Honda VT750C2 Manual PDF
Honda VT750C2 Manual PDF
GENERALINFORMATION .
i==========
===FR=A=M=EIB==O=DY=PA=N=E=L=S=/E=X=H=A=U=S=T=S=Y=S=T=EM===_
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Sections 1and 4apply tothe whole motorcycle. Section 3illustrates
procedures for removal/installation of components that may be
requiredtoperform servicedescribedIn thefollowing sections.
Section 5 through 21 describe parts of the motorcycle, grouped
accordingtolocation.
Find the section you want on this page, then turn to the table of
contentsonthefirstpageofthesection.
Most sections start with an assembly orsystem illustration, service
information and trOUbleshooting for the section. The subsequent
pagesgivedetailedprocedure.
If you don't know the source of the trouble, go to section 23
Troubleshooting.
Your safely, and the safely of others, is very important. To help
you make informed decisions we have provided safely
messages and other information throughout this manual. Of
course, it is not practical orpossible to warn you about all the
hazardsassociatedwithservicingthisvehicle.
You mustuseyourowngoodjudgement.
You will find important safely information in a variely of forms
including:
SafelyLabels- onthe vehicle
SafelyMessages- precededby asafelyalertsymbol&and
one of three signal words, DANGER, WARNING, or CAU-
TION.
Thesesignalwordsmean:
You WILL be KILLED or SERIOUSLY
HURTifyou don'tfollowinstructions.
You CAN be KILLED or SERIOUSLY
HURTifyou don'tfollowinstructions.
You CAN be HURT if you don't follow
instructions.
Instructions- howtoservicethisvehIclecorrectlyandsafely.
Asyoureadthismanual,youwillfindinformationthatisprecededbya
[NOm:EJ symbol. The purpose of this message is to help prevent
damagetoyourvehicle,otherproperty. ortheenvironment.
LUBRICATION SYSTEM
ALTERNATOR/STARTERCLUTCH
CRANKSHAFTrrRANSMISSION
COOLINGSYSTEM
CYLINDERJPISTON'
ENGINEREMOVAL/INSTALLATION
CYLINDERHEADNALVE
REARWHEELlBAAKElSUSPENSION
IGNITIONSYSTEM
WIRING DIAGRAMS
BATTERY/CHARGINGSYSTEM
FRONTWHEEL/SUSPENSIONISTEERING
CLUTCH/GEARSHIFTLINKAGE
FUELSYSTEM
FINALDRIVE
HYDRAULICBRAKE
ELECTRICSTARTER
LIGHTSIMETERSISWITCHES
z
:it
0:
...
W
>
C
C
z
<t
w
z
a
z
w
....I
<t
o
t;
W
TROUBLESHOOTING
INDEX
-
DateofIssue: September.2006
.. .. -
---_.---_.
SYMBOLS
" The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to
these symbols, it would be explained specifically in the text without the use of the symbols.
..
IIiiiil'
Replace the part (s) with new one (s) before assembly.
Use recommended engine oil, unless otherwise specified.
Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio of 1 : 1).
""""1
-,
....wM
Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent).
Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or
equivalent).
Example: Molykote BR-2 plus manufactured by Dow Corning U.S.A.
Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan
Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or
equivalent).
Example: Molykote G-n Paste manufactured by Dow Corning U.S.A.
Honda Moly 60 (US.A. only)
Rocol ASP manufactured by Rocol Limited, UK.
Rocol Paste manufactured by Sumico Lubricant, Japan
Use silicone grease.
Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
,..
~
~
ew
~
Apply sealant.
Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified.
Use Fork or Suspension Fluid.
I
..
1. GENERALINFORMATION
B
SERVICERULES.. 1-2
MODELIDENTIFICATION.. .... ..1-2
GENERALSPECIFICATIONS.......... 1-5
LUBRICATIONSYSTEM
SPECIFICATIONS...... ..........1-7
FUELSYSTEMSPECIFICATIONS.. 1-7
COOLINGSYSTEMSPECIFICATIONS1-7
CYLINDERHEAD/VALVE
SPECIFICATIONS.. .. :.......1-8
CYLINDER/PISTONSPECIFICATIONS1-8
CLUTCH/GEARSHIFTLINKAGE
SPECIFICATIONS 1-9
ALTERNATOR/STARTERCLUTCH
SPECIFICATIONS 1-9
CRANKSHAFT/TRANSMISSION
SPECiFiCATIONS 1-10
FINALDRIVESPECIFICATIONS....1-10
FRONTWHEEL/SUSPENSION/STEERING
SPECIFICATIONS.. ....1-11
REARWHEEUBRAKE/SUSPENSION
SPECIFICATIONS 1-11
HYDRAULICBRAKESPECIFICATIONS1-11
BATTERY/CHARGINGSYSTEM
SPECIFICATIONS.. .. .. ..........1-12
IGNITIONSYSTEMSPECIFICATIONS1-12
ELECTRICSTARTER
SPECIFICATIONS 1-12
LIGHTS/METERS/SWITCHES
SPECIFICATIONS 1-12
STANDARDTORQUEVALUES.. .. 1-13
ENGINE& FRAMETORQUEVALUES .. 113
LUBRICATION&SEALPOINTS.. 1-19
CABLE&HARNESSROUTING122
EMISSIONCONTROLSYSTEMS 139
1-1
------ . - --------- --------
GENERALINFORMATION
SERVICERULES
1. Use genuine Honda orHonda-recommended parts and lubricants ortheirequivalents. Partsthat don'tmeet Honda's
designspecificationsmaycausedamagetothemotorcycle.
2. Usethespecialtoolsdesignedforthisproducttoavoiddamageandincorrectassembly.
3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with
Englishfasteners.
4. Install newgaskets,a-rings,cotterpins,and lockplateswhen reassembling.
5. When tightening bolts ornuts, begin with the largerdiameterorinnerboltfirst. Then tighten tothe specified torque
diagonallyin incrementalstepsunlessaparticularsequenceisspecified.
6. Clean partsincleaningsolventupondisassembly.Lubricateanyslidingsurfacesbefore reassembly.
7. Afterreassembly,checkall partsforproperinstallationandoperation.
8. Routeallelectricalwiresas shownintheCableand HarnessRouting (page1-22).
ABBREVIAl"ION
Throughoutthismanual,thefollowingabbreviationsareusedtoidentifytherespective partsorsystems.
Abbrev.tenn Fulltenn
SE valve StartingEnrichmentvalve
TPsensor ThrottlePositionsensor
EOP switch EngineOil Pressureswitch
VS sensor VehicleSpeedsensor
ICM IgnitionControlModule
CAVcontrolvalve CarburetorAirVentcontrolvalve
PAIR PulsedSecondaryAirInjection
EVAP EvaporativeEmission
ECTsensor EngineCoolantTemperaturesensor
MODELIDENTIFICATION
1-2
GENERALINFORMATION
SERIALNUMBERS
The Vehicle Identification Number (VIN) is stamped on the right side of
the steering head.
The engine serial number is stamped on the right side of the
crankcase.
The carburetor identification number is stamped on the throttle
position sensor side ofthe c'arburetor body.
.........
CARBURETOR IDENTIFICATION NUMBER
.
LABELS
The Safety Certification Label is located on the right side of the frame
down tube.
1-3
GENERALINFORMATION
The color label is attachedtotheframe, behind ofthe leftside cover..
When orderingcolor-coded parts,alwaysspecifYthedesignatedcolor
code.
The Emission Control Information Label ('07 model) is located on the r-EM-IS-S-I-O-N-C-O-N-T-R-O-L---------..
rearfenderandframecrosspipeas shown.
INFORMATIONLABEL
(Canadatype)
EMISSIONCONTROL
INFORMATIONLABEL
(ExceptCanadatype)
TheEmissionControl InformationLabel (After'07)islocatedontheleft
sideoftheframedowntube.
z
, EMISSION CONTROL
"INFORMATIONLABEL
. (Canadatype)
,
. Revised:May2007.2007-2006Vf750C2
1.-4
GENERALINFORMATION
GENERALSPECIFICATIONS
ITEM SPECIFICATIONS
DIMENSION Overall length
Overall width
Overall height
Wheelbase
Seat height
Footpeg height
Ground clearance
Curb weight (49 states/Canada type)
(California type)
Maximum weight capacity
(49 states/California type)
(Canada type)
2,430 mm (95.7 in)
835 mm (32.9 in)
1,130 mm (44.5 in)
1,655 mm (65.2 in)
655 mm (25.8 in)
283 mm (11.1 in)
130 mm (5.1 in)
243 kg (536 Ibs)
246 kg (542 Ibs)
180 kg (397 Ibs)
184 kg (406 Ibs)
FRAME Frame type
Front suspension
Front axle travel
Rear suspension
Rear axle travel
Front tire size
Rear tire size
Tire brand Front
Rear
Front brake
Rear brake
Caster angle
Trail length
Fuel tank capacity
Double cradle
Telescopic fork
115 mm (4.5 in)
Swingarm
90 mm (3.5 in)
90/90-21 M/C 54S
160/80-15M/C 74S
EXEDRA G701 (BRIDGESTONE)
D404F (DUNLOP)
EXEDRA G702 (BRIDGESTONE)
D404 (DUNLOP)
Hydraulic single disc
Internal expanding shoe
3430'
158 mm (6.2 in)
14 liters (3.7 US gal, 3.1 Imp gal)
ENGINE Cylinder arrangement
Bore and stroke
Displacement
Compression ratio
Valve train
Intake valve opens
closes
Exhaust valve opens
closes
Lubrication system
Oil pump type
Cooling system
Air filtration
Engine dry weight
Firing order
Cylinder number
2 cylinders 52V transverse
79 x 76 mm (3.1 x 3.0 in)
745 cm
3
(45.4 cu-in)
9.6: 1
Silent cam chain driven, OHC
Front: 0BTDC (at 1 mm lift)
Rear: 5ATDC (at 1 mm lift)
25ABDC (at 1 mm lift)
35BBDC (at 1 mm lift)
Front: 0ATDC (at 1 mm lift)
Rear: 5BTDC (at 1 mm lift)
Forced pressure and wet sump
Trochoid
Liquid cooled
Viscous paper element
72.3 kg (159.4Ibs)
Front - 308- Rear - 412- Front
Front: #2/Rear: #1
CARBURETOR Type
Throttle bore
Constant velocity (CV)
34 mm (1.3 in)
'-5
--- ---- -----------
I
GENERALINFORMATION
ITEM SPECIFICATIONS
DRIVE TRAII;II Clutch system
Clutch operation system
Transmission
Primary reduction
Secondary reduction
Third reduction (Output drive reduction)
Final reduction
Gear ratio 1st
2nd
3rd
4th
5th
Gearshift pattern
Multi-plate, wet
Cable operating
Constant mesh, 5-speeds
1.763 (67/38)
0.891 (33/37)
1.058 (18117)
3.091 (34111)
2.400 (36/15)
1.550 (31/20)
1.174 (27/23)
0.960 (24/25)
0.852 (23/27)
Left foot operated return system,
1-N-2-3-4-5
ELECTRICAL Ignition system
Starting system
Charging system
Regu'lator/rectifier
Lighting system
Full transistorized ignition
Electric starter motor
Triple phase output alternator
SCR shortedltriple phase full-wave
rectification
Battery
1-6.
GENERALINFORMATION
LUBRICATIONSYSTEMSPECIFICATIONS
Unit mm (in)
ITEM STANDARD SERVICELIMIT
Engine oil capacity At draining 2.5 liters (2.6 US qt, 2.2 Imp qt) -
At oil filter change 2.6 liters (2.7 US qt, 2.3 Imp qt) -
At disassembly 3.2 liters (3.4 US qt, 2.8 Imp qt) -
Recommended engine oil Pro Honda GN44-stroke oil (U.S.A. and
Canada) or equivalent motor oil
API service classification: SG or higher -
JASO T 903 standard: MA
Viscosity: SAE 10W-30
Oil pressure at EOP switch 530 kPa (5.4 kgf/cm
2
, 77 psi)
-
at 5,000 rpm/(80C/176F)
Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008)
Body clearance 0.15 - 0.21 (0.006 - 0.008) 0.35 (0.014)
Side clearance 0.02 - 0.08 (0.001 - 0.003) 0.10 (0.004)
FUELSYSTEMSPECIFICATIONS
ITEM SPECIFICATIONS
Carburetor
identification number
49 states/Canada type VE5EA
California type VE5ES
Main jet Standard #122
High altitude #120
Slow jet #50
Pilot screw Initial/final opening See page 6-25
High altitude adjustment See page 6-26
Float level 18.5 mm (0.73 in)
Engine idle speed 1,200 100 rpm
Throttle grip freeplay 2 - 6 mm (1/16 -1/4 in)
COOLINGSYSTEMSPECIFICATIONS
ITEM SPECIFICATIONS
Coolant capacity Radiator and engine 1.58 liters (1.67 US qt, 1.39 Imp qt)
Reserve tank 0.38 liter (0.40 US qt, 0.33 Imp qt)
Radiator cap relief pressure 108 - 137 kPa (1.1 -1.4 kgf/cm
2
, 16 - 20 psi)
Thermostat Begin to open 80 - 84C (176 -183F)
Fully open 95C (203F)
Valve lift 8 mm (0.3 in) minimum at 95C (203F)
Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality
ethylene glycol antifreeze containing silicate-free corrosion
inhibitors
Standard coolant concentration 1 : 1 (mixture with distilled water)
1-7
1-8
GENERALINFORMATION
CYLINDERHEAD/VALVESPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cylinder compression at 400 rpm 1,373 98 kPa (14.0 1.0 kgf/cm<,
199 14 psi)
-
Valve clearance IN 0.15 0.02 (0.006 0.001) -
EX 0.20 0.02 (0.008 0.001) -
Cam chain tensioner wedge B length - 6 (0.2)
Camshaft Cam lobe height IN 37.188 - 37.348 (1.4641 - 1.4704) 37.16 (1.463)
EX 37.605 - 37.765 (1.4805 - 1.4868) 37.58 (1.480)
Runout IN/EX - 0.05 (0.002)
Journal 0.0. IN/EX 21.959 - 21.980 (0.8645 - 0.8654) 21.90 (0.862)
Oil clearance IN/EX 0.020 - 0.141 (0.0008 - 0.0056) 0.16 (0.006)
Rocker arm, Rocker arm shaft 0.0. IN/EX 11.966 - 11.984 (0.4711 - 0.4718) 11.83 (0.466)
rocker arm Rocker arm 1.0. IN/EX 12.000 - 12.018 (0.4724 - 0.4731) 12.05 (0.474)
shaft
Rocker arm-to-shaft clearance 0.016 - 0.052 (0.0006 - 0.0020) 0.07 (0.003)
Valve, valve Valve stem 0.0. IN 5.475 - 5.490 (0.2156 - 0.2161) 5.45 (0.215)
guide EX 5.455 - 5.470 (0.2148 - 0.2154) 5.41 (0.213)
Valve gUide 1.0. IN 5.500 - 5.510 (0.2165 - 0.2169) 5.56 (0.219)
EX 5.500 - 5.512 (0.2165 - 0.2170) 5.56 (0.219)
Stem-to-guide IN 0.010 - 0.035 (0.0004 - 0.0014) 0.10 (0.004)
clearance
EX 0.030 - 0.057 (0.0012 - 0.0022) 0.11 (0.004)
Valve guide projection IN 18.7 - 18.9 (0.736 - 0.744) -
above cylinder head EX 17.2 - 17.4 (0.68 - 0.69) -
Valve seat width IN/EX 0.90 - 1.10 (0.035 - 0.043) 1.5 (0.06)
Valve spring Free length IN 42.14(1.659) 40.58 (1.598)
EX 46.11 (1.815) 44.72 (1.761)
Cylinder head warpage - 0.10 (0.004)
CYLINDER/PISTONSPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Cylinder /.D. 79.000 - 79.015 (3.1102 - 3.1108) 79.10 (3.114)
Out-of-round - 0.06 (0.002)
Taper - 0.06 (0.002)
Warpage - 0.10 (0.004)
Piston, piston
pin, piston
Piston O.D. at 17 mm (0.7 in) from
the bottom
78.97 - 78.99 (3.109 - 3.110) 78.90 (3.106)
rings Piston pin bore 1.0. 18.002 - 18.008 (0.7087 - 0.7090) 18.05 (0.711)
Piston pin 0.0. 17.994 - 18.000 (0.7084 - 0.7087) 17.98 (0.708)
Piston-to-piston pin clearance 0.002 - 0.014 (0.0001 - 0.0006) 0.04 (0.002)
Piston ring end
gap
Top 0.15 - 0.25 (0.006 - 0.010) 0.4 (0.02)
Second 0.25 - 0.40 (0.010 - 0.016) 0.6 (0.02)
Oil (side rail) 0.20 - 0.80 (0.008 - 0.031) 1.0 (0.04)
Piston ring-to-
ring groove
clearance
Top 0.025 - 0.055 (0.0010 - 0.0022) 0.08 (0.003)
Second 0.015 - 0.045 (0.0006 - 0.0018) 0.07 (0.003)
Cylinder-to-piston clearance 0.010 - 0.045 (0.0004 - 0.0018) 0.10 (0.004)
Connecting rod small end I.D. 18.016 - 18.034 (0.7093 - 0.7100) 18.07 (0.711)
Connecting rod-to-piston pin clearance 0.016 - 0.040 (0.0006 - 0.0016) 0.06 (0.002)
Revised: September 2008. 2007-2009 VT750C2
---------- ---- ---------
GENERAL INfORMATION
CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Clutch lever freeplay 10 - 20 (3/8 -13/16) -
Clutch Spring free length 45.3 (1.78) 43.9 (1.73)
Disc thickness
I
Disc A 2.62 - 2.78 (0.103 - 0.109) 2.3 (0.09)
I
End disc 2.92 - 3.08 (0.115 - 0.121) 2.6 (0.10)
Plate warpage - 0.30 (0.012)
Clutch outer guide
I
I.D. 21.991 - 22.016 (0.8658 - 0.8668) 22.03 (0.867)
I
0.0. 31.959 - 31.975 (1.2582 -1.2589) 31.92 (1.257)
Mainshaft O.D. at clutch outer guide 21.967 - 21.980 (0.8648 - 0.8654) 21.95 (0.864)
Clutch outer guide-to-mainshaft clearance 0.011 - 0.049 (0.0004 - 0.0019) 0.08 (0.003)
Clutch outer I.D. 32.000 - 32.025 (1.2598 - 1.2608) 32.09 (1.263)
Clutch outer-to-outer guide clearance 0.025 - 0.066 (0.0010 - 0.0026) 0.18 (0.007)
Oil pump drive sprocket I.D. 32.025 - 32.145 (1.2608 1.2655) 32.16 (1.266)
Oil pump drive sprocket-to-c1utch outer guide
clearance
0.050 - 0.186 (0.0020 - 0.0073) 0.23 (0.009)
ALTERNATOR/STARTER CLUTCH SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
Starter driven gear
I
I
1.0.
0.0.
37.000 - 37.025 (1.4567 -1.4577)
57.749 - 57.768 (2.2736 - 2.2743)
37.10 (1.461)
57.73 (2.273)
Starter clutch outer I.D. 74.414 -74.440 (2.9297 - 2.9307) 74.46 (2.931)
1-9
GENERALINFORMATION
CRANKSHAFTITRANSMISSIONSPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICELIMIT
Crankshaft Connecting rod big end side clearance 0.05 - 0.20 (0.002 - 0.008) 0.30 (0.012)
Crankpin bearing oil clearance 0.028 - 0.052 (0.0011 - 0.0020) 0.07 (0.003)
Main journal oil clearance 0.020 - 0.038 (0.0008 - 0.0015) 0.07 (0.003)
Crankshaft runout - 0.03 (0.001)
Main journal 0.0. 52.982 - 53.000 (2.0859 - 2.0866) 52.976 (2.0857)
I
Main journal 1.0. 58.010 - 58.022 (2.2839 - 2.2843) 58.070 (2.2862)
Shift fork, fork 1.0. 13.000 -13.018 (0.5118 - 0.5125) 13.03 (0.513)
shaft
Claw thickness 5.93 - 6.00 (0.233 - 0.236) 5.6 (0.22)
Fork shaft 0.0. 12.966 -12.984 (0.5105 - 0.5112) 12.90 (0.508)
Shift drum 0.0. at left end 11.966 -11.984 (0.4711 - 0.4718) 11.94 (0.470)
Shift drum journal 1.0. 12.000 - 12.018 (0.4724 - 0.4731) 12.05 (0.474)
Shift drum-to-shift drum journal clearance 0.016 - 0.052 (0.0006 - 0.0020) 0.09 (0.035)
Transmission Gear 1.0. M3,M5 28.000 - 28.021 (1.1024 - 1.1032) 28.04 (1.104)
C1,C4 31.000 - 31.025 (1.2205 - 1.2215) 31.05 (1.222)
C2 24.000 - 24.021 (0.9449 - 0.9457) 24.04 (0.946)
Gear busing 0.0. M3,M5 27.959 - 27.980 (1.1007 -1.1016) 27.94 (1.100)
C1, C4 30.950 - 30.975 (1.2185 -1.2195) 30.93 (1.218)
C2 23.959 - 23.980 (0.9433 - 0.9441 ) 23.94 (0.943)
Gear-to-bushing M3, M5, C2 0.020 - 0.062 (0.0008 - 0.0024) 0.10 (0.004)
clearance C1, C4 0.025 - 0.075 (0.0010 - 0.0030) 0.11 (0.004)
Gear bushing 1.0. M3 25.000 - 25.021 (0.9843 - 0.9851) 25.04 (0.986)
I C2 20.000 - 20.021 (0.7874 - 0.7882) 20.04 (0.789)
Mainshaft 0.0. at M3 bushing 24.959 - 24.980 (0.9826 - 0.9835) 24.94 (0.982)
CountershaftO.D. at C2 bushing 19.980 -19.993 (0.7866 - 0.7871) 19.96 (0.786)
Bushing-to-shaft M3 0.020 - 0.062 (0.0008 - 0.0024) 0.10 (0.004)
clearance C2 0.007 - 0.041 (0.0003 - 0.0016) 0.07 (0.003)
Output drive Output gear 1.0. 24.000 - 24.021 (0.9449 - 0.9457) 24.04 (0.946)
train Output gear 0.0. 23.959 - 23.980 (0.9433 - 0.9441) 23.70 (0.933)
bushing
1.0. 20.020 - 20.041 (0.7882 - 0.7890) 20.06 (0.790)
Output drive gear shaft 0.0. 19.979 - 20.000 (0.7866 - 0.7874) 19.97 (0.786)
Gear-to-bushing clearance 0.020 - 0.062 (0.0008 - 0.0024) 0.082 (0.0032)
Gear bushing-to-shaft clearance 0.020 - 0.042 (0.0008 - 0.0017) 0.08 (0.003)
Output gear damper spring free length 62.3 (2.45) 59 (2.3)
Output drive gear backlash 0.08 - 0.23 (0.003 - 0.009) 0.40 (0.016)
Backlash difference between
measurements
- 0.10 (0.004)
FINALDRIVESPECIFICATIONS
Unit mm (in)
ITEM STANDARD SERVICELIMIT
Recommended final drive oil Hypoid gear oil, SAE #80 -
. Final drive oil capacity
I
At draining 160 ~ (5.4 US OZ, 5.6 Imp oz) -
I
At disassembly 170 cm
3
(5.7 US OZ, 6.0 Imp oz) -
Final drive gear backlash 0.05 - 0.15 (0.002 - 0.006) 0.30 (0.012)
Backlash difference between measurements - 0.10 (0.004)
Ring gear-to-stop pin clearance 0.30 - 0.60 (0.012 - 0.024) -
Final drive gear assembly pre-load 0.2 - 0.4 Nm (2 - 4 kgf'cm,
-
0.1 - 0.3 Ibfft)
1-10
GENERALINFORMATION
FRONTWHEEL/SUSPENSION/STEERINGSPECIFICATIONS
Unit mm (in)
ITEM STANDARD SERVICELIMIT
Minimum tire tread depth - 1.5 (0.06)
Cold tire
pressure
Up to 90 kg (200 Ibs) load 200 kPa (2.00 kgf/cm
2
, 29 psi) -
Up to maximum weight capacity 200 kPa (2.00 kgf/cm
2
, 29 psi) -
Axle runout - 0.2 (0.01)
Wheel rim Radial - 2.0 (0.08)
runout Axial - 2.0 (0.08)
Wheel balance weight - 60 g max.
Fork Spring free length 371.8 (14.64) 364.4 (14.35)
Tube runout - 0.2 (0.01)
Recommended fork fluid Pro Honda Suspension Fluid SS-8
(10W)
-
Fluid level 100 (3.9) -
Fluid capacity 478 2.5 cm
3
(16.2 0.08 US OZ,
16.8 0.09 Imp oz)
-
Steering head bearing pre-load 8.5 -12.7 N (0.9 - 1.3 kgf) -
REAR WHEEL/BRAKE/SUSPENSIONSPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICELIMIT
Minimum tire tread depth -
200 kPa (2.00 kgf/cm
2
, 29 psi)
2.0 (0.08)
Cold tire
I
Up to 90 kg (200 Ibs) load
pressure
I
Up to maximum weight capacity
Axle runout
Wheel rim
I
Radial
runout
I Axial
-
250 kPa (2.50 kgf/cm
2
, 36 psi) -
-
-
-
-
180.0 -180.3 (7.09 -7.10)
0.2 (0.01)
2.0 (0.08)
2.0 (0.08)
Wheel balance weight 70 g max.
Brake drum 1.0.
Brake pedal height
.
Brake pedal freeplay
181 (7.1)
75 mm (3.0 in) above the top of the
footpeg
20 - 30 (13/16 -1-3/16)
-
-
Shock absorber spring pre-load adjuster setting 2nd position -
HYDRAULICBRAKE SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICELIMIT
Recommended brake fluid 00T4 -
Front Brake disc thickness 5.8 - 6.2 (0.23 - 0.24) 5.0 (0.20)
Brake disc warpage - 0.30 (0.012)
Master cylinder 1.0. 11.000 - 11.043 (0.4331 - 0.4348) 11.05 (0.435)
Master piston 0.0. 10.957 - 10.984 (0.4314 - 0.4324) 10.945 (0.4309)
Caliper cylinder 1.0. 27.000 - 27.050 (1.0630 - 1.0650) 27.060 (1.0654)
Caliper piston 0.0. 26.935 - 26.968 (1.0604 -1.0617) 26.930 (1.0602)
1-11
- -- --
------------ -------
GENERALINFORMATION
BATTERY/CHARGINGSYSTEMSPECIFICATIONS
ITEM SPECIFICATIONS
Battery Capacity 12 V - 10 Ah or 12 V -11 Ah
Current leakage 1 mA max.
Voltage (20C/
68F)
Fully
charged
13.0 -13.2 V
Needs
charging
Below 12.4 V
Charging current Normal 1.1 Al5-10 h
Qui(::k 5.5 AltO h
Alternator Capacity 0.35 kW/5,000 rpm
Charging coil resistance (20C/68F) 0.1 -1.0 n
IGNITIONSYSTEMSPECIFICATIONS
ITEM SPECIFICATIONS
Spark plug
I
Standard
I
For extended high speed riding
Spark plug gap
Ignition coil primary peak voltage
DPR6EA-9 (NGK), X20EPR-U9 (DENSO)
DPR7EA-9 (NGK), X22EPR-U9 (DENSO)
0.8 - 0.9 mm (0.03 - 0.04 in)
100 V minimum
Ignition pulse generator peak voltage 0.7 V minimum
Ignition timing ("F"mark) 13BTDC at idle
TP sensor
I
Resistance (20C/68F)
I
Input voltage
4-6 kn
5V
ELECTRICSTARTERSPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICEUMIT
Starter motor brush length 12.5 (0.49) 6.5 (0.26)
LIGHTS/METERS/SWITCHESSPECIFICATIONS
ITEM SPECIFICATIONS
Bulbs Headlight 12 V -60/55 W
Brake/taillight 12 V - 21/5 W
License light 12V -5W
Front turn signal/position light 12 V - 21/5 W x 2
Rear turn signal light 12V-21Wx2
Instrument light LEDx6
Turn signal indicator LED
High beam indicator LED
Neutral indicator LED
Oil pressure indicator LED
Coolant temperature indicator LED
Fuse Main fuse 30A
Sub fuse 10 A x 5, 20 A x 1
ECT sensor
switch
Start to close (ON) 112 -118C (234 - 244F)
Stop to open (OFF) 108C (226F) minimum
Fan motor
switch
Start to close (ON) 103 -107C (217 - 225F)
Stop to open (OFF) 94 - 98C (201 - 208F)
1-12
GENERALINFORMATION
STANDARDTORQUEVALUES
FASTENER TYPE
TORQUE
Nm (kgfm, Ibfft)
FASTENER TYPE
TORQUE
Nm Ikgfm, Ibfft)
5 mm bolt and nut
6 mm bolt and nut
8 mm bolt and nut
10 mm bolt and nut
12 mm bolt and nut
5.2 (0.5, 3.8)
10 (1.0, 7)
22 (2.2,16)
34 (3.5, 25)
55 (5.6, 41)
5 mm screw
6 mm screw
6 mm flange bolt (8 mm head, small
flange)
6 mm flange bolt (8 mm head, large
flange)
6 mm flange bolt (10 mm head) and
nut
8 mm flange bolt and nut
10 mm flange bolt and nut
4.2 (0.4, 3.1)
9 (0.9, 6.6)
9 (0.9, 6.6)
12 (1.2, 9)
12 (1.2, 9)
27 (2.8, 20)
39(4.0,29)
ENGINE& FRAMETORQUEVALUES
Torque specifications listed below are for important fasteners.
Others should be tightened to standard torque values listed above.
ENGINE
FRAME/BODY PANELS/EXHAUST SYSTEM
ITEM Q'TY
THREAD
DlA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Left crankcase rear cover socket bolt
Exhaust pipe joint stud bolt
1
4
6
8
10 (1.0, 7)
- See page 3-11
MAINTENANCE
ITEM Q'TV
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Spark plug
Timing hole cap
Crankshaft hole cap
.
Valve adjusting screw lock nut
Engine oil filter cartridge
Oil filter boss (crankcase side)
Engine oil drain bolt
Alternator cover socket bolt
4
1
1
6
1
1
1
3
12
14
30
7
20
20
14
6
18 (1.8, 13)
10 (1.0, 7)
15 (1.5, 11)
23 (2.3, 17)
26 (2.7, 19)
18 (1.8, 13)
29 (3.0, 21)
10 (1.0, 7)
Apply grease to the threads
Apply grease to the threads
Apply engine oil to the
threads and seating surface
Apply engine oil to the
threads
Apply locking agent to the
threads
LUBRICATION SYSTEM
ITEM Q'TY
THREAD
DlA. (mm)
TORQUE
N'm (kgfm, Ibfft)
REMARKS
EQP switch
EOP switch terminal screw
Oil pump assembly bolt
1
1
3
PT118
4
6
1211.2,9)
1.9 (0.2, 1.4)
13(1.3, 10)
Apply sealant to the threads
P-,
i
1-13 I
GENERALINFORMATION
FUEL SYSTEM
ITEM Q'TY
THREAD
DIA. (mm)
TORQUE
Nm (kgf'm, Ibfft)
REMARKS
PAIR check valve cover bolt 4 5 7 (0.7, 5.2)
Vacuum chamber cover screw 4 4 2.1 (0.2, 1.5)
TP sensor torx screw 1 5 3.4 (0.3, 2.5)
Carburetor heater set plate screw 2 5 3.4 (0.3, 2.5)
Float chamber screw 4 4 2.1 (0.2, 1.5)
Accelerator pump cover screw 3 4 2.1 (0.2, 1.5)
Air cut-off valve cover screw 2 4 2.1 (0.2, 1.5)
Accelerator pump link mounting bolt 1 5 3.4 (0.3, 2.5)
Throttle cable stay mounting screw 2 5 3.4 (0.3, 2.5)
SE valve nut 1 12 2.3 (0.2, 1.7)
Carburetor drain screw 1 6 1.5 (0.2, 1.1)
Slow jet 1 6 1.8 (0.2, 1.3)
Needle jet holder 1 7 2.3 (0.2, 1.7)
Main jet 1 5 2.1 (0.2, 1.5)
COOLING SYSTEM
ITEM Q'TY
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Water pump cover bolt 5 6 13 (1.3, 10)
CYLINDER HEAD/VALVE
ITEM Q'TY
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Cylinder head cover bolt
Cylinder head bolt
Cylinder head nut
Cam sprocket bolt
Cam chain tensioner bolt
Camshaft holder bolt
Camshaft holder nut
Over head cover socket bolt
4
4
8
4
4
6
4
8
6
8
10
7
6
8
8
6
10 (to, 7)
23 (2.3, 17)
47 (4.8,35)
23 (2.3, 17)
10 (to, 7)
23 (2.3,17)
23 (2.3, 17)
10 (to, 7)
Apply engine oil to the
threads and seating surface
Apply engine oil to the
threads and seating surface
Apply locking agent to the
threads
See page 9-25
CYLINDER/PISTON
ITEM Q'TY
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Cylinder stud bolt
Cylinder stud bolt
Cylinder stud bolt
2
6
2
8
10
12
-
-
-
See page 10-8
See page 10-8
See page 10-8
CLUTCH/GEARSHIFT LINKAGE
ITEM Q'TY
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Clutch lifter plate bolt 4 6 12 (1.2,9)
Clutch center lock nut 1 18 128 (13.1,94) Lock nut; replace with a new
one and stake
Apply engine oil to the
threads and seating surface
Oil pump driven sprocket bolt 1 6 15 (1.5, 11) Apply locking agent to the
threads
Clutch cover socket bolt 5 6 10 (1.0, 7)
Primary drive gear bolt 1 12 88 (9.0,65) Apply engine oil to the
threads and seating surface
Gearshift spindle return spring pin
Gearshift spindle oil seal stopper
1 8 23 (2.3, 17)
plate bolt 1 6 13 (1.3, 10)
1-14
GENERALINFORMATION
ALTERNATOR/STARTER CLUTCH
ITEM Q'TY
THREAD
DIA. (mm)
TORQUE
N'm (kgfm, Ibfft)
REMARKS
Flywheel bolt
Stator socket bolt
Starter one-way clutch outer socket
bolt
Stator wire holder socket bolt
1
3
6
1
12
6
8
6
128 (13.1, 94)
12(1.2,9)
30 (3.1, 22)
12 (1.2, 9)
Left hand threads
Apply engine oil to the
threads and seating surface
Apply locking agent to the
threads
Apply locking agent to the
threads
Apply locking agent to the
threads
CRANKSHAFT/TRANSMISSION
ITEM Q'TY
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Crankcase bolt 15 8 23 (2.3, 17)
Gearshift cam plate bolt 1 6 12 (1.2, 9) Apply locking agent to the
threads
Crankpin bearing cap nut 4 8 33 (3.4, 24) Apply engine oil to the
threads and seating surface
Output gear case mounting bolt
Output drive gear assembly
3 8 31 (3.2,23) Apply sealant to the threads
mounting bolt
Output driven gear assembly
2 8 31 (3.2,23) Apply engine oil to the
threads and seating surface
mounting socket bolt
Output drive gear bearing lock nut
4 8 3; (3.2,23) Apply engine oil to the
threads and seating surface
(inner) 1 30 73 (7.4, 54) Lock nut; replace with a new
one and stake
Apply engine oil to the
.
