina l - blue/yellow wire

1 6- 5
IGN ITIO N S YSTEM

I G N ITION P U LS E G E N ERATOR
I N S PECT I O N
r(i') I G N ITI O N P U LS E
G E N E RATO R C O N

"
NOTE

It is not necessary to remove the ignition pu lse generator to


make this i nspection.

Remove the left steering cover.


Disconnect the ignition pulse generator 4P connector
(WH ITE) .
M easure the resistan ces between the white/yellow a n d yellow
wires(front ignition pulse generator) and white/blue and blue
wires( rear ignition pulse generator)

STAN DAR D : 450 - 550 0 (20 C/68 F)

For ignition pulse generator replacement, refer to section 8 .

SIDE STA N D SWITCH


I N SPECT I O N

'88 , '89 , '9 1 -'93 :


Re move the seat a n d left side cove r . D i s c o n n ect the 2 P
( G reen) c o n n e ctor a n d t h e G reen/White w i r e .

C h e c k the conti n u ity between e a c h term i n a l of t h e s i d e sta n d


switch .

SIDE STAND DOWN (RELEASED) S I D E STA N D U P ( PU S H E D )


Side sta n d Tester
Term i n a l s
position Reading
rO 0 ,..() ()-
S i d e stand up
(pushed ) G ree n/White to Green N o conti n u ity
-ignition circuit Y e l l o w / B l a c k to G reen C o nti n u ity
( 1 1 TO
open
( 1 ) TO
WA R N I N G

Side sta nd down
<,.) WA R N I N G 9-
( released) G re e n/White to G reen Conti n u ity LIGHT
LIGHT


-ig nition circuit Y e l l o w / B l a c k to G re e n N o conti n u ity
closed
(21 TO
-. Y/BI
I II ( 2 ) TO -- Y/BI I
SPARK U N I T SPARK U N I T
--GIW .,. --- G/W
G G

1 6- 6
I G N IT I O N S Y ST E M

After '93 :
Remove the left side cover.
Disconnect the side stand 3 P g reen connector and check for
conti n u ity between each terminals as shown below.
There should be continuity between the 0-0 positions on the
conti n u ity chart.

G reen/White Yellow/ B lack G reen


Side sta n d () -o
down
Side stan d
0 0 ( 1 ) D OWN
up

( 1 ) B O LT
R E M OVAL/ I N STA L LATI O N
Remove t h e left side cover.
Discon nect the side stand 3 P g reen connector.

Remove the side stand switch mounting bolt,setting plate,


washer a n d side stand switch.

I nstall the switch in the reverse order of removal.

N OTE
Align the switch pin with the side stan d h ole.Aiign the
switch g ro ove with the setting plate tang and align the
setting plate solt with the side stand return spring holding
pin.

TO R Q U E :
Side stand switch mounting bolt : 9 N m (0 . 9 kg-m , 7 ft-lb)

R oute the side stand switch wire properly.

I G N ITION TI M I NG
NOTE

r
The ignition control module system is factory pre-set and
can not be adjusted.lgnition tim i n g inspectio n procedures
a re g iven to inspect the fu nction of the ignition control
module com ponents.

Con nect the timing light to the other spark plug wire if you
see that the ignition timing is i ncorrect,and you might be
able to see the timing is correct.

Warm up the engine to operating temperature.


Remove the timing inspection hole cap on the right crankcase
cover.

Connect the timing light to the front spark plug wire.

1 6-7
I G N ITION SYSTEM

The timing is correct if the " F" mark aligns with the index
mark on the right crankcase cover at idle for each cylinder.

Raise the engine rpm and the " F " mark should begin to rotate
counterclockwise for each cylinder.

If the ignition timing is incorrect, make a system inspection (1 l "F" MARK


( page 1 6-3) and replace any faulty parts .

(2) I NDEX
MARK

1 6-8
MEMO
ELECTRIC S TARTER

( 8 ) CLUTCH
SWITCH
I
I
I
I
I
I
I
I
I

(7) D I O D E

A FT E R '93 ;

( 1 2) STARTER RELAY
SWITCH

B l : Black
( 1 4) S I D E STAN D SWITCH ( 1 l M A I N FUSE Y : Yellow
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
30A G: G reen
R: Red
(4) SIDE W: White
( 5 ) I G N ITI O N Lg : Light green
STAND C O NT R O L
SWITC H M O D U LE
( 2 l BATT E R Y DOWN
I I
1 2 V 8AH
( 1 2) STARTER
RELAY Lg/R G/W
SWITCH

(8) CLUTCH SWITCH -=- G


( 6 ) N EUTRAL
(7) CLUTCH D I O D E SWITCH
G/R--+------+-t-+-1 L g/R_...-a--

R--o'--o-- R t BI---<f\...J>-- BI ----o


I G N ITION ( 1 0 } S U B- F U S E ( 9 ) STARTER
(1 1 )
SWITCH 1 OA SWITCH
'------ Y t R--------'

1 7 -0
1 7. ELECTR IC STARTER
S ERV I C E I N FO RMATIO N 1 7- 1 STARTER RELAY SWITCH 1 7-6

T RO U B L E S HOOTING 1 7- 1 C L UTC H D IO D E 1 7-7

STARTER MOTO R 1 7-3

SERVICE I N FORMATION
G E N E RA L

T h e starter motor a n d i g mt1 o n p u l s e g e n e rator c a n be removed with the e n g i n e i n t h e f r a m e .


To i ns p e ct t h e i g n it i o n p u l s e ge nerator, r e f e r to Secti o n 1 6 .
Refer to secti o n 8 for starter c l utch removal a n d i n sta l l at i o n .

SPEC I F I CATI O N
Unit: m m (in)

ITEM STA N DA R D SERVICE LIMIT

S t a rter m o t o r b r u s h le ngth 1 2 . 5 (0.49) 6.5 (0.26)

TRO U BLESHOOTI NG
N OT E

T h e starter motor s h o u l d turn w hen t h e tra n s m i s s i o n is i n neutral a n d the c l u t c h d i seng aged .

C h e c k f o r t h e f o l l o w i n g before t r o u b l e s hooting the syste m .