(outer)
Output driven gear bearing lock nut
1 64 98 (10.0, 72)
threads and seating surface
Lock nut; replace with a new
one and stake
Apply engine oil to the
threads and seating surface
(inner) 1 30 73 (7.4, 54) Lock nut; replace with a new
one and stake
Apply engine oil to the
threads and seating surface
(outer) 1 64 98 (10.0, 72) Lock nut; replace with a new.
one and stake
Apply engine oil to the
threads and seating surface
Output drive gear shaft bolt 1 10 49 (5.0, 36)
ELECTRIC STARTER
ITEM Q'TY
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Starter motor cable terminal nut
Starter motor assembly bolt
. Negative brush screw
1
2
1
6
5
5
10 (to, 7)
4.9 (0.5, 3.6)
3.7 (0.4, 2.7)
LIGHTS/METERS/SWITCHES
ITEM Q'TY
THREAD
DIA. (mm)
TORQUE
Nm lkgfm, Ibfft)
REMARKS
Neutral switch
VS sensor mounting bolt
1
1
10
6
12 (1.2, 9)
9.8 (1.0,7.2)
1-15
GENERAL INFORMATION
FRAME
FRAME/BODY PANELS/EXHAUST SYSTEM
ITEM Q'TV
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Seat mounting socket bolt
Grab rail mounting bolt
Fuel tank mounting bolt
Fuel valve nut
Fuel valve lever screw
Exhaust pipe joint nut
Muffler stay mounting bolt
Muffler mounting nut
Muffler bracket bolt
2
6
1
1
1
4
4
2
2
8
10
8
22
5
8
8
10
8
26 (2.7, 19)
64 (6.5,47)
27 (2.8,20)
34 (3.5, 25)
0.6 (0.1, 0.4)
25 (2.5, 18)
27 (2.8,20)
44 (4.5, 32)
34 (3.5,25)
ALOC screw; replace with a
new one
MAINTENANCE
ITEM Q'TV
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Air cleaner cover socket bolt
Final drive oil filler cap
Final drive oil drain bolt
5
1
1
5
30
8
1.5 (0.2, 1.1)
12 (1.2,9)
12 (1.2,9)
FUEL SYSTEM
ITEM Q'TV
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Air cleaner chamber stay mounting
screw
Air cleaner chamber connecting tube
band screw
1
1
5
4
1.1 (0.1, 0.8)
0.7 (0.1,0.5)
COOLING SYSTEM
ITEM Q'TV
THREAD
DIA. (mm)
TORQUE
Nm (kgf'm, Ibfft)
REMARKS
Fan motor mounting bolt
>
Cooling fan mounting nut
Radiator filler mounting bolt
Thermostat housing cover bolt
Water hose band screw
Fan motor assembly mounting bolt
3
1
2
2
6
3
5
5
6
6
-
6
5.1 (0.5,3.8)
2.7 (0.3,2.0)
10 (1.0,7)
10 (1.0,7)
-
8.4 (0.9, 6.2)
Apply locking agent to the
threads
See page 7-10
ENGINE REMOVAl/INSTALLATION
ITEM Q'TV
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Engine mounting nut
Engine hanger plate bolt
Main footpeg bracket mounting bolt
Main footpeg bracket mounting nut
Gearshift arm pinch bolt
4
8
3
1
1
10
8
10
10
6
54 (5.5, 40)
26 (2.7, 19)
39 (4.0,29)
39 (4.0,29)
12(1.2,9)
CLUTCH/GEARSHIFT LINKAGE
ITEM Q'TV
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Gearshift pedal pivot bolt 1 10 39 (4.0,29)
1-16
GENERALINFORMATION
FINAL DRIVE
ITEM Q'TV
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Pinion retainer 1 64 108 (11.0, 80)
Pinion retainer lock tab bolt 1 6 10 (1.0, 7)
Pinion joint nut 1 16 108 (11.0, 80) Apply locking agent to the
threads
Dust guard plate bolt 1 6 10 (1.0, 7)
Final gear case cover bolt 2 10 47 (4.8, 35) Apply locking agent to the
threads
. Final gear case assembly mounting
6 8 25 (2.5, 18)
nut 4 10 64 (6.5,47)
Final gear case stud bolt
Rear shock absorber lower mounting
4 10 - See page 14-22
bolt (left side) 1 8 22 (2.2, 16)
FRONT WHEEUSUSPENSION/STEERING
ITEM Q'TV
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Clutch lever pivot bolt 1 6 1 (0.1,0.7)
Clutch lever pivot nut 1 6 6 (0.6, 4.4)
Handlebar upper holder bolt 4 8 23 (2.3, 17)
Handlebar lower holder nut 2 8 23 (2.3,17)
Front brake disc bolt 6 8 42 (4.3,31) ALOC bolt; replace with a
new one
Spoke 52 BC4 4.2 (0.4, 3.1)
Front axle bolt 1 14 59 (6.0, 44)
Front axle pinch bolt 2 8 22 (2.2, 16)
Fork center socket bolt 2 10 29.5 (3.0, 22) Apply locking agent to the
threads
Fork cap 2 38 22.1 (2.3, 16)
Tire valve nut 1 8V1 4 (0.4, 3.0)
Fork top bridge pinch bolt . 2 8 22 (2.2, 16)
Fork bottom bridge pinch bolt 2 10 49 (5.0, 36)
Steering top thread 1 26 - See page 15-32
Steering top thread lock nut 1 26 - See page 15-32
Steering stem nut 1 24 103 (10.5, 76)
REAR WHEEUBRAKE/SUSPENSION
ITEM O'TV
THREAD
DIA. (mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Spoke 52 BC4 4.2 (0.4, 3.1)
Tire valve nut 1 8V1 4 (0.4, 3.0)
Rear axle nut 1 18 88 (9.0, 65) U-nut
Rear axle pinch bolt 1 8 27 (2.8, 20)
Rear brake stopper arm nut 1 8 22 (2.2, 16)
Rear brake arm pinch bolt 1 8 26 (2.7, 19)
Rear shock absorber upper mounting
bolt 2 8 26 (2.7, 19)
Rear shock absorber lower mounting
bolt (right side) 1 10 34 (3.5, 25)
Stopper plate bolt 5 6 20 (2.0, 15) ALOC bolt; replace with a
new one
Swingarm left pivot bolt 1 30 103 (10.5, 76)
Swingarm right pivot bolt 1 30 - See page 16-26
Swingarm right pivot bolt lock nut 1 30 103 (10.5, 76)
1-17
GENERALINFORMATION
HYDRAULIC BRAKE
ITEM Q'TV
THREAD
DIA.(mm)
TORQUE
N'm (kgfm, Ibfft)
REMARKS
Brake caliper bleed valve 1 8 5.5 (0.6,4.1)
Front master cylinder reservoir cap
screw 2 4 1.5 (0.2, 1.1)
Brake pad pin 1 10 18 (1.8, 13)
Brake pad pin plug 1 10 2.5 (0.3, 1.8)
Brake hose oil bolt 2 10 34 (3.5, 25)
Brake lever pivot bolt 1 6 1 (0.1,0.7)
Brake lever pivot nut 1 6 6 (0.6, 4.4)
Front brake light switch screw 1 4 1.2 (0.1, 0.9)
Front master cylinder holder bolt 2 6 12 (1.2,9)
Front brake caliper bracket pin 1 8 12 (1.2, 9) Apply locking agent to the
threads
Front brake caliper pin 1 8 27 (2.8,20) Apply locking agent to the
threads
Front brake caliper mounting bolt 2 8 30(3.1,22) ALOC bolt; replace with a
new one
BATTERY/CHARGING SYSTEM
ITEM Q'TV
THREAD
DIA.(mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Battery case cover screw 1 6 1 (0.1,0.7)
LIGHTS/METERS/SWITCHES
ITEM Q'TV
THREAD
DIA.(mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Headlight unit mounting bolt
Brakeltail light mounting nut
Speedometer mounting socket bolt
Ignition switch mounting bolt
Ignition switch cover screw
Fan motor switch
.
Sidestand switch bolt
ECT sensor switch
Horn mounting bolt
2
3
2
2
1
1
1
1
1
5
6
6
6
4
16
6
PT 1/8
8
4.1 (0.4,3.0)
6.3 (0.6, 4.6)
10 (1.0, 7)
12 (1.2, 9)
1 (0.1,0.7)
18 (1.8,13)
10 (1.0,7)
7 (0.7, 5.2)
21 (2.1,15)
ALOC bolt; replace with a
new one
Apply sealant to the threads
OTHERS
ITEM Q'TV
THREAD
DIA.(mm)
TORQUE
Nm (kgfm, Ibfft)
REMARKS
Sidestand pivot bolt
Sidestand pivot lock nut
Sidestand bracket bolt
Tool box screw
1
1
2
2
10
10
10
4
9 (0.9, 6.6)
30 (3.1, 22)
49 (5.0, 36)
2 (0.2, 1.5)
Apply grease to the sliding
surface
1-18
GENERALINFORMATION
LUBRICATION&SEALPOINTS
ENGINE
MATERIAL LOCATION REMARKS
Molybdenum disulfide
oil (a mixture of 1/2
engine oil and 1/2
molybdenum disulfide
grease)
Camshaft lobes and journal surface
Valve stem (valve guide sliding surface)
Rocker arm slipper surface
Rocker arm shaft outer surface
Crankpin bearing thrust surface
Crankshaft main journals
Clutch outer guide outer surface
Transmission gear shift fork groove
Transmission bushing sliding surface
Connecting rod small end inner surface
Engine oil Piston outer surface
Piston ring outer surface
Piston pin outer surface
Primary drive gear bolt threads and seating surface
Flywheel bolt threads and seating surface
Starter one-way clutch sprag
Starter idle and reduction gear shaft outer surface
Clutch center lock nut threads and seating surface
Clutch lifter arm sliding surface of the right crankcase cover
Clutch lifter arm sliding surface and slit
Clutch discs and plates
Cylinder wall
Cylinder stud bolt threads
Valve adjusting screw lock nut threads and seating surface
Shift fork shaft whole surface
Crankpin bearing cap nut threads and seating surface
Output drive gear assembly mounting bolt threads and seating
surface
> Output driven gear assembly mounting socket bolt threads
and seating surface
Output drive gear bearing lock nut (inner/outer) threads and
seating surface
Output driven gear bearing lock nut (inner/outer) threads and
seating surface
Cylinder head bolt/nut threads and seating surface
Transmission gear tooth
Engine oil filter cartridge threads
Crankshaft main journal bearing surface
Oil pipe seal
Each bearings rotating area
Each O-rings
Multi-purpose grease Crankshaft hole cap threads
Timing hole cap threads
Each oil seal lips
Sealant EOP switch threads
Right and left crankcase mating surface
Right crankcase cover mating surface
Left crankcase cover mating surface
Output gear case mounting bolt threads
Do not apply to the
sealant to the head
3-4 mm (0.1-0.2 in)
1-19
GENERALINFORMA1"ION
MATERIAL LOCATION REMARKS
Locking agent Cam sprocket bolt threads
Starter one-way clutch outer socket bolt threads
Oil pump driven sprocket bolt threads
Final gear case stud bolt threads (gear case side)
Stator wire holder socket bolt threads
Gearshift cam plate bolt threads
Transmission bearing setting plate bolt threads
Cam chain tensioner setting plate bolt threads
Stator socket bolt threads
Oil filter boss crankcase side threads
Left crankcase cover bolt threads (marked "8')
Coating width:
6.5 1 mm
(0.26 0.04 in)
Coating width:
6.5 1 mm
(0.26 0.04 in)
Coating width:
6.5 1 mm
(0.26 0.04 in)
Coating width:
6.5 1 mm
(0.26 0.04 in)
Coating width:
6.5 1 mm
(0.26 0.04 in)
Coating width:
6.5 1 mm
(0.26 0.04 in)
Pro Honda Hondabond
HT or equivalent
Cylinder head cover-to-gasket groove
1-20
GENERALINFORMATION
FRAME
MATERIAL LOCATION REMARKS
Sealant Final gear case cover mating surface
ECT sensor switch threads Do not apply to the
thread head
Multi-purpose grease Sidestand pivot Apply 1 g
Main step sliding area
Pillion step sliding area
Throttle pipe flange groove and sliding surface Spreading 0.2 - 0.3 g
Clutch lever pivot bolt sliding surface
Gearshift spindle oil seal lips
Gear shift pedal dust seal lips
Front axle sliding surface
Shock absorber mount inner surface
Rear brake middle rod joint pivot and dust seal lips
Rear brake cam sliding surface Spreading 0.5 - 1.0 g
Brake shoe-to-anchor pin sliding surface Spreading 0.5 - 1.0 g
Brake pedal pivot sliding surface
Brake pedal dust seal lips
Rear brake joint pins
Front wheel dust seal lips
Final gear case O-ring
Final gear case oil seal lips
Urea based multi- Steering head bearings Apply 3 - 5 g for each
purpose grease with bearing
extreme pressure Steering head bearing dust seal lips
(example: EXCELITE
EP2 manufactured by
KYODO YUSHI, Japan)
or equivalent
Swingarm pivot bearing needle rollers
Swingarm pivot dust seal lips
Apply 1.0 - 1.5 g for
each bearing
Molybdenum disulfide Output drive gear and damper cam splines Apply 1 g
grease Final drive shaft oil seal lip Apply 0.5 g
Final drive shaft splines (universal joint side) Apply 1 g
Final drive pinion joint splines Apply 2 g
Molybdenum disulfide Final driven flange (rear wheel hub mating surface) Apply 0.5 - 1.0 g
paste Final driven flange O-ring
Final gear case O-ring guide and driven flange joint surface Apply 4- 5 g
Thrust washer and rear wheel hub end (final driven flange Apply 2- 3 g
side)
Cable lubricant Throttle cable outer inside
Clutch cable outer inside
Choke cable outer inside
Pro Honda Handgrip Handlebar grip inside
Cement or equivalent Handlebar and throttle pipe outer surface (grip rubber
contacting area)
I
Engine oil Steering top threads
Rear brake cam felt seal
Silicone grease Brake lever pivot bolt sliding surface Apply 0.1 g
Brake lever-to-master piston contacting area Apply 0.1 g
Brake caliper and bracket pin boot inside Apply 0.4 g
Brake caliper dust seal
DOT 4 brake fluid Brake master piston and cups
Brake caliper piston and piston seals
Pro Honda Suspension Fork dust seal and oil seal lips
Fluid SS-8 (10W)
Fork cap O-ring
Locking agent Pinion joint nut threads
Final gear case cover 10 mm bolt threads
Fork center socket bolt threads
Front brake caliper bracket pin threads
Front brake caliper pin threads
Final gear case stud bolt threads
Steering stem cover bolt threads
Cooling fan mounting nut threads
1-21
GENERALINFORMATION
CABLE& HARNESSROUTING
THROTrLE CABLES
RIGHT HANDLEBAR
SWITCH WIRE
FRONT BRAKE HOSE CLUTCH CABLE
FRONT TURN SIGNAL LIGHT WIRES
FOG LIGHT 3P LEFT HANDLEBAR SWITCH RIGHT HANDLEBAR SWITCH
CONNECTOR (Option) 6P (BLACK) CONNECTOR 6P (RED) COI\INECTOR
LEFT HANDLEBAR SWITCH
6P (BLUE) CONNECTOR
HEADLIGHT 3P CONNECTOR
1-22
--------
GENERALINFORMATION
RIGHTHANDLEBAR SWITCHWIRE
Up
t
~ '-'-1~ t side
~ .J. 30 5
1-23
0 __-
GENERALINFORMATION
CLUTCH CABLE
~ 4
-------------------
GENERALINFORMATION
FUEL TANK
FUEL TANK BREATHER HOSE
BREATHER HOSE
(Except California type)
FUEL TANK BREATHER HOSE
(Except California type)
WATER HOSE
(Except California type)
FUEL VALVE
Revised: May 2007, 2007-2008 VT750C2
-,""",,
1-25
- - ---------
-------
GENERALINFORMATION
. (1) SIDESTANDSWITCHWIRE
(2) GROUNDCABLE
(3) STARTER MOTORCABLE
(4) ALTERNATORWIR.E
(5) NEUTRAUOILPRESSURESWITCHWIRE
(6) VS SENSORWIRE
(7) IGNITIONSWITCHWIRE
IGNITION SWITCHWIRE
(1) (5)
(4)
STARTER MOTORCABLE
(1)
(1)
NEUTRAUOILPRESSURE
SWITCHWIRE
SIDESTANDSWITCHWIRE.
1-26
GENERAL INFORMATION
FUEL TANK BREATHER (California type: EVAP CANISTER) HOSE
to fuel tank
CARBURETOR AIR VENT
RADIATOR RESERVE
TANK BREATHER HOSE
SIPHON HOSE
HOSE (Except California type)
1-27
~ ~ ~ _ ~ --------
GENERALINFORMATION
SUB AIR CLEANERS
/
STARTER MOTOR CABLE
GROUND CABLE
1-28
GENERALINFORMATION
INSIDE BOOT CONNECTORS:
IGNITION PULSE GENERATOR 2P (RED) CONNECTOR
FAN MOTOR 2P (NATURAL) CONNECTOR
REAR BRAKE LIGHT SWITCH 3P (LIGHT GRAY) CONNECTOR
PAIR COI\JTROL VALVE VACUUM HOSE
MAIN WIRE HARNESS
THROTTLE CABLES
FUEL TANK BREATHER (California type:
EVAP CANISTER) HOSE
Left side
CARBURETORAIR VENT HOSE
(Except calif6riJia type)
IGNITION PULSE GENERATOR WIRE
1-29
GENERALINFORMATION
PAIR CONTROL VALVE VACUUM HOSE
t Up
~ ~ ~ 4 5 0 ~ ~ !
1 ~ ~ _--.
. Left side
i
Revised: May 2007,2007-2008 VT750C2
1-30
GENERALINFORMATION
PAIR CONTROL VALVE
PAIR CONTROL VALVE VACUUM HOSES
SUB AIR CLEANERS
1-31
GENERALINFORMATION
FUEL TANK BREATHER
(California type: EVAP CANISTER)
HOSE
LEFT REAR SPARK PLUG WIRE
BRAKEITAIULICENSE
LIGHT WIRE
RIGHT REAR SPARK PLUG WIRE
REAR TURN SIGNAL
REGULATOR/RECTIFIER
LIGHT WIRES
TURN SIGNAL RELAY
STARTER RELAY SWITCH
BATTERY POSITIVE (+) CABLE
PRIMARY WIRES
1-32
GENERALINFORMATION
INSIDE BOOT CONNECTORS:
RIGHT REAR TURN SIGNAL LIGHT 2P (LIGHT BLUE) CONNECTOR
LEFT REAR TURN SIGNAL LIGHT 2P (ORANGE) CONNECTOR
rCM 22P CONNECTOR
BRAKEfTAIULICENSE LIGHT 3P ~ A T U R A L CONNECTOR
INSIDE BOOT CONNECTORS: ICM
. IGNITION SWITCH 2P (BLACK) AND 1P (NATURAL) CONNECTOR
SIDESTAND SWITCH 2P (GREEN) CONNECTOR
VS SENSOR 3P (NATURAL) CONNECTOR
ALTERNATOR 3P (NATURAL) CONNECTOR
NEUTRAUEOP SWITCH 2P (BLACK) CONNECTOR
1-33
GEI\lERALINFO .
RMATION
LEFT REAR TUR
SIGNAL LIGHT R
BRAKEfT
LIGHT AIULICENSE
WIRE
1-34
GENERAL INFORMATION
EVAP CONTROL SYSTEM (California type only)
EVAPCAV
CONTROLVALVE
VACUUMHOSE
FUELCUT-OFFSOLENOID MAINWIRE HARNESS
VALVEVACUUM HOSE
SECONDARYAIR
SUPPLYHOSE
EVAP CAVCONTROL.
EAVAPPURGECONTROL
VALVE HOSE (tofuel
VALVE HOSE(tocanister)
SIPHON HOSE
cut-offsolenoidvalve)
EVAP PURGE CONTROL
VALVE HOSE(tothrottlebore)
EVAPCAVCONTROL
VALVEHOSE(tocanister)
FUELHOSE
Revised:May2007,2007-2008VT750C2
1-35
GENERAL INFORMATION
RADIATOR RESERVE
TANK BREATHER
HOSE
EVAP CAN ISTER HOSE
(to fuel tank)
Revised: May 2007. 2007-2008 VT750C2
1-36
GENERALINFORMATION
EVAP CAV CONTROL
VALVE VACUUM HOSE
EVAP CAV CONTROL VALVE HOSE
(to fuel cut-off solenoid valve)
EVAP PURGE CONTROL
VALVE HOSE (to <.:anister)
FUEL CUT-OFF
SOLENOID VALVE
VACUUM HOSE
to rear PAIR check valve
EVAPPURGECONTROL
VALVE HOSE (to throttle bore)
EVAP CAN ISTER
HOSE
EVAPCAVCONTROL VALVE
HOSE (to sub air cleaner)
EVAP CAV CONTROL
VALVE HOSE (to canister)
FUEL CUT-OFF SOLENOID
VALVE HOSE (to float chamber)
EVAP PURGE CONTROL VALVE
VACUUM HOSE
FUEL HOSE
Revised: May 2007, ~ 7 2 8 VT750C2
-------- -_.. -- ---
1-37
GENERALINFORMATION
FUEL CUT-OFF
SOLENOID VALVE WIRE
EVAPCAVCONTROL VALVE HOSE
(to fuel cut-off solenoid valve)
FUEL CUT-OFF SOLENOID
VALVE VACUUM HOSE
EVAP CAV CONTROL VALVE
HOSE (to sub air cleaner)
EVAP CAV CONTROL
VALVE HOSE (to canister)
EVAPPURGECONTROL
VALVE VACUUM HOSE
EVAP CAV CONTROL
VALVE VACUUM HOSE
May 2007, 2007 VT750C2
1":38
GENERALINFORMATION
EMISSIONCONTROLSYSTEMS
EXHAUSTEMISSIONREQUIREMENT
The U.S. Environmental Protection Agency (EPA), California Air Resources Board (CARB) and Transport Canada require
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.
NOISEEMISSIONREQUIREMENT
The EPA also required that motorcycles built after January 1, 1983 comply with applicable noise emission standards for
one year or 6,000 km (3,730 miles) after the time of sale to the ultimate purchaser, when operated and maintained
according to the instructions provided.
WARRANTYCOMPLIANCE,
Compliance whhthe terms'of}be Dil?tributor's Limited Warranty for Honda Motorcycle Emission Control Systems is
necessary in order to keep the emissions system warranty in effect.
SOURCEOFEMIS'SIONS
The combustion process produces carbon monoxide (CO), oxides of nitrogen (NOx) and hydrocarbons (HC). Control of
carbon monoxide, oxides of nitrogen and hydrocarbons is 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 is toxic.
Honda Motor Co., ltd. utilizes appropriate carburetor settings as well as other systems, to reduce carbon monoxide, and
hydrocarbons.
CRANKCASEEMISSIONCONTROLSYSTEM
The engine is equipped with ~ l o s e d crankcase system to prevent discharging crankcase emissions into the atmosphere.
Blow-by gas is returned to the combustion chamber through the air cleaner and carburetor. .
AIR CLEANER
; FRESH AIR
~ BLOW-BY GAS
'..39
GENERALINFORMATION
EXHAUSTEMISSIONCONTROLSYSTEM
Theexhaustemissioncontrolsystem iscomposedofapulsesecondaryairsupplysystemandleancarburetorsettings.
No adjustmentshould be madeexceptidlespeed adjustmentwiththethrottlestopscrew.Theexhaust emissioncontrol
systemis separatefromthecrankcaseemissioncontrolsystem.
SECONDARYAIRSUPPLYSYSTEM
Thepulsesecondaryairsupplysystemintroducesfilteredairintotheexhaustgasesintheexhaustport.Fresh airisdrawn
intotheexhaustportbythefunctionofthePAIR (PulseSecondaryAirInjection)controlvalve.
This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of
hydrocarbonsandcarbonmonoxideintorelativelyharmlesscarbondioxideandwatervapor.
Thereedvalvepreventsreverseairflowthroughthesystem.ThePAIRcontrolvalvereactstohighintakemanifoldvacuum
andwillcutoffthesupplyoffresh airduringengine therebypreventingafterburnintheexhaustsystem.
No adjustmentstothe secondary airsupplysystem should be made, although periodicinspection ofthe components is
recommended.
FRESHAIR
..EXHAUSTGAS
-41.'11 NEGATIVE PRESSURE
OXIDATIONCATALYTICCONVERTER(Californiatypeonly)
Thismotorcycleisequippedwithan oxidationcatalyticconverter.
The oxidation catalytic converter is in the exhaust system. Through chemical reactions, itconverts HC and CO in the
engine'sexhausttocarbondioxide(C02) and watervapor.
FUELPERMEATIONEMISSIONCONTROLSYSTEM
This motorcycle complies with the Fuel Permeation Emission regulations ofthe U.S. Environmental Protection Agency
(EPA), California Air Resources Board (CARB), and Environment Canada (ECl.The fuel tank, fuel hoses, and fuel vapor
chargehosesusedonthismotorcycleincorporatefuel permeationcontroltechnologies.Tamperingwiththefueltank,fuel
hoses,orfuelvaporchargehosestoreduceordefeattheeffectivenessofthefuel permeationtechnologiesisprohibitedby
federal regulations.
Revised:May2007.2007-2008VT750C2
1-40
GENERALINFORMATION
EVAPORATIVEEMISSIONCONTROLSYSTEM(Californiatypeonly)
This model complies with CARB evaporative emission requirements. Fuel vapor from the fuel tank is routed into the
evaporative emission (EVAP) canister where it is absorbed and stored whilethe engine is stopped. When the engine is
running and the EVAP purge control solenoid valve is open, fuel vapor in the EVAP canister is drawn intothe engine
throughthecarburetor.
EVAPPURGECONTROLVALVE
EVAPCAVCONTROLVALVE
(ATENGINESTOP)
EVAPCAVCONTROL
VALVE
(ATENGINE RUNNING)
<-
FUELVAPOR
(ATENGINESTOP)
..
FUELVAPOR
FUELTANK
(ATENGINE RUNNING)
NEGATIVE PRESSURE
EVAPCANISTER
I\lOISEEMISSIONCONTROLSYSTEM
TAMPERINGWITH THE NOISE CONTROLSYSTEM IS PROHIBITED: U.S.Federal lawprohibits,orCanadian provincial law
mayprohibitthefollowingactsorthecausingthereof:(1)Theremoval orrendering inoperativebyanyperson,otherthan
forpurposesofmaintenance,repairorreplacement,ofanydeviceorelementofdesign incorporated intoanyvehicle for
the purpose ofnoisecontrol priorto itssale ordeliverytotheultimatecustomerorwhileitis in use; (2) the use ofthe
vehicleaftersuchdeviceorelementofdesignhas been removed orrendered inoperativebyanyperson.
AMONGTHOSE ACTS PRESUMEDTO CONSTITUTETAMPERINGARETHEACTSLISTED BELOW:
1. Removal of,orpuncturingofthemuffler,baffles, headerpipesoranyothercomponentwhichconductsexhaustgases.
2. Removal of,orpuncturingofanypartoftheintakesystem.
3. Lackofpropermaintenance.
4. Replacing any moving parts of the vehicle, or parts ofthe exhaust or intake system, with parts other than those
specified bythemanufacturer.
1-41
MEMO
--------------,----
2. TECHNICALFEATURE
OXIDATION CATALYTIC CONVERTER
PROTECTION FROM UNBURNED
GASOLINE (California type only) 2-2
2-1
TECHNICALFEATURE
OXIDATION CATALYTIC CONVERTER PROTECTION FROM
UNBURNEDGASOLINE(Californiatypeonly)
OUTLINE
Thismotorcycleisequippedwith heat-tubeenhancedoxidationcatalyticconverters.Throughthechemical reactions,they
convertHC and CO intheengine'sexhausttocarbon dioxide(C02) and watervapor. Ifthe unburned (raw) gasolinefrom
thecombustionchamberflowsintothe catalyticconverter, itwill damagethecatalyticconverterthrough excessivetem-
peratures.A damagedcatalyticconvertercannotbeeffectiveforexhaustemissionscontrol.
Thefuelcut-off solenoidvalveand heat-tubeprotecttheoxidationcatalyticconverterfromdamagebyrawgasoline.
FUELCUT-OFFSOLENOIDVALVE
CONSTRUCTION
Rawgasolinecanenterthecatalyticconverterunderthefollowingconditions:
- Theenginestopswitchisturnedto suddenlywhiletheengineisrunning.
- Ignitioncutsystem(revlimiter)operateswhentheengineisoverrewed.
The fuel cut-offsolenoidvalve is controlled bythe ICM, andthefloatchamberairventpassage ischanged according to
abovedescribedconditions.
Thefuelcut-offsolenoidvalveconsistsofacoilandvalve,and3passages.
1. Connectiontosubaircleaner(atmosphere)
2. Connectiontothrottlebore
3. Connectiontofloatchamberairvent
Thefuel cut-offsolenoidvalveopenspassages 1to3passagewhenthereis nooperationvoltage.
OPERATION
NormalOperation(Whenthefuelcut-offsolenoidvalvedoesnotoperate):
1. NooperationvoltagefromtheICM.
2. Thefloatchamberairventisopentoatmosphere.
3. Thefloatchamberpressure(surfaceofthegasolineinthefloatchamber)isatmosphere.
4. Thecarburetoroperatesnormally.
FuelCutOperation(Whenthefuelcut-offsolenoidvalveoperates):
1. Theoperationvoltagecomesfrom'theICM.
2. Thefloatchamberairventpassage isclosedtoatmosphere.
3. Thefloatchamberairventisopenedtothethrottlebore.
4. Thefloatchamberpressure(surfaceofthegasolineinthefloatchamber) becomesnegative.
5. Thefloatchamberpressurewill besameasthrottleborepressure.
6. Thecarburetorstopsfuel supply.
VALVE TOTHROTTLE BORE
FUELCUT-OFF
TOATMOSPHERE
t
OPERATION
VOLTAGE
SOLENOIDVALVE
CARBURETOR
/l------, FUELCUT-OFFSOLENOID
VALVE DOES NOT
OPERATE:
..FUELCUT-OFFSOLENOID
VALVE OPERATES:
2-2.
TECHNICALFEATURE
HEAT-TUBE
Rawgasolinecan enterthecatalyticconverterunderthefollowingconditions:
- Theenginestopswitchisturnedto suddenlywhiletheengineis running.
- The engine stopswitch isturnedto suddenlywhiletheengine is running and thethrottle is snapped open (addi-
tionalfuelisdischargedfromtheacceleratorpump).
The heat-tubeis installed upstream oftheoxidationcatalyticconvertertoprotectthecatalyticconverterfromdamageby
chemical reactions.
ACCELERATOR PUMP
OXIDATIONCATALYTICCONVERTER
2-3
MEMO
--- --------- ---
3. FRAME/BODYPANELS/EXHAUSTSYSTEM
-
SERVICEINFORMATION 3-2
TROUBLESHOOTING 3-2
SEAT ..33
SIDECOVER 3-3
FUELTANK 3-4
STEERINGSIDECOVER 3-5
LEFTCRANKCASEREARCOVER 3-5
FRONTFENDER 3-6
REAR FENDER 3-6
EXHAUSTSYSTEM 3-8
~ ...~
3-1
FRAME/BODYPANELS/EXHAUSTSYSTEM
SERVICEINFORMATION
GENERAL
Thissectioncoversremoval andinstallationofthebodypanels,fueltankand exhaustsystem.
Seriousburnsmayresultiftheexhaustsystem is notallowedtocool beforecomponentsare removedorserviced.
Alwaysreplacetheexhaustsystemgasketswithnewonesafterremovingtheexhaustsystemfromtheengine.
Wheninstallingtheexhaustsystem,looselyinstallall oftheexhaustpipefasteners.Alwaystightentheexhaustclamps
first,thentightenthemountingfasteners.
Alwaysinspecttheexhaustsystemforleaksafterinstallation.
TORQUEVALUES
Seatmountingsocket8mmbolt 26Nm (2.7 kgfm,19lbfft)
Grabrail mountingbolt 64N'm(6.5 kgfm,47 Ibfft)
Fueltankmountingbolt 27 Nm(2.8 kgfm,20 Ibfft)
Fuelvalvenut 34N'm(3.5 kgf'm,25 Ibfft)
Leftcrankcase rearcoversocketbolt 10N'm(1.0kgfm,7Ibfft)
Exhaustpipejointnut 25 Nm(2.5 kgfm,18Ibfft)
Mufflerstaymountingbolt 27 Nm (2.8 kgfm,20 Ibfft)
Mufflermountingnut 44Nm(4.5 kgfm,32 Ibfft)
Mufflerbracketbolt 34Nm(3.5 kgfm,25 Ibfft)
Exhaustpipejointstud bolt See page3-11
TROUBLESHOOTING
Excessiveexhaustnoise
Brokenexhaustsystem
Exhaustgasleak
Poorperformance
Deformedexhaustsystem
Exhaustgasleaks
Cloggedmuffler
3-2
FRAME/BODYPANELS/EXHAUSTSYSTEM
SEAT
REMOVAL
Remove the 8 mm socket bolts, 6 mm bolt, washer
and seat by moving it rearward.
INSTALLATION
Install the seat by inserting its prong under the
raised lip of the frame.
Install the washer, 6 mm bolt and tighten the 6 mm
bolt securely.
Install and tighten the 8 mm socket bolts to the
specified torque.
TORQUE:26Nm(2.7 kgfm, 19Ibf.ft)
SIDECOVER
REMOVALIINSTALLATION
Be careful not to Remove the side cover by releasing its bosses from
damage the side the frame grommets.
cover bosses.
Install the side cover by inserting its bosses into the
frame grommets.
SIDE COVER
3-3
FRAME/BODYPANELS/EXHAUSTSYSTEM
FUELTANK
REMOVAL
Removethefollowing:
- Speedometerassembly(page21-10)
- Seat(page3-3)
TurnthefuelvalvetoOFF.
Disconnectthefuel andvacuumhosesfromthefuel
valve.
Disconnectthebreatherhose(Californiatype: EVAP
canisterhose)fromthefueltank.
Removethemountingbolt,washerandcollar.
Removethefueltankbymovingitrearward.
INSTALLATION
Installthefueltankbyinsertingitsgroovesoverthe
mountingrubbers.
Install the collar and washer with the flat of the
washerfacing rearward.
Installandtightenthemountingbolttothespecified
torque.
TORQUE:27Nm(2.8kgfm,20Ibf.ft)
Route thehoses Install the removed parts in the reverse order of
properly removal.
(page 1-22).
DISASSEMBLY
Removethefueltank(page3-4).
FUELVALVE
Drain the fuel from the fuel tank into an approved
gasolinecontainer.
Loosenthenutand removethefuelvalve.
WASHER
BREATHER (EVAPCANISTER) HOSE
Removethefuel strainerscreenandO-ring.
Wash the fuel strainer screen in high flash-point
cleaningsolvent.
Check the fuel strainer screen for clog or damage,
replaceitifnecessary.
ASSEMBLY
Install a newO-ring and fuel strainer screen to the
fuelvalve.
STRAINERSCREEN
O-RING S!I
3-4.
FRAME/BODYPANELS/EXHAUSTSYSTEM
Installthefuelvalveintothefueltank.
Tighten the nuttothe specified torque while hold-
ingthefuelvalve.
TORQUE:34Nm(3.5kgfm,25Ibftt)
Installthefueltank(page3-4).
FUELVALVE
STEERINGSIDECOVER
REMOVAL/INSTALLATION
Removethespeedometerassembly(page21-10).
STEERING SIDE COVERS CLIP
Removethebolts.
Removetheretainingclipbyslidingitrearward.
Be carefulnotto Remove the steering side covers by releasing the
damage theboss leftcoverbossfromtherightcoverslot.
andslot.
Installationisinthereverseorderofremoval.
NOTE:
After installation, check that the wire harness and
cablesdonotinterferewithhandlebarrotation.
f
LEFTCRANKCASEREARCOVER
REMOVALIINSTALLATION
RemovetheB-clipandwasher.
Remove the socket bolt and left crankcase rear
coverbyreleasing itsbossesfromthegrommets.
Check the B-clip forfatigue ordamage, replace itif
necessCiry
InlrtallatiQnisinthereverseorderofremoval.
TORQU.E:
socketbolt:
10Nm(1;()kQ"m,7IbHI:)
SOCKETBOLT WASHER
I B-CLIP
LEFTCRANKCASE REAR COVER
3-5
FRAME/BODYPANELS/EXHAUSTSYSTEM
FRONTFENDER
REMOVAUINSTALLATID1\1
Removethefollowing:
GROMMETS/COLLARS
- Nuts
- Collars
- Frontfenderbrace
- Frontfender
- Grommets
- Bolts
Installationisinthereverseorderofremoval.
BRACE
REAR FENDER
REAR FENDERASSEMBLY
REMOVAL
Removetheseat(page3-3).
Disconnect the brakeltail/license light 3P and rear
turnsignallight2P connectors.
3-6.
-- ---
FRAME/BODYPANELS/EXHAUSTSYSTEM
Removethefollowing:
GRABRAILS
- Bolts
- Washers
- Grabrails
- Rearfenderassembly
NOTE:
When removing the rear fender assembly, be care-
ful nottodamagethewires.
INSTALLATION
Route the wires Installationisinthereverseorderofremoval.
properly
(page 1-22). TORQUE:
Grabrailmountingbolt:
64Nm(6.5kgfm,47Ibf.ft)
REAR FENDER
ASSEMBLY
REAR FRAME/REARFENDERA
REMOVAL
Removetherearfenderassembly(page3-6).
Releasetherearframe bosses fromthe rear fender
holes,then removetherearframe/rearfenderA.
NOTE:
When removing the rear frame/rear fender A, be
carefulnottodamagethewires.
RemovetherubberfromtherearfenderA.
Removethegrommetfromtherearfender.
HOLES
~ E R
~ ._-
3-7
FRAME/BODYPANELS/EXHAUSTSYSTEM
DISASSEMBLYI ASSEMBLY
Removethefollowing:
- Rearturnsignal lights(page21-7)
GROMMETS
- Brake/taillight(page21-8)
- Licenselight(page21-8)
Remove the mounting bolt, collars, grommets and
rearfenderA.
Removethenutand reflector.
Assemblyisinthereverseorderofdisassembly.
INSTALLATION
Routethewires Installationisinthereverseorderofremoval.
properly
(page 1-22).
COLLAR
BOLT
EXHAUSTSYSTEM
REMOVAL
Removetheexhaustpipejointnuts.
Remove the nuts, bolts, washers, collars and muf-
flerassembly.
REAR FENDER A
3-8.
FRAME/BODYPANELS/EXHAUSTSYSTEM
Removethefrontandreargaskets.
FLANGE
Removetheexhaustpipejointcollarsandflanges.
JOINTCOLLAR
DISASSEMBLY
Rear muffler only: Drivetherearexhaustpipeprotectorusingaplastic
PLASTICHAMMER
hammerand breakthe locktab (reverse side ofthe
protector)andremoveit.
NOTE:
The rearexhaustpipe protectorcan be removed
wit/:loutremovingthe exhaust system from the
n g i r i ~
[)onofreusE! theremovedprotector.
Loosenthemufflerjointbandbolt.
Removethemounting bolts, mufflerstayandsepa-
ratethemufflers.
STAY MOUNTING BOLTS
3-9
FRAME/BODYPANELS/EXHAUSTSYSTEM
ASSEMBLY
."REAR EXHAUST REAR MUFFLER
IIIiiiijjlII PIPE PROTECTOR
Installanewgasketontothefrontmufflerjointpipe.
Assemblethefrontmufflerand rearmuffler.
Install the mufflerstay, mounting bolts and tighten
themountingboltstothespecifiedtorque.
TORQUE:27 Nm(2.8kgfm,20Ibf.ft)
Tightenthemufflerjointbandboltsecurely.
Rear muffler only: Installanewrearexhaustpipeprotector.
PROTECTOR
IIIiiiijjlII
3-10
------------
FRAME/BODYPANELS/EXHAUSTSYSTEM
INSTALLATION
MUFFLER ASSEMBLY
If the exhaust pipejoint stud bolts are loose, tighten
them. Be s.ure tb verify the distance from the top of 40.0-40.2 mm
the stud to the cylinder head as shown.
(1.57 -1.58 in)
Install the flanges and exhaust pipe joint collars.
FLANGE
JOINT COLLAR
3-11
FRAME/BODYPANELS/EXHAUSTSYSTEM
Installnewgaskets.
Installthemufflerassembly.
NOTE:
Inserting the rear exhaust pipeto the rear exhaust
portfirst, then insertthe front exhaust pipe to the
frontexhaustport.
Temporarilyinstalltheallfasteners.
Tightentheexhaust pipejointnutstothespecified
torque.
TORQUE:25Nm(2.5kgfm,18Ibfft)
Tighten the mufflermounting nuts to the specified
torque.
TORQUE:44Nm(4.5kgfm,32Ibfft)
NOTE:
Always inspect the exhaust system for leaks after
installation.
3-12
4. MAINTENANCE
SERVICE INFORMATION ......4-2
MAINTENANCE SCHEDULE 4-4
FUEL LINE .. 4-5
THROTTLE OPERATION 4-5
CHOKE OPERATION 4-6
AIR CLEANER .................... .. .... .. .. 4-7
SUB AIR CLEANER 4-8
CRANKCASE BREATHER 4-8
SPARK PLUG 4-9
VALVE CLEARANCE 4-10
ENGINE OIL .. .... .. ........ .. ............ 4-12
ENGINE OIL FILTER 4-13
ENGINE IDLE SPEED 4-15
RADIATOR COOLANT 4-15
COOLING SySTEM 4-15
SECONDARY AIR SUPPLY SYSTEM ...... 4-16
EVAPCONTROLSYSTEM
(California type only) 4-17
FINAL DRIVE OIL 4-18
BRAKE FLUID 4-19
BRAKE SHOES/PADS WEAR 4-20
BRAKE SYSTEM 4-20
BRAKE LIGHT SWITCH 4-22
HEADLIGHT AIM 4-22
CLUTCH SYSTEM 4-22
SIDESTAND .. .. ......................4-23
SUSPENSiON ...... .............. ...... 4-24
NUTS, BOLTS, FASTEI\lERS 4-24
WHEELS/TIRES 4-25
STEERING HEAD BEARINGS 4-26
4-1
~ ~ ~ ~ _ ~ ~ ~ --------- ~
MAINTENANCE
SERVICEINFORMATION
GENERAL
Placethemotorcycleon levelgroundbeforestartinganywork.
Gasolineis extremelyflammableandisexplosiveundercertainconditions.
Workin awell ventilated area. Smoking orallowing flames orsparks in theworkarea orwherethegasolineisstored
cancauseafireorexplosion.
Theexhaustcontainspoisonouscarbonmonoxidegasthatmaycause lossofconsciousnessand mayleadtodeath.
Runtheengineinandopenarea orwithan exhaustevacuationsysteminan enclosedarea.
SPECIFICATIONS
ITEM SPECIFICATIONS
Throttlegripfreeplay 2- 6mm(1/16- 1/4in)
Sparkplug Standard DPR6EA-9(NGK),X20EPR-U9(DENSO)
Forextendedhighspeed riding DPR7EA-9(NGK),X22EPR-U9 (DENSO)
Sparkpluggap 0.8- 0.9mm(0.03- 0.04in)
Valveclearance IN 0.150.02 mm(0.0060.001 in)
EX 0.200.02mm(0.0080.001 in)
Recommendedengineoil Pro HondaGN44-strokeoil (U.S.A.andCanada)orequiva-
lentmotoroil
API serviceclassification:SG orhigher
JASOT903 standard:MA
Viscosity:SAE 10W-30
Engineoil Atdraining 2.5liters(2.6USqt,2.2Impqt)
capacity Atoilfilterchange 2.6liters(2.7 USqt,2.3Impqt)
Atdisassembly 3.2 liters(3.4USqt,2.8Impqt)
Engineidlespeed 1,200100rpm
Recommendedantifreeze ProHondaHPcoolantoran equivalenthighqualityethyl-
eneglycolantifreezecontainingsilicate-freecorrosion
inhibitors
Recommendedfinaldriveoil Hypoidgearoil,SAE #80
Final driveoil Atdraining 160cm
3
(5.4USoz,5.6Impoz)
capacity Atdisassembly 170cm
3
(5.7 USoz,6.0Impoz)
Recommendedbrakefluid DOT4
Brake pedal height 75mm(3.0in)abovethetopofthefootpeg
Brakepedalfreeplay 20-30mm(13/16-1-3/16in)
Clutch leverfreeplay 10- 20 mm(3/8-13/16in)
Coldtirepressure Upto90kg(200Ibs) Front 200kPa (2.00kgf/cm
2
, 29 psi)
load
Rear 200kPa (2.00kgf/cm
2
, 29 psi)
Uptomaximum Front 200kPa (2.00kgf/cm
2
, 29 psi)
weightcapacity
Rear 250kPa (2.50kgf/cm
2
, 36psi)
Tiresize Front 90/90-21M/C545
Rear 160/80-15M/C74S
Tirebrand BRIDGESTONE Front EXEDRAG701
Rear EXEDRAG702
DUNLOP Front D404F
Rear D404
Minimumtiretreaddepth Front 1.5 mm(0.06in)
Rear 2.0mm(0.08in)
4-2.
MAINTENANCE
TORQUEVALUES
Sparkplug
Valve adjustingscrewlocknut
Timing holecap
Engineoilfiltercartridge
Engineoildrainbolt
Final driveoilfillercap
Finaldriveoildrainbolt
Frontmastercylinderreservoircapscrew
Aircleanercoversocketbolt
Crankshaftholecap
Alternatorcoversocketbolt
Spoke
SEvalvenut
TOOLS
18 N'm(1.8 kgfm,13Ibfft)
23 N'm(2.3 kgf'm,17 Ibfft)
10 Nm(1.0 kgf'm,7Ibfft)
26 Nm(2.7 kgf'm,19 Ibfft)
29 N'm(3.0 kgf'm,21 Ibfft
12 N'm(1.2 kgfm,9Ibfft)
12 Nm(1.2 kgfm,9Ibfft)
1.5 N'm(0.2 kgfm,1.1 Ibfft)
1.5 N'm(0.2 kgf'm,1.1 Ibfft)
15N'm(1.5 kgfm,11 Ibfft)
10 Nm(1.0 kgfm,7Ibfft)
4.2 N'm(0.4kgfm,3.1 Ibfft)
2.3 Nm(0.2 kgfm,1.7 Ibfft)
Applyengineoiltothethreadsand
seating surface
. Applygreasetothethreads
Applyengineoiltothethreads
Applygreasetothethreads
Valve adjustingwrench Oil filterwrench Spokewrench
07908-KE90000 07HAA-PJ70101
or07908-KE90100(U.S.A.only)with or07HAA-PJ70100(U.S.A.only)
10-mmoffsetboxwrench . or07HAA-PLCA100(U.S.A. only)
4-3
---------------
MAINTENANCE
MAINTENANCE SCHEDULE
PerformthePre-rideinspectionintheOwner'sManualateach scheduled maintenanceperiod.
I: Inspectandclean,adjust,lubricateorreplace ifnecessary.C: Clean. R: Replace.A: Adjust. L: Lubricate.
The following itemsrequire some mechanical knowledge.Certain items(particularlythose marked *and **) mayrequire
moretechnical informationandtools.ConsultyourHondadealer.
FREQUENCY WHICHEVER
13-1
I
CRANKSHAFTITRANSMISSION
COMPONENT LOCATION
23 Nm (2.3 kgf'm, 17 Ibf.ft)
I'
33 Nm (3.4 kgf'm, 24 Ibf.ft)
CRANKCASE SOLT: 23 N'm (2.3 kgf'm, 17 Ibf.ft)
13-2
CRANKSHAFTITRANSMISSION
SERVICEINFORMATION
GENERAL
Thecrankcasemustbe separatedtoservicethefollowing:
- Oil pump
- Crankshaft/connecting rod
- Outputgear
- Transmission
Thefollowing partsmustberemoved beforeseparatingthecrankcase:
- Oilfiltercartridge(page4-13)
- Waterpump(page7-16)
- Cylinderhead(page9-14)
- Cylinder(page10-4),piston (page10-5)
- Clutch (page11-7).gearshiftlinkage(page11-14)and primarydrivegear(page11-12)
- Flywheel(page12-5)
- Startermotor(page20-6)
- VS sensor(page21-11)
- Neutralswitch(page21-19)
- EOP switch(page5-5)
- Intakemanifold(page6-23)
Becareful nott6 damagethecrankcasematingsurfaceswhenservicing.
Markand storetheconnecting rods, bearing capsand bearing insertsto be sureoftheircorrectlocationsforreassem-
bly. .
Thecrankpinand mainjournal bearinginsertsareselectfitandareidentified bycolorcodes. Selectreplacementbear-
ings from the code tables. After selecting new bearings, recheckthe oil clearance. Incorrectoil clearance can cause
majorenginedamage.
Priortoassemblingthecrankcasehalves,applysealanttotheirmatingsurfaces.Wipeoffexcesssealantthoroughly.
Wheneveryou replace theoutputdriven/drivegears, bearings, bearing holderorgearcase, performthe gearcontact
pattern and backlash inspection and adjusttheshim. Theextension linesfrom the gearengagementsurfaces should
intersectatonepoint.
Whenusingthelocknutwrenchfortheoutputgearcase, useadeflectingbeamtypetorquewrench20incheslong.The
locknutwrenchincreasesthetorquewrench'sleverage,sothetorquewrench readingwillbelessthanthetorqueactu-
allyappliedtothe locknut.The specification given isthe actual torqueappliedtothe locknut, notthereading onthe
torquewrench. Do notovertightenthelocknuts.Thespecificationlaterinthetextgivesbothactualandindicated.
Protecttheoutputgearcasewitha shoptowelorsoftjawswhileholdingitinvise. Do notclampittootightlyasitcould
damagethegearcase.
13-3
CRANKSHAFT/TRANSMISSION
SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICELIMIT
Crankshaft Connecting rod big end side clearance 0.05 - 0.20 (0.002 - 0.0081 0.30 (0.012)
Crankpin bearing oil clearance 0.028 - 0.052 (0.0011 - 0.0020) 0.07 (0.003)
Main journal oil clearance 0.020 - 0.038 (0.0008 - 0.0015) 0.07 (0.003)
Crankshaft runout - 0.03 (0.001)
Main journal 0.0. 52.982 - 53.000 (2.0859 - 2.0866) 52.976 (2.0857)
Main journal 1.0. 58.010 - 58.022 (2.2839 - 2.2843) 58.070 (2.2862)
Shiftfork, fork 1.0. 13.000 -13.018 (0.5118 - 0.5125) 13.03 (0.513)
shaft Claw thickness 5.93 - 6.00 (0.233 - 0.236) 5.6 (0.22)
Fork shaft 0.0. 12.966 - 12.984 (0.5105 - 0.5112) 12.90 (0.508)
Shift drum 0.0. at left end 11.966 -11.984 (0.4711 - 0.4718) 11.94 (0;470)
Shift drum journal 1.0. 12.000 -12.018 (0.4724 - 0.4731) 12.05(0.474)
Shift drum-to-shift drum journal clearance 0.016 - 0.052 (0.0006 - 0.0020) 0.09 (0.035)
Transmission Gear 1.0. M3, M5 28.000 - 28.021 (1.1024 -1.1032) 28.04 (1.104)
C1, C4 31.000 - 31.025 (1.2205 -1.2215) 31.05 (1.222)
C2 24.000 - 24.021 (0.9449 - 0.9457) 24.04 (0.946)
Gear busing 0.0. M3, M5 27.959 - 27.980 (1.1007.,.. 1.1016) 27.S4 (1.100)
C1, C4 30.950 - 30.975 (1.2185 -1.2195) 30.93 (1.218)
C2 23.959 - 23.980 (0.9433 - 0.9441 ) 23.94 (0.943)
Gear-to-bushing M3, M5, C2 0.020 - 0.062 (0.0008 - 0.0024) 0.10 (0.004)
clearance
C1, C4 0.025 - 0.075 (0.0010 - 0.0030) 0.11 (0.004)
Gear bushing 1.0. M3 25.000 - 25.021 (0.9843 - 0.9851) 25.04 (0.986)
C2 20.000 - 20.021 (0.7874 - 0.7882) 20.04 (0.789)
Mainshaft 0.0. at M3 bushing 24.959 - 24.980 (0.9826 - 0.9835) 24.94 (0.982)
Countershaft 0.0. at C2 bushing 19.980 - 19.993 (0.7866 - 0.7871) 19.96 (0.786)
Bushing-to-shaft M3 0.020 - 0.062 (0.0008 - 0.0024) 0.10 (0.004)
clearance
C2 0.007 - 0.041 (0.0003.,.. 0.0016) 0.07 (0.003)
Output drive Output gear 1.0. 24.000 - 24.021 (0.9449 - 0.9457) 24.04 (0.946)
train Output gear bush- 0.0. 23.959 - 23.980 (0.9433 - 0.9441) 23.70 (0.933)
ing
1.0. 20.020 - 20.041 (0.7882 - 0.7890) 20.06 (0.790)
Output drive gear shaft 0.0. 19.979 - 20.000 (0.7866 - 0.7874) 19.97 (0.786)
Gear-to-bushing'clearance 0.020 - 0.062 (0.0008 - 0.0024) 0.082 (0.0032)
Gear bushing-to-shaft clearance 0.020 - 0.042 (0.0008 - 0.0017) 0.08 (0.003)
Output gear damper spring free length 62.3 (2.45) 59 (2.3)
Output drive gear backlash 0.08 - 0.23 (0.003 - 0.009) 0.40 (0.016)
Backlash difference between
measurements
- 0.10 (0.004)
13-4
CRANKSHAFT/TRANSMISSION
TOEQUEVALUES
Crankcase bolt(8mm)
Crankpin bearingcap nut
Gearshiftcam platebolt
Outputgearcase mountingbolt
Outputdrivegearassemblymountingbolt
Outputdrivengearassemblymounting
socketbolt
Outputdrivegearbearing locknut
(inner)
(outer)
Outputdrivengearbearinglocknut
(inner)
(outer)
Outputdrivengearshaftbolt
23 l\Im (2.3 kgfm,17 Ibfft)
33 Nm(3.4kgfm,24Ibfft)
12 Nm(1.2 kgfm,9Ibfft)
31 Nm (3.2 kgfm,23 Ibfft)
31 N'm(3.2 kgf'm,23 Ibfft)
31 N'm(3.2 kgf'm,23 Ibfft)
73N'm(7.4 kgfm,54Ibfft)
98 Nm(10.0 kgfm,72 Ibfft)
73Nm(7.4 kgf'm,54Ibfft)
98 Nm(10.0kgf'm,72 Ibfft)
49N'm(5.0 kgf'm,36Ibfft)
Applyengineoiltothethreadsand
seatingsurface
Applylockingagenttothethreads
Applysealanttothethreads
Applyengineoiltothethreadsand
seatingsurface
Applyengineoiltothethreadsand
seatingsurface
Locknut;replacewithanewoneand
stake
Applyengineoiltothethreadsand
seatingsurface
Locknut;replacewithanewoneand
stake
Applyengineoiltothethreadsand
seatingsurface
Locknut;replacewithanewoneand
stake
Applyengineoiltothethreadsand
seatingsurface
Locknut;replacewithanewoneand
stake
Applyengineoiltothethreadsand
seatingsurface
13-5
CRANKSHAFT/TRANSMISSION
TOOLS
Driver
07749-0010000
Attachment, 62 X 68 mm
07746-0010500
Pilot, 20 mm
07746-0040500
Bearing remover set, 20 mm
07936-3710600
Attachment, 42 x 47 mm
07746-0010300
Pilot, 22 mm
07746-0041000
Pilot, 30 mm
07746-0040700
Remover weight
07741-0010201
or 07936-371020A or 07936-3710200
(U.S.A. only)
Attachment, 52 x 55 mm
07746-0010400
Pilot, 17 mm
07746-0040400
Remover handle
07936-3710100
Driver, 57 mm
070MF-MEG0100
13..6
CRANKSHAFTITRANSMISSION
Metal installer set
070MF-MEG0200
Damper spring compressor
07964-ME90000
Shaft holder A
07PAB-001 01 00
or 07923-6890101 (U.S.A. only)
Holder handle
07PAB-0010400
Lock nut wrench, 36 x 47.8 mm
07916-MB00002
Differential inspection tool
07KMK-HC50101
or 07KMK-HC5010A (U.S.A. only)
Bearing remover set, 17 mm
07936-3710300
Oil seal driver
07965-KE80200
Driver, 40 mm 1.0.
07746-0030100
Attachment, 30 mm 1.0.
07746-0030300
Assembly bolt
07965-1660200
Assemb1y collar
07965-1660302
or 07965-166030A
13-7
CRANKSHAFTITRANSMISSION
Threaded adaptor
07965-KA30000
Snap ring pliers
07914-5670101
not available in U.S.A. or
07914-5670100
Compressor seat
07967-9690200
TROUBLESHOOTING
Excessiveenginenoise
Worn main journal bearings
Worn crankpin bearings
Worn or damaged transmission gear
Worn or damaged transmission bearings
Excessivenoiseinsidegear
Worn or damaged output shaft and final drive shaft gears
Worn or damaged output gear case bearing
Incorrect adjusted shim
Hardtoshift
Improper clutch operation (page 11-9)
Incorrect engine oil viscosity
Bent shift forks
Bent shift fork shaft
Bent shift fork claw
Damaged shift drum cam grooves
Bent gearshift spindle
Transmissionjumpsoutofgear
Worn gear dogs or holes
Worn gear shifter groove
Bent shift fork shaft
Broken shift drum stopper arm
Worn or bent shift forks
Broken drum stopper arm spring
Broken gearshift spindle return spring
13-8
CRANKSHAFTITRANSMISSION
CRANKCASESEPARATION
Removetheenginefromtheframe(page8-4).
RefertoServiceInformation(page13-3)forremoval
ofnecessarypartsbeforeseparatingthecrankcase.
Remove the bolts and cam chain tensioner setting
plates.
Removethecam chains.
SHAFTHOLDERA BOLTIWASHER
Hold the outputdriven gearshaftusing thespecial
tools, loosen the output drive gear shaft bolt and
removeitwiththewasher.
TOOLS:
ShaftholderA 07PAB-0010100or
07923-6890101
(U.S.A.only)
Holderhandle 07PAB-0010400
Removetheboltsand bearingsettingplate.
Loosen and removethe 6mm and 8 mm boltsin a
crisscrosspatterninseveral steps.
13-9
CRANKSHAFTITRANSMISSION
Loosen and removethe 6 mmand8 mmboltswith
washerinacrisscrosspatterninseveralsteps.
Turntheshiftdrumuntilthe positionas shown.
Place the crankcase with the left crankcase down
andremovetherightcrankcase.
NOTE:
Separatethe rightcrankcase from the leftcrank-
casewhilepryingatthepointsas shown.
Separatethe rightcrankcase fromthe leftcrank-
casewhiletappingthematseveral locationswith
asofthammer.
Removethedowelpinsandpipeseal.
Clean offthe sealant from the left and right crank-
case matingsurfaces.
PIPE SEAL
CRANKSHAFT/CONNECTINGROD
CRANKSHAFTREMOVAL
Separatethecrankcase(page13-9).
Duringcrankshaft Removethecrankshaft/connecting rod fromthe left
andconnectingrod crankcase.
service, becareful
notto damagethe
mainjournalor
crankpinbearing
inserts.
13-10
CRANKSHAFTITRANSMISSION
SIDECLEARANCEINSPECTION
Before removingtheconnecting rods, checkthe big
FEELER GAUGE
endsideclearance.
Measure the side clearance by inserting the feeler
gauge between the crankshaft and connecting rod
bigend.
SERVICELIMIT: 0.30mm(0.012in)
CONNEC"rlNG ROD REMOVAL
Tap the side of the Removethecrankpin bearingcapnutsandthebear-
CAPS
cap lightly if bearing ingcaps.
cap is hard to
remove.
Mark the rods, bearingsand caps as you remove
themtoindicatetheGorrectcylinderandpositionon
thecrankpinsforreassembly.
Forthe o n n ~ t i n rod smallendinspection
(page10-7).
13-11
CRANKSHAFTITRANSMISSION
CRANKSHAFTINSPECTION
Check the crankshaft journal surfaces for damage,
discolorationorscratch.
CRANKSHAFTRUNOUT
Placethecrankshafton astandorV-blocks.
Setadialindicatoronthemainjournals.
Rotatethecrankshafttwo revolutions and read the
runout.
SERVICELIMIT: 0.03mm(0.001 in)
10 mm(0.4in)
....1..-
40 mm(1.6in)
I......'
MEASUREMENTPOINT
CONNECTINGROD INSTALLATION
INOTICE I '
Do not interchange the bearing inserts. They must
be installed in their original locations or the correct
bearing oil clearance may not be obtained, resulting
in engine damage.
Wipeanyoirfrol11theconnecting rod,capand bear-
ingil}serts('-> Align
..;j9serts on the connecting rods
tabwiththegroove.
Apply molybdenum disulfide oil to the thrust sur-
face ofthecrankpin bearings.
Installtherods and capsonthecrankshaftbyalign-
ing the I.D. code on the rod and cap. Be sure each
partisinstalledinitsoriginalposition,asnoteddur-
ingremoval.
NOTE:
Facetheoiljetoffrontcylinderconnecting rodto
rearward(intakeside)ofthecylinder. Oil JET
Face theoiljetofrearcylinderconnecting rodto
rearward(exhaustside)ofthecylinder.
Applyengineoiltothe bearingcap nutthreadsand
seating surface, then tighten them in several steps
alternately.
TORQUE:33Nm(3.4kgfm,24Ibfft)
Aftertighteningthenuts, checkthattheconnecting
rodsmovefreelywithoutbinding.
13-12
CRANKSHAFTITRANSMISSION
CRANKSHAFTINSTALLATION
Apply molybdenum disulfide oil to the crankshaft
mainjournalsand installthecrankshaft intothe left
crankcase.
Assemblethecrankcase(page 13-49).
_,
CJonoirf,terchlIhgetlJe inserts. They must
be or the correct
bearing maynot be obtained, resulting
in engine damage,
Rernovethe rod (page 13-11).
-. _ . _. _.c.,' :" : " "-.' '. - _. - ". - ",
CheckthCe unusualwear,damage
BEARINGS
orpeelinganareplacethem ifnecessary.
Selectthereplacementbearing(page 13-14).
OILCLEARANCEINSPECTION
Clean offanyoilfromthebearing insertsandcrank-
pins.
Put.a strip of plastigauge lengthwise on each
cranl<pinavQidingtheoil hole.
. connecting rods and bearing
cal#orrttie' correct
. - "'.0.'
13-13
CRANKSHAFTITRANSMISSION
Do not rotate the Applyengineoiltothethreadsandseatingsurfaces
crankshaft during ofthebearingcap nuts.
inspection. Installthenutsandtightenthemevenly.
TORQUE:33 Nm(3.4kgfm,24Ibf.ft)
Remove the bearing caps and measure the com-
pressed plastigauge at its widest point on each
crankpintodeterminetheoilclearance.
SERVICE LIMIT: 0.07mm(0.003in)
Iftheclearance exceeds theservice limit,selectthe
correctreplacementbearingsasfollows.
BEARINGSELECTION
Recordtheconnecting rod 1.0.codenumber.
NOTE:
Number3or4ontheconnecting rod isthecodefor
theconnecting rod1.0.
Recordthecrankpin0.0.codeletter.
NOTE:
Let!ersA orBon each crankweight isthe code for
thecrankpin0.0.
Cross, reference the connecting rod and crankpin
codes todetermine the replacement bearing color
code. .
CONNECTING ROD 1.0.CODE NUMBER
13-14
CRANKSHAFTITRANSMISSION
CRANKPIN BEARING SELECTIONTABLE:
CONNECTING ROD J.D. CODE
3 4
43.000-43.008mm 43.008- 43.016mm
(1.6929- 1.6932in) (1.6932- 1.6935in)
CRANKPIN0.0.
CODE
A
39.982- 39.990mm
(1.5741 -1.5744in)
C
(Pink)
B
(Yellow)
B
39.974- 39.982mm
(1.5738-1.5741 in)
B
(Yellow)
A
(Green)
BEARINGTHICKNESS:
IDENTIFICATIONCOLOR
A (Green): Thick
B(YeJlow): t
C Thin
INE>TII; I
Afterse.Je 'ng new bearings, recheck the clearance
vyith a
2
ql a.l)ge. Incorrect clearance can cause
evereJi, .
CONNECTINGROD SELECTION
Analphabeticalweightcodeisstampedonthecap.
rod requires replacement, you
a rod with the same weight code as
.tllg'ofigll"la'L
unavailable, you may use one ofthe
s' inthefollowingchart.
RC1>DWEIGHTCOMBINATION
-1 table indicated thatmatch-
ingis. thecrossedcodes.
WEIGHTCODE
WEIGHT
A 398- 4039(14.0- 14.2oz)
B 403- 408 9(14.2- 14.4oz)
C 408-413g(14.4-14.6oz)
REARWEIGHTCODE
B C
I- A 0 0
I- :r:W f---j------I------+---------1
BOO 0
a: W U f---j------I------+---------1
i.C 0 0
.