- B l o w n m a i n ( 3 0 A ) or s u b ( 1 O A ) f u s e .
- Loose battery a n d starter motor c a b l e s .
- D i s c h a rg e d batte ry .

Starter motor does not turn

_I
1 -1 . C h e c k the starter relay s w it c h for opera- "CLICK"

I I
ti o n . Y o u s h o u l d h e a r the r e l a y " C LI C K " H EA R D 1 - 2 . A p p l y battery voltage t o t h e starter motor

J J
w h e n t h e starte r switch button is de- d i rectly a n d check the operati o n .
pr e s s e d . ( pa g e 1 7 - 6 )
TURNS DOES NOT TURN

Loose c a b l e s .
Fau lty sta rter motor
" C L I C K " NOT H E A R D .
Fau lty sta rter relay ( page 1 7 - 3 )
switch ( page 1 7 - 6 )
A B N O R M AL
2. Check t h e n e u t r a l i n d icator for f u n cti o n . .
F a u lty neutral s w itch ( p age 1 8 - 1 1 ) .

.
Loose neutral s w itch connectors
N O R MAL .
Fau lty i g n it i o n s w itch ( p age 1 8 - 6 )

3. C h e c k t h e starter r e l a y s w i t c h v o l t a g e N O V O LTAGE
.
Loose c l u t c h d i o d e con nector
( page 1 7-6) .
F a u lty starter relay sw itch ( page 1 7 - 6 )
BATTERY
.
Fau lty cl utch d i o d e ( page 1 7 - 7 )
V O LTA G E C O M E S
.
Open or s h o rt c i rcuit in w i re harness

4 . C h e c k t h e starter r e l a y switch f o r c o n t i n u ity ABN ORMAL


.
F a u lty st a rter relay switch
( p age 1 7 - 7 ) I
N ORMAL
.
Loose starter rela y switch c o n n e ctor

1 7- 1
ELECTRIC S TARTER

The starter motor can turn i n the neutral position, but should not turn except with the gear selector i n neutral , the side stand
up and the cluth lever pulled in.
BATTERY VOLT

I
Measure the Voltage between the Green/White AGE M EASURED
(+) and Green (-) terminals of the side stand
t-------+!J Check the clutch switch ( page 1 8-1 1 ) .
connector (wire harness side ) .
There should b e battery voltage .

N O VOLTAG E
(or too l ittle voltage)
Check the side stand switch ( page 1 6- 5 )

Starter motor turns engine slowly


Low specific gravity

Excessive resistance i n circuit

Binding in starter motor

Starter motor turns, but engine does not turn


Faulty starter clutch
Faulty starter motor gears

Starter motor and engine turns, but engine does not start
Faulty ignition system
Engine problems
- Low compression
- Fouled spark plugs

1 7-2
ELECTRIC STARTER

STARTER MOTOR
R E M OVAL

With the ignition switch OFF, remove the negative cable at the
battery before servicing the starter motor.

Remove the rubber cap and disconnect the starter motor


cable.
Remove the motor mounting bolts .
Remove the motor from the left side.

D I S A S S E M B LY (1 l FRONT COVER
(4) REAR COVER
Remove the following components :
- motor case screws.
- front and rear covers.
- armature .

NOTE

Record the location and number of shims.

( 2 ) CASE

I N S P ECT I O N

Measure each brush length .

SERVICE LIMIT: 6 . 5 mm (0.26 in)

Check for continuity from the cable terminal to the motor case
and from the cable termina to the brush wire ( black) . (1 CONTINU ITY

CABLE TERMINAL-MOTOR CASE


N O CONTI N U ITY : NORMAL

CABLE TERMI NAL-BRUSH ( B LACK WIRE)


C O N T I N U ITY: NORMAL

Disassemble the brush holder if necessary .

1 7-3
ELECTRIC STARTER

I nspect the commutator bars for discoloration . (1 l C O M M UTATOR


Bars discolored in pairs indicate grounded armature coils.

Check for continuity between pairs of commutator bars .

There should be continuity .

Check for continuity between individual commutator bars and


the armature shaft.

There should be no continuity .

Check the front cover oil seal for wear or fatigue. (1 ) O I L SEAL

(2) FRONT COVER

1 7 -4
ELECTRIC STARTER

A S S E M B LY

( 2 ) CASE

(5) BRUSH HOLDER

(7) 0-RING
(4) SHIMS

( 1 0) 0-RI N G
( 1 3) S H I M S
,
( 1 2 ) N UTS
( 1 ) FRONT COVER

( 1 0) CABLE TERM I NAL AND BRUSHES

( 9 ) REAR COVER

Set the brushes on the brush holder.


Align the starter motor case notch with the brush holder tab .

I nstall the a rmature i n t h e case.


Set the brush springs.

Install the rear shims in the same location and number when
disassembled .
Install the 0-ring on the case.
Install the rear cover, aligning its slot with the brush holder pin.

(3) SLOT

1 7-5
ELECTRIC STARTER

I nstall the front shims in the same location and number when (2) FRONT
disassembled . COVER

Instal l the 0-ring on the case .


I nstall the lock washer, aligning its tabs with the slots of the
front cover.
Apply grease to the dust seal and instal l the front cover.

(5) LOCK WASHER (3) 0-RING

Align i ndex marks of the front cover, case and rear cover as
shown.

Instal l and tighten the starter motor case screws and apply oil
to the 0-ring and install it on the front cover.

(3) REAR COVER (2) 0-RING

I N STALLATI O N

I nstall the starter motor in the engine.


I nstall and tighten the motor mounting bolts securely.

NOTE

Install the ground cable with one mounting bolt as show n .

Connect t h e motor cable t o t h e motor terminal a n d install the


rubber cap over the terminal.

Connect the battery negative cable .

T
STARTER RELAY SWITCH
O P E RATI O N I N S PECT I O N
OR
Depress t h e starte switch button with the ignition switch O N .
The c o i l is normal if the starter relay switch clicks.

V O LTA G E I N S PE CT I O N

If you don ' t hear t h e switch "CLI C K " , disconnect t h e switch


connector.
t
Shift the transmission into neutral and turn the ignition switch
ON.
Measure t h e voltage between the yellow/red (+) a n d green/red
(-) wires of the relay connector as you press the starter.
The tester should show battery voltage. If it does not, make
the following continuity inspection.