- Cdnrtecting ro.p(page13-12)
- Crankshaft(p:age:J3-13)
13-15
CRANKSHAFT{TRANSMISSION
MAINJOURNALBEARING
INOTICE I
Do not interchange the bearing inserts. They must
be installed in their original locations or the correct
bearing oil clearance may not be obtained, resulting
in engine damage.
Removethecrankshaft(page 13-10).
BEARINGINSPECTION
Clean offanyoilfromthebearings.
Check the bearings for unusual wear, damage or
peelingand replacethemifnecessary.
Measure the main journal bearing 1.0. at between
the bearing groove and crankcase outside end of
thebearing,and 90 degreestotheindexmark.
Cleanoffanyoilfromthecrankshaftjournals.
Measure and record the crankshaft main journal
0.0.
SERVICELIMIT: 52.976mm(2.0857in)
CalculatElthemainjournaloilclearance.
$ERVICELIMIT: 0.07mm(0.003in)
Iftheclearance e)(ceeds theservice limit,selectthe
bearing.
BEARINGSELECTION
Setaspecialtooland hydraulicpressontheoutside
ofthecrankcase.
TOOL:
Driver/57mm 070MF-MEG0100
13-16
CRANKSHAFTITRANSMISSION
Pressthemainjournalbearingstowardtheinsideof
thecrankcase.
DRIVER
BEARING
Measureand recordthecrankcase mainjournal1.0.
at between the main journal groove and crankcase
outsideend,and90 degreestotheindexmark.
SERVICELIMIT: 58.070mm(2.2862in)
Depending upon the results ofthe
ments there are four possible scenarios for mam
journalbearingselection:
Crankshaftandcrankcasearereplaced
Crankcaseonlyisreplaced
Crankshaftonlyis replaced
Mainjournalbearingsonlyarereplaced
Carefully refer to the following instructions and
tablesformainjournalbearingselection.
Record,the bearingsupport1.0. codeletter.
NOTE:
LettersA orBon each crankcase isthecodeforthe
crankcase1.0. L ----:---'
Recordthemainjournal0.0.codenumber.
NOTE:
Letters1,2or3oneachcrankweightisthecodefor
crankshaftjournal0.0.
Cross-referencethecrankshaftandcrankcasecodes
todeterminethereplacementbearingcolor.
13-17
CRANKSHAFTITRANSMISSION
In case the crankshaft and crankcase are replaced:
<
58.016 - 58.022 mm BEARING
A
(2.2841 - 2.2843 in) SUPPORT
I.D. CODE 58.010 - 58.016 mm
B
(2.2839 - 2.2841 in)
In case the crankcase only is replaced:
1
52.994- 53.000 mm
(2.0864 - 2.0866 in)
C
(Brown)
D
(Green)
MAIN JOURNAL O.D. CODE
2 3
52.988 - 52.994 mm 52.982 - 52.988 mm
(2.0861 - 2.0864 in) (2.0859 - 2.0861 in)
B A
(Black) (Blue)
C B
(Brown) (Black)
MAIN JOURNAL O.D.
52.994 - 53.000 mm 52.988 - 52.994 mm 52.982 - 52.988 mm 52.976 - 52.982 mm
12.0864 - 2.0866 in) (2.0861 - 2.0864 in) (2.0859 - 2.0861 in) (2.0857 - 2.0859 in)
BEARING
A
58.016 - 58.022 mm
SUPPORT (2.2841 - 2.2843 in)
C
(Brown)
B A
(Black) (Blue)
A
(Blue)
I.D. CODE
B
58.010 - 58.016 mm
(2.2839 - 2.2841 in)
D
(Green)
C B
(Brown) (Black)
A
(Blue)
In case the crankshaft onlyjs replaced:
MAIN JOURNAL O.D. CODE
1 2 3
52.994-53.000 mm 52.988 - 52.994 mm 52.982 - 52.988 mm
(2.0864 - 2.0866 in) (2.0861 - 2.0864 in) (2.0859 - 2.0861 in)
MAIN JOURNAL 58.010 - 58.016 mm D C B
I.D. (2.2839 - 2.2841 in) (Green) (Brown) (Black)
58.016 - 58.022 mm C B A
(2.2841 - 2.2843 in) (Brown) (Black) (Blue)
58.022 - 58.034 mm B A A
(2.2843 - 2.2848 in) (Black) (Blue) (Blue)
58.034 - 58.046 mm A O.S.G O.S.G
(2.2848 - 2.2853 in) (Blue) (Red) (Red)
58.046 - 58.058 mm O.S.G 0.5. F 0.5. F
(2.2853 - 2.2857 in) (Red) (Pink) (Pink)
58.058-58.070 mm 0.5. F 0.5. E 0.5. E
(2.2857 - 2.2862 in) (Pink) (Yellow) (Yellow)
In case of main bearing replacement only:
MAIN JOURNAL O.D.
52.994 - 53.000 mm
(2.0864 - 2.0866 in)
52.988 - 52.994 mm
(2.0861 - 2.0864 in)
52.982 - 52.988 mm
(2.0859 - 2.0861 in)
52.976 - 52.982 mm
(2.0857 - 2.0859 in)
BEARING
SUPPORT I.D.
58.010 - 58.016 mm
(2.2839 - 2.2841 in)
58.016 - 58.022 mm
(2.2841 - 2.2843 in)
D
(Green)
C
(Brown)
B
(Black)
A
(Blue)
C
(Brown)
B
(Black)
A
(Blue)
A
(Blue)
58.022- 58.034 mm
. 12.2&43';- 2.2848 in)
B
(Black)
A
(Blue)
A
(Blue)
O.S.G
(Red)
mm
..
A
(Blue)
O.S.G
(Red)
0.5. G
(Red)
0.5. F
(Pink)
58.046-'- 58.058mm
(2.2853::
2
?;2857 in)
O.S.G
(Red)
0.5. F
(Pink)
0.5. F
(Pink)
0.5. E
(Yellow)
58.058
(2.2857 ",:.
0.5. F
(Pink)
O.S. E
(Yellow)
0.5. E
(Yellow)
0.5. E
(Yellow)
13-18
-----------' - --
CRANKSHAFTITRANSMISSION
BEARINGTHICKNESS:
IDENTIFICATIONCOLOR
0.5.E(Yellow): Thick
0.5.F(Pink):
0.5.G(Red):
A(Blue): Middle
B(Black):
!
C(Brown):
o(Green): Thin
BEARINGINSTALLATION
Applyengineoi.1 tqiiel(llbeafingsurface.
Setnewbearin"gi totf1e metal installer aligning its
sideedgewiththemetalinstallergrooves.
"
TOOL:
Metalinstallerset 070MF-MEG0200
Tighten the boltsalternatelyinseveral steps to the
specifiedtorque.
TORQUE:23Nm(2.3kgfm,17Ibfft)
BOLTS
~ g n
, BEARING
Set the bearings and special tools assembly on
inside ofthe crankcase, fitting the bearing edge in
thecrankcasemainjournal.
AlignthetTlatinglineofthebearingswiththeindex
markonthecrankcaseas shown.
Setthehyaraulicpress.
TOOL:
M.eialinstaller set 070MFMEG0200
METAL
INSTALLERSET
BEARING
13-19
CRANKSHAFT/TRANSMISSION
Press the new bearings until the metal installer
INSTALLERSET
flangefullyseated.
I BEARING
Make sure the bearing mating line aligns with the
indexmarkonthecrankcase.
Checktheoilclearance(page13-16).
After selecting newbearings, recheck the clear-
ance. Incorrect clearance can cause severe
enginedamage.
Installthecrankshaft(page13-13).
TRANSMISSION
REMOVAL
Separatethecrankcase(page13-9).
Removetheforkshaftfromtheshiftforks.
Removetheshiftforksand shiftdrum.
13-20
CRANKSHAFTITRANSMISSION
Remove the mainshaft and countershaft together.
MAINSHAFT
TRANSMISSIONDISASSEMBLY
Disassemble the mainshaft and countershaft.
MAINSHAFT
INSPECTION
GEARS
Check the gear dogs. dog slots and teeth for dam-
age or excessive wear.
COUNTERSHAFT
DOG
Measure the I.D. of each gear.
SERVICE LIMITS:
M3, M5 gears: 28.04 mm (1.104 in)
C1, C4 gears: 31.05 mm (1.222 in)
C2 gear: 24.04 mm (0.946 in)
SLOT
13-21
--
CRANKSHAFTITRANSMISSIOI\l
BUSHINGS
Checkthebushingsforwearordamage.
Measurethe0.0.ofeach bushing.
SERVICE LIMITS:
M3,M5,gearbushings:27.94mm(1.100in)
C1,C4gearbushings: 30.93mm(1.218in)
C2 gearbushing: 23.94mm(0.943 in)
Measurethe1.0. ofeach bushing.
SERVICELIMITS:
M3gearbushing: 25.04mm(0.986in)
C2gearbushing: 20.04mm(0.789in)
MAINSHAFTICOUNTERSHAFT
Check the spline grooves and sliding surfaces for
abnormalwearordamage.
Measljretl1e0,0.ofthemainshaftandcountershaft
atthegearand bushingslidingareas.
SERVICE LIMiTS:
Mainshaft(atM3gearbushing):
24.94mm(0.982in)
Cauntershaft(atC2 gearbushing):
19.96mm(0.786in)
Calculate the gear-to-bushing and bushing-to-shaft
clearance.
SERVICE LIMITS:
Gear-ta-bushing
M3,M5,C2: 0.10mm(0.004in)
C1,C4: 0.11 mm(0.004in)
Bushing-ta-shaft
M3: 0.10mm(0.004in)
C2: 0.07 mm(0.003in)
SHIfTFORK
Checkforodeformationorabnormalwear.
Measure};theshiftforkclawthickness.
SERVICE'L1MIT: 5.6mm(0.22in)
Measuretheshiftfork1.0.
SERVICE LIMIT: 13.03mm(0.513in)
t
C2
13-22
____0 _
CRANKSHAFTITRANSMISSION
SHIFTFORKSHAFT
Check the shift fork shaft for bend, abnormal wear
ordamage.
Measuretheshiftforkshaft0.0.
SERVICELIMIT: 12.90mm(0.508in)
SHIFTDRUM/SHIFTDRUMBEARING
Removetheboltandgearshiftcam plate.
CAM PLATE BOLT
Removethedowelpinandbearing.
Remove the dowel pins from the gearshift cam
DOWELPINS
plate.
\
DOWELPIN
CAM PLATE
13-23
CRANKSHAFT/TRANSMISSION
Temporarilyinstallthebearing on theshiftdrum.
BEARINGS
Turntheouterrace ofthebearing withyourfinger.
Thebearingshouldturnsmoothlyandquietly.
Alsocheckthatthebearing innerracefitstightlyon
theshiftdrum.
Removeand discardthe bearing iftheraces donot
turnsmoothly,quietly,orifitfitslooselyontheshift
drum.
Checkthe shift drum end forscoring, scratches, or
evidenceofinsufficientlubrication.
Checktheshiftdrum groovesforabnormalwearor
damage.
MeasuretheshiftdrumO.D. atleftend.
SERVICE I.IMIT: 11.94mm(0.470in)
Checktheshiftdrumjournalintheleftcrankcasefor
excessjvewearordamage.
Measuretheshiftdrumjournall.D.
SERVICELIMIT: 12.05mm(0.474in)
Calculatetheshiftarum-to-shiftdrumjournal clear-
ance.
S R V I ~ I LIMIT: 0.09mm(0.035in)
InstalLthe dowel pins into the gearshift cam plate
holes. .
CAM PLATE
13-24
CAM PLATE
",
...;/
BOLT ew
CRANKSHAFT/TRANSMISSION
Installthebearingontheshiftdrum.
BEARING
Installthedowelpin intotheshiftdrumhole.
/
Install the gearshift cam plate by aligning its hole
withthedowel pin.
Cleanandapplyalockingagenttothegearshiftcam
platebolt(page1-19).
Installandtightenthebolttothespecifiedtorque.
TORQUE: 12Nm(1.2kgfm,9Ibfft)
13-25
M5GEAR BUSHING
SNAPRING
M3GEAR(23T)
M1 GEAR (15T)
M4GEAR(25T)
CRANKSHAFTITRANSMISSION
TRANSMISSIONASSEMBLY
Clean all partsinsolvent.
Applyengineoiltotheallgearteeth.
Applymolybdenumdisulfideoiltothegearbushing
sliding surface and shiftforkgroovestoensure ini-
tiallubrication.
Assembleall partsintotheiroriginal positions.
NOTE:
Checkthe gears for freedom of movement or
rotationontheshaft.
Installthe washers and snap rings with the
chamferededgesfacingthethrustloadside.
Do notreuseawornsnapringwhichcouldeasily
spininthegroove.
Check that the snap rings are seated in the
grooves and align their end gaps with the
groovesofthespline..
Ali9'1;thelockwashertabswiththesplinewasher
grooves.
Alignthe oil holes in the M5 gear bushing and
m<:linshaft,andC1, C4 gearbushingand counter-
shaft
MAINSHAFT
M2GEAR(20T)
CRANKSHAFTITRANSMISSION
COUNTERSHAFT
C2 GEAR (31T)
C2 GEAR BUSHING
COUNTERSHAFT
THRUSTWASHER FAINAL DRIVE GEAR (37T)
INSTALLATION
Install the mainshaft and countershaft together into
MAINSHAFT
the left crankcase.
Be sure to install the thrust washers of the counter-
shaft both ends.
The shift forks have the following identification
marks.
"L": Left shift fork
"C": Center shift fork
"R": Right shift fork
"R" MARK "C" MARK
13-27
CRANKSHAFT/TRANSMISSION
Install the shift forks into the shifter gear grooves
with the markings facing up (right crankcase side).
Install the shift drum by aligning the shift fork guide
pins with the shift drum guide grooves.
Apply engine oil to the shift fork shaft whole sur-
face.
Insert the shift fork shaft through the shift forks into
the right crankcase.
After installation, check for smooth transmission
operation.
Assemble the crankcase (page 13-49).
OUTPUT GEAR
Descriptionof theoutputgearassembly:
DAMPER CAM
--- ----
--------
CRANKSHAFTITRANSMISSION
REMOVAL
Separatethecrankcase (page 13-9).
i THRUSTWASHER
Removethefollowing:
- Crankshaft(page13-10)
- Transmission (page13-20)
Removethethrustwasherandoutputgear.
Remove the bushing from the output drive gear
BUSHING
shaft.
(E).Ccept U$.A.)
Sefthedamperspringcompressorontothedamper
camandoutputclrivegears.haft.
Compressthe damper spring by turning the com- _ I I l I I I ~
pressor bolt clockwise until the snap ring can be
removed.
TOOL:
Damperspringcompressor 07964-ME90000
13-29
----- ------ -----
CRANKSHAFTITRANSMISSION
(U.S.A.only)
Place thethreadedadaptorin the end ofthe output
drivegearshaftandtightentheadaptor.
Place the compressorseat overthethreaded adap-
torwiththesteppedsidefacingupward.
Installthe assembly boltthrough the assemblycol-
larandattach ittothethreadedadaptor.
Center the compressor seat with the damper cam
thenbegintotightenthe23mmnutoftheassembly
bolt until the snap ring is visible so it can be
remoVed.
TOQLS; .
AsserntilYcbolt 07965-1660200
Assemblycollar 07965-166030Aor
07965-1660302
Compressorseat 07967-9690200
Threadedadaptor 07965-KA30000
Snapringpliers 07914-5670101 not
availableinU.S.A.
or
07914-5670100
Remove the snap ring, special tools, damper cam
andspringfromthedrivegearshaft.
Removetheboltandstay.
Removetheoutputgearcase mountingbolts.
RemovetheoutputgearcaseassemblyandO-ring.
ASSEMBLYBOLT
ASSEMBLYCOLLAR
It::::: THREADEDADAPTOR
COMPRESSORSEAT
SNAPRING
DAMPERCAM
OUTPUTDRIVEGEARSHAFT
-
13-aO
--- --- --- -------
CRANKSHAFTITRANSMISSION
Removetheorificeand O-rings.
Checktheorificeforclogordamage.
Replace itifnecessary.
INSPECTION
DAMPERCAM
Checktheprojectionsofdampercamfordamageor
excessivewear.
PROJECTIONS
OUTPUTGEAR
Check the,output gearteeth for damage or exces-
sivewear,andthegeardog holesfordamage.
MeasuretheoutputgearI.D.
SERVICELIMIT: 24.04mm10.946in)
BUSHING
Checktheoutputgearbushingforwearordamage.
MeasurethebushingI.D.andO.D.
SERVICELIMIT: 0.0. 23.70mm(0.933in)
1.0. 20.06mm(0.7g0in)
Calculatetheoutputgear-to-bushingclearance.
SERVICELIMIT: 0.082mm(0.0032in)
13-31
CRANKSHAFT/TRANSMISSION
OUTPUTDRIVEGEARSHAFT
Measure the 0.0. ofthe output drive gear shaft at
thebushingslidingarea.
SERVICELIMIT: 19.97mm(0.786in)
Calculatethebushing-to-shaftclearance.
SERVICE LIMIT: 0.08 mm(0.003in)
DAMPERSPRING
Measurethedamperspringfreelength.
SERVICE LIMIT: 59mm(2.3in)
Turn the outputdrivegearshaftand checkthatthe
output drive and driven gearshafts turn smoothly
andquietlywithoLltbinding.
Ifthe shafts do not turn smoothly or quietly, the
gearsand/orbearing maybedamagedorfaulty.
They must be checked after disassembly; replace
faultyparts/assembliesas required.
BACKLASHINSPECTION/GEAR
TOOTHCONTACTPATrERNCHECK
NOTE:
Performthebacklashinspectionandcontactpattern
checkwheneveryou replacetheoutputdriven/drJve
gears, bearings, bearing holderand gearcase. The
extension linesfromthegearengagementsurfaces
shouldintersectatonepoint.
13-32
CRANKSHAFTITRANSMISSION
BACKLASHINSPECTION
Settheoutputgearcaseinavisewithsoftjaws.
OUTPUTDRIVE GEAR SHAFT
Set a horizontal type dial indicator on the output
drivengear,throughtheVS sensorhole.
Holdtheoutputdrivegearshaftwithyourhandand
rotatethedriven gearshaft until gearslackis taken
up.
Turn the driven gear shaft back and forth to read
backlash.
STANDARD: 0.08- 0.23mOl(0.003- 0.009in)
SERVICE LIMIT: 0.40mOl(0.016in)
Remove the dial indicator. Turn the driven gear
\
shaft120
0
andmeasurebacklash. Repeatthisproce-
dureoncemore.
Comparethedifferenceofthethreemeasurements.
Backlashdifferencebetweenmeasurements
SERVICELIMIT: 0.10mOl(0.004in)
Ifthe difference in measurements exceeds the ser-
vice limit, it indicates that the bearing is not
installedsquarelyorthecase isdeformed.
Inspectthebearingsandcase.
OUTPUT
DRIVEN GEAR DIALINDICATOR
Ifthe backlash is.E!xcessive,replacetheoutputdrive
gear one.
Ifthe backlash replacetheoutputdrive
shim.witha
0.06- 0.07 mm(0.002
-O'Q,O:.tihl when.$himthickness ischanged by0.10
mm(O:pJ)4 in).
.OUTPUT'DFlI\(EGEARSHIMS:
0;30.mm(O;012in)
.Cijsmm(0.014in)
mOl (0.016in)
0.45mOl (0.018in)
0.50mOl (0.020in)- Standard
0.55mm(0.022in)
0.60mOl(0.024in)
O.65rrirn(0.026in)
0.70mOl(0.028in)
0.75mOl (0.030in)
OUTPUTDRIVEGEARSHIMREPLACEMENT
Removetheboltsanddrivegearassemblyfromthe
BOLTS
gearcase.
13-33
CRANKSHAFT/TRANSMISSION
Remove the dowel pin, shim and O-ring from the
bearing holder.
Selectthereplacementshim(page13-33).
Coata newO-ring withengineoiland install itinto
thebearing holdergroove.
Installthedowelpinandshim.
Install the drive gear assembly into the gear case
andtightenthebolts(page13-44),
Recheckthebacklash(page13-32).
After backlash adjustment has been made, check
thegeartoothcontactpatternas describedbelow.
SHIM DOWELPIN
GEARTOOTHCONTACTPATTERNCHECK
O-RING fI"7I
Description of the tooth:
COASTSIDE
(contactswhenenginebrakeisapplied)
------
DRIVE SIDE
(contactswhenenginepowerisapplied)
Removethedrivegearassemblyfromthegearcase
DRIVEN GEARTEETH
(page13-33).
Apply a thin coat of Prussian Blue to the output
drivengearteeth.
Reinstallthedrivegearwiththeshim.
Rotatethedrivegearshaftseveraltimesinthe nor-
maldirectionofrotation.
Removethedrivegearassemblyandcheckthegear
toothcontactpattern.
Contact is normal ifPrussian Blue is transferred to
theapproximatecenterofeachtoothandslightlyto
thetoe.
Ifthepattern is notcorrect, removeand replace the
outputdrivengearshim.
SHIM HEEL
--
TOE _ HEEL
FACE
FLANK ..
13-34
CRANKSHAFTITRANSMISSION
Replace the shim with athinner one ifthe contact
pattern istoohigh,towardtheface.
Replace the shim with a thicker one ifthe contact
pattern istoolow,towardtheflank.
Thepatternwillshiftabout1.5- 2.0mm(0.06- 0.08
in)whentheshimthicknessischanged by0.10mm
(0.04in).
OUTPUTDRIVENGEARSHIMS:
0.20 mm(O.OOBin)
0.25mm(0.010in)
0.30mril(0.012in)
0.35mm(0.014in)
0.4Q I'Ilm (0.016in)- Standard
0;45mm(0.Q_1Sin)
0.50mm in)
0.55mm(O.022in)
0.60mOl (0.024in)
OUTPUTDRIVENGEARSHIMREPLACEMENT
Holdtheoutputgearcasein avisewithsoftjaws.
Removetneboltsand outputdrivengearassembly.
Remove the shim and O-ring from the bearing
holOer.
Selectthereelacementshim (page13-35).
CQat!'! oil and install itinto
gXbove.
ltista'lltieshim; .' ..
assembly to the gear case
ancftightentt1e 13-41).
(page13-34).
Toohigh:
DRIVE SIDE COASTSIDE
FACE
COASTSIDE
Toolow:
DRIVE SIDE
OUTPUTDRIVEN GEARASSEMBLY
fI "71O-RING
SHIM
13-35
----- ---------------------
CRANKSHAFTITRANSMISSION
OUTPUTDRIVEGEARDISASSEMBLY
Hold the output gear case in a vise with soft jaws.
Unstake the bearing inner/outer race lock nuts.
Remove the bearing inner race lock nut using the
special tools.
TOOLS:
ShaftholderA 07PAB-0010100or
07923-6890101
(U.S.A. only)
Holderhandle 07PAB0010400
Locknutwrench,36x47.8 mm 07916-MB00002
Remove the bearing outer race lock nut using a spe-
cial tool.
TOOL:
Locknutwrench,36x47.8 mm 07916-MB00002
Remove the two bolts and drive gear assembly from
the gear case.
13-36
CRANKSHAFTITRANSMISSION
Remove the dowel pin, shim and O-ring from the
O-RING
bearing holder.
SHIM DOWEL PIN
Press the drive gear out of the bearing using a
hydraulic press.
Press the drive gear bearing out of the bearing
holder using the special tools and a hYdraulic press.
TOOLS:
Driver. 07749-0010000
Attacblllent, 52 x 55 mm 07746-0010400
PiJot,30mm 07746-0040700
OU"rpUTDRIVENGEAR
DISASSEMBLY
HoJ<jthe<jutllutgear case in a vise with soft jaws.
STOPPER RING
ring and oil seal.
13-37
CRANKSHAFTITRANSMISSION
Unstakethebearing innerand outerrace locknuts.
Holdthe driven gearshaftand remove the bearing INSPECTIONTOOL
SHAFTHOLDER
innerrace locknutusingthespecialtools.
TOOLS:
ShaftholderA 07PAB-0010100 or
079236890101
(U.S.A. only)
Locknutwrench,36x47.8mm 07916-MB00002
Differentialinspectiontool 07KMK-HC50101 or
07KMK-HC5010A
(U.S.A.only)
Removethebearingouterrace locknutusingaspe-
cialtool.
TOOL:
Locknutwrench,36x47.8 mm 07916-MB00002
Remove the bolts and driven gear assembly from
thegearcase.
LOCKNUTWRENCH
13-38
CRANKSHAFTITRANSMISSION
Remove the shim and O-ring from the bearing
O-RING
holder.
SHIM
Press the driven gear out of the bearing using a
hydraulicpress.
Press the driven gear bearing out of the bearing
holderusingthespecialtoolsandahydraulicpress.
TOOLS:
Driver 07749-0010000
Attachment,52x55 mm 07746-0010400
Pilot,30mm 07746-0040700
Removethedrivengearcasebearing usingthespe-
cialtools.
TOOLS:
Bearingremoverset,17mm 07936-3710300
Removerhandle 07936-3710100
Removerweight 07741-0010201 or
07936371020Aor
07936-3710200
(U.S.A.only)
BEARING
,
13-39
CRANKSHAFTITRANSMISSION
Blow oil passage in the output gear case with com-
pressed air.
OUTPUTDRIVENGEARASSEMBLV
"71
$I O-RING
"71 31 Nm (3.2kgfm. 23 IbHt) SHIM
Drive a new bearing into the gear case with the
DRIVER
marked side facing up until it is fully seated.
TOQLS:
077490010000
42 x 47mm 07746-0010300
Pilot, 17 mm 07746-0040400
BEARING
"
13-40
CRANKSHAFT/TRANSMISSION
Pressanewbearingintothebearingholderwiththe
marked side facing up until it is fully seated and
makesureitrotatesfreelyafterinstallation.
TOOL:
Oilsealdriver 07965-KE80200
If the output driven Supportthebearing innerrace andpresstheoutput
gear requires drivengearintothebearing holderusingthespecial
replacement, the tools.
driven and drive
gear must be
TOOLS:
replaced asaset. Driver,40mm1.0. 07746-0030100
Attachment,30mm1.0. 07746-0030300
Coat anewO-ring with engine oil and install itinto .,--:7M O-RING
thebearing holdergroove. __
Installtheshim.
NOTE:
When the-bearing, gear, holder and/or case have
been replaced, use the0.40 mm (0.016 in) shimfor
.initialreference.
DRIVER
.,
BEARING
.,.
.
ATTACHMENT
. II
SHIM
Holdthl;loutputgearcaseinavisewithsoftjaws.
Install thedriven gearassemblyintothegearcase,
aligningwiththeboltholes.
Applyengine oil tothethreads and seatingsurface
oftheboltsandtightenthem.
TORQUE:31 Nm(3.2kgfm,23Ibf.ft)
13-41
CRANKSHAFTITRANSMISSION
Refer to torque
wrench reading
information, on
page 13-3'Service
information'.
Refer to torque
wrench reading
information, on
page 13-3'Service
information'.
Applyengine oil tothethreadsand seating surface
ofanewbearingouterrace locknutandtightenitto
thespecifiedtorqueusingaspecialtool.
TOOL:
Locknutwrench,36x47.8 mm 07916-MB00002
TORQUE:
Actual: 98 Nm(10.0kgfm,72Ibf.ft)
Indicated:89Nm(9.1 kgfm,66Ibf.ft)
Applyengineoil tothethreads and seating surface
ofanewinnerrace locknut.
Holdthedrivengearshaftandtightenittothespec-
ifiedtorqueusingthespecialtools.
TOOLS:'
ShaftholderA 07PAB-0010100or
07923-6890101
(U.S.A.only)
Locknutwrench,36x47.8 mm 07916-MB00002
Differentialinspectiontool 07KMK-HC50101 or
07KMK-HC5010A
(U.S.A.only)
TORQUE:
Actual: 73 Nm(7.4kgfm,54Ibfft)
Indicated:66Nm(6.7kgfm,49lbfft)
Stakethebearinginnerandouterrace locknuts.
Pack grease intotheseal lipcavityofanewoil seal
and installitimtilthe ring groove is visible so the
stopperringcan be installed.
Install the stopper ring into the bearing holder
groovesecurely.
NOTE:
Installthestopperring withthechamfered edge
facingthethrustloadside.
Do notreusewornstopperringwhichcouldeas-
ilyspininthegroove.
Check that the stopper ring is seated in the
groove.
INSPECTIONTOOL SHAFTHOLDER
...,,/It
II lIliijjll
INNERLOCK NUT
13-42
CRANKSHAFTITRANSMISSION
OUTPUTDRIVEGEARASSEMBLV
13-43
If the output drive
gear requires
replacement, the
drive and driven
gears must be
replaced as aset.
OUTPUTGEAR
O-RINGS
.t'"7I
fII:
, >
""7J31 Nm(3.2 kgfm,23 IbHt)
Pressanewbearingintothebearingholderwiththe
facing upuntllitisfullyseated.
TOOLS:
Driver 07749-0010000
62x68mm 07746-0010500
P!lot,30.mll1 07746-0040700
Supportthebearing innerraceand presstheoutput
drivegearusingthespecialtools.
TOOLS:
Driver,.40mm1.0.
30mm1.0.
fum
NOTE:
Place the pilot's threaded end into the drive
shaft.
If the bearing, gear, holder and/or case is
replaced,anewshimmustbeselected(Seepage
13-33,Backlash Inspection).
07746-0030100
07746-0030300
07746-004UjOO
CRANKSHAFTITRANSMISSION
Refer to torque
wrench reading
information, on
page 13-3'Service
information',
Coat anewO-ring with engine oil and install itinto
thebearing holdergroove.
Installthedowelpinandshim.
NOTE:
Whenthe bearing,gear,holderand/orcase have
been replaced, use the 0.50 mm (0.020 in) shim
forinitial reference.
Installthedrivegearassemblyintothegearcase.
Applyengineoiltotheboltthreadsandseatingsur-
face.
Tightentheboltstothespecifiedtorque.
TORQUE:31 Nm(3.2kgfm,23Ibf.ft)
Holdthegearcase in avisewithsoftjaws.
Applyengine oil tothethreadsand seating surface
ofanewbearingouterrace locknutandtightenitto
thespecifiedtorqueusingaspecialtool.
TOOL:
Locknutwrench,36x 47.8 mm 07916MB00002
TORQUE:
Actual: 98 Nm(10.0kgfm,72Ibfft)
N'm(9.1 kgfm,66Ibfft)
APJ:lly,engine oil threadsand seating surface
cof bearingir:merracelOcknutandtightenitto
thespecifiedtorqueusingthespecialtools.
TOOtS:
Lockntitwrench,36x 47.8 mm 07916MB00002
ShaftholderA 07PAB0010100or
079236890101
(U.S,A.
Holderetiandle 07PAB-0010400
TORQUE:
AC'b,(al: 73 Nm(7.4kgfm,54Ibfft)
Indlcated:66Nm(6.7kgfm,49Ibfft)
O-RING ..
...jjilllfil
DOWELPIN
INNER LOCK NUT
at,
I
I
." 'Il
IIliijjIII OUTER LOCK NUT
13-44
CRANKSHAFTITRANSMISSION
Stakethebearing innerand outerrace locknuts.
INSTALLATION
Coat new ~ r i n s with engine oil and install them
intothe6rificegrooves.
Installtheorificeintothecrankcase.
Coata newO-ring with engineoil and install itinto
thegrooveinthegearcase.
Install the output gear case assembly into the left ..0
crankcase byaligningthedowelpinwiththecrank- "0.
case hole.
Applysealanttotheoutputgearcase mountingbolt
threads.
Tightentheboltstothespecifiedtorque.
TORQUE:31 Nm(3.2kgfm,23 Ibfft)
Install thestay, aligning its hole with thegearcase
bossandtightentheboltsecurely.
13-45
---------- -- --
CRANKSHAFTITRANSMISSION
13-46
Apply 1 g of molybdenum disulfide grease to the
outputdrivegearanddampercamsplines.
Installthedamperspringovertheoutputdrivegear
withthetightlywoundcoilfacingtheleftcrankcase.
Installthedampercamontothespring.
Installthesnapringonthedampercam.
(ExceptU.S.A.)
Setthedamperspringcompressorontothedamper
cam and drivegearshaft.
Compress the damper spring by turning the com-
pressor boltclockwise untilthesnap ring groove is
visible.
TOOL:
Damperspringcompressor 07964ME90000
(U.S.A.only)
Place thethreaded adaptorin theendofthe output
drivegearshaftandtightentheadaptor.
Place the compressorseat overthethreaded adap-
torwiththesteppedsidefacing upward.
InstalltheasselT!blybolt]hrqughthe assemblycol-
lar and attachit tothetnfe.aejedadaptor.
Centerthe, compressor:seatwith the damper cam
thenbegintotightenthe23mm nutoftheassembly
boltuntilthesnaprihggrOOveisvisiblesosnapring
Cah be1Ilstalledintothegroove.
T O t l s ~ ~
Assemblybolt 079651660200
Assemblycollar 07965166030Aor
079651660302
Compressorseat 079679690200
Threadedadaptor 07965KA30000
Installthesnapringintothegrooveintheshaft.
TOOLS:
Snapringpliers_ 079145670101
notavailablein
U.S.A.or
07914-5670100
NotE:
Install the snap ring with the chamfered edges
facingthethrustloadside;
Do notreuse wornsnap ring which could easily
spininthegroove;
Checkthatthesnapring isseatedinthegroove.
Loosen and removethespecialtool.
ASSEMBLYBOLT
ASSEMBLYCOLLAR
THREADEDADAPTOR
COMPRESSOR SEAT
I --- SNAPRING
DAMPER CAM
OUTPUTDRIVE GEAR SHAFT
CRANKSHAFTITRANSMISSION
Installthebushingintotheoutputgearshaft.
OUTPUTGEAR
Install theoutputgearontothe gearshaftbyalign-
ing the damper cam projections with the output
gearholes.
Installthethrustwasher.
Installthefollowing:
- Crankshaft(page13-13)
.7 Transmission(page13-27)
':"Oilpump(page5-11)
Assemblethecrankcase(page13-49).
THRUSTWASHER
CRANKCASEBEARINGREPLACEMENT
INSPECTION
Removethefollowing:
- Cranksnaft(page13-10)
- Transmission(page13-20)
- Outputgear{page13-29)
- Oil pump(page5-6)
Turntheinnerraceofeach bearingwithyourfinger.
.Thebearipgssh041dturnsmoothlyand quietly.
Also'checktnatihebearingouterrace fitstightlyin
thecrankcase. ..
Remove and discardthEfoearihgsifthe races does
not turn smoothly, quietlY, or ifthey fit loosely in
thecrankcase.
LEFTCRANKeASEBEARINGS
",-Cr- --. -; -'=._.\
and countershaft bearings
usingthe'specialtools.
TOols:
Bearirtgremoverset,20mm
handle .
07936-3710600
07936-3710100
"",,eight 07741-0010201 or
07936-371020Aor
07936':3710200
(U.S.A.'onlyJ
BEARING
13-47
CRANKSHAFT/TRANSMISSION
Removetheoil guideplatefromthecrankcase.
Checktheoilguideplateforclogordeformation.
Installtheoilguideplateintothecrankcase.
Drive newbearings intothe left crankcase withthe
markedsidefacingupuntiltheyarefullyseated.
TOOLS:
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
RIGHTCRANKCASEBEARINGS
Drivethebearingsoutoftherightcrankcase.
OUTPUTDRIVEGEAR
SHAFTBEARING
Drivenewbearingsintotherightcrankcasewiththe
markedsidefacingupuntiltheyarefullyseated.
TOOLS:
Mainshaft bearing:
Driver 07749-0010000
Attachment, 52 x 55 mm 07746-0010400
Pilot, 22 mm 07746-Q041000
Countershaftloutput drive gear shaft bearillgs:
Driver 07749':0010000
Attachment, 42 x 47 mm 0774&-0010300
Pilot,20mm 07746-0040500
13-48
----- ------
CRANKSHAFTITRANSMISSION
CRANKCASEASSEMBLY
Clean the left and right crankcase mating surfaces
thoroughly,beingcarefulnottodamagethem.
Makesuretheall partsareinstalledintheleftcrank-
case.
Apply liquid sealant tothe right and left crankcase
matingsurfaces.
Installthetwodowelpinsintotheleftcrankcase.
Coatanewpipeseal withengineoil and installitto
;theojlpipe.
~ : . . .
NOTE:
Install a new pipe seal with itstapered sidefacing
out.
Installtherightcrankcaseovertheleftcrankcase.
Turntheshiftdrumuntilthepositionas shown.
InstalltherightcrankcaseCboltswiththewasher.
Tighten the 8 mm boltl; in a crisscross pattern in
severalsteps.
TORQUE:
8rnmbolt:23 N;m(2.3kgfm,17Ibfft)
Tightenthe6mmboltssecurely.
13-49
--- ----------------
CRANKSHAFTITRANSMISSION
Installtheleftcrankcase boltsandtightenthe8mm
boltsinacrisscrosspattern inseveral steps.
TORQUE:
8mmbolt:23Nm(2.3kgfm,17Ibfft)
Tightenthe6mmboltssecurely.
Clean and apply locking agent to the bolt threads
(page 1-19).
Install the bearing setting plate and tighten the
bolts.
r ~
Installandtightentheboltwiththewasher byhold-
SHAFTHOLDERA BOLTIWASHER
ing the output driven gear shaft using the special
tools.
TOOLS:
ShaftholderA 07PAB-0010100or
07923-6890101
(U.S.A.only)
Holderhandle 07PAB-0010400
TORQUE:49Nm(5.0kgfm,36Ibfft)
Rechecl('theall crankcase bolttorquevalues.
Installthecamchains.
Applylockingagenttothecam chaintensionerset-
tingplateboltthreads(page1-19).
Install the cam chain tensioner setting plates and
tightenthebolts.
Installtheremaining parts(page13-3).
Installtheengineintotheframe(page8-7).
j.
13-50
----------
14. FINALDRIVE
COMPONENTLOCATION....14-2 FINALDRIVEDISASSEMBLYI
INS,PECTION 14-8
SERVICEINFORMATION 14-3
FINALDRIVEASSEMBLy 14-17
TROUBLESHOOTING 14-6
FINALDRIVEINSTALLATION 14-22
FII\lALDRIVEREMOVAL 14-7
14-1
FINALDRIVE
COMPONENTLOCATION
64 N'm (6.5 kgfm, 47 Ibfft)
22 Nm (2.2 kgfm, 16 Ibfft)
14-2
---- ---------------
FINALDRIVE
SERVICEINFORMATION
GENERAL
Thefinal drivegearassemblyandfinal driveshaftmustbe removedtogether.
Perform the gearcontactpattern and backlash inspection wheneveryou replace the bearings, gears orgearcase. ~
extension linesfromthegearengagementsurfacesshouldintersectatonepoint.
Protectthegearcase withashoptowelorsoftjawswhileholdingitinavise. Do notclampthegearcasetootightlyor
itcould bedamaged.
Replacethering andpiniongearsas aset.
SPECIFICATIONS
Unit:mm(in)
ITEM STANDARD SERVICELIMIT
Recommendedfinal driveoil Hypoidgearoil,SAE#80 -
Final driveoilcapacity
I
Atdraining 160 cm
3
(5.4 USOZ, 5.6 Impoz) -
I
Atdisassembly 170 cm
3
(5.7 USOZ, 6.0 Impoz) -
Final drivegearbacklash 0.05 - 0.15 (0.002 - 0.006) 0.30 (0.012)
Backlashdifferencebetweenmeasurements - 0.10 (0.004)
Ring gear-to-stoppinclearance 0.30 - 0.60 (0.012 - 0.024)
-
Finaldrivegearassemblypre-load 0.2 - 0.4 N'm(2 - 4 kgf'cm,
-
0.1 - 0.3 Ibfft)
TORQUEVALUES
Pinionretainer
Pinionretainerlocktabbolt
Pinionjointnut
Dustguardplatebolt
Finalgearcasecover10 mmbolt
Finalgearcasecover8mmbolt
Finalgearcaseassemblymountingnut
Rearshockabsorberlower.mountingbolt
(leftside)
Finalgearcasestudbolt
108 N'm(11.0 kgf'm,80 Ibfft)
10 N'm(1.0 kgfm,7 Ibfft)
108 N'm(11.0 kgf'm,80 Ibfft)
10 N'm(1.0 kgf'm,7Ibfft)
47 N'm(4.8 kgfm,35 Ibfft)
25 N'm(2.5 kgf'm,18 Ibfft)
64 Nm(6.5 kgf'm,47 Ibfft)
22 N'm(2.2 kgf'm,16 Ibfft)
See page14-22
Applylockingagenttothethreads
Applylockingagenttothethreads
14-3
FINALDRIVE
TOOLS
Driver Attachment,32 x35 mm Attachment,52x 55 mm
07749-0010000 07746-0010100 07746-0010400
Attachment,72x75 mm Pilot, 19mm Driver,40 mm1.0.
07746-0010600 077460041400 07746-0030100
Attachment,25 mm1.0. Pinionholderplate Collarset"C"
07746-0030200 07924-ME40010 07924-ME40020
Oil seal driver Retainerwrench Pinionpullerbase
070MF-MEG0300 07910-MA10100 07HMC-MM80110
(
or07HMC-MM8011A(U.S.A.only)
14-4
FINALDRIVE
Puller shaft
07931-ME40000
or 07931-ME4010B and
07931-HB3020A (U.S.A. only)
Bearing remover, 35 mm
07936-3710400
Remover handle
07936-3710100
Remover weight
07741-0010201
or 07936-371020A or
07936-3710200 (U.S.A. only)
Bearing remover, 20 mm
07936-3710600
or equivalent commercially
available in U.S.A.
Bearing driver attachment
07GAD-SD40101
Oil seal driver attachment
07LAD-SM40100
or 07LAD-SM4A100 (U.S.A. only)
Oil seal driver, 55.7 x 60.3 mm
07965-KE80200
Attachment, 44 x 49.5 mm
07945-3330300
14':..5
FINALDRIVE
TROUBLESHOOTING
Excessive noise
Worn or scored ring gear shaft and driven flange
Scored driven flange and wheel hub (page 16-7)
Worn or scored drive pinion and splines
Worn pinion and ring gears
Excessive backlash between pinion and ring gears
Oil level too low
Worn or damaged pinion gear and/or pinion joint splines
Oil leak
Clogged breather
Oil level too high
Damaged seals
Loose case cover bolts
Excessiverearwheelbacklash
Worn drive shaft splines
Excessive backlash between pinion and ring gears
Worn driven flange and ring gear splines
Excessive play in final drive case bearings
Worn drive shaft, universal joint and/or pinion joint splines
Excessive play or worn universal joint bearing
~ 6
FINALDRIVE
FINALDRIVEREMOVAL
Drainthefinal driveoil(page4-18).
Removetherearwheel(page 16-6).
Remove the left shock absorber lower mounting
bolt.
Removethefourmountingnutsandfinaldrivegear
caseassembly.
Remove the drive shaft from the final drive gear
case assemblybygentlyturningthedriveshaftand
pullingit.
~
~ R C S E
NUTS ASSEMBLY
DRIVE SHAFT
Remove the spring, oil seal and stopper ring from
thedriveshaft.
INSPECTION
Checkthesplinesofthedriveshaftforwearordam-
age.
Ifthesplines ofthe driveshaftare damaged,check
theuniversaljointsplinesalso(page16-24).
SPRING
Turn the pinionjointand checkthatthe pinion and
PINIONJOINT RING GEAR SHAFT
ring gearsturnsmoothlyand quietlywithout bind-
ing.
If the gears do not turn smoothly or quietly, the
gearsand/orbearing maybe damagedorfaulty.
They must be checked after disassembly; replace
faultyparts/assembliesas required.
14-7
FINALDRIVE
FINALDRIVEDISASSEMBLYI
INSPECTION
NOTE:
Performthebacklashinspectionandcontactpattern
check whenever you replace the pinion gear, ring
gear, bearings and gear case. The extension lines
fromthegearengagementsurfacesshouldintersect
atonepoint.
Removethefinal driveanddriveshaft(page14-7).
BACKLASHINSPECTION
Removetheoilfillercap.
Do not over-tighten Hold the final drive gear case assembly in a vise
the vice on the final withsoftjaws.
drive case.
Install the special tools ontothe gearcase and into
thepinionjointtoholdthepiniongear.
TOOLS:
Pinionholderplate 07924-ME40010
Collarset"C" 07924-ME40020
Set ahorizontaltypedial indicatoronthering gear,
throughtheoilfillerhole.
Turnthe ring gearback and forth to read the back-
lash.
STANDARD: 0.05- 0.15mm(0.002- 0.006in)
SERVICELIMIT: 0.30mm(0.012in)
Remove'thedial indicatorand specialtools.
Turntheringgear120
0
and measurethebacklash.
Repeatthisprocedureoncemore.
Comparethedifferenceofthethreemeasurements.
SERVICELIMIT: 0.10mm(0.004in)
Ifthe difference in measurements exceeds theser-
vice limit, it indicates that the bearing is not
installedsquarely,orthecase isdeformed.
Inspectthebearingsandcase.
Ifthe backlash is excessive, replace the ring gear
shimwithathickerone.
Ifthe backlash is too small, replace the ring gear
shimwithathinnerone.
RING GEARSHIMS:
A: 1.82mm(0.072in) G:2.18mm(0.086in)
B: 1.88mm(0.074in) H:2.24mm(0.088in)
C: 1.94mm(0.076in). I: 2.30mm(0.091 in)
D: 2.00mm(0.079in)- Standard
E: 2.06mm(0.081 in)
F: 2.12mm(0.083in)
Forring gearshimreplacement(page14-11).
POINTOF INTERSECTION
PINION GEAR RING GEAR SHIM
-----!+-'81--++-++-
, RING GEAR
14-8
FINALDRIVE
FINALGEARCASESEPARATION
Remove the bolt, washer and the dust guard plate
byturningitclockwise.
Removethea-ring.
Loosenthecoverboltsin acrisscrosspatterninsev-
eral stepsand removethem.
Prythegearcasecoverand removeitfromthecase.
Removethewavewasher.
GEARTOOTH CONTACTPATTERN
CHECK
Descriptionofthetooth:
COASTSIDE
Keep dust and dirt Cleanthesealingmaterialoffthematingsurfacesof
ApplyPrussianBlue
out ofthe case and the gear-case and cover, being careful notto dam-
cover. agethem.
ApplyathincoatofPrussianBluetothepiniongear
teeth.
Installthewavewasher.
GEAR CASE COVER a-RING
TOE (insideofgear)
(contactswhenenginebrakeisapplied)
---------
(contactswhenenginepowerisapplied)
WAVEWASHER
14-9
--
---- ------------ --- ------ --------------
FINALDRIVE
Replace the pinion gear shim with a thicker one if ,-----------------------,
thecontactpattern istoohigh,towardtheface. TooHigh: PINIONSHIM
14-10
Installthecasecoverandtightentheboltsinacriss-
cross pattern in several stepsuntilthecoverevenly
touchesthegearcase.
Tightenthetwo10 mmboltstothespecifiedtorque
inseveral stepsalternately.
TORQUE:47Nm(4.8kgfm,35Ibfft)
Tightenthesix8mmboltstothespecifiedtorquein
acrisscrosspatterninseveraltimes.
TORQUE:25Nm(2.5kgfm,18Ibfft)
Removetheoilfillercap.
Rotate the ring gear several times in normal direc-
tionofrotation.
Checkthegeartoothcontactpatternthroughtheoil
fillerhole.
Contactis normalifthePrussian Blueistransferred
totheapproximatecenterofeachtoothand slightly
towardstheface.
Ifthe patterns are notcorrect, remove and replace
thepiniongearshimwithasuitableone
(page 14-12).
Replace the pinion gear shim with athinner one if
thecontactpatternistoolow,towardtheflank.
The patterns will shift about 1.5 - 2.0 mm (0.06 -
0.08 in) whenthethickness ofthe shim ischanged
by0.1 mm(0.004in).
PINIONGEARSHIMS:
A: 1.82mm(0.072in)
B: 1.88mm(0.074in)
C: 1.94 mm(().076in)
D: 2.00mm(0.079in)- Standard
E: 2.06mm(0.081 in)
F: 2.12mm(0.083in)
G:2.18mm(0.086in)
Forpiniongearshimreplacement(page14-13).
8mmBOLTS GEAR CASECOVER
Normal:
TOE
TOE HEEL
HEEL
-
COASTSIDE FLANK FLANK DRIVESIDE
FACE
SIDE
TooLow:
+ DRIVE
COAST
FLANK SIDE SIDE FLANK
FACE
COAST i
SIDE
-------------- ----
FINALDRIVE
RINGGEARREMOVAL/SHIM
REPLACEMENT
Remove the final gear case cover (page 14-9).
If the ring gear stays in the cover, remove it as fol-
lows:
Press the ring gear out of the gear case cover using
the special tools and hydraulic press.
TOOLS:
Driver 077490010000
Oil seal driver attachment 07LAD-SM40100 or
07LAD-SM4A100
(U.S.A. only)
Remove the oil seal.
If the bearing remained in the cover, remove it as
follows:
Press the ail seal and bearing out of the cover using
the special tools and hydraulic press.
TOOLS:
Driver 07749-0010000
Oiheal driver 070MFMEG0300
Attachment, 72 x 75 mm 07746-0010600
If the bearing remained on the ring gear, remove it
as follows:
Remove the ring gear bearing using a commercially
avaiiapJe/bearingpulier.
This. b.earing may not need to be replaced after
inspect the bearing for excessive
play after removal.
Replace it if necessary.
14-11
FII\IALDRIVE
Selectthereplacementshim(page14-8).
NOTE:
Whenthegearset, pinionbearing,ringgearbearing
and/orgearcase has been replaced, use a2.00 mm
(0.079 in)thicknessshimforinitial reference.
SHIM
\
CJ
BEARING
Press the ring gear bearing intothe cover with the
markedsidefacinginsideuntilitisfullyseated.
TOOLS:
Driver 07749-0010000
Bearing:driverattachment 07GAD-SD40101
PINIONGEARREMOVAL
Holdthegearcaseinavisewithsoftjaws.
HOLDER PLATE
Hold the pinion joint and remove the pinion joint
nutusingthespecialtools.
TOOLS:
Pinionholderplate 07924-ME40010
Collarset"C" 07924-ME40020
Removethepinionjoint.
Removetheboltandretainerlocktab.
COLLAR
14-12
------------------------------
--
FINALDRIVE
Removethepinionretainerusingthespecialtool.
RETAINER WRENCH
TOOL:
Retainerwrench 07910-MA10100
Remove the O-ring and oil seal from the pinion
OILSEAL
retainer.
O-RING
Install the special tools onto the pinion gear shaft
PULLERSHAFT
andgearcase.
TOOLS:
ExceptU.S.A.
Pinionpullinbase 07HMC-MM80110
Pullershaft 07931-ME40000
U.S.A.only
.Pullerbase"A" 07HMC-MM8011A
Assemblyshaft,22x 1.5x240mm
07931-ME4010Band
Specialnut 07931HB3020A
Pullthepiniongearassemblyoutofthegearcase.
Check the pinion gear needle bearing in the gear
caseforwearordamage.
PII\JIOI\Jc..;EAR REMOVALI
SHIMREPLACEMENT
Pull the pinion gear bearing from the shaftwith a
commerciallyavailablebearing puller.
This bearing may not need to be replaced after
removal.However,inspectthebearingforexcessive
playafterremoval.
Removethepinionshim.
Replace the pinion Replace itifnecessary.
gear bearing and
inner races as a set.
BEARING/SHIM
14-13
----------- -_.._-- --._------------
FINALDRIVE
Select the replacement shim (page 14-10).
Install the shim, bearing and inner races onto the
pinion gear.
NOTE:
When the gear set, pinion bearing, ring gear bearing
and/or gear case has been replaced, use a 2.00 mm
(0.079 in) thickness shim for initial reference.
INNER RACES
PINION GEAR
BEARING
Drive the bearing with the marked side facing up.
TOOLS:
Driver, 40 mm 1.0. 07746-0030100
Attach"!lent, 25 mm 1.0. 07746-0030200
CASE BEARING REPLACEMENT
RING GEAR CASE BEARING
Be sure to wear Heat the gear case to 80C (176F) evenly using a
BEARING REMOVER WEIGHT
heavy gloves when heat gun.
handling the heated Remove the ring gear case bearing from the gear
gear case. caseiJsing the special tools.
TOOLS:
~ r i g g remover, 35 mm 07936-3710400
Remover handle 07936-3710100
Remo""r weight 07741-0010201 or
07936-371020A or
07936-3710200
(U.S.A. only)
Remove the oil seal.
BEARING
14-14
FINALDRIVE
Removethe breathercap and blowcompressed air
throughthehole.
Installthebreathercap.
Applygreasetoanewoilseal lips.
Drivetheoilseal intothegearcasewiththemarked
sidefacing downuntilitisfullyseated.
TOOLS:
Driver 07749-0010000
Attachment, 44 x 49.5 mm 079453330300
Drive a new ring gear case bearing into the gear
case with the marked side facing inside until it is
fullyseated usingthespecialtools.
TOOLS:
Driver 07749-0010000
Attachment, 52 x 55 mm 077460010400
PINION
15-31
FRONTWHEEL/SUSPENSION/STEERING
Tighten the steering top thread to the specified
torque.
TOOL:
Steering stem socket 07916-3710101 or
07916-3710100
(U.S.A. only)
TORQUE: 25 Nm (2.5 kgfm, 18 Ibf.ft)
Turn the steering stem left and right, lock-to-Iock
five times to seat the bearings.
Retighten the steering top thread to the specified
torque.
TORQUE: 25 Nm (2.5 kgfm, 18 Ibf.ft)
Install a new lock washer, aligning its bent tabs with
the grooves in the steering top thread.
Install the lock nut until it contacts with the lock
washer.
Further tighten the locknut, within 90, to align its
grooves with thetabs of the lock washer.
Bend up the lock washer tabs into the grooves of
the locknut.
LOCK NUT TABS
15-32
FRONTWHEEL/SUSPENSION/STEERING
Install the steering stem cover onto the steering
stem.
Tighten the nuts Temporarily install the headlight case bracket, bolts
securely after and nuts.
installing the
headlight case.
Install the front brake hose, bolt and tighten the bolt
securely.
Install the top bridge, washer and stem nut.
Install the fork legs into the steering stem and top
bridges (page 15-27).
Tighten the stem nut to the specified torque.
TORQUE: ;03Nm(10.5 kgfm,76Ibfft)
Turn the steering stem left and right, lock-to-Iock
several times to make sure the steering stem moves
smoothly, without play or binding.
Route the hose, Install the following:
wires and cables
- Front wheel (page 15-18)
into the cable
- Front fender (page 3-6)
guides properly
- Handlebar (page 15-9)
(page 1-22).
- Headlight case (page 21-5)
- Turn signal light (page 21-6)
Tighten the headlight case bracket nuts securely.
BOLTS/NUTS BRACKETS
15-33
FRONTWHEEUSUSPENSION/STEERING
Make sure there is
no cable, wire
harness or hose
interference.
STEERING BEARING PRE-LOAD
Supportthemotorcyclesecurelyand raisethefront
wheelofftheground.
Positionthesteeringstem straightahead.
Hook a spring scale to the fork tube between the
forktopandbottombridges.
Pullthespringscalekeeping itatarightangletothe
steeringstem.
Read thescale atthepointwherethesteering stem
juststartstomove.
STEERING BEARING PRE-LOAD:
8.5 -12.7 N (0.9 -1.3 kgf)
Ifthe readingsdQ notfall withinthe limits,readjust
thesteeringt6j:llhread.
15-34
16. REAR WHEEL/BRAKE/SUSPENSION
COMPONENT LOCATION 16-2
REAR BRAKE 16-14
SERVICE INFORMATION 16-3 BRAKE PEDAL 1617
TROUBLESHOOTING 16-5 SHOCK ABSORBER 1621
REAR WHEEL .. 16-6 SWINGARM 16-22
~
REARWHEEL/BRAKE/SUSPENSION
COMPONENTLOCATION
103 Nm (10.5 kgfm, 76 IbHt)
64 N'm (6.5 kgf'm, 47 IbHt)
22 N'm (2.2 kgfm, 161bHt)
88 N'm (9.9 kgfm, 65 IbHt)
REAR WHEEL/BRAKE/SUSPENSION
SERVICEINFORMATION
GENERAL
ACAUTION
Frequentinhalationofbrakeshoedust,regardlessofmaterialcompositioncouldbehazardoustoyourhealth.
Avoid breathingdustparticles.
Neveruseanairhoseorbrushtoclean brakeassemblies. Use an OSHA-approvedvacuumcleaner.
Ridingondamaged rimsimpairssafeoperationofthevehicle.
A hoist or equivalent is required to support the motorcycle when servicing the rear wheel, shock absorber, or
swingarm.
UseonlygenuineHondareplacementboltsand nutsforallsuspensionpivotand mountingpoints.
When using the lock nutwrench forthe adjusting bolt locknut, use adeflecting beam typetorquewrench 20 inches
long. The locknutwrenchincreasesthetorquewrench's leverage, sothetorquewrench readingwill be lessthanthe
torqueactuallyappliedtotheswingarmrightpivotlocknut.Thespecification given intheactualtorqueappliedtothe
swingarm rightpivotlocknut, notthereading onthetorquewrench.Do notovertightenthelocknut.Thespecification
laterinthetextgivesbothactual and indicated.
SPECIFICArlONS
Unitmm(in)
ITEM STANDARD SERVICELIMIT
Minimumtiretreaddepth - 2.0(0.08)
Coldtirepres- I Upto90kg (200 Ibs) load 200kPa (2.00kgf/cm
2
, 29 psi) -
sure
I
Uptomaximumweightcapacity 250 kPa (2.50kgf/cm
2
, 36 psi) -
Axlerunout - 0.2(0.01)
Wheel rim
I
Radial - 2.0(0.08)
runout
I
Axial - 2.0(0.08)
Wheel balanceweight - 709 max.
Brakedrum1.0. 180.0-180.3(7.09-7.10) 181 (7.1)
Brakepedalheight 75 mm(3.0in)abovethetopofthe
-
footpeg
I
Brake pedalfreeplay . 20- 30(13/16-1-3/16) -
Shockabsorberspringpre-loadadjustersetting 2ndposition -
TORQUEVALUES
Spoke
Rearaxlenut
Swingarm leftpivotbolt
Swingarm rightpivotbolt
Swingarm rightpivotlocknut
Stopperplatebolt
Rearaxlepinchbolt
Rear brakestopperarm nut
Rear brakearm pinch bolt
Rearshockabsorberuppermountingbolt
Rear shockabsorberlowermountingbolt
(rightside)
Rearshockabsorberlowermountingbolt
(leftside)
4.2N'm(0.4kgf'm,3.1 Ibfft)
88 Nm (9.0kgf'm,65 Ibfft)
103N'm(10.5kgfm,76Ibfft)
Seepage16-26
103N'm(10.5kgfm,76Ibfft)
20 N'm(2.0 kgfm, 15 Ibfft)
27 N'm(2.8kgfm,20Ibfft)
22 Nm (2.2kgf'm,16Ibfft)
26 N'm(2.7 kgf'm,19Ibfft)
26 N'm(2.7kgf'm,19 Ibfft)
34Nm (3.5 kgf'm,25 Ibfft)
22 N'm(2.2 kgfm,16Ibfft)
U-nut
ALOC bolt;replacewithanewone
6 ~
REARWHEEL/BRAKE/SUSPENSION
TOOLS
Driver
07749-0010000
Attachment, 37 x 40 mm
07746-0010200
Attachment, 42 x 47 mm
07746-0010300
Pilot, 20 mm
07746-0040500
Bearing remover shaft
07GGD-0010100
Bearing remover head, 20 mm
07746-0050600
S
W)
..... _.--'
Spoke wrench
Lock nut wrench
07908-4690003
16..4
REARWHEEUBRAKE/SUSPENSION
TROUBLESHOOTING
Softsuspension
Incorrectsuspensionadjustment
Weakshockabsorberspring
Oil leakagefromdamperunit
Lowtirepressure
Stiffsuspension
Incorrectsuspensionadjustment
Bentdamperrod
Damagedshockabsorberrubbermounts
Damagedswingarmpivotbearings
HightirepressurEl
Rearsuspensionnoise
Loosesuspensionfasteners
Bindingshockabs.orbercase
Wornshockabsorberrubbermounts
Faultyrearshockabsorber
Rearwheelwobbles
Bentrim ,';!?
Unbalanced reartireandwheel
Insufficienttirepressure
Faultyswingarmpivotbearings
Axlefastenernottightenedproperly
Faultytire
Rearwheelturnshard
Faultywheel bearings
Bentaxle
Brakedrag
Finalgearbearingsdamaged(page 14-7)
Poorbrakeperforrnallce
Improperbrakeadjustrnent
Wornbrakeshoes
greasyordirty
WornbtakEfcam
WOfnsbrsxedrtim
improperlyengaged
BrakeshoElswornatcamcontactarea
16-5
",
REARWHEEL/BRAKE/SUSPENSION
REARWHEEL
REMOVAL
Removetheexhaustsystem (page3-8).
Removetheaxlenut.
Supportthe motorcyclesecurely and raise the rear
wheelofftheground.
Removetheadjusting nut,jointpinandspring.
Removethe cotter pin, nut, washer, rubberwasher
and bolt.
Loosenthepinchboltand removetheaxleandright ~ S i COLLAR
sidecollar.
Movetherearwheeltotherighttoseparate itfrom
the final drive gear case and carefully remove the
rearwheeloutoftheframe.
Removethe leftsidecollarfromthering gear.
16-6
REARWHEEL/BRAKE/SUSPENSION
INSPEC"nON
AXLE
SettheaxleinV-blocks.
Turnthe axle and measure the runout using a dial
indicator.
Actual runoutis1/2 thetotalindicatorreading.
SERVICE LIMIT: 0.2mm(0.01 in)
WHEELRIM
Checkthe rim runoutbyplacingthe wheel in atru-
ingstand.
Spinthe wheel slowlyand read the runoutusing a
dialindicator.
Actual runoutis1/2thetotalindicatorreading.
SERVICE LIMITS:
. Radial: 2.0mm(0.08in)
Axial: 2.0mm(0.08in)
FINALDRIYENFLANGE
Checkthedrivenflangesplinesforwearordamage.
If damaged,checkthesplinesoftheringgearalso.
WHEELBALANCE
Forwheel balance(page15-17). Do notadd balance
weight 70gtotherearwheel.
WHEELBEARING
RemovethebraKepanelanddrivenflange
(page16-8).
.Turntheinnerraceofeach bearingwithyourfinger.
The bearingsshouldturnsmoothlyandquietly.
Also thebearing outerracefitstightlyin
thehub.
Replace the wheel Removeanddiscardthebearingsiftheracesdonot
bearings in pairs. turnsmoothlyandquietly,orjftheyfitlooselyinthe
hub.
16-7
REAR WHEEL/BRAKE/SUSPENSION
DISASSEMBLY
Remove the brake panel assembly from the right
wheelhub.
RemovetheO-ring.
Removethefinal drivenflange from the leftwheel
hub.
Removethethrustwasher.
00 not reuse the Remove the boltsin acrisscross pattern in several
bolts. steps.
RemovetheO-ring.
16-8
REARWHEEL/BRAKE/SUSPENSION
Align the arrow on the stopper plate between the
projectionsonthewheel hubbyturningthestopper
plateand removethestopperplate.
Removetherubberdampers.
Replace the rubber Checktherubberdampersfordeteriorationordam-
dampersasaset. age.
Replace the wheel Installtheremoverheadintothebearing.
bearingsinpairs. From the opposite side of the wheel, install the
Donotreuseold remover shaft and drive the bearing out of the
bearing. wheel hub.
Removethe distance collarand driveoutthe otheL
bearing.
TOOLS:
Bearing removershaft 07GGD-0010100
Bearingremoverhead,20mm 07746-0050600
16-9
REARWHEEL/BRAKE/SUSPENSION
ASSEMBLY
RUBBERDAMPERS
THRUSTWASHER ..--'iB
20 Nm(2.0 kgfm, 15Ibf.ft)
111
II O-RING
Drive in a new right bearing squarely with the
markedsidefacing upuntilitisfullyseated.
Installthedistancecollar.
Drivein newleftbearing squarelywiththemarked
sidefacingupuntilitisfullyseated.
TOOLS:
Driver 07749-0010000
Attachment,42x47 mm 07746-0010300
Pilot, 20 mm 07146-0040500
16-10
----------
REARWHEEUBRAKE/SUSPENSION
WHEEL CENTER ADJUSTMENT
Measure the distance B (rim width) and calculate
B A
distance A as follows:
A =70.5 mm (2.78 in) - 8/2
Adjust the rim position and distance A by tightening
Q
the spokes to the specified torque in several pro-
/ I \1 70.5mm
gressive steps.
I I I'
)i I 1\ (2.78 in)
/' I
TOOL:
Spoke wrench 07JMA-MR60100
I
TORQUE: 4.2 Nm (0.4 kgfm, 3.1 Ibfft)
Install the stopper Install the stopper plate, aligning the arrow between
plate with the 'OUT the projections on the wheel hub.
SIDE' mark facing Align the bolt holes by turning the stopper ring.
up_
Pack molybdenum disulfide paste into the G-ring
groove inthe wheel hub.
Coat a disulfide paste
and install it into hub groove.
Install and tighten new bolts to the specified torque.
TORQUE: 20 Nm (2.0kgfm, 15 Ibfft)
16-11
REARWHEEL/BRAKE/SUSPENSION
Apply 2 - 3 g of molybdenum disulfide paste to the
mating surface of the thrust washer and rear wheel
hub end (driven flange side).
Apply 0.5 - 1.0 g of molybdenum disulfide s t ~ to
the rear wheel hub mating surface of the final
driven flange.
Coat a new O-ring with molybdenum disulfide paste
and install it into the driven flange groove.
Install the driven flange into the left wheel hub.
Install the brake panel assembly into the right wheel
hub.
16-12
REARWHEEUBRAKE/SUSPENSION
INSTALLATION
Install the left side collar into the ring gear.
Apply 4 - 5 g of molybdenum disulfide paste to the
joint surface of the final gear case O-ring guide and
driven flange.
Hold the wheel Place the rear wheel into the swingarm and engage
securely and be the driven flange spline with the ring gear spline.
careful not to
damage the gear
case.
Install the right side collar and rear axle.
Install and tighten the axle nut to the specified
torque while holding the axle.
TORQUE: 88N'm19.0kgfm,65Ibfft)
SPLINES
16-13
-------------------------------------------------
REAR WHEEL/BRAKE/SUSPENSION
Withthe rearbrake applied, pumptheswingarmup
anddownseveraltimestoseattheaxle.
Tightenthepinchbolttothespecifiedtorque.
TORQUE: 27 Nm(2.8kgf'm,20Ibfft)
Connect the stopper arm to the brake panel with
bolt,rubberwasher,washerand nut.
Tightenthenuttothespecifiedtorque.
TORQUE: 22Nm(2.2kgfm,16Ibfft)
n s t ~ anewcotterpin.
Installthespring,jointpinandadjusting nut.