1 7-6
ELECTRIC STARTER

C O N T I N U I TY I N S P E C T I O N

Remove the starter relay switc h .


Connect an ohmmeter t o t h e switch large terminals.

Connect a fully charged 1 2 V battery positive wire to the start


er relay switch Yellow/Red wire terminal, and the battery neg
ative wire to the G reen/Red wire terminal.

There should be continuity while the battery is connected to


the terminals, and no continuity when the battery is discon
nected .

CLUTCH DIODE
R E M OVAL

Remove the left side cover.


Remove the clutch diode from the wire harness.

I N S P ECTI O N

Check for continuity with a n ohmmeter.

Connect the positive probe to the (+) terminal and the negative
probe to the (-) terminal of the diode.

There should be continuity, then reverse the probes, there


should be no continuity .

N OTE

The test results shown above are for a positive ground ohm ( 1 ) CONTI N U ITY
meter and the opposite results will be obtained when a neg
ative ground ohmmeter is used .

1 7- 7
MEMO
1 8. LI GHTS/ M ETER/SWITCH ES
S E RVI C E I N FO R MATIO N 1 8- 1 F U E L P U MP RELAY 1 8-9

T RO U BL ES HOO T I N G 1 8-2 F U E L P U MP 1 8- 1 0

H EA D L I G H T 1 8-3 O I L P R ESS U R E SWITCH 1 8- 1 0

B U L B R EP LA C E M ENT 1 8-4 N E UTRAL SWITCH 1 8- 1 1

SP E E DO M ET E R 1 8-4 BRAKE L I G H T SWITCH 1 8- 1 1

I G N ITIO N SWITCH 1 8-6 CLUTCH SWITCH 1 8- 1 1

H A N D L EBAR S WITCH ES 1 8- 7 TURN S I G NAL R E LAY 1 8- 1 2

T H E R MO STAT I C SWITCH 1 8-8 HO RN 1 8- 1 2

COO LA N T T E MP ERATURE I N D I CATO R 1 8-8

SERVICE I N FORMATION

If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.

Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area with the engine stopped.
Do not smoke or allo w flames or sparks in the work area or where gasoline is stored.

G E N E RA L
Some wires have different colored bands around them near the connector. These are connected to other wires which cor
respond to the band color.
A l l p last i c co nnecto rs have lock ing tabs that must be released befo re d isco nnect i ng, and must be a l igned and fu l ly engaged
when reco nnect i ng.
To isolate an electrical failure, check the continuity of the electrical path through the part. A continuity check can usually
be made without removing the part from the motorcycle. Simply disconnect the wires and connect a continuity tester or
volt-ohmmeter to the terminals o r connections.
A contin u ity tester is useful when checking to find out whether or not there is an electrical connection between the two
points . An ohmmeter is needed to measure the resistance of a circuit, such as when there is a specific coil resistance in
volved , o r when checking for high resistance caused by corroded connections.

S P E C I F I C ATI O N S
headlight 12 V 60 W/55 W
Brake/ta i l l ight 1 2 V 32/3 cp ( 2 7/8 W) x 2
Turn signal lights Front 1 2 V 32/3 cp ( 2 3/8 W) x 2
Rear 1 2 V 32 cp ( 2 3 W)
License light 12 V 4 cp
Indicator lights turn signal 1 2 V 1 .7 W
neutral 1 2 V 1 .7 W
high beem 1 2 V 1 .7 W
M eter light 1 2 v 3.4 w
Main fuse 30 A
Sub-fuse '88, '89 1 0 A x 6, 1 5A x 1
After '89 1 0 A x 3, 1 5A x 1
F uel pu m p f low capacity 800 cc ( 0.76 USqt, 0.70 l mpqt)

TO R Q U E V A L U E S
Radiator thermostatic switch 1 8 Nm (1 .8 kg-m, 1 3 ft-lb)
Oil pressure switch 1 2 Nm (1 .2 kg-m, 9 ft-lb) - Apply sealant to the threads
Ignition switch mounting bolt 1 1 Nm (1 .1 kg-m , 8 ft-lb) - Shear bolt

1 8- 1
LIG HTS/METER/S W I TC H ES

TROUBLESHOOTI NG
N o Lights Come O n When Ignition Switch I s Turned O N : All Lights Come O n , but Dimly, when Ignition Switch I s

Bulb at fault or burned out Turned ON:

Faulty switch
Battery voltage low

Wiring to that component has open circuit


Faulty bulb

Fuse blown

Wiring loose, broken, or at fault Headlight Beam Does Not Shift When HI-LO Switch Is Op

Battery dead or disconnected erated:



Beam filament burned out
Faulty dimmer switch

Wiring loose, broken, or at fault

1 8-2
L I G HTS/M ETER/SWITC H ES

H EADLIGHT
I
R E M OVAL/ I N STALLAT I O N I
I
I
Remove the two screws a n d headlight.

Disconnect the headlight connector and remove the rubber


protector.

Remove the headlight retainer clip and replace the headlight (1 ) RETAINER CLIP (2) HALOGEN BULB
bulb.

CAUTION

This motorcycle is equipped with a halogen headlight bulb.

Do not put finger prints on the headlight bulb, they may create
hot spots on the hulb.

If you touch the bulb with your bare hands, clean it with a cloth
moistened with alcohol to prevent its early failure.

Do not try to replace the bulb or clean the headlight with the
light ON.

After replacing the bulb, install the rubber boot tightly against
the unit.

NOTE

Instal l the rubber protector with the top mark facing u p .

I nstall t h e headlight in t h e reverse order of removal .

1 8-3
LIG HTS/M ETER/SWITC H ES

BULB REPLACE M E NT
NOTE

See page 1 8- 5 for speedometer bulb replacement.

T U R N S I G NAL LIGHT

Remove the turn signal lens attaching screws.


While pushing i n , turn the bulb counterclockwise to remove .
Replace the bulb, if desired .

I nstall i n the reverse order of removal .

NOTE

Seat the rubber packing properly.