Installtheexhaustsystem(page3-11).
Adjustthebrakepedal freeplay(page4-21).
REAR BRAKE
R.EMOVAL
Removetherearwheel(page 16-6).
Removethebrakepanelfromtherearwheel
(page 16-8).
INSPECTION
MeasurethebrakedrumI.D.
SERVICELIMIT: 181 mm(7.1 in)
16-l4
REARWHEEUBRAKE/SUSPENSION
DISASSEMBLY
Removethecotterpinsand setting plate.
NOTE:
Alwaysreplacethebrakeshoesas aset.
Whenthe brake shoesare reused, markall parts
before disassembly so they can be installed in
theiroriginal locations.
Removethebrakeshoesand springs.
Removetheboltand brakearm.
Removetheindicatorplate,brakecam andfeltseal.
16-15
REAR WHEEL/BRAKE/SUSPENSION
ASSEMBLY
BRAKE PANEL
SETIINGPLATE CaTIERPINS f1I
Apply0.5- 1.0g ofgrease tothe brakecam sliding
surface.
Installthebrakecam intothebrakepanel.
Applyengineoiltoanewfeltseal andinstall itonto
thebrakepanel.
Install the wear indicator plate on the brake cam
alignHigitswidetoothwiththewidegrooveonthe
brakecam.
16-16
REAR WHEEUBRAKE/SUSPENSION
Install the brake arm aligning the punch marks of
thearmandthebrakecam.
Install and tighten the brake arm pinch bolt to the
specifiedtorque.
TORQUE:26N'm(2.7 kgfm, 19Ibf.ft)
Apply 0.5:-.J.{) to the brake shoe-to-
anchor . ace,'
sa(idSprings.
NOTE: ..... ' .
j . bfake;. shoesar;reused, the shoes and
in their original
locations. .
iristafithespringswiththeirendsfacing up.
cotter pins as
SPRINGS
setting plate and new
kepanelintothewheel hub
BRAKE PEDAL
REMOVAL
Removetheexhaustsystem (page3-8).
Removetheadjustingnut,jointpinandspring.
16-17
----- ---------
REARWHEEL/BRAKE/SUSPENSION
Removetheboltandmiddlerodjoint.
Removethemiddlerodjointpivotand dustseals.
Checkthedustsealsforwearordamage.
Unhookthebrake pedal and rear brake lightswitch
returnsprings.
Remove the snap ring, washer and brake pedal
assembly.
Removethedustseals.
Checkthedustsealsforwearordamage.
Removethecotterpinandjointpin.
JOINTPIN
16-18
REAR WHEEL/BRAKE/SUSPENSION
Remove the cotter pins and joint pins.
COTTER PINS/JOINT PINS
Check the brake pedal, rods, middle rod joint and
pivot for wear or damage.
Check the joint pins for wear or damage.
Replace these parts if necessary.
MIDDLE ROD JOINT
INSTALLATION
"BRAKE ROD
DUST SEALS ..........
.; .
-.ItCOTTER PINS
.... ds;Joint pins and new cotter pins
lIiiiII'
to' the rnl dlEl'rQd joint. .
0.:- - _C.- - _' - . "" _"
..........
JOINT PINS
16-19
REARWHEEL/BRAKE/SUSPENSION
Applygreasetothejointpin.
Installthe middle brake rod, jointpin and newcot-
ter.
Applygreasetothedustseal lips.
Installthedustsealsintothebrake pedal.
..
Apply grease to the brake pedal pivot sliding sur-
face.
Installthebrakepedalassemblytothebracketprop-
erly.
Installthewasherandsnapring.
NOTE:
Install the washers and snap rings with the
chamferededgesfacingthethrustloadside.
Do notreuse wornsnap ring which could easily
spin inthegroove.
Checkthatthesnapring isseatedinthegrooves.
Hook the brake pedal and rear brake light switch
returnspringstothepedal.
Apply grease to the dust seal lips and middle rod
jointpivotslidingsurface.
Installthedustsealsandmiddlerodjointpivot.
Install the middle rod jointtothe pivotandtighten
theboltsecurely.
...---
16-20
REARWHEEUBRAKE/SUSPENSION
Installthespring,jointpinandadjustingnut.
Installtheexhaustsystem(page3-11).
Adjustthefollowing:
- Brakepedalfreeplay(page4-21)
- Brakepedal height(page4-21)
- Rearbrakelightswitch(page4-22)
Supportthe frame and swingarm securely using a
hoistorequivalent.
bolts, washers, and the
shockabsorber.'
Replace the shock Checkfordeformationoroilleakage.
absorber asan Check the rubber mounts and collars for wear or
assembly. damage,repJacethemifnecessary.
AIlPlygreasetoilie mount inner
surfaCe.
Install the shock absorber in the reverse order of
remo\ial;
TORQUE:
bllller ......;:c ..,
. 26 . ( . '.. . ... i:1fllJ)t:Jtl
LT)de):
34 ... ).
Ii$Id.): RUBBER MOUNTS/COLLARS
16-21
REAR WHEEL/BRAKE/SUSPENSION
SWINGARM
REMOVAL
Removethefollowing:
- Leftcrankcaserearcover(page3-5)
- Rearwheel(page16-6)
- Final drivegearcase(page 14-7)
Remove the right shock absorber lower mounting
bolt.
Californiatypeonly: DisconnecttheEVAPcanisterairventhosefromthe
EVAP
Removetheboth pivotboltcaps.
Loosen the rightpivotlocknutusing a special tool
andremoveit.
TOOL:
Locknutwrench 07908-4690003
Loosentherightpivotbolt,butdonotremoveityet.
w-..................'!"""""!'"
REARWHEEUBRAKE/SUSPENSION
Loosen the left pivot bolt, but do not remove it yet.
Release the joint boot from the output gear case.
Remove the left and right pivot bolts, and swingarm
from the frame.
Remove the universaljoint from the output shaft.
Remove the following:
- Cotter pin
Nut
- Washer
- Spring,washer
- Bolt
- Stopper arm
Remove the pivot bearings and joint boot.
INSPECTION
Check the boot for cuts or other damage.
STOPPER ARM NUTIWASHERS/BOLT
BEARING
16-23
REARWHEEL/BRAKE/SUSPENSION
Checkthattheuniversaljointmovessmoothlywith-
outbindingornoise.
Checkthesplinesforwearordamage.
Ifdamaged, checkthesplines ofthe outputdriven
gearshaftanddriveshaftalso.
Both bearings, Checkthebearingsanddustsealsforwearordam-
outer races and age.
grease holders Check theouter races.f()r wear or damage.
must be replaced Check thEt grease holders for damage or deforma-
as a set if any part tion. .
is damaged or
worn.
PIVOTBEARINGOUTERRACE
REPLACEMENT
Punch or drill an appropriate hole into the grease
holder.
Insert a suitable driver through the swingarm and
drivethe other grease holderoutof
theswing.ar
rn
:.,. ....
Drivethe puhchedor drilled side outer race and
greaseholderputoftheswingarm.
Installanewgreaseholderintothepivot.
Drive in anewouter race squarely until it is fully
seated.
TOOLS:
Driver 07749-0010000
. 37x 040 mm 077460010200
SPLINES
18. BATTERYICHARGINGSYSTEM
BATTERY 18-6
SYSTEM LOCATION.. .. ..18-2
SYSTEMDIAGRAM18-2 CHARGINGSYSTEMINSPECTION18-7
SERVICEINFORMATION18-3 REGULATOR/RECTIFIER... 18-8
TROUBLESHOOTING18-5 ALTERNATORCHARGINGCOIL18-9
18-1
-- --
--------------- --------- -- ---
BATTERYICHARGINGSYSTEM
SYSTEMLOCATION
.
ALTERNATOR
SYSTEMDIAGRAM
MAIN FUSE
30A
Y Y YR/W G
ffi e
REGULATOR/RECTIFIER
BATTERY
ALTERNATOR
8 ~
Y: Yellow
G: Green
R: Red
W: White
BATTERYICHARGINGSYSTEM
SERVICEINFORMATION
GENERAL
AWARNING
Thebatterygivesoffexplosivegases;keepsparks,flamesandcigarettesaway. Provideadequateventilationwhen
charging.
Thebatterycontainssulfuricacid (electrolyte).Contactwithskin oreyesmaycausesevere burns.Wearprotective
clothingandafaceshield.
-Ifelectrolytegetsonyourskin,flushwithwater.
- Ifelectrolytegetsinyoureyes,flushwithwaterforatleast15 minutesandcall aphysician immediately.
Electrolyteis poisonous.
- Ifswallowed,drinklargequantitiesofwaterormilkandcallyourlocalPoisonControlCenteroracall aphysician
immediately.
NOTICE I
Alwaysturnoff theignitionswitchbeforedisconnectinganyelectricalcomponent.
Someelectricalcomponentsmaybedamagedifterminalsorconnectorsareconnectedordisconnectedwhiletheigni-
tionswitchisturnedto ONandcurrentispresent.
Forextendedstorage,removethebattery,giveitafullcharge,andstoreitinacool,dryspace.
Forabatteryremaininginastored motorcycle,disconnectthenegativebatterycablefromthebatteryterminal.
Thebatterysealingcapsshouldnotbe removed.Attemptingtoremovethesealingcapsfromthecellsmaydamagethe
battery.
Themaintenancefree(MF) batterymustbe replacedwhenitreachestheend ofitsservicelife.
The batterycan be damagedifoverchargedorundercharged,oriflefttodischargeforlong period.Thesesamecondi-
tionscontributetoshorteningthe"lifespan"ofthebattery.Even undernormaluse,theperformanceofthebatterydete-
rioratesafter2- 3years.
Battery voltage may recover after battery charging, but under heavy load, the batteryvoltage will drop quickly and
eventuallydie out. Forthis reason, thecharging system is often suspected as the problem. Battery overcharge often
resultsfromproblemsinthebatteryitself,whichmayappeartobean overchargingsymptom.Ifoneofthebatterycells
is shorted and batteryvoltage does notincrease,the regulator/rectifiersupplies excess voltagetothe battery. Under
theseconditions,theelectrolyte levelgoesdownquickly.
Beforetroubleshootingthechargingsystem,checkforproperuseand maintenanceofthebattery. Checkifthe battery
isfrequentlyunderheavyload,suchas havingtheheadlightandtaillightON forlongperiodsoftimewithoutridingthe
motorcycle.
The batterywill self-dischargewhenthemotorcycleisnotin use. Forthisreason, chargethe batteryevery2weeksto
preventsulfationfromoccurring.
Whenservicingthechargingsystem,alwaysfollowthestepsinthetroubleshootingflowchart(page 18-5).
Foralternatorservice(page12-4).
BATrERYCHARGING
TurnpowerON/OFFatthecharger,notatthebatteryterminal.
Forbatterycharging,donotexceedthechargingcurrentandtimespecified on thebattery. Usingexcessivecurrentor
extendingthechargingtimemaydamagethebattery.
Quickchargingshouldonlybedoneinan emergency;slowchargingis preferred.
BATTERYTESTING
Refertothebatterytester'sOperationManualfortherecommended batterytesterfordetailsaboutbatterytesting.
The recommended batterytesterputsa"load"onthebatterysotheactual batteryconditionoftheloadcan bemeasured.
RecommendedBatteryTester:BM-210-AH(U.S.A.only),BM-210orBATTERYMATE(MTP08-0192,U.S.A.only)orequivalent
BATTERYICHARGINGSYSTEM
SPECIFICATIONS
ITEM SPECIFICATIONS
Battery Capacity 12 V - 10 Ah or 12 V -11 Ah
Current leakage 1 mAmax.
Voltage (20C/
B8F)
Fully
charged
13.0 -13.2 V
Needs
charging
Below 12.4 V
Charging current Normal 1.1 A/5 -10 h
Quick 5.5 A/1.0 h
Alternator Capacity 0.35 kW/5,000 rpm
Charging coil resistance (20C/68F) 0.1 -1.0 n
TORQUEVALUE
Battery case cover screw 1 N'm (0.1 kgfm, 0.7 Ibf.ft)
TOOLS
Battery tester Christie battery charger Battery Mate tester/charger
BM-210-AH (U.S.A. only) MC101212 (U.S.A. only) MTP08-0192 (U.S.A. only)
18-4
------------- -- -
BATTERYICHARGINGSYSTEM
TROUBLESHOOTING
BATIERYISDAMAGEDORWEAK
1.. BATIERYTEST
Removethebattery(page 18-6).
Checkthebatterycondition usingtherecommended batterytester.
RECOMMENDEDBATIERYTESTER:BM210.AH(U.S.A.only),BM210orBATIERYMATE(MTP08
0192,U.S.A.only)orequivalent
Isthebatterygoodcondition?
NO - Faultybattery.
YES - GO TO STEP 2.
2. CURRENTLEAKAGETEST
Installthebattery(page18-6).
Checkthebatterycurrentleakagetest(Leaktest;page18-7).
Isthecurrentleakagebelow1mAl
YES - GO TO STEP 4.
NO - GO TO STEP3.
3. CURRENTLEAKAGETESTWITHOUTREGURETOR/RECTIRRECONNECTOR
Disconnecttheregulator/rectifierconnectorand recheckthebatterycurrentleakage.
Isthecurrentleakagebelow1mAl
YES - Faultyregulator/rectifier.
NO -.Shortedwireharness
Faultyignitionswitch
4. ALTERNATORCHARGINGCOILINSPECTION
Checkthealternatorchargingcoil(page 18-8).
Isthealternatorchargingcoilresistancewithin0.1- 1.0n (20OCI68Fj?
NO - Faultychargingcoil.
YES - GO TO STEP5..
5. CHA.89INGVOLTAGEINSPECTION
Measureand thebatteryvoltageusingadigitalmultimeter(page18-6).
Startthe
ithargingvoltage(page18-7).
toresultofthefollowingcalculation.
voltage<Measuredchargingvoltage<15.5V
withinthestandardvoltage?
YES
t\lP - GQ:rOSTEP6.
6. REGlfLATOR/RECTIRERSYSTEMINSPEC"nON
Checkthevoltageand resistanceattheregulator/rectifierconnectors(page 18-8).
Aretheresuhsof checkedvohageandresistancecorrect?
YES - Faultyregulator/rectifier.
NO _. Opencircuitinrelatedwire
Looseorpoorcontactsofrelatedterminal
Shortedwireharness
BATTERYICHARGINGSYSTEM
BATTERY
REMOVAL/INSTALLATION
Removethefollowing:
- Seat(page3-3)
POSITIVE (+) CABLE
- ICM (page 19-9)
Removethescrew.
Remove the battery case cover by unhooking the
batterycase hooks.
With the ignition switch turned to OFF, disconnect
the battery negative (-) cable first, then disconnect
thebatterypositive(+) cable.
Removethebatteryfromthe batterycase.
Installthebatteryinthereverseorderofremoval.
NOTE:
Connectthe positive (+) cablefirst,then connect
thenegative(-)cable.
Afterconnectingthe batterycables, coattheter-
minalswithgrease.
TORQUE:
Batterycasecoverscrew:
1Nm(O.1 kgfm,0.7Ibf.ft)
BATIERYCASECOVER
VOLTAGEINSPECTION
Removethebatterycasecover(page18-6).
Measure the battery voltage using a commercially
availabledigitalmulti meter.
VOLTAGE{20C/68F):Fullycharged:13.0- 13.2V
Needscharging:Below12.4V
BATTERYICHARGINGSYSTEM
CHARGINGSYSTEMINSPECTION
CURRENTLEAKAGETEST
Removethebatterycase cover(page 18-6).
With the ignition switch turned to OFF, disconnect
thenegative(-)cablefromthebattery.
,Connectthe ammeter(+) probe tothe negative H
cable and the ammeterH probeto the battery (-)
terminal.
With the ignitionswitch turned to OFF, check for
currentleakage.
NOTE,
' whehrrieasuringcurrentusingatester,setittoa
rangedowntoan
higher than the
rangeselected'n1ih'''filg\ft thefuseinthetester.
While notturntheignition
switch to ON.'Asudc!en surge of current may
blowthefuseintheteSter.
SPECIFIEDCURRENTLEAKAGE:1mAmaximum
If current leakage exceeds the specified value, a
shortedcircuitistheprobablecause.
Locate theshortbydisconnecting connections one
byoneandmeasuringthecurrent.
CHARGINGVOLTAGEINSPECTION
NOTE:
MakeureJM isin good condition before
.... ' .
Start itup to the operating
temperature;thenstoptheengine.
Donotdisconnect Removethe. batterycasecover(page 18-6).
thebatt/fry.orany
cablein the the positive and
chargingsystem
witboutJirst !o,;" ','c'. ..
switching offthEf N.OTEf C-_- --
ignitio'!
olutely certain which
Failure to followthis 'at .th
rminalsorcable.
ptecauiiorfcarJ'
damagethetester Wit
.m,restarttheengine.
p-multimeter when the
orelectrical
components,
'BV<'Measuredcv<15.5V
Voltage(page18-6)
CV=ChargingVoltage
18-7
.._-- ----
BATTERYICHARGINGSYSTEM
REGULATOR/RECTIFIER
WIRE HARNESS INSPEC"nON
BATrERYCHARGINGLINE
Removetherightsidecover(page3-3).
With the ignition switch turned to OFF, disconnect
theregulator/rectifier5P connector.
Measure the voltage between the Red/white wire
terminal (+) ofthewireharness sideconnectorand
ground(__).
Thereshouldbebatteryvoltageatalltimes.
GROUNDLINE
Checkforcontinuitybetween theGreen wiretermi-
nalofthewireharnesssideconnectorand ground.
Thereshouldbecontinuityatalltimes.
CHARGING: COILLINE
CheckthecejrltinuitybetweentheYellowwiretermi-
nala,ndgl"qllnd.
nocontinuity.
between the Yellow wire'
terminals. ..
If regulator/rectifier
5PconneCt6risabnormal,measuretheresistanceat
thealternator3P connector(page18-9).
18-8
BATTERYICHARGINGSYSTEM
REMOVAUINSTALLATION
Removetherightsidecover(page
With the ignition switch turned to OFF, disconnect
theregulator/rectifier5Pconnector.
Removethenuts,regulator/rectifierandspacer.
Install the regulator/rectifier in the orderof
removal.
ALTERNATORCHARGINGCOIL
INSPECTION
Removetheseat(page3-3).
With the ignition switch turned to OFF, disconnect
thealternator3P(Natural)connector.
Measure the resistance between the Yellow wire
terminalsofalternator/statorsideconnector.
STANDARD: 0.1 - 1.0n at 20C(68F)
Checkforcontinuitybetweeneachwireterminalsof
thealternator/statorsideconnectorandground.
Thereshouldbenocontinuity.
Replacethestatorifthe resistance isoutofspecifi-
cation,orifanywirehascontinuitytoground.
Foralternator/starterreplacement(page
18-9
MEMO
-------- ---
19. IGNITIONSYSTEM
SYSTEM LOCA'ION 19-2 IGNITIONCOIL , 19-8
ICM 19-9
SYSTEM DIAGRAM..19-2
SERVICEINFORMATION19-3
IGNITIONTIMING 19-9
TROUBLESHOOTING.. .. .. .. 19-4 TPSENSOR.. .. .. .. .. 19-10
IGNITIONSYSTEMINSPECTION..19-5
~
IGNITIONSYSTEM
SYSTEM LOCATION
NEUTRALSWITCH
TPSENSOR
SYSTEMDIAGRAM
IGNITION MAIN
FUSE lOA SWITCH FUSE30A
r--
BVG
1
L..o"'-0- BIIW
currC" sw""" eI
1
ENGINE STOP
SWITCH
9Y
BI BI
To Neutral
indicator
6P(BLUE)
DIODEr-----4---,
.-LgIR--+*.......--.
DOWN
GIW ,p SIDESTAND
6" SWITCH
GIW
-e::'-o--Lg
G
_ NEUTRALSWITCH
-L
BVW
.........L....L..L.-....lIC-M-J.....L.....L...L...J,
l
l
1k IGNITION
COIL
V
e
U
FRONT REAR
IGNITIONPULSE BI: Black
SPARK U"
GENERATOR Y Yellow
PLUGS
Bu Blue
G Green
R Red
W Whtte
Lg UghlGreen
19-2
IGNI1"IONSYSTEM
SERVICEINFORMATION
GENERAL
NOTICE
The ICMmaybedamagedifdropped.Also,iftheconnectorisdisconnectedwhencurrentisflowing,theexcessivevolt-
agemaydamagetheICM.Alwaysturntheignitionswitchto OFFbeforeservicing. .
Usesparkplugswiththecorrectheatrange. Usingsparkplugswithanincorrectheatrangecandamagetheengine.
Someelectricalcomponentsmaybe damagedifterminalsorconnectorsareconnectedordisconnectedwhiletheigni-
tionswitchisturnedtoON andcurrentispresent.
Whenservicingtheignitionsystem,alwaysfollowthestepsinthetroubleshootingtableon page19-4.
Thetransistorized ignitionsystem usesan electricallycontrolled ignitiontimingsystem. Noadjustmentscan be made
totheignitiontiming.
TheICMvariesignitiontimingaccordingtotheenginespeed.TheTPsensorsignalstheICMtocompensatetheignition
timingaccordingtothethrottleopening.
Afaultyignitionsystem isoftenrelatedtopoorconnections. Checkthoseconnectionsbeforeproceeding.
Make sure the battery is adequately charged. Using the startermotorwith aweak battery results in a slowerengine
cranking speed aswellas nosparkatthesparkplugs.
Forsparkpluginspection(page4-9).
Refertothefollowingcomponentsinformations:
- Ignitionswitch (page21-16)
- Enginestopswitch(page21-17)
- Neutralswitch (page21-19)
- Sidestandswitch (page21-20)
- Diode(page20-16)
SPECIFICATIONS
ITEM SPECIFICATIONS
Sparkplug
I
Standard
I
Forextended highspeed riding
Sparkpluggap
Ignitioncoilprimarypeakvoltage
DPR6EA-9 (NGK),X20EPR-U9(DENSO)
DPR7EA-9(NGK),X22EPR-U9 (DENSO)
0.8- 0.9 mm(0.03- 0.04in)
100Vminimum
Ignitionpulsegeneratorpeakvoltage 0.7Vminimum
Ignitiontiming("F"mark) 13BTDCatidle
TPsensor
I
Resistance(20C/68F)
I
Inputvoltage
4-6kn
5V
TORQUEVALUES
Alternatorcoversocketbolt 10N'm(1.0kgfm,7Ibfft)
Timingholecap 10N'm(1.0kgf'm,7Ibfft) Applygreasetothethreads
TOOLS
Peakvoltageadaptor IgnitionMatepeakvoltagetester
07HGJ-0020100(notavailablein only)
U.S.A.)
withcommerciallyavailabledigital
multimeter(impedance10MWDCV
minimum)orpeakvoltagetester
(U.S.A. only)
IGNITIONSYSTEM
TROUBLESHOOTING
Inspectthefollowingbeforediagnosingthesystem.
- Faultysparkplug
- Loosesparkplugcaporsparkplugwireconnection
- Waterinthesparkplugcap (Leakingtheignitioncoilsecondaryvoltage)
Ifthere is nospark at eithercylinder,temporarilyexchangethe ignition coil with a known-good one and performthe
sparktest. Ifthereisspark,theoriginalignitioncoilisfaulty.
"Initialvoltage"oftheignitionprimarycoil is thebatteryvoltagewiththeignitionswitchturnedtoON and theengine
stopswitchat"0".(Theengineisnotcranked bythestartermotor.)
Nosparkatsparkplugs
UNUSUALCONDITION PROBABLECAUSE(Checkinnumericalorder)
Ignitioncoil
primaryvolt-
age
Noinitialvoltagewiththeignition
switchturnedtoON andthe
enginestopswitchat"0".(Other
electricalcomponentsare nor-
mal)
1. Faultyenginestopswitch.
2. AnopencircuitinBlackJwhitewirebetweentheignition
coilandenginestopswitch.
3. Looseorpoorconnectionoftheprimaryterminal,oran
opencircuitintheprimarycoil.
4. FaultyrCM (incasewhentheinitialvoltageis normal
withtheICMconnectordisconnected).
1. Incorrectpeakvoltageadaptorconnections.(System is
normalifmeasuredvoltageisoverthespecifications
withreverseconnections.)
2. Batteryisundercharged.(Voltagedropslargelywhenthe
engineisstarted.)
3. NovoltageattheBlackwireoftheICMconnector,or
looseorpoorlyconnectedICM connector.
4. Looseorpoorconnectionoran opencircuitinBlue/
yelloworYellow/bluewirebetweentheignitioncoilsand
ICM.
5. Ashortcircuitintheignitionprimarycoil.
6. Faultysidestandswitchorneutralswitch.
7. Looseorpoorconnectionoran opencircuitinNo.6
relatedwires.
- Sidestandswitch line:Greenlwhitewire
- Neutralswitch line: Lightgreenwire
8. Faultyignitionpulsegenerator.(Measurepeakvoltage.)
9. FaultyICM (incase whenaboveNo.1through8arenor-
mal).
1. Incorrectpeakvoltageadaptorconnections.(System is
normalifmeasuredvoltageisoverthespecifications
with reverseconnections.)
2. Faultypeakvoltageadaptor.
3. FaultyICM(incase whenaboveNo.1 and 2arenormal).
1. ThemiJltimeterimpedanceistoolow;below10MQ/DCV.
2. Crankingspeedistooslow.(Batteryisundercharged.)
3. Thesamplingtimingofthetesterand measuredpulse
werenotsynchronized.(Systemisnormalifmeasured
voltageisoverthestandardvoltageatleastonce.)
4. FaultyICM(incasewhenaboveNo.1through3are nor-
mal).
1, Faultysparkplugorleakingignitioncoilsecondarycur-
rentampere.
2. Faultyignitioncoil(s).
1. Themultimeterimpedanceistoolow;below10 MQ/DCV.
2. Crankingspeedistooslow.(Batteryisundercharged.)
3. Thesamplingtimingofthetesterand measuredpulse
werenotsynchronized.(Systemisnormalifmeasured
voltageisoverthestandardvoltageatleastonce.)
4. Faultyignitionpulsegenerator(incasewhenaboveNo.1
through are normal).
1- Faultypeakvoltageadaptor.
2. Faultyignitionpulsegenerator.
Initialvoltageisnormal,butit
dropsby2- 4Vwhilecranking
theengine.
.
Initialvoltageisnormalbutthere
isnopeakvoltagewhilecranking
theengine.
Initialvoltageisnormalbutpeak
voltageislowerthanthestandard
value.
Initialandpeakvoltagesarenor-
mal butnosparkjumps.
Ignitionpulse
generator
Peakvoltageislowerthanthe
standardvalue.
Nopeakvoltage.
IGNITIONSYSTEM
IGNITIONSYSTEMINSPECTION
NOTE:
Ifno spark jumps atthe plug, check all connec-
tionsforlooseorpoorcontactbefore measuring
thepeakvoltage.
Use a commercially available digital multimeter
withan impedanceof10Mil/DCVminimum.
The displayvaliJe,differs depending upon the
internalimpedahceofthemultimeter.
Connect the peak voltage adaptor to the digital
rnultimeterorusethepeakvoltagetester.
Peak adalJtor 07HGJ-0020100
(notava'ilablein
U.S.A.)
multimeter
or
Igtlitiolll\l!atJ
- . .' MTP070286
(U.S.A.only)
.IGNITION.COILPRIMARYPEAK
VOLTAGE
NOTE:
Check all system connections before performing
this inspection. Loose connectors can cause
incorrectreadings.
Check that the cylinder compression is normal
for each cylinder and the spark plugs are
installedcorrectlyineach cylinderhead.
Disconnect' allsparkplugcapsfromthesparkplugs.
Connect the known-good spark plugs to all spark
plugcapsandgroundthemtothecylinderheadsas
doneinasparktest.
DIGITALMULTIMETER
.........\
............,....
I
II; ill
FI
!@ ":
PEAKVOLTAGEADAPTOR
19-5
---
IGNITIONSYSTEM
FRONT: Removethefueltank(page3-4).
REAR: Removethefollowing:
- Rightsidecover(page3-3)
- Fuse box/turnsignal relay(page 19-8)
Withtheignitioncoil primarywiresconnected,con-
nectthepeakvoltagetesteroradaptorprobestothe
ignitioncoil primaryterminal and ground.
TOOLS:
Peakvoltageadaptor 07HGJ-0020100
(notavailablein
U.S.A.)
withcommerciallyavailabledigitalmultimeter
(impedance10Mn/DCVminimum)or
IgnitionMatepeakvoltagetester
MTP07-0286
(U.S.A.only)
CONNECTIONS:
FRONT:Blue/yellow(+) - ground(-)
REAR: Yellow/blue(+) - ground(-)
TurntheignitionswitchtoONwiththeenginestop
switchat"0".
Checktheinitialvoltageatthistime.
Thebatteryvoltageshouldbemeasured.
Iftheinitialvoltagecannotbemeasured,followthe
checksinthetroubleshootingtable(page19-4).
Shiftthetransmissionintoneutral.
Crank the engine with the starter motor and mea-
suretheignitioncoil primarypeakvoltage.
PEAKVOLTAGE: 100V minimum
NOTE:
Although measured values are different for each
ignition coil, theyaren6rr;rialas long as voltage is
higherthanthe
Ifthepeakvoltageislowertllanthestandardvalue,
followthe'Checksinthetroubleshootingtable
..
InstallThe removed parts i.n the reverse order of
removal.
19-6
IGNITIONSYSTEM
IGNITIONPULSEGENERATORPEAK
VOLTAGE
NOTE:
Check that the cylinder compression is normal for
each cylinder and the spark plug is installed cor-
rectlyinthecylinderhead.
RemovetheICM (page 19-9).
Connect the peak voltage tester or adaptor probes
tothewireharl)esssideICM connectorterminals.
TOOLS:
Peakvoltage 07HGJ-0020100
(notavailablein
U.S.A.)
withc:o' . igitalmultimeter
."'um)or
IgnitiQn 8 tester
MTP07-0286
(U.S.A.only)
CONNECTION:White/yellow(+)- YellowH
TurntheignitionswitchtoON withtheenginestop
switchat"0".
Shiftthetransmissionintoneutral.
Crank the engine with the starter motor and mea-
suretheignitionpulsegeneratorpeakvoltage.
PEAKVOLTAGE: 0.7Vminimum
If the voltage measured at the (CM connector is
abnormal, measurethepeakvoltage attheignition
pulsegeneratorconnector.
Removethesteeringsidecovers(page3-5).
TurntheignitionswitchtoOFF.
Disconnect the ignition pulse generator 2P (Red)
connector and connect the peak voltage tester or
adaptor probes to the connector terminals of the
ignitionpulsegeneratorside.
connector, mea-
ittothevoltage
If th. . .)mel3suredatthe(CM isabnor-
at the ignition pulse
-the wire harness has an
orl()oseconnection.
If standardvalue,
chac ;tbEL t-roubleshooting table
(page19-'4j-; . ....
.removed parts in the reverse order of
removal:
--------------- ._--
19-7
IGNITIONSYSTEM
IGNITIONCOIL
FRONTIGNITIONCOIL
REMOVAL/INSTALLATION
Removethefollowing:
- Fueltank(page3-4)
- Steeringsidecovers(page3-5)
Disconnectthesparkplugcaps.
Disconnect the ignition coil primary wire connec-
tors.
Remove the bolts, spacers and front ignition coil
fromtheframe.
Route the spark Install thefrontignition coil in the reverse orderof
plug wires properly removal. .
(page 1-22).
REMOVAL/INSTALLATION
Removetherightsidecover(page3-3).
Removethefuse box/turn signal relaywiththestay
fromthebatteryboxbyreleasingtheirtabs.
Discon pllJgcpaps.
Disconnect igi)iti9n'coil primary wire connec-
tors: .
the bolts, spacers and rear ignition coil,
fromthebracket. ... .. .
Route the spark .Install the rear ignition coil in the reverse order of
plug wires properly removal.
(page 1-22).
FUSE BOXfTURNSIGNALRELAY
.
19-8
IGNITIONSYSTEM
ICM
REMOVAL/INSTALLATION
Removetheseat(page3-3).
Remove the ICM from the battery case cover and
disconnecttheICM22Pconnector.
InstalltheICM inthereverseorderofremoval.
IGNITIONTIMING
Start the engine, warm it up to normal operating
temperatureandthenstopit.
Removethesocketboltsandalternatorcover.
.
Removethetimingholecap.
Connect. atachometer.
Read the Cormect the timing lightto the front or rear spark
manufacturers pIlJ$lvvi reo
instructions for
S1:a"rtthe engine, letit idle and check the ignition
timing light
timing.-
operation.
IDLESPEED: 1,200100 rpm
19-9
IGNITIONSYSTEM
Thetimingiscorrectifthe "F" markontheflywheel
"F" MARK
aligns with the index notch on the left crankcase
cover.
Coatanewa-ringwithengineoil and install itinto
thetimingholecap groove.
Applygreasetothethreadsofthetimingholecap.
Installthetimingholecap andtightenittothespec-
ifiedtorque.
TORQUE: 10Nm(1.0kgfm,7Ibfft)
Install the alternator cover and tighten the socket
boltstothespecifiedtorque.
TORQUE: 10Nm(1.0kgfm,7Ibfft)
, a-RING
"
INDEXNOTCH
TPSENSOR
INSPECTION
RemovetheICM(page19-9).
Measuretheresistance betweentheYellow/redand
Blue/greenwireterminals ofthe wire harness side
connector.
STANDARD: 4- 6k.Q (20C/68F)
Check that the resistance between the Red/yellow
andBlue/greenwireterminalsvaries withthethrot-
tlepositionwhileoperatingthethrottlegrip.