B R A K E/TA I L L I G H T

Remove the taillight lens attaching screws .


While pushing i n , turn the bulb cou nterclockwise to remove .
Replace the bulb, if desired .

I nstall i n the reverse order of removal .

N OTE
Seat the rubber packing properly.

LICENSE LIGHT

Remove the bolts and license light case mounting nuts .


Replace the bulb with a new one.

SPEEDOM ETER (1 l S P E E D O M ET E R
CABLE
R E M OVAL

Disconnect the speedometer cable from the meter.


Remove the steering covers and disconnect the speedometer
connector (6P Black) .
Remove the speedometer stay mounting bolts and meter from
the fork bridge .

1 8-4
LIG HTS/M ETER/SWITC H ES

B U L B R E PLAC E M E N T

Remove t h e trip-meter knob b y removing the attaching screw .


Romove the speedomater cover mounting screws and cover.
Replace the meter bulb with new one.

( 5 ) SPEEDOMETER

(3) STAY

( 2 ) MOUNTI NG
SCREWS

(8) 6P BLACK
( 1 ) 0-RI N G CON NECTOR

( 1 0) SPEEDOMETER
CABLE ( 9 ) SPEEDOM ETER
COVER

Assemble the removed parts in the reverse order of disassem ( 1 ) SPEEDO


bly M ETER
WIRE
Route the speedometer wire as shown and instal l and tighten
the mounting screws.

I N STA L LAT I O N

I nstall the speedometer i n the reverse order o f remova l .

1 8- 5
LIG HTS/M ETER/SWITC H ES

I N D I CATO R PAN E L B U L B R E PLAC E M E N T

Remove the indicator bulbs from the indicator panel, b y first


pulling out each bulb and socket together.
Replace the bulb, if desired .

I G N ITION SWITCH
I N S PECTI O N

Remove the seat and right side cover.


Disconnect the ignition switch 4P White and 2P Black connec
tor.

Check for continuity between the ignition switch connector


terminals in each switch position .

Continuity should exsist between the color coded wires in


each chart below.
'88, '89:
BAT IG FAN TL1 TL2 p

ON 0 -o 0 -o

OFF
p 0 -o

COLOR R R/BI Bu/0 Br/W Br Y/BI

After '89:

R E PLAC E M E N T ( 2 ) MOUNTING RUBBER

Remove t h e ignition switch cover b y removing t h e bolt.


Remove the shear bolt heads using a drill then remove the
switch (cylinder) .
Install the new switch and new shear bolts .
Tighten the shear bolts u ntil the head twist off.

(1 ) HOLDER

1 8- 6
LIGHTS / M ETER/S WITC H ES

HAN DLEBAR SWITCHES (1 ) LEFT HANDLEBAR


SWITCH
The handlebar switches (dimmer, turn signals, horn, starter,
engine stop, etc . ) must be replaced as assemblies.
Remove the steering covers.

L E FT H A N D L E B A R SWITCH

Disconnect the left handlebar switch connector (9P White) .


And check for continuity between the terminals.
Contin uity should exsit between the color coded wires in each
chart.
Dimmer Switch

------- H L2 Hi Lo
Lo 0 -o

(N)
Hi 0 -o

Color code Bu/W Bu w

Turn Signal Switch


' 8 8 . ' 89 . '9 1 :

------- w R L TL1 PR PL
RIGHT 0--- --o 0 -o

N
LEFT 0 -o 0 -o

Color code Gr Lb 0 B r/BI 0/W Lb/W


Horn Button Turn Signal Switch
'88 . '89 . '9 1 : After '9 1 : After '91 :

------ Ho1 Ho2 ------ Ho1 Ho2 ------ w R L TL PR PL


R I G HT 0 0 .()
Released Released

-o
0
D epressed -o Depressed 0 -o
N ().

LEFT 0 {) 0 -o
Color code W/G Lg Color code BI/Br Lg
Coler code Gr Lb 0 B r/ B I Lb/W 0/W
R I G H T H A N D L E B A R SWITC H

Disconnect the right handlebar switch connector (9P Red) and


check for continuity between the terminals .
Continuity should exist between the color coded wires as indi
cated in each chart.
'88 . '89 . '9 1 -'93 : After '93 :

------ IG1 ST HL HL1 IG2 ST HL H L1


Released 0 --o R leased 0

Pushed Pushed 0 {)

Color code Bl Y/R BI/R Bu/W Color code 81/W Y/ R BI/R B u /W

Engine Stop Switch


'88 , '89 , ' 9 1 -'93 : After '93:

------ IG1 IG2 ------- IG, I G2


RUN 0 -o RUN
OFF OFF
Color code Bl BI/W Color code BI/G B I /W

1 8-7
LIG HTS/ M ET ER/SWITC H ES

THERMOSTATIC SWITCH
I N S P E CT I O N
T h e the rmostati c switch senses t h e temperature o f t h e r a d i a
tor coolant a n d s i g n a l s t h e f a n moto r . The motor c o m e s i nto
action at 9 8 - 1 0 2 C ( 2 08 - 2 1 6 F ) a n d stops at b e l o w
9 3 - 9 7 C ( 1 9 9 - 2Q1 F ) .

Before testing c h e c k the c o o l a n t level at warm-up the e n g i n e


to operating temperature .
If the fan does not t u r n , d i s c o n n ect the connectors from t h e
thermostatic s w itch a n d j u m p the term i n a l s using a j u m p e r
w i r e . T u r n t h e i g n it i o n s w itch O N .
I f the fan turns, replace t h e thermostatic switc h .
If t h e f a n does n o t start test t h e f a n moto r : D i sconn ect t h e f a n
motor connecto r . ( 2 P B l a c k ) at t h e l eft steering h e a d c o n n e c
tor h o l d e r . ( 1 ) T H E R M O M ET E R
Check for battery b o l t a g e b e t w e e n the b l ue/black w i re a n d
g r o u n d with the i g n it i o n s w itch O N .

[]]
I f there i s n o voltage, c h e c k the su b-fuse ( 1 0 A ) . o r loose ter
m i n a l s or connector, o r an o p e n c i r c u it

Suspend the therm ostati c switch i n a p a n of coolant ( 50 - 50


m i xture) a n d c h e c k the tempe ratures at w h i c h the s w itch
opens a n d closes .
0
M a ke s u re that there is no conti n u ity at room temperat u re a n d
t h e n g r a d u a l l y r a i s e the c o o l a nt temperature . The switch
s h o u l d show c o n t i n u ity ( c l o s e ) at 9 3 - 9 7 C ( 1 9 9 - ( 2 ) T H E R M OSTAT I C
207 F ) . SWITCH

N OTE
o
Keep the temperature for 3 m i n utes to confirm cont i n u it y .
A s u d d e n c h a n g e of t e m p e rature w i l l c a u se error tempera
ture reading between the thermometer a n d switc h .
o
Do not let the s w itch or thermo meter touch the pan as it w i l l
g i ve a false read i n g .
o
I m merse the s w itch i n c o o l a n t u p to its thread s .

I nsta l l a n e w 0 - r i n g on t h e switc h .
A p p l y sea l a nt t o t h e switch thread a n d i n sta l l i t .
T i g hten the s w i t c h to the s p e c i f i e d torq u e .

TORQUE: 1 8 N m ( 1 .8 kg-m, 1 3 ft-l b )

NOTE
o
Do not over tig hten t h e sw itch .

COOLANT TEM P E RATU RE I N DICATOR


SYSTEM I N S P E C T I O N

R e m ove the horn .


Disconnect the sensor w i re from the thermosensor a n d s h o rt it
to ground using a j u m pe r w i r e .
T u r n t h e ignition s w i t c h O N .
T h e temperature i n d icator l i g h t s h o u l d come o n . I f the i n d i c a
tor l i ght d o e s n o t c o m e o n , c h e c k the su b-fuse ( 1 0 A ) a n d
w i res f o r a loose c o n n ection o r a n o p e n c i rcuit; if n o rm a l , re
p l a c e the meter with a new one .

1 8-8
L I G HTS/ M ETER/SWITC H ES

TH ERMOS E N S O R I N S PECTI O N (1) T H E R M O M ET E R

D r a i n the coo l a nt from t h e t h e r m ostat housing by removing

m
the d r a i n bolt i n t h e h o u s i n g .
D i sconn ect the w i re from t h e t h e rmosensor a n d remove the
thermosenso r .
Suspend t h e thermosensor i n o i l o v e r a he ater a n d measure the
resistance thro u g h t h e sensor as the o i l heats u p . Q
Temperatur ( C/ F ) 50/ 1 2 2 80/ 1 7 6 1 20/248
Resista nce ({}) 1 53 . 9 51 .9 1 6. 1

Wear gloves and eye protection.

NOTE

O i l must be u s e d as the h e ated l i q u i d to check the f u n ction


a bove 1 00 C ( 2 1 2 F ) .

You w i l l get f a l s e rea d i n g s if either the sensor or


thermometer touches t h e p a n .

R e p l a ce t h e sensor if i t is o u t o f s pecifications by more t h a n


1 0 % a t a n y temperature l i sted .
A p p l y sea l a n t to t h e threads of t h e thermosensor a n d tig hten it
i n the thermostat h o u s i n g .

NOTE

Keep the c l e a r n a c e of 3 - 4 mm ( 0 . 1 - 0 . 2 i n ) betw een the


case and the t h e rmosensor threads e n d s .

C o n nect the w i r e to t h e thermose nsor.

FU EL PUM P R E LAY

Gasoline is extremely flammable and is explosive under certain


conditions. Work in a well ventilated area. Do not smoke or
allow flames or sparks in the your work area or where gasoline
is stored.

Remove the seat a n d right s i d e cover.


Check the sub-fuse ( 1 0 A ) .
Re move the r e l a y from t h e rubber b racket a n d check the re l a y
c o n n e ctor term i n a l s for l o o s e n e s s and co rrosi o n .

Inspect as follows :
D i s con nect t h e c o n n e ctor a n d test the w i res on the m a i n har
ness side .

ITEM STA N DA R D
Between Bl ( + ) a n d b o d y g r o u n d ( - ) Battery voltage
w ith the i g n it i o n s w itch " O N " s h o u l d come .
Y /Bu wire bet w e e n the p u m p
C O N T I N U I TY
relay a n d s p a r k u n it
BI/Bu wire betwe e n the p u m p
C O N T I N U ITY
re l a y and fuel p u m p

1 8-9
L I G H TS / M ETER/SWITC H ES

FU EL PUM P
S Y S T E M I N S P ECTI O N

Turn the ignition switch O F F a n d remove the seat and discon


nect the fuel pump wire connectors and temporarily connect
the balck and black/blue wire teminals at the main harness
connector with a jumper wire.

Disconnect the fuel outlet tube at the fuel pump and connect a
fuel tabe or equivalent to the pump outlet line.
Hold a graduated beaker under the pump outlet line.

Gasoline is extremely flammable and is explosive under certain


conditions. Work in a well ventilated area. Do not smoke or
allow flammes or sparks in your work area or where gasoline is
stored.

Turn the ignition switch on and let fuel flow into the beaker for
5 seconds, then turn the ignition switch off .
M u ltiply the amount in the beaker by 1 2 to determine the fuel
pump flow capacity per minute .

FUEL PUMP FLOW CAPACITY :


800 cc (0. 76 US qt 0. 70 Imp qt) min . /minute

O I L P R ESSU RE SWITCH
Make sure that the oil pressure warning light comes on with
the ignition switch " O N " .

I f the light does not come on, inspect a s follows:


Remove the drive sprocket cover ( Page 1 3- 1 4) .
Disconnect the oil pressure switch wire from the switch by re
moving the terminal screw.
Short it to ground using a jumper wire . Turn the ignition switch
"ON".

The oil pressure warning l ight should come on.


If the light does not come on, check the bulb, sub-fuse ( 1 0 AI
a n d wires f o r a loose connection or an open circuit.

Start the engine and make sure that the light goes out. If the
light does not go out, check the oil pressure (page 2 -5) . - !I
( 1 ) O I L PRESS R E SWITC
If the oil pressure is normal, replace the oil pressure switch
( page 2 -5) .