Fullyopen- Fullyclosedposition:
Resistancedecreases
Fuliyclosed- Fullyopenposition:
Resistanceincreases
19-10
IGNITIONSYSTEM
If the correct measurements cannot be obtained,
removethefueltank(page3-4).
DisconnecttheTPsensor3Pconnector.
Measuretheresistance betweenthe Blueand Black
wireterminalsoftheTP sensorsideconnector.
STANDARD: 4- 6k.Q (20C/68F)
Check that the resistance between the Yellow and
Blackwireterminalsvarieswiththethrottleposition
whileoperatingthethrottlegrip.
Fullyopen- Fullyclosedposition:
Resistancedecreases
Fullyclosed- Fullyopenposition:
Resistanceincreases
Ifthe measurementatthe ICM is abnormal and
theoneattheTP sensor is normal,checkforan
open or short circuit, or loose or poor connec-
tionsinthewireharness.
Ifboth measurementsare abnormal, removethe
carburetorand replacetheTPsensor(page6-10).
ConnecttheICM 22Pconnector.
Turnthe ignitionswitchtoON withtheenginestop
switchat"0".
Measure the inputvoltage between the Yellow/red
(+) andBlue/green(-)wireterminalsofthewirehar-
nesssideoftheTPsensor3P connector.
STANDARD: 5V
Ifthe input voltage is abnormal, or ifthere is no
inputvoltage, checkforan open or shortcircuit in
the wire harness, or loose or poor ICM connector
contact.
Install the' removed parts in the reverse order of
removal.
19-11
~ ~ ~ ~ _
MEMO
20. ELECTRICSTARTER
SYSTEMLOCATION 20-2 STARTERMOTOR .. 20-6
SYSTEM DIAGRAM 20-2 STARTERRELAYSWiTCH 20-15
SERVICE INFORMATION 20-3 DIODE ..20-16
TROUBLESHOOTING 20-4
..
20-1
ELECTRICSTARTER
SYSTEMLOCATION
ENGINE STOPSWITCH
STARTER SWITCH
IGNITIONSWITCH
CLUTCH SWITCH
SIDESTANDSWITCH
STARTER MOTOR BATIERY
FUSE BOX
.DIODE
.SUB FUSE 10A
MAIN FUSE 30 AJ
STARTER RELAYSWITCH
SYSTEMDIAGRAM
IGNITION
SWITCH
R --C-o RlBI------.
6P(RED) JSUBFUSE
MAINFUSE
30A
'----Y/R-0-0-- BI/W---0-0- BI/G-.JL;LBI 10A
STARTER ENGINE ---v.r
SWITCH STOPSWITCH
STARTER
GlR RELAYSWITCH 6P(BLUE) CLUTCHSWITCH
DIODE GJW BI
UP DOWN
L.l:!JLLg/R----...To NEUTRAL
1
SIDESTAND
SWITCH
Lg INDICATOR
A NEUTRAL
BI: Black R: Red
SWITCH
G: Green Y: Yellow
Lg: Lightgreen W: White
STARTER
MOTOR
20-2
ELECTRICSTARTER
SERVICEINFORMATION
GENERAL
NOTICE
Ifthecurrentiskeptflowingthroughthestartermotorto turnitwhiletheengineisnotcrankingover, thestartermotor
maybedamaged. .
Alwaysturntheignitionswitchto OFFbeforeservicingthestartermotor. The motorcouldsuddenlystart,causingseri-
ousinjury.
Thestartermotorcan beservicedwiththeengineintheframe.
Whencheckingthestartersystem,alwaysfollowthestepsinthetroubleshootingflowchart(page20-4).
Aweakbatterymaybeunabletoturnthestartermotorquicklyenough,orsupplyadequateignitioncurrent.
Refertothefollowingcomponentsinformation:
- Ignitionswitch(page21-16)
- Enginestopswitch(page21-17)
- Starterswitch(page21-17)
- Neutralswitch(page21-19)
- Sidestandswitch(page21-20)
- Clutchswitch(page21-19)
SPECIFICATION
Unit:mm(in)
ITEM STANDARD SERVICELIMIT
Startermotorbrush length 12.5(0.49) 6.5(0.26)
TORQUEVALUES
Startermotorcableterminalnut
Startermotorassemblybolt
Negativebrush screw
10N'm(1.0 kgfm,7Ibfft)
4.9Nm(0.5kgfm,3.6Ibfft)
3.7 N'm(0.4kgf'm,2.7Ibfft)
20..3
ELECTRICSTARTER
TROUBLESHOOTING
Startermotordoesnotturn
1. FuseInspection
Checkforblownmainfuse30 Aorsubfuse 10 A.
Is the fuse blown?
YES - Replacethefuse.
NO - GO TO STEP 2.
2. BatteryInspection
Makesurethebatteryisfullychargedand ingoodcondition(page 18-6).
Is the battery in good condition?
YES - GO TO STEP 3.
NO - Chargeorreplacethebattery.
3. StarterRelaySwitchOperation
Checkthestarterrelayswitchoperation.
You shouldheartherelay"CLICK" whenthestarterswitch buttonisdepressed.
Is there a "CUCK'?
YES - GO TO STEP 4.
NO - GO TO STEP 5.
4. StarterMotorInspection
Applybatteryvoltagedirectlytothestartermotorand checktheoperation.
Does the starter motor turn?
YES -.Poorlyconnectedstartermotorcable
Faultystarterrelayswitch(page 20-15)
NO - Faultystartermotor(page20-6).
5. RelayCoilGroundLinesInspection
Disconnectthestarterrelayswitchconnector,andchecktherelaycoilgroundlinesas belowforcon-
tinuity:
1. Green/redterminal- diode- neutral switch line(withthetransmissioninneutralandclutch lever
released).
2.. Green/red terminal - clutch switch - sidestand switch line (in any gear except neutral, and with
theclutch leverpulledinandthesidestand up.
Is there continuity?
NO -.Faultyneutral switch(page21-19)
Faultydiode(page20-16)
Faultyclutchswitch(page21-19)
Faultysidestandswitch(page21-20)
Looseorpoorcontactconnector
Opencircuitinwireharness
YES - GO TO STEP 6.
6. StarterRelayVoltageInspection
Connectthestarterrelayswitchconnector.
With the ignition switch to ON and engine stop switch button "0" and the starter switch button
pushed,measurethevoltageatthestarterrelayswitchconnector(betweenYellow/red(+) andbody
ground(-)).
Is there battery voltage?
NO -.Faultyignitionswitch(page21-16)
Faultystarterswitch(page21-17)
Faultyenginestopswitch(page21-17)
Looseorpoorcontactconnector
Opencircuitinwireharness
YES - GO TO STEP 7.
20..4
------------ ----
ELECTRICSTARTER
7. StarterRelaySwitchContinuityInspection
Connectthestarterrelayswitchconnector.
TurntheignitionswitchtoON andtheenginestopswitch"0",checkforcontinuityatthestarterrelay
switchterminalswhenthestarterswitchbuttonispushed.
Is there continuity?
NO - Faultystarterrelayswitch.
YES - Looseorpoorcontactstarterrelayswitchconnector.
Thestartermotorturnswhenthetransmissionisinneutral,butdoesnotturnwiththetransmissionin
anypositionexceptneutral,withthesidestandupandtheclutchleverpulledin.
1. ClutchSwitchInspection
Checktheclutchswitchoperation(page21-19).
Is the clutch switch operation normal?
NO - Faultyclutchswitch.
YES - GO TO STEP 2.
2. SidestandSwitchInspection
Checkthesidestandswitchoperation(page21-20).
Is the sidestand switch operation normal?
NO - Faultysidestandswitch(page21-20).
YES -.Opencircuitinwireharness
Looseorpoorcontactconnector
Startermotorturnsslowly
Lowbatteryvoltage
Poorlyconnected batteryterminalcable
Poorlyconnectedstartermotorcable
Faultystartermotor
Poorlyconnected batterygroundcable
Startermotorturns,butenginedoesnottum
Starter(llotorisrunningbackwards
- Case assembledimproperly
- Terminalsconnectedimproperly
Faultystarterclutch
Damagedorfaultystarteridlegearand/orreduction gear
Starterrelayswitcl1"Clicks",butenginedoesnotturnover
Crankshaftdoesnotturnduetoengineproblems
20-5
ELECTRICSTARTER
STARTERMOTOR
REMOVAL
Disconnectthebatterynegative(-)cable
(page18-6).
Open the terminal cover and remove the terminal
nut.
Disconnectthestartermotorcable.
Removetheboltsandgroundcable.
Removethestartermotorfromthecrankcase.
Removethea-ringfromthestartermotor.
DISASSEMBLVIINSPECTION
Removetheassemblyboltsanda-rings.
20-6
ELECTRICSTARTER
Remove the front cover and O-ring.
FRONT COVER
/
O-RING
Remove the starter motor case and O-ring.
Remove the armature from the rear cover.
REAR COVER O-RING
ARMATURE STARTER MOTOR CASE
Remove the brushes and springs from the brush
holder.
Remove the stopper from the rear cover.
Check for continuity between starter motor cable
terminal and positive brushes.
There should be continuity.
20-7
ELECTRICSTARTER
Check forcontinuity between positive brushes and
REARCOVER NEGATIVEBRUSHES
rearcover.
Thereshouldbe nocontinuity.
Checkforcontinuitybetween negative brushes and
rearcover.
Thereshouldbecontinuity.
Checkforcontinuitybetween positive and negative
brushes.
Thereshouldbenocontinuity.
Removethescrewand negativebrushes.
Removetheterminalnut.
Removethewasher,insulator,terminalstopperand
a-ring.
ELECTRIC STAR"fER
Remove the terminal bolt, positive brushes and
brush holder.
Check the brush holder for crack or damage.
BRUSH HOLDER TERMINAL BOLT
INSPECTION
Measure each brush length.
SERVICE UMIT: 6.5 mm (0.26 in)
Check the
wear.
commutator for damage or abnormal
ARMATURE
Do not use emery
or sand paper on
the commutator.
Check the commutator bar for discoloration.
Clean the metallic debris off between commutator
bars..
Replace the armature with a new one if necessary.
20-9
-----------_._--
ELECTRICSTARTER
Checkforcontinuity between each individual com- qNOCONTINUITY:
COMMUTATORBAR
mutatorbarandthearmatureshaft.
Thereshouldbe nocontinuity.
Check the dust seal and ball bearing for wear or
damage.
Checktheball bearing rotatessmoothly.
Check the bushing of the rear cover for wear or
damage.
20-10
REAR COVER
O-RING :II
INSULATOR
TERMINAL STOPPER
4.9 N'm (0.5 kgfm, 3.6 IbHt)
---.......11.
BRUSHES
3.7 N'm (0.4 kgf'm, 2;7 IbHt)
NEGATIVE BRUSHES ~
SPRING
BRUSH HOLDER
ELECTRICSTARTER
Install the brush holder, positive brushes and termi-
BRUSH HOLDER
nal bolt.
TERMINAL BOLT
20-11
ASSEMBLY
:11 O-RING
~ O-RING
ARMATURE
P O S T V ~
Install a new O-ring, terminal stopper, insulator and
washer.
POSITIVE BRUSHES
TERMINAL STOPPER
INSULATOR
/
/-
WASHER
ELECTRICSTARTER
Install and tighten the terminal nut securely.
Install the negative brushes and tighten the screw to
the specified torque.
TORQUE: 3.7 Nm (0.4 kgfm, 2.7Ibfft)
Install the brush springs to the brush holder
grooves.
Install the stopper to the rear cover.
Install the brushes to the brush holder.
SPRINGS
20-12
ELECTRICSTARTER
Installthearmaturetotherearcoverassembly.
ARMATURE
Install anewO-ringtothestartermotorcase.
Install the starter motorcase with its groove with
thestopperontherearcoverassembly.
I NOTICE I
The coil may be damaged if the magnet pulls the
armature against the case.
Install anewO-ringtothestartermotorcase.
Installthefrontcovertothestartermotorcase.
Align the index marks on the front cover, starter
motorcaseandrearcover.
O-RING
Illiiil'
Align STARTER MOTORCASE
20-13
ELECTRICSTARTER
InstallnewO-ringstotheassemblybolts.
Install and tighten the assembly boltsto the speci-
fiedtorque.
TORQUE:4.9Nm(0.5kgfm,3.6Ibf.ft)
20-14
Route the cable
properly
(page 1-22).
Route the cable
properly
(page 1-22).
BOLTS
INSTALLATION
ApplyengineoiltoanewO-ring and installittothe ,"'cF\,,;ri<'
O-RING
startermotorgroove.
.... ,
-,
Installthestartermotorontothecrankcasefromthe
rightside.
Connectthegroundcable.
Installandtighten'theboltssecurely.
Connectthestartermotorcable.
Install and tighten theterminal nuttothe specified
torque.
TORQUE: 10Nm(1.0kgfm,7Ibfft)
Closetheterminalcover.
Connectthebatterynegative(-Icable(page18-61.
ELECTRICSTARTER
STARTER RELAYSWITCH
INSPECTION
Removethefollowing:
- Rightsidecover(page3-3)
- Fuse box/turnsignal relay(page19-8)
Shiftthetransmissionintoneutral.
TurntheignitionswitchtoON withtheenginestop
switchat"0".
Pushthestarterswitchbutton.
Thecoil isnormalifthestarterrelayswitchclicks.
Ifyou do not hear the switch "CLICK", inspect the
relayswitchusingtheprocedurebelow.
GROUNDLINE
Disconnectthestarterrelayswitch4Pconnector.
Check for continuity between the Green/red wire
(groundline)terminalandground.
If there is continuity when the transmission is in
neutral or when the clutch is disengaged and the
sidestandisretracted,thegroundcircuitoftherelay
coilisnormal.(In neutral,thereisaslightresistance
duetothediode.)
STARTER RELAYVOLTAGE
Connectthestarterrelayswitch4Pconnector.
Shiftthetransmissionintoneutral.
TurntheignitionswitchtoON withtheenginestop
switchat"0".
Measure the voltage between the yellow/red wire
terminal(+) andground(-),
If the battery voltage appears when the starter
switchbuttonispushed,thepowersupplycircuitof
ther ~ y coilisnormal.
20-15
8
ELECTRICSTARTER
OPERATIONCHECK
Removethestarterrelayswitch(page20-16).
Connect a fully charged 12 V battery to the relay
switchas shown.
Thereshouldbecontinuitybetweenthecabletermi-
nalswhilethebatteryisconnected,and no continu-
ity whenthebatteryisdisconnected.
REMQVALIINSTALLATION
Removethefollowing:
- Rightsidecover(page3-3)
- Fuseboxlturnsignal relay(page 19-8)
TurntheignitionswitchtoOFF.
Disconnectthebatterynegative(-)cable
(page18-6).
Disconnectthestarterrelay4Pconnector.
Removethesocketboltsandcables.
Removethestarterrelayswitch.
Installationisinthereverseorderofremoval.
DIODE
INSPEctiON
Removethe rightsidecover(page3-3).
Openthefuse boxcoverand removethediode.
20-16
ELECTRICSTARTER
Check for continuity between the diode terminals.
DIODE
When there is continuity, a small resistance value
will register.
If there is continuity in one direction, the diode is
normal.
B
20-17
MEMO
21. LIGHTS/METERS/SWITCHES
SYSTEMLOCA...ION .. .. 21-2
SERVICEINFORMATION....21-3
HEADLIGHT 21-5
TURNSIGNALLIGHT .. 21-6
BRAKEITAILLIGHT 21-7
LICENSE LIGHT 21-8
SPEEDOMETER/VSSENSOR.. .. 21-9
COOLANTrEMPERATUREINDICATORI
ECTSENSORSWITCH21-12
FANMOTORSWITCH 21-14
OILPRESSUREINDICATOR 21-15
IGNrnONSWITCH 21-16
HANDLEBARSWITCH 21-17
BRAKELIGHTSWITCH... 21-18
CLUTCHSWITCH 21-19
NEUTRALSWiTCH .. .. .. 21-19
SIDESTANDSWiTCH .... 21-20
HORN 21-21
TURNSIGNALRELAy .....21-21
21-1
LIGHTS/METERS/SWITCHES
SYSTEMLOCATION
FRONT BRAKE LIGHT SWITCH
LEFT HANDLEBAR SWITCH
CLUTCH SWITCH
HORN
FAN MOTOR SWITCH
REAR BRAKE LIGHT SWITCH
SIDESTAND SWITCH
NEUTRAL SWITCH EOP SWITCH
21-2
LIGHTS/METERS/SWITCHES
SERVICEINFORMATION
GENERAL
NOTICE
Notethefollowingwhenreplacingthehalogenheadlightbulb.
- Wearclean gloves while replacing the bulb. Do notputfingerprints on the headlightbulb, as theymaycreate hot
spotsonthebulbandcauseitto fail.
- Ifyoutouchthebulbwith yourbarehands,cleanitwithaclothmoistenedwithalcoholto preventitsearlyfailure.
Be suretoinstallthedustcoverafterreplacingthebulb.
A halogenheadlightbulbbecomesveryhotwhiletheheadlightis on,and remainshotforawhileafteritisturnedoff.
Besuretoletitcool downbeforeservicing.
Checkthebatteryconditionbeforeperforminganyinspectionthatrequiresproperbatteryvoltage.
Acontinuitytestcan be madewiththeswitchesinstalledonthemotorcycle.
Thefollowingcolorcodes usedareindicatedthroughoutthissection.
Bu =Blue
BI =Black
Br=Brown
G=Green
Gr=Gray
Lb=LightBlue
Lg =LightGreen
0=Orange
Y=Yellow
R=Red
W=White,
SPECIFICATIONS
ITEM SPECIFICATIONS
Bulbs Headlight 12V-60/55W
Brake/taillight 12V-21/5W
License light 12V-5W
Frontturnsignal/positionlight 12V-21/5Wx2
Rearturnsignal light 12V-21Wx2
Instrumentlight LEDx6
Turnsignal indicator LED
High beamindicator LED
Neutralindicator LED
Oil pressureindicator LED
Coolanttemperatureindicator LED
Fuse Mainfuse 30A
Subfuse 10Ax 5, 20Ax 1
ECTsensor
switch
Starttoclose(ON) 112-118e(234- 244F)
Stoptoopen(OFF) 108e(226F) minimum
Fan motor
switch
Starttoclose(ON) 103-107C(217- 225F)
Stoptoopen(OFF) 94- 98e(201 - 208F)
TORQUEVALUES
ECTsensorswitch
Fan motorswitch
Ignitionswitch mountingbolt
Ignitionswitchcoverscrew
Neutralswitch
Sidestandswitch bolt
Hornmountingbolt
Speedometermountingsocketbolt
EOP switchterminalscrew
Headlightunitmountingbolt
Brake/tail lightmountingnut
VS sensormountingbolt
7Nm(0.7kgf'm,5.2 Ibfft)
18N'm(1.8kgf'm,13 Ibfft)
12N'm(1.2 kgf'm,9Ibfft)
1N'm(0.1 kgf'm,0.7 Ibfft)
12Nm(1.2 kgfm,9Ibfft)
10 N'm(1.0 kgf'm,7Ibfft)
21 N'm(2.1 kgfm,15Ibfft)
10 N'm(1.0 kgfm,7Ibfft)
1.9N'm(0.2 kgf'm,1.4 Ibfft)
4.1 N'm(0.4kgf'm,3.0Ibfft)
6.3 N'm(0.6kgf'm,4.6Ibfft)
9.8Nm(1.0 kgfm,7.2 Ibfft)
Applysealanttothethreads
ALoebolt;replacewithanewone
~ 3
LIGHTS/METERS/SWITCHES
TOOL
Inspection test harness
07GMJ-ML80100
21-4
LIGHTS/METERS/SWITCHES
HEADLIGHT
BULBREPLACEMENT
Remove the bolts. collars and headlight unitfrom
theheadlightcase.
Disconnecttheheadlight3Pconnector.
HEADLIGHTUNIT
RETAINER
BULB DUSTCOVER
Removethedustcover.
Unhooktheretainerandremovethebulb.
I NOTICE I
Avoid touching the halogen headlight bulb. Finger
prints can create hot spots that cause a bulb to
break.
Installanewbulb.aligningitstabswiththegrooves
intheheadlightunit.
Hooktheretainer.
Installthedustcoverwithits"TOP" markfacingup.
Connecttheheadlight3Pconnector.
Install the'headlight unitintothe headlightcase by
aligning the headlight unithookwiththe headlight
casetab.
Installthecollarsandbolts.
Tightentheboltstothespecifiedtorque.
TORQUE:4.1 Nm(0.4kgfm,3.0Ibfft)
HEADLIGHTUNIT
HEADLIGHTCASEREMOVAL/
INSTALLATION
Removethefollowing:
- Headlightunit(page21-5)
- Frontturnsignallight(page21-6)
Releasethewireharnessesfromtheclamps.
Remove the wire harnesses from the headlight
case.
CLAMPS
HEADLIGHTCASE
21-5
LIGHTS/METERS/SWITCHES
Removethe nuts,boltsand headlightcase fromthe
HEADLIGHTCASE
brackets.
Route the wire Install the headlight case in the reverse order of
harnesses properly removal.
(page 1-22J. Adjusttheheadlightaim(page4-22).
TURNSIGNALLIGHT
BULB REPLACEMENT
/
BOLTS
Removethescrewandturnsignal lightlens.
While pushingthe bulbin,turn itcounterclockwise
toremoveit,and replaceitwithanewone.
Make sure the lens gasket is installed in position
and is in good condition, and replace itwith a new
oneifnecessary.
Install the lens, aligning its slotwith the tabofthe
turnsignal light,andtightenthescrew.
SCREW GASKET LENS
REMOVAUINSTALLATION
FRONT
Removethe headlightunit(page21-5).
Disconnecttheturnsignal3Pconnectors.
Lightblue: Rightturnsignalconnector
Orange: Leftturnsignalconnector
HEADLIGHTCASE
3PCONNECTORS
Removethebolt,collarandturnsignal light.
TURN SIGNALLIGHT
Route the turn Installationisinthereverseorderofremoval.
signal wire properly
(page 1-22J.
'"
21-6
BRAKE/TAILLIGHT
BULBREPLACEMENT
Removethescrews.
Remove the brakeltail light lens while pushing it
downand release itstabsfromtherearfenderA.
LENS
While pushing inthe bulb,turn itcounterclockwise
toremoveit,and replaceit.
Make sure thatthe lens gasket is installed in posi-
tionand is in good condition, and replace itwith a
newoneifnecessary.
Install the removed Pl;Irts in the
removal.
reverse order of
GASKET SCREWS
LIGHTS/METERS/SWITCHES
Align
TURNSIGNALLIGHT
Route the turn
signa/light wire
properly
(page 1-22).
REAR
Removetherearframe/rearfenderA(page3-7).
Releasetheturnsignallightwirefromtheclampsof
therearframe.
Removethe boltandturn signal lightfromthe rear
frame.
Installtheturnsignal light,aligning itstabwiththe
rearframeslotandtightenthebolt.
Installtherearframe/rearfenderA (page3-7).
I.IGHTS/METERS/SWITCHES
REMOVAL/INSTALLATION
RemovetherearframelrearfenderA (page3-7).
Release the brake/tailllicense light wire from the
clampsoftherearframe.
Disconnect the license light 2P connector and
removeitfromtherearfenderA.
Removethenuts,collarsand brake/taillight.
Route the wires Installationisinthereverseorderofremoval.
properly
TORQUE:
(page 1-22).
Brake/taillightmountingnut:
6.3Nm10.6kgfm,4.6Ibfft)
COLLAR BRAKEfTAILLIGHT
LICENSE LIGHT
BULBREPLACEMENT
Removethescrewsand licenselightcover.
LICENSE LIGHTCOVER
Removethebulband replaceit.
Make sure thatthe lens gasket is installed in posi-
tion and is in good condition, and replace itwith a
newoneifnecessary.
Install the removed parts in the reverse order of
removal.
GASKET SCREWS
REMOVAL/INSTALLATION
Removetherearframe/rearfenderA (page3-7).
Disconnectthelicenselight2P connector.
Removethenuts,collars,clampand licenselight.
Route the wires Installationisinthereverseorderofremoval.
properly
. (page 1-22).
2P CONNECTOR
BULB
CLAMP LICENSE LIGHT
21-8
LIGHTS/METERS/SWITCHES
SPEEDOMETER/VSSENSOR
POWER/GROUNDLINEINSPECTION
Removethespeedometerassembly(page21-10).
POWERINPUTLINE
MeasurethevoltagebetweentheBrownwiretermi-
SPEEDOMETERCONNECTORS
nal (+) of the speedometer 12P connector and
ground(-).
(viewedfromthewireharnessside)
There should be battery voltage with the ignition
switchturnedtoON.
Ifthereis novoltage,checkthefollowing:
- Open circuitintheBrownwire
- Blownsubfuse10A(METER,TAIL)
GROUNDLINE
Checkfor continuity between the Green/blackwire
terminalandground.
Thereshouldbecontinuityatalltimes.
Ifthereis no continuity,checkforan open circuitin
theGreen/blackwire.
BACK-UPVOLTAGELINE
Checkthis line ifthe odometer/trip meterdoes not
function.
MeasurethevoltagebetweenthePinkwireterminal
(+) andground(-).
Thereshouldbebatteryvoltageatalltimes.
Ifthereisnovoltage,checkthefollowing:
- OpencircuitinthePinkwire
- Blownsubfuse10A(ODOMETER)
- OpencircuitintheRed wire
BROWN
SPEEDOMETER CONNECTORS
(viewedfromthewireharnessside)
SPEEDOMETERINSPECTION
Speed()meterdoesnotoperate
el1eCkthattheindicatorsfunction properly.
Iftheydonotfunction,checkthepower/groundline
Cpage 21-9).
Removethespeedometerassembly(page21-10).
Supportthe motorcyclesecurely and raise the rear
wheelofftheground.
Shiftthetransmissionintoneutralandturntheigni-
tionswitchtoON.
Measure the voltage between the Black/yellow (+)
andGreen/black(-)wireterminalsof thespeedome-
terconnector.
Slowlyturntherearwheelbyhand.
Thereshouldbe0Vto5Vpulsevoltage.
Ifpulsevoltage appears, replacethe speedome-
ter.
If pulse voltage does not appear, check the fol-
lowing:
- Black/yellowwireforan openorshortcircuit.
- Green/blackwireforan opencircuit.
IfthewiresareOK,checktheVSsensor
(page21-11).
SPEEDOMETERCONNECTORS
(viewedfromthewireharnessside)
BLACKIYELLOW GREEN/BLACK
21-9
LIGHTS/METERS/SWITCHES
SPEEDOMETERREMOVAL/
INSTALLATION
..
Removethebolts and speedometerassemblyfrom
(SPEEDOMETERASSEMBLY
thefueltank.
Slidethe dustcoverand disconnectthespeedome-
ter12Pconnector.
Remove the screws, switch cover and trip meter
resetswitch.
Remove the screws, clamp, speedometer and 0-
ring.
Check the O-ring is in good condition, replace it if
necessary.
Install the removed parts into the speedometer
coverinthereverseorderofremoval.
NOTE:
Installtheresetswitchwithitsbossfacingdown.
21-10
LIGHTS/METERS/SWITCHES
Connectthespeedometer12Pconnectorand install
12PCONNECTOR
thedustcover.
Install the speedometer assembly on the fuel tank,
aligningthefueltanktabwiththe meterslot.
Installandtightentheboltstothespecifiedtorque.
TORQUE:10Nm(1.0 kgf'm,7Ibfft)
VSSENSORINSPECTION
Removetheseat(page3-3).
DisconnecttheVS sensor3P(Natural)connector.
Turn the ignition switch to ON and measure the
voltage at 3P (Natural) connector ofthe wire har-
nessside.
CONNECTION: Brown(+) - Green/Black(-)
STANDARD: BatteryYoltage
Thereshould be batteryvoltage.
Ifthereisnovoltage,checkforan opencircuitinthe
Brownand Green/blackwires.
Supportthe motorcycle securely and raise the rear
wheelofftheground.
ConnectthetestharnessbetweentheVS sensor3P
(Natural)connector.
TOOL:
Inspectiontestharness 07GMJ-MLB0100
Measure thevoltage between the Red clip (+) and
Whiteclip(-).
CONNECTION: Red clip(+) - Whiteclip(-)
STANDARD: Repeat0to5V
Shiftthetransmission intoneutralandturntheigni-
tionswitchtoON.
Slowlyturntherearwheelbyhand.
Ifpulsevoltagedoesnotappear,replacetheVSsen-
sor.
VSSENSORREPLACEMENT
Removethefollowing:
- Seat(page3-3)
- Leftsidecover(page3-3) .
- Leftcrankcase rearcover(page3-5)
DisconnecttheVS sensor3P(Natural)connector.
21-11
COOLANTTEMPERATUREINDICATORI
ECTSENSORSWITCH
INSPECTION
Thec.Qoh,mttempltratureistoohigh,butthe
indicatordoesnotcomeon
Check that the neutral and oil pressure indicators
function properly.
Iftheydonotfunction,checkthepowerinputlineof
thespeedometer(page21-9).
COOLANTTEMPERATUREINDICATOR
Removethesteeringsidecovers(page3-5).
Disconnect the ECT sensor switch connector and
groundit.
TurntheignitionswitchtoON andchecktheindica-
tor.
Iftheindicatorcomeson,inspecttheECTsensor
switch.
Ifthe indicator does notcome on, check for an
open circuit in theGreen/bluewire. Ifthewire is
OK, replacethespeedometer(page21-10).
21-.12
LIGHTS/METERS/SWITCHES
Route the VS
sensor wire
properly
(page 1-22).
Release the VS sensor wire from the clamps and
wirebands.
RemovetheboltandVS sensorfromthecrankcase.
CoatanewO-ring with engineoil and install itinto
theVS sensorgroove.
InstalltheVSsensorand mountingbolt.
Tightenthemountingbolttothespecifiedtorque.
TORQUE:9.8Nm(1.0kgfm,7.2 Ibfft)
Install the removed parts in the reverse order of
removal.
iF"'..... .....
LIGHTS/METERS/SWITCHES
Wear insulated
gloves and
adequate eye
protection.
Keep flammable
materials away
from the burner.
The coolant temperature is low but the indicator
comes on.
DisconnecttheECTsensorswitchconnector.
TurntheignitionswitchtoON andchecktheindica-
tor.
If the indicator does not come on, inspect the
ECTsensorswitch.
Iftheindicatorcomeson,checkforashortcircuit
in theGreen/bluewire. Ifthewire isOK, replace
thespeedometer(page21-10).
ECTSENSORSWITCHINSPECTION
Drain fromthecoolingsystem
(page
Removethe.ECTsensorswitch(page21-13).
Heatthe'coolant(1 : 1mixturewithdistilledwater)
withan electricheatingelement.
the ECT sensor switch in heated coolant
and checkthe continuitythrough the switch as the
coolantheatsup.
NOTE:
Soakthe ECT sensor switch in coolant up to its
threadswithatleast40 mm(1.6in)fromthebot-
tomofthepantothebottomoftheswitch.
Keeptemperatureconstantfor3minutesbefore
testing. A sudden change of temperature will
result iniricorrect readings. Do not letthe ther-
mometerorECTsensorswitchtouchthepan.
StoptoopenAOFF} Below108C(226F)
THERMOMETER
ECTSENSORSWITCH
ReplacetheECTsensorswitch ifitisoutofspecifi-
cations.
InstalltheECTsensorswitch(page21-13).
ECTSE-NSORSWITCH REPLACEMENT
Rrainthecoolantfromthecoolingsystem
(page'7-7k' '., '. .
RemovethestEl.eringsidecovers(page3-5).
Disconnecttile. ECTsensorswitchconnector.
RemovetheECl'sensorswitchfromthethermostat
hOL!.l:li@
Do not apply ofa new ECT sensor
sealant to the switch. ",' , .. ,.
thread head. Il'lstl:l1landtightentht:jECTsensorswitch.
TORQUE:7Nm(O.7ijt.m,5.2Ibf.ft)
Fill and bleedthecoolingsystem(page7-7).
Installthesteeringsidecovers(page3-5).
21-13
LIGHTS/METERS/SWITCHES
FAN MOTORSWITCH
INSPECTION
The coolant temperature is low but the fan motor
does not stop
Disconnecttheconnectorfromthefan motorswitch
andturntheignitionswitchtoON.
Ifthefan motordoes notstop, check for ashort
circuitintheBlackwire.
If the fan motor stops, replace the fan motor
switch.
The coolant temperature indicator comes on but
the fan motor does not start
Before testing, check for a blown sub fuse 20 A
(FAN).
Disconnecttheconnectorfromthefan motorswitch
andgroundit.
Turn the ignition switch to ON and check the fan
motor.
Ifthemotorstarts,replacethefan motorswitch.
Ifthefan motordoes notstart,removethesteer-
ingsidecovers(page3-5) anddisconnectthefan
motlif2P (Natural)connector.
MeasurethevoltagebetweentheBlack/bluewire
andground.
...: voltage, replace the fan
motor{page
- Ifthereisnovoltage,checkforan open circuit
intheGreen and Black/bluewires.
21-14
LIGHTS/METERS/SWITCHES
REPLACEMEI\lT
Drainthecoolant(page7-7).
Disconnect the connector from the fan motor
switch.
Removethefan motorswitchfromthe radiator.
Install a new O-ring into the fan motor switch
groove.
Installandtightenthefan motorswitch.
TORQUE: 18Nm(1.8kgfm,13Ibfft)
Connecttheconnectortothefan motorswitch.
Fill and bleedthecoolingsystem(page7-7).
OILPRESSUREINDICATOR
INSPECTION
Indicatordoesnotcomeonwiththeignitionswitch
turnedtoON
Checkthattheneutralandcoolanttemperatureindi-
catorsfunctionproperly.