1 8- 1 0
LIGHTS/METER/SWITC H ES

N EUTRAL SWITCH
I N S P E CT I O N

Remove t h e left side cover a n d disconnect the 2P ( Black) con


nector.
Check the neutral switch for continuity between the light
green/red connector and body gro u n d .

There s h o u l d b e contin uity between t h e l ight green/red con


nector and body ground .

There should be continuity with the transmission i n neutral and


no continuity with the transmission in any gear.

If there is no continuity i n neutral , remove the drive sprocket


cover (page 1 3- 1 4) and check the wire connection for an open
circuit.

BRAK E LI GHT SWITCH


F R O N T I N S P E CT I O N

Disconnect the front brake light switch connectors and check


for contin u ity between the switch terminals.

There should be continuity with the front brake applied, and no


continu ity with the brake release d .

Replace t h e switch i f necessary .

R E A R I N S P ECTI O N

Disconnect the rear brake light switch connector and check for
contin u ity between the terminals.

There should be continuity with the rear brake applied and no


continuity with the rear brake released .

Replace the rea r brake light switch , if necessary .

CLUTCH SWITCH
I N SPECTI O N

Disconnect the clutch switch wire connectors.

Check for continuity between the switch terminals. \


There should be continuity with the clutch applied and no con
tinuity with the clutch released .

Replace the clutch switch if necessary.

1 8- 1 1
LIG HTS/ M ET E R/SWITC H ES

TU RN SIG NAL RELAY


Remove the seat, then remove the turn signal relay from the
rubber bracket .

Check the turn signal circuit for proper connections before


making this test.

Connect each terminal as indicated below :


White/G ree n : D . C . 1 2 V Positive ( + )
G reen : D . C . 1 2 V Negatvie (-)
G ray: Turn signal wire of one side; connect the
other side to ground (frame ) .

Check for correct lighting ON a n d OFF.

If the turn signal relay fails this test, replace it.

HORN
Disconnect the wire connectors from the horn a n d connect a
1 2 V battery to the horn wire terminals. The horn is normal if it
sounds.

1 8- 1 2
1 9. WI R I N G DIAG RAM
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W I R ING D I AGRAM

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1 9- 2
W I RING D I A G R A M

'92 , '93 ;

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1 9- 3
W I R IN G DIAGRAM

After '93 :

1 9-4
20. TROUBLESHOOTI NG
E N G I N E DO ES NOT START O R I S POO R PERFO R MANCE AT H I G H
H A R D TO START 20- 1 SPEED 20-4

E N G I N E LACKS PO W E R 20-2 POO R H A N D L I N G 20-4

PO O R PERFO RM A N C E AT LOW A N D
IDLE SPEEDS 20-3

E N G I N E DOES NOT START OR IS HARD TO START


POSSIBLE CAUSE

1 . Check fuel flow to carburetor N OT REAC H I N G CARBU RETO R --- Fuel tank empty
Clogged fuel line or fuel filter
REAC H I N G CARBURETOR Sticking float valve
Faulty fuel pump
Faulty fuel pump relay
Clogged fuel tank vent hole
Loose or disconnected fuel pump
relay wire

2. Perform spark test WEAK OR NO SPARK ------ GO TO PAG E 1 6-2

WET PLUG ------ Mixture too rich


Carburetor flooded
SPARK Carburetor choke on, or partially

1
closed
Cylinder flooded
Air cleaner dirty

3 . Test cylinder compression LOW COMPRESSION ------+ Improper valve clearance (too small )
Valve stuck open
C O M PRESSION NORMAL Worn cylinder and piston rings

l
Damaged cylinder head gasket
Seized valve
Improper valve timing
I mproper valve and seat contact

4. Sta by fol lowing no,mal pmcedu" E N G I N E STARTS BUT STOPS --- Improper choke operation
Carburetor incorrectly adjusted
E N G I N E DOES NOT FIRE I ntake pipe leaking

l
Improper ignition timing
( Faulty spark u nit or pulse gener
ator)
Fuel contaminated

5 . Sta with choke applied

20- 1
TROUBLESHOOTING

E N G I N E LACKS POWER
POSSIBLE CAUSE

1. Raise wheels off ground and spin WHEELS DO NOT SPIN FREE LY --- Brake dragging
by hand Worn or damaged wheel bearings
Wheel bearing needs lubrication
WHEELS SPIN FREELY Drive chain too tight


Axle nut excessively tight

2. Check tire pressure PRESSURE LOW--------1 Punctured tire


Faulty tire valve
PRESS U R E NORMAL
+
3. Check for clutch slippage CLUTCH SLIPS --------. Faulty clutch l ifter system
Worn clutch disc/plate
C LUTCH ENGAGED PROPERLY Warped clutch disc/plate


Weak clutch spring

4. Accelerate lightly E N G I N E SPEED DOES NOT I N C REASE - Carburetor choke closed


Clogged air cleaner
E N G I N E SPEED I N C REASES Restricted fuel flow
Clogged muffler
Clogged fuel cap vent hole
Faulty fuel pump
Faulty fuel pump relay
Loose , broken or shorted , wire or
connection of pump relay

5. Check ignition timing INCORRECT ----------..... F a u lty i g n it i o n c o ntrol m o d u l e


F a u lty i g n it i o n p u lse g e n e rator
CORRECT
t
6. Check valve clearance INCORRECT ----------..... I mproper valve adjustment
Worn valve seat
CORRECT

7.
+
Test cylinder compression TOO LOW ------ Valve stuck open
Worn cylinder and piston rings
NORMAL Leaking head gasket

j
I mproper valve timing
Seized valve
I mproper valve and seat contact

8. Check carburetor for clogging CLOGGED ------ Carburetor not serviced frequently
enough
N OT CLOGGED
t
9. Check spark plug condition FOU LED OR D I SCOLORED----___, Plugs not serviced frequently
enough
NOT FOULED OR DISCOLORED Wrong heat range
t
1 0 . Check oil level and condition I N C O RRECT-------- Oil level too high
Oil level too low
CORRECT Contaminated oil

1
20-2
TROUBLESH OOTI N G

POSSIBLE CAUSE

1 1 . Remove cylinder head cover and VALVE TRAIN NOT LUBRICATED -- Clogged oil passage
inspect lubrication PROPERLY Clogged oil control orifice
Contaminated oil
VALVE TRAI N LUBRICATED Faulty oil pump
PROPERLY

1 2 . Check for engine overheating OVERHEATING --------___, . Coolant level low
Fan motor not working
NOT OVERH EATI N G (thermostatic switch)
Thermostat stuck closed
Excessive carbon build-up in com-
bustion chamber
Use of poor quality fuel
Clutch slipping
Lean fuel mixture

1 3 . Accelerate o r r u n a t h i g h speed ENGINE KNOCKS _____


___
_.. ,. Worn piston and cylinder
Wrong type of fuel
E N G I N E DOES NOT KNOCK Excessive carbon build-up in com
bustion chamber
Ignition timing too advanced
( Fa u lty i g n ition control m o d u l e )
Lean f u e l mixture

POOR P ERFORMANCE AT LOW AND I DLE SPEEDS


POSSIBLE CAUSE

.
1 Check ignition timing and valve I NCORRECT _________ ___, . I mproper valve clearance
clearance Improper ignition timing
- Faulty i g n it i o n control m o d u l e
CORRECT - F a u lty i g n it i o n p u lse g e n e rator

+
2. Check carburetor pilot screw I N CO RRECT -------___, . See Fuel System, Section 4
adjustment

CORRECT

3 . Check for leaking intake pipe LEAKING ------ Loose carburetor
Damaged insulator
NO LEAKAG E

4.
+
Perform the spark test WEAK OR I NTERM ITTENT SPARK- Faulty, carbon or wet fouled spark
plug
GOOD SPARK GO TO PAG E 1 6-2

20-3
TRO U BLESH OOTI N G

POOR PE RFORMANCE AT H IGH SPEED


POSSIBLE CAUSE

1. Check i g n ition t i m i n g a n d v a l v e I N C O R R E C T -------__, . I m p roper valve clearance


clearance I m p roper i g n it i o n t i m i n g
- F a u lty i g n it i o n c o ntrol m o d u l e
C O R R ECT - F a u lty i g n it i o n p u lse g e n e rator

2 . D i s c o n n ect fuel l i n e at c a r b u retor F U E L FLOW R E ST R I CT E D ____
__,. Clogged fuel l i n e
Clogged fuel c a p vent h o l e
F U E L F LOWS F R E E LY Clogged f u e l v a l v e

1
Fau lty fuel p u m p o r relay
Clogged fuel filter

3 . Remove carbu retors a n d c h e c k for C L O G G E D ------- Clogged jets


clogged jets

NO C L O G G E D J ETS

4 . Check t alve t i m i n g I N C O R R E C T -------- C a m s h aft not i n s t a l l e d properly

C O R RECT

5 . Check valve spring tension W E A K ------- Fau lty v a l v e s p r i n g

POOR HA N DL I N G ---- C h e c k t i r e pressure


POSSIBLE CAUSE

1 . I f steering is heavy ----- Bea r i n g adjustment nut too tight


D a m a g e d ste e r i n g h e a d bearings
Bent stee r i n g stem

2. If either wheel i s w o b b l i n g ---- Excessive w h e e l b e a r i n g p l a y



Bent rim(s)

I m p roperly i n st a l l e d w h e e l h u b ( s )
S w i n g a r m p ivot b e a r i n g s
excessively w o r n

Bent frame or s w i n g a rm
Loose s w i n g a r m p i vot bolt

3. If the motorcycle pulls to o n e side ------- I n co rrect d rive c h a i n adjustment


Front a n d r e a r w h e e l s not a l i g n e d

Bent fork legs

Bent swingarm

B e n t fra m e

20-4
2 1 . I N DEX
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Alternator/Starter Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 1 EVAP Carburetor Air Vent Control Valve I nspectio n
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-9
. (California m o d e l o n ly) . . . . . . . . . . . ..
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1 7
Battery/Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-2 Evaporative Emission Control System . . . . . . . . . . . . . . . . . 3- 1 3
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-4
. Evaporative Emission Purge Control Valve Inspection
Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4- 1 1 (California model only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1 6
Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 5 Flywheel I nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Replacement/Air Bleeding . 1 4-4. . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Brake Light Switch . . . .
. . . .
. . . . . . . . . . . . . . 1 8- 1 1 . . . . . . . . . . . . . . . . . . . . Fork . . . . . . . . . . : . ..
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . 1 2- 1 3
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 7
. Front Wheel/Suspension/Steering . . . . . . . . . . . . . . . . . . . . . . . 1 2- 1
Brake Pad/Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4-5
. Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2-7
Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 - 1 0
. Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 4- 1
Shoe/Pad Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 6 Line . . . . . . . . . . . . . . . . . . . . .....
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 6
. Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8- 1 0
Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-4 Relay . . ... . . . . . . . . . .; . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-9
Cable & Harness Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 0 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .. . . . . . . .. . . . . . . . . . . .
.. 4-3
Camshaft Installation . . . . . . . . . . . . . s- 1 8
. . . . . . . . . . . . . . . . . . . . . . . . . . Gearshift Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 7-8
Removal . . . . . .
. . . . . . . . . . . . . . . . ..
. . . .9- 4
. . . . . . . . . . . . . . . . . . . . General I nformation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 -1
Carburetor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1 0
. Safety . . . . . . . . . ..
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -1
Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 . . . . . . . . . . . . . . . . . . . . . . H andlebar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 2-4
D isassembly . . .
. . . . . . . . .. .
. . . . . . . . . . . 4-6 . . . . . . . . . . . . . . . . . . Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 8-7
Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 1
. Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 8-3
I n stallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1 5
. Aim .
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 8
Removal . ..
. . . . . . . . . . . . . . . . . . . 4-6
. . . . . . . . . . . . . . . . . . . . . . . . . . High Altitude Adjustment ( U . S . A . Only) . . . . . . . . . . . . . . 4- 1 6
Separation/ Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1 3 . Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8- 1 2
Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 0
. Hydraulic Disc Brake . . ; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 1 4- 1
Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-7
. Ignition Control Module Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6-4
Clutch/Gearshift Linkage . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 1 Ignition Pulse Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6-6
Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7-7 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 6-2
I nstallation .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1 2
. Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 . Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-6
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8- 1 1 . Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 6-6
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 8 . Left Crankcase Cover I nstallation . . . . . . . . . . . . . . . . . . . . . . . 8-6
Control Cable Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 1 2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 8-2
Coolant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 5-3 Lights/Meter/Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8- 1
Temperatu re Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-8 . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 2- 1
Coolant/Reserve Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 5-9 Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 2- 1 2
Cooling System . . . . . . .. . .
. . . . . . . . . . 3- 1 2 , 5 - 1
. . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1
Crankcase . ... .
. . . . . . . . . . . . . . . . . . . . . . 1 1 -1 3
. . . . .. . . . . . . . . . . . . . . . . . . . . . . Sched u le ' 8 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 - 1 9
. Schedule ' 8 9 , ' 9 1 -'93 : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 3-8 Sched ule After '93 : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 -4
. . Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 4-8
Crankshaft/Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 - 1 . Model ldentifiction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 -2
Crankshaft/Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 -5 . Neutral Switch . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - . . . . 1 8- 1 1
Cylinder Head/Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 9- 1 N uts, Bolts, Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 3-20
Cylinder/Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0- 1 O i l Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 2- 5
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0-2
. Oil Pressure Check . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 5
Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 2
. Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 8- 1 0
Cylinder Head . . . . . . . . ... .
. . . . . . . . . . . . 9-8
. . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 2-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 1 5
. Pilot Screw Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1 5
Cylinder Head Cover Installation . . . . . . . . . . . . . . . . . . . . . . . 9-2 1 . Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 0-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 0-5
Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 1 6 . Ring I nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 0-5
I nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0-6
. Primary Drive Gear . . . . . . . . ...
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 1
D rive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3
. Radiator Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 1
Electric Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 - 1
. Radiator/Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 5-5
Emission Control I nformation Labels . . . . . . . . . . . . . . . . . . . 1 -22 Rear Wheel/Brake/Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3- 1
Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2 1 Brake .
. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3-7
Engine Removal/Installation . . . . 6 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . - Wheel . . .
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . 1 3-3
Engine I nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Regulator/Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1 5- 8
Engine Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