Ifthey do not function properly, check the power
inputlineofthespeedometer(page21-9).
Removetheleftcrankcaserearcover(page3-5).
Remove the rubber cap, and disconnect the EOP
switchwirebyremovingtheterminalscrew.
Groundthewireterminal.
Turn the ignition switch to ON and check the oil
pressureindicator.
If the indicator comes on, replace the EOP
switch.
Ifthe indicator does notcome on, check for an
opencircuitintheBlue/redwire.IfthewireisOK,
replacethespeedometer(page21-10).
Indicatorstaysonwhiletheengineisrunning
Remove the rubber cap, and disconnect the EOP
switchwirebyremovingtheterminalscrew.
Checkforcontinuitybetween thewireterminal and
ground.
Ifthereis,checkforashortcircuitintheBlue/red
wire.
Ifthere is no continuity, check the oil pressure
(page5-5).
If the oil pressure is normal, replace the EOP
switch.
After inspection, connect the EOP switch wire and
tightentheterminalscrew.
TORQUE: 1.9Nm(0.2kgfm,1.4Ibfft)
Installtherubbercap properly.
Installtheleftcrankcaserearcover(page3-5).
OILPRESSURE INDICATOR
21-15
LIGHTS/METERS/SWITCHES
IGNITIONSWITCH
INSPEC1"ION
Removetheseat(page3-3).
Disconnect the ignition switch 2P (Black) and 1P
(Natural)connectors.
Check for continuity between the switch side con-
nectorterminalsineach switch position.
Continuity should exist between the color coded
wiresas showninthechart.
BulO RlBI R
REMOVAUINSTALLATION
RemovethefollOWing:
- Seat(page3-3)
- Leftsidecover(page3-3)
Disconnect the ignition switch 2P (Black) and 1P
(Natural)connectors.
Releasethewirefromthewireband.
RemovethescrewandIgnitionswitchcover.
Removetheboltsandignitionswitchassembly.
Removethebolts, ignitionswitch,collarand switch
basefromthestay.
Install theswitch base, ignitionswitch and collarto
thestay.
Tighten newboltstothespecifiedtorque.
TORQUE: 12Nm(1.2 kgfm,9Ibf.ft)
Installtheignitionswitchassemblytotheframe.
Install the ignition switch cover and tighten the
screw.
TORQUE: 1Nm(0.1 kgfm,0.7Ibfft)
Routetheignitionswitchwireproperly(page 1-22).
Connecttheignitionswitch2P(Black)and 1P(Natu-
ral) connectors.
Installthefollowing:
- Leftsidecover(page3-3)
- Seat(page3-3)
BOLTS BOLTS
IGNITIONSWITCH/COLLAR/SWITCH BASE
The ignition switch
mounting bolt
heads are broken
by tighten them to
the specified
torque.
21-16
LIGHTS/METERS/SWITCHES
HANDLEBARSWITCH
Removetheheadlightunit(page21-5).
6PCONNECTORS
Disconnectthefollowingconnectors:
Lefthandlebarswitch6P (Blue)
- Lefthandlebarswitch6P (Black)
- Righthandlebarswitch6P (Red)
- Dimmerswitch2P(Black)
- Turnsignallight3P(Lightblue)and3P(Orange)
Check forcontinuity between the connector termi-
nalsineachswitchposition.
Continuity should exist between the color coded
.wiresas showninthecharts.
2PCONNECTOR
RIGHTHANDLEBARSWITCH
ENGINESTOPSWITCH
ENGINE STOPSWITCH
IG BAT2
COLOR BIIW BI/G
STARTERSWITCH
ST IG BAT4 HL
FREE
0-
f-o
PUSH
0-
f-O
COLOR YIR 811W BIIR BulW
STARTERSWITCH
FREE
Ho BAT3
W R L
Gr Lb 0 Br LblW OIW
LEFTHANDLEBARSWITCH
TURNSIGNALSWITCH
COLOR
PUSH
HORNSWITCH
DIMMERSWITCH
COLOR BuNI W Bu
21-17
LIGHTS/METERS/SWITCHES
BRAKELIGHTSWITCH
FRONT
Disconnect the brake light switch connectors and
check for continuity between the switch terminals.
There should be continuity with the brake lever
squeezed and no continuity with the lever released.
REAR
Remove the steering side covers (page 3-5).
Disconnect the rear brake light switch 3P (Light
gray) connector and check for continuity between
the switch side connector terminals.
There should be continuity with the brake pedal
depressed and no continuity with the pedal
released.
REAR BRAKE LIGHTSWITCH
REMOVAL/INSTALLATION
Remove the steering side covers (page 3-5).
Remove the wire band and disconnect the rear
brake light switch 3P (Light gray) connector.
Unhook the return spring and remove the rear brake
light switch.
Route the wire Installation is in the reverse order of removal.
properly Adjust the rear brake light switch (page 4-22).
(page 1-22).
21-18
LIGHTS/METERS/SWITCHES
CLUTCH SWITCH
Disconnect the clutch switch wire connectors and
checkforcontinuitybetweentheswitchterminals.
There should be continuity with the clutch lever
squeezedand nocontinuitywiththeleverreleased.
NEUTRALSWITCH
Removetheleftcrankcaserearcover(page3-5).
INSPECTION
Disconnecttheneutralswitch connector.
Check for continuity between the switch terminal
and engineground.
There should be continuity when the transmission
is in neutral, and nocontinuitywhen thetransmis-
sionisingearexceptneutral.
REPLACEMENT
Disconnecttheneutralswitchconnector.
Removetheneutral switch with thesealing washer
fromthecrankcase.
Installtheneutralswitchwithanewsealingwasher
andtightenit.
TORQUE: 12N'm(1.2kgfm,9Ibf.ft)
Connecttheneutralswitchconnector.
Installtheleftcrankcase rearcover(page3-5).
21-19
-- ---- -----------------
LIGHTS/METERS/SWITCHES
SIDESTANDSWITCH
Do not reuse the
sidestand switch
bolt.
INSPECTION
Removetheseat(page3-3).
Disconnectthesidestandswitch2P (Green) connec-
tor.
Check for continuity between the switch side con-
nectorterminals.
There should be continuity with the sidestand
retracted and nocontinuitywiththesidestand low-
ered.
REMOVALlINSTAlLATION
Removethefollowing:
- Seat(page3-3)
- Leftsidecover(page3-3)
- Leftcrankcase rearcover(page3-5)
Supportthemotorcyclesecurely.
Disconnectthesidestandswitch2P(Green)connec-
tor.
Release the sidestand switch wire from the wire
bandsandclamps.
Removethe boltand sidestandswitch.
Install thesidestand switch byaligning its pinwith
the sidestand hole and switch groove with the
bracketpin.
...--"""'"=-....
21-20
LIGHTS/METERS/SWITCHES
Installanewsidestandswitchbolt.
Tightenthebolttothespecifiedtorque.
TORQUE: 10Nm(1.0kgfm,7Ibfft)
Route the Install the removed parts in the reverse order of
sidestand switch removal.
wire properlv
(page 1-22).
HORN
INSPECTION
Disconnecttheconnectorsfromthehorn.
Connecta12Vbatterytothehornterminals.
The horn is normal ifitsoundswhenthe 12 V bat-
teryisconnectedacrossthehornterminals.
REMOVAL/INSTALLATION
Disconnecttheconnectorsfromthehorn.
Removetheboltandhorn.
Installthehorntotheframe,aligningitsflatwiththe
hornstay.
Installandtightenthebolttothespecifiedtorque.
TORQUE:21 Nm(2.1 kgfm,15Ibfft)
Connecttheconnectors.
... ...._
TURNSIGNALRELAV
Turnsignallightdoesnotblink
Removetherightsidecover(page3-3).
Removetheturnsignal relayfromthestay.
Slidetherubbercap anddisconnecttheconnector.
ConnecttheWhite/greenandGraywireterminalsof
thewireharnesssideconnectorwithajumperwire.
Turn the ignition switch to ON and checkthe turn
signallightsbyoperatingtheturnsignalswitch.
Ifthe lightdoes notcomeon,checkforan open
circuitintheWhite/greenand Graywires.
Ifthelightcomes on,checktheconnectortermi-
nalsforlooseorpoorcontact.
If the connector terminals are OK, replace the
turnsignalrelay.
21-21
MEMO
22. WIRINGDIAGRAMS
WIRING DIAGRAM WIRINGDIAGRAM(Californiatype) 22-4
(49statesICanadatype) .. 22-3
"e
22-1
-
-
J
G
L.b
Br
GIBI
BVY
P
GIBu
LgIR
au
o
BuIR
WIRING DIAGRAM (49 statesICanada type)
ENGINESTOPSWITCH STARTERSWITCH
(
COOLANTTEMPERATURE
INDICATOR
NEUiRAlINDICATOR
HIGHBEAMINDICATOR
TURNSIGNALINDICATOR
OILPRESSUREINDICATOR
INSTRUMENTLIGHT
LEDX6 ENGINESTOP-STARTERSWITCH
FRONTBRAKE D
LIGHTSWITCH
--
(
TRIPRESETSWITCH
TURNSIGNALRELAY
FOG LAMP
RIGHTFRONT
(OPTION)
TURN SIGNALLIGHT
12V2115W
mOP
1"a;
YJR=======
LEFTFRONT
BIIW
12V2115W OPO
BllBu-
0&:g:
HORN 3:
:>
?;Omm.9':9 It
!!!"
lD
I'-hTI I
I L-, qh
It lD
III I I
81
0
(
IGNITIONSWITCH
CLUTCHSWITCH TURN SIGNALoDIMMERoHORNSWITCH VS SENSOR FUSEBOX
FAN MOTORSWITCH
FUSE A lOA (HEAOUGHT)
TURNSIGNALLIGHTSWITCH DIMMERSWITCH HORNSWITCH
'"
W R L PO PR PI.
R 0 -0
N
1< - -0
l
""- Hl
La Hi
La
-0
(N)
Hi
B1M (METER-TAIl)
IGNITIONSWITCH
ClOA (lGNITIONoSTARTER)
olOA (TURNoHORNoSTOP)
E 2lIA (FANllOIOR)
FlOA (ODOMETER)
1"'-
FAN IG BAT1 KEY
10rO-
ON
-0
KEY ON
OFF KEYOF!'
EOPSWITCH ""
WIRINGDIAGRAMS
STARTERRELAYSWITCH ....'N FUSE ...
IGNITIONPULSE
GENERATOR
): l
Et>
STARTERMOTOR
IGNITIONCOILS g
-+----- I II
ECTSENSORSWITCH
TPSENSOR +
@=
3P .;;AIY-
:
WIY-
ICM
II
_
o
e
BATTERY
12V 11M
14P Y
LIGHTSWITCH
REARBRAKE
-t'1t.""GRAY
RIGHTREAR
TURNSIGNALLIGHT
aP
f-GlY:uJ:GIY- f-- GIY
'-G G-.--G
L- Br Br - p-- Br
BRAKEITAILLIGHT
12V211SW
2P
c..:::
LICENSELIGHT
12V5W
>->->-
I c..::::= g:OJ:
MaP
2PO
LEFTREAR
TURNSIGNALLIGHT
12V21W
>->->-
f
0
REGULATOR! 0
RECTIFIER
SIDESTANDSWITCH
ALTERNATOR
TRALSWITCH
-
.-
BI BLACK Br BROWN
Y YELLOW 0 ORANGE
Bu BLUE Lb LIGHTBLUE
G GREEN Lg LIGHTGREEN
R RED P PINK
W WHITE Gr GRAY
0030l-MFE-6700
22-3
-
~
J
WIRINGDIAGRAMS
WIRINGDIAGRAM (Californiatype)
ENGINE STOP SW
COOLANTTEMPERATURE
INDICAlOR
NEUTRAL INDICATOR
G
Lb
Br
GlBI
BI/Y
P
G
HIGH BEAM INDICAlOR
l\JRN SIGNAL INDICAlOR
OIL PRESSURE INDICATOR
INSTRUMENT LIGHT
ENGINE smP-STARTEF
FRONT BRAKE D ~
LED X
LIGHT SWITCH ~ W
mm ~ ~ ~ ~ ~
~
TRIP RESET SWITCH
l\JRN
FOG LAMP
RIGHT FRONT
(OPTION)
l\JRN SIGNAL LIGHT
12V2115W
CLUTCH SWITCH l\JRN SIGNALoDlMMERoHORN SWITCH VS SENSOR
I'"
HL Lo HI
Lo 10
(N)
HIIO
rO
TURN SIGNAL LIGHT SWITCH DIMMER SWITCH HORN SWITCH
FUSE AlOA IHEADUGtlT)
BlDA (METER-TAIL)
~
C lOA (lGNmCJNo6TARTER)
D lOA (lURNoH<JRNoSTOP)
E 2DA IFAN NOTOR)
F lOA (ODONETERI
22-4
rCH STARTERSWITCH
D
ECTSENSORSWITCH
14P Y
leM
STARTERMOTOR
TPSENSOR
WN-
Y -
I BuIY-
ym
u
:
--'
IGNmONPULSE
GENERAlOR
FUELCLIT-0FF
SOLENOIDVALVE
SWITCH
IIGNALRELAY
BfiAKEITAILLIGHT
12V2115W
2!'
LICENSELIGHT
12V5W
>
--===g=ill . I
...
LEFTREAR
Ol TURNSIGNALLIGHT
12V21W
o
SIDESTANDSWITCH
B'SJ
ALTERNATOR
CH
EOPSWITCH NEUTRALSWITCH
FAN MOTORSWITCH
ImONSWITCH BI BLACK Br BROWN
Y YELLOW 0 ORANGE
Bu BLUE l.b LIGHTBLUE (
G GREEN- Lg LIGHTGREEN
R RED P PINK
W WHITE Gr GRAY
\ FAN
IG
""'"
KEY
KEVON
,
KEVOF1'
0030Z-MFE-7700
I
23.TROUBLESHOOTING
ENGINEDOESNOTSTARTORISHARD POORPERFORMANCEAT
TOSTART 23-2 HIGHSPEED 23-6
ENGINELACKSPOWER 23-3 POORHANDLING 23-7
POORPERFORMANCEATLOWAND
IDLESPEED 23-5
23-1
TROUBLESHOOTING
ENGINE DOESNOTSTARTOR ISHARDTOSTART
1. FuelLineInspection
Checkfuelflowtocarburetor.
Does fuel reach the carburetor?
NO -.Cloggedfuellineandstrainer
Cloggedfueltankbreather
Stickingfloatvalve
Pinchedfuelvalvevacuum hose
YES - GO TO STEP 2.
2. SparkPlugInspection
Removeandinspectsparkplugs.
Is the spark plug wet?
YES -.Floodedcarburetor
SE valveON position(open)
Throttlevalve open
Dirtyaircleaner
NO - GO TO STEP 3.
3. SparkTest
Performsparktest.
Is there weak or no spark?
YES -.Faultysparkplug
Fouledsparkplug
looseordisconnectedignitionsystemwires
Faultyignitionpulsegenerator-
Faultyignitioncoil
FaultyICM
Faultyenginestopswitch
NO - GO TO STEP 4.
4. CylinderCompfession
Testcylindercompression.
Is the compression low?
YES -.Valvestuckopen
Worncylinderandpistonrings
Damagedcylinderheadgasket
Seizedvalve
Impropervalvetiming
NO - GO TO STEP 5.
5. EngineStartingCondition
Startenginebyfollowingnormalprocedure.
Does the engine start then stops?
YES -.Improperchokeoperation
Incorrectlyadjustedcarburetor
. Leakingcarburetorinsulatororintakemanifold
Improperignitiontiming(FaultyICM,ignitionpulsegeneratororTPsensor)
Contaminatedfuel
23-2
TROUBLESHOOTING
ENGINELACKS POWER
1. DriveTrainInspection
Raisewheeloffthegroundandspinitbyhand.
Does the wheel spin freely?
NO -.Brakedragging
Wornordamagedwheel bearings
Finalgearbearingdamaged
YES - GO TO STEP 2.
2. TirePressureInspection
Checktirepressure.
Are the tire pressures low?
YES -.Faultytirevalve
Puncturedtire
NO - GO TO STEP 3.
3. ClutchInspection
Accelerate rapidlyfromlowtosecond.
Does the engine speed change accordingly when the clutch is engaged?
NO -.Clutch slipping
Wornclutchdiscs/plates
Warpedclutchdiscs/plates
Weakclutchspring
Additiveinengineoil
YES - GO TO STEP 4.
4. EnginePerformanceInspection
Acceleratelightly.
Does the engine speed increase?
NO -::. SEvalveON position(open)
Dirtyaircleaner
.Restrictedfuelflow
Clogged muffler
Cloggedfueltankbreather
FaultyTPsensor
YES - GO TO STEP 5.
5. SparkPlugInspection
Removeand inspectsparkplugs.
Is the spark plug fouled or discolored?
NO _. Plugsnotservicedfrequentlyenough
Incorrectsparkplugheatrange
Incorrectsparkpluggap
YES - GO TO STEP 6.
6. EngineOilInspection
Checkoil levelandcondition.
Is there correct level andgood condition?
NO -.Oil leveltoohigh
Oil leveltoolow
Contaminatedoil
YES - GO TO STEP 7.
---------------- ---
TROUBLESHOOTING
7. IgnitionTimingInspection
Checkignitiontiming.
Is the ignition timing correct?
NO -.FaultyICM
Faultyignitionpulsegenerator
FaultyTP sensor
YES - GO TO STEP 8.
8. CylinderCompressionInspection
Testcylindercompression.
Is the compression low?
YES -.Valveclearancetoosmall
Valvestuckopen
Worncylinderandpistonrings
Damagedcylinderheadgasket
Impropervalvetiming
NO - GO TO STEP 9.
9. CarburetorInspection
Checkcarburetorforclogs.
Is the carburetor clogged?
YES - Carburetornotservicedfrequentlyenough.
NO - GO TO STEP 10.
10.LubricationInspection
Removecylinderhead coverandinspectlubrication.
Is the valve train lubricated properly?
NO -.Cloggedoilpassage
Cloggedoilorifice
YES - GO TO STEP 11.
11.OverHeatingInspection
Checkforengineoverheating.
Is the engine over heating?
YES _. Coolantleveltoolow
Fan motornotworking
Thermostatstuckclosed
Excessivecarbonbuild-upincombustionchamber
Useofpoorqualityfuel
Wrongtypeoffuel
Clutchslipping
NO - GO TO STEP 12.
12.EngineKnockingInspection
Accelerateorrun athighspeed.
Is there knocking?
YES _. Wornpistonandcylinder
Wrongtypeoffuel
Excessivecarbonbuild-upincombustionchamber
Ignitiontimingtooadvance(FaultyICM)
Leanfuel mixture
FaultyTP sensor
NO - Enginedoesnotknock.
23-4
TROUBLESHOOTING
POORPERFORMANCEATLOWANDIDLESPEED
1. PilotScrewInspection
Checkcarburetorpilotscrewadjustment.
Is the adjustment correct?
NO - See page6-25
YES - GO TO STEP 2.
2. IntakeAirLeakInspection
Checkthecarburetorinsulatorand intakemanifoldforleaks.
Are these leaks?
YES -.Looseinsulatorbands
Damagedinsulator
FaultyO-ring
NO - GO TO STEP 3.
3. SparkTest
Performsparktest.
Is there weak or intermittent spark?
YES _. Faultysparkplug
Fouledsparkplug
Looseordisconnectedignitionsystemwires
Faultyignitionpulsegenerator
Faultyignitioncoil
Faultyenginestopswitch
FaultyICM
NO - GO TO STEP 4.
4. IgnitionTImingInspection
Checkignitiontiming.
Is the ignition timing correct?
NO -.FaultyICM
Faultyignitionpulsegenerator
FaultyTPsensor
23-5
TROUBLESHOOTING
POORPERFORMANCEATHIGHSPEED
1.
2.
3.
4.
5.
6.
7.
FuelLineInspection
Disconnectfuel lineatcarburetor.
Does fuel flow freely?
NO -.Restrictedfuel lineandstrainer
Restrictedfueltankbreather
Faultyfuelvalvevacuumhose
YES - GO TO STEP 2.
SparkPlugInspection
Removeand inspectthesparkplug.
Is the spark plug in good condition?
NO _. Plug notservicedfrequentlyenough
Incorrectsparkplug heatrange
Incorrectsparkpluggap
FaultySE valve
Aircleanerdirty
YES - GO TO STEP 3.
CarburetorInspection
Checkcarburetorforclogging.
Is the carburetor clogged?
YES - Carburetornotservicedfrequentlyenough.
NO - GO TO STEP 4.
IgnitionTimingInspection
Checkignitiontiming.
Is the ignition timing correct?
NO -.FaultyrCM
Faultyignitionpulsegenerator
FaultyTP sensor
YES - GO TO STEP 5.
ValveTimingInspection
Checkvalvetiming.
Is the valve timing correct?
NO - Cam sprocketsnotinstalledproperly.
YES - GO TO STEP 6.
ValveSpringInspection
Checkvalvesprings.
Is the valve spring free length within specification?
NO - Faultyvalvespring.
YES - GO TO STEP 7.
CamshaftInspection
Removeand inspectthecamshaft.
Is the cam lobe height within specification?
NO - Faultycamshaft.
YES - CamshaftisOK
TROUBLESHOOTING
POOR HANDLING
Steeringisheavy
Steering top thread too tight
Damaged steering head bearings
Low tire pressure
Eitherwheeliswobbling
Excessive wheel bearing play
Bent rim
Improperly installed wheel hub
Excessively worn swingarm pivot bearings
Bentframe
Motorcyclepullstooneside
Front and rear wheels not aligned
Bent fork
Bent swingarm
Bent axle
Bentframe
23-7
MEMO
24. INDEX
AIR CLEANER.. .. .. .. .... ..
AIR CLEANER HOUSING........ .... .. 6-6
ALTERNATORCHARGINGCOIL .. .. 18-9
ALTERNATOR/STARTERCLUTCH
SPECIFICATIONS.. .. 1-9
BATTERy .. .... .. .. 18-6
BATTERY/CHARGINGSYSTEMSPECIFICATIONS.. 1-12
BRAKE FLUID.. .. .. .. .. .. 4-19
BRAKE FLUID REPLACEMENT/AIRBLEEDING 17-5
BRAKE LIGHTSWITCH
L1GHTS/METERS/SWITCHES .. .. .. 21-18
MAINTENANCE.. .. .. 4-22
BRAKE PAD/DISC .. .. .. .. 17-7
BRAKE PEDAL........ .. .. .. .. 16-17
BRAKE SHOES/PADSWEAR.. ...... .. .... ..4-20
BRAKE SYSTEM.. .. .. .... ........ .. 4-20
BRAKEITAILL1GHT........ .. .. .. ........ 21-7
CABLE &HARNESSROUTING .. .. .. 1-22
CAMSHAFTINSTALLATION.. .. .. .............. 9-26
CAMSHAFT REMOVAL .. .. .. .... .. .. 9-8
CARBURETORASSEMBLY.. .. ........ .. 6-15
CARBURETORDISASSEMBLY/INSPECTION.. .. .. 6-9
CARBURETORINSTALLATION .. .. .... ......6-21
CARBURETORREMOVAL .. .. .. 6-7
CHARGING SYSTEM INSPECTION .. ......18-7
CHOKE OPERATION.. .. .. ..
CLUTCH INSTALLATION.. .. .. ........ .. .... 11-18
CLUTCH REMOVAL .. .. .. 11-7
CLUTCH SWITCH .. .. ..21-19
CLUTCH SYSTEM.. .. .. .. .. .. 4-22
CLUTCH/GEARSHIFTLINKAGE SPECIFICATIONS.....1-9
COMPONENTLOCATION
ALTERNATOR/STARTERCLUTCH .. 12-2
CLUTCH/GEARSHIFTLINKAGE.. 11-2
CRANKSHAFTrrRANSMISSION 13-2
CYLINDERHEADNALVE .... 9-2
CYLINDER/PISTON ............: .. .. .. ..10-2
ENGINE REMOVAUINSTALLATION 8-2
FINALDRiVE .. .. .. ........ ..14-2
FRONTWHEEUSUSPENSION/STEERING.......... 15-2
FUELSYSTEM .. .. .. .. .. .. 6-2
HYDRAULICBRAKE .. .... 17-2
REARWHEEUBRAKE/SUSPENSION.. .. .. 16-2
COOLANTREPLACEMENT ..7-6
COOLANTTEMPERATURE INDICATOR/
ECTSENSORSWITCH .. 21-12
COOLING SYSTEM .. ..
COOLING SYSTEM SPECIFICATIONS .. 1-7
CRANKCASEASSEMBLY .. 13-49
CRANKCASEBEARING REPLACEMENT 13-47
CRANKCASEBREATHER .. ..
CRANKCASESEPARATION.. .. .. .. .. 13-9
CRANKPIN BEARING........ ........ .. ..13-13
CRANKSHAFT/CONNECTING ROD .. .... .. 13-10
CRANKSHAFTITRANSMISSION
SPECIFICA-nONS........ ; .. .. .. ........ .... 1-10
CYLINDERCOMPRESSION .. .. .... 9-6
CYLINDERHEADASSEMBLY...... .. .. .. 9-22
CYLINDER HEADCOVER INSTALLATION ..9-31
CYLINDER HEADCOVER REMOVAL .. ;9-6
CYLINDERHEADDISASSEMBLY .. .. 9-15
CYLINDERHEADINSTALLATION 9-24
CYLINDER HEADREMOVAL...... ; .. 9-14
CYLINDERHEADNALVESPECIFICATIONS.. 1-8
CYLINDER/PISTON INSTALLATION.. ...... .. .. 10-9
CYLINDER/PISTON REMOVAL.. .. .. .. 10-4
CYLINDER/PISTON SPECIFICATIONS 1-8
DIODE 20-16
ELECTRICSTARTERSPECIFICATIONS.... 1-12
EMISSIONCONTROLSYSTEMS........ ........1-39
ENGINE& FRAMETORQUEVALUES .. .. .. .. 1-13
ENGINEIDLE SPEED .. ..4-15
ENGINEINSTALLATION .. .. .. .. 8-7
ENGINEOIL............ .. .. 4-12
ENGINEOILFILTER 4-13
ENGINEREMOVAL .... .. 8-4
EVAPCONTROLSYSTEM (Californiatypeonly)
FUELSYSTEM 6-30
MAINTENANCE 4-17
EXHAUSTSYSTEM 3-8
FAN MOTORSWiTCH.. .. 21-14
FINALDRIVEASSEMBLY ..
FINALDRIVE DISASSEMBLY/INSPECTION.. .. 14-8
FINALDRIVE INSTALLATION .. .. ..
FINALDRIVE OIL.. .......... .. .. ..4-18
FINALDRIVE REMOVAL .. .... .. .. 14-7
FINALDRIVE SPECIFICATIONS.. ...... .. 1-10
FLYWHEEUSTARTERCLUTCH ...... .. 12-5
FORK ................ .. .. 15-19
FRONTBRAKE CALIPER .. .. .. .. .. .. 17-13
FRONTFENDER.. .. .. .. .. .. .. .. .. .. 3-6
FRONTWHEEL .. .. .. 15-13
FRONTWHEEUSUSPENSION/STEERING
SPECIFICATIONS .. .. .. 1-11
FUEL LINE .. .. .. .. .. ..
FUELSYSTEMSPECIFICATIONS .. 1-7
FUEL TANK .. 3-4
GEARSHIFTLINKAGE .. .... 11-14
GENERALSPECIFICATIONS 1-5
HANDLEBAR.. .. .. .. .. .. .. 15-6
HANDLEBARSWITCH .... .... .. 21-17
HEADLIGHT 21-5
HEADLIGHTAIM 4-22
HIGHALTITUDEADJUSTMENT 6-26
HORN 21-21
HYDRAULICBRAKE SPECiFiCATIONS ...... 1-11
ICM .. ...... .... .. .. .. .... 19-9
IGNITIONCOIL .. .. .. 19-8
IGNITIONSWITCH 21-16
IGNITIONSYSTEM INSPECTION 19-5
IGNITIONSYSTEMSPECIFICATIONS.. .. 1-12
IGNITIONTIMING .. .... .. .. .. 19-9
INTAKEMANIFOLD 6-23
LEFTCRANKCASEREAR COVER 3-5
LICENSELIGHT 21-8
LIGHTS/METERS/SWITCHESSPECIFICATIONS 1-12
LUBRICATION &SEALPOINTS...... .. 1-19
LUBRICATION SYSTEM DIAGRAM 5-2
LUBRICATION SYSTEMSPECIFICATIONS 1-7
MAINJOURNALBEARING 13-16
MAINTENANCESCHEDULE .. .. .... 4-4
MASTERCyLINDER .. .. .. .. .... ..17-8
MODELIDENTIFICATION 1-2
NEUTRALSWiTCH ..21-19 .
NUTS,BOLTS,FASTENERS .. .
OILPRESSURE INDICATOR 21-15 --.
OILPRESSURE INSPECTION 5-5
OILPUMP.. .. .. 5-6
OUTPUTGEAR .... .. .. .. ..13-28
OXIDATIONCATALYTICCONVERTER
PROTECTION FROM UNBURNEDGASOLINE
(Californiatypeonly) 2-2
PILOTSCREWADJUSTMENT 6-25
PRIMARYDRIVE GEAR .... 11-12
RADIATORCOOLAI\lT .. 15
RADIATORRESERVE TANK .. .. 7-17
RADIATOR/COOLING FAN .... .. .. 7-11
REAR BRAKE .. .. .. ..16-14
24-1
II\1DEX
REAR FENDER .. .. .. .. .. 3-6
REAR WHEEL 16-6
REAR WHEEUBRAKE/SUSPENSION
SPECIFICATIONS 1-11
REGULATOR/RECTIFIER .. .. .. .. .. .. .. 18-8
RIGHTCRANKCASECOVER INSTALLATION 11-21
RIGHTCRANKCASECOVER REMOVAL 11-5
SEAT 3-3
SECONDARYAIRSUPPLYSYSTEM
FUELSYSTEM 6-28
MAII\lTENAI\lCE.. .... .. 4-16
SERVICE INFORMATION
ALTERNATOR/STARTERCLUTCH 12-3
BATTERY/CHARGING SYSTEM 18-3
CLUTCH/GEARSHIFTLINKAGE .. 11-3
COOLINGSYSTEM 7-3
CRANKSHAFTITRANSMISSION .. .... 13-3
CYLINDERHEADNALVE.. .. .. 9-3
CYLINDER/PISTON .. .. .. 10-3
ELECTRICSTARTER .. .. 20-3
ENGINEREMOVAUII\lSTALLATION 8-3
FINALDRIVE 14-3
FRAME/BODYPANELS/EXHAUSTSySTEM 3-2
FRONTWHEEUSUSPENSION/STEERING 15-3
FUELSYSTEM 6-3
HYDRAULICBRAKE .. .. .. ..17-3
IGNITIONSySTEM .. 19-3
LIGHTS/METERS/SWITCHES 21-3
LUBRICATION SySTEM.... .. .. .. ........5-3
MAINTENANCE 4-2
REARWHEEUBRAKE/SUSPENSION 16-3
SERVICE RULES .. .. .. .. .. .. .. .. 1-2
SHOCKABSORBER 16-21
SIDE COVER 3-3
SIDESTAND .. .. .. .. ..4-23
SIDESTANDSWiTCH.. .. .. 21-20
SPARKPLUG .... .. .... 4-9
SPEEDOMETERIVS SENSOR : 21-9
STANDARDTORQUEVALUES.... .. 1-13
STARTERMOTOR...... .. .. 20-6
STARTERRELAYSWITCH 20-15
STATORINSTALLATION.. .. .. .. 12-11
STATORREMOVAL .. .. 12-4
STEERING HEAD BEARINGS 4-26
STEERINGSIDE COVER 3-5
STEERINGSTEM 15-28
SUBAIRCLEANER 4-8
SUSPENSiON.. .. .. .. 4-24
SWINGARM .... .. .. .. .. .. 16-22
SYSTEM DIAGRAM
BATTERY/CHARGINGSYSTEM .. .. .. 18-2
ELECTRIC STARTER.. .. .. .. .. 20-2
IGNITIONSYSTEM.. .. 19-2
SYSTEM FLOWPATTERN.... .. .. 7-2
SYSTEM LOCATION
BATTERY/CHARGINGSYSTEM.. .. 18-2
ELECTRICSTARTER.. .. .. 20-2
IGNITIONSYSTEM .. 19-2
LIGHTS/METERS/SWITCHES .. .. 21-2
SYSTEMTESTING 7-5
THERMOSTAT 7-8 .,
THERMOSTATHOUSiNG.. 7-9
THROTTLE OPERATION .. ..4-5
TPSENSOR .. .. .. .. 19-10
TRANSMISSION.... ...... .. 13-20
TROUBLESHOOTING
ALTERNATOR/STARTER CLUTCH.. .. 12-3
BATTERY/CHARGINGSYSTEM.... .. .. .. 18-5
CLUTCH/GEARSHIFTLINKAGE.... .. ..11-4
COOLING SYSTEM 7-4
CRANKSHAFTITRANSMISSION .. .. 13-8
CYLINDER HEADNALVE .. .. ..9-5
CYLINDER/PISTON 10-3
ELECTRICSTARTER .. .. ..20-4
ENGINE DOESNOTSTARTOR ISHARD
TO START .. ...... .. 23-2
ENGINE LACKS POWER.. .. 23-3
FINALDRIVE........ ...... .. .. 14-6
FRAME/BODYPANELSIEXHAUSTSYSTEM 3-2
FRONTWHEEUSUSPENSION/STEERING 15-5
FUELSYSTEM 6-4
HYDRAULICBRAKE.. .. .