21 -1
I N D EX

Right Crankcase Cover Installation . 7-1 4 . . . . . . . . . . . . . . . . . . . . Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8


Removal . .. . . . .. .
. . . . . . . . . . . . .
. . . . . 7-3
. . . . . . . . . . . . . . . . . . . . . Guide Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 1 1
Seat/Rear Fender/Sub-frame 1 3- 1 8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat l nspection/Refacing . . . . . . . . . . . . . . . . . . . . . . . . . 9- 1 2
Service I nformation Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Alternator/Starter Clutch . . . . . . . . . . . . . . . . . . . . . . . . 8- 1 .
Wheels/Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 20
Battery/Charging System . . . . . . . . . . . . . . . . . . . . . . . . 1 5-2 . Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 9- 1
Clutch/Gearshift Linkage . .. .. .. .. .. .. .. .. .. .. .. . . 7- 1 .

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 1
Crankshaft/Transmission . . . . . . . . . . . . . . . . . . . . . . . 1 1 - 1 . .

Cylinder Head/Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1


Cylinder/Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0- 1
Electric Starter . . . . . .. . . . . . . . . . . . . . 1 7- 1 . . . . . . . . . . . . . . . . . . .

Engine Removal/Installation . . . . . . . . . . . . . . . . . . . . 6-2 . .

Front Wheel/Suspension/Steering . . . . . 1 2- 2 . . . . . . . . .

Fuel System . .. . . . . . . . . . . . . . . .. . . . 4- 1 . . . . . . . . . . . . . . . . . . . . .

Hydraulic Disc Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4- 2


Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6- 2
.

Lights/Meter/Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8- 1 . .

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 2- 2
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 3- 1
Rear Wheel/Brake/Suspension . . . . . . . . . . . . . . . . . 1 3- 1 .

Service Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1-1
Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . 1 3- 1 1
.

Side Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 9
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6-6
.

Spark Plugs .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .
. 3- 8
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -3
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-4
Starter Clutch . . ... .... .. ..
. . . . . . . . . . .. . . . 8-4
. . . . . . . . . . . . . . . . . . . . .

Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7-3
Relay Switch . .. . ..
. . . . . . . . . . . . . . . . 1 7-6 . . . . . . . . . . . . . . . . . . . .

Steering Head Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 2 1


Stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2- 20
. . . . . . . . . . . . . . . . . . . . .

Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 9
Swingarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3- 1 4
.

System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 5-2
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Thermostatic Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-8
.

Throttle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 3-6
Tools 1 -8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque Values ...........................................


. . . . . . 1 -5
Transmission . . . . . . .........
. . . . .. . ...........
. . . . . . . 1 1 -1 1 . . . . . . . . . . .

Assembly/Installation . . . . .... . ..... 1 1 -1 7 . . . . . . . . . . . . . . . .

Troubleshooting
Battery/Charging System . . . . . . . . . . . . . . . . . . . . . . . . 1 5-3 .

Clutch/Gearshift Linkage . . . . . . . . . . . 7-2 . . . . . . . . . . . . . . .

Cooling System . . .. .. .. .. .. .. .. . . .. . . .. .. .. .. .. . . . . . . 5- 1
Crankshaft/Transmission . . . . . . . . . . . . . . . . . . . . . . . . 1 1 -3 .

Cylinder Head/Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2


Cylinder/Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0- 1
Electric Starter . . . . ... .. . . . 1 7- 1
. . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Wheel/Suspension/Steering . . . . . . . . . . . . 1 2- 3 . .

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 4- 3
Hydraulic Disc Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4-2 . .

Ignition System .. .. . . . . . . .. . . . . . . . . .. . . . . . . . . . . .. . . 1 6-2


..

Lights/Meter/Switches . . . . . . . . . . . . . . . . . . . . . . . . .. . 1 8-2 ..

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.. 2-2
Rear Wheel/Brake/Suspension . . . . .. . . . . . . . . .. 1 3-2 ..

Turn Signal Relay . . . . . . . . .


. . . . . . . . . . . . . . . 1 8- 1 2 . . . . . . . . . . . . . . . . . . . .

2 1 -2 (278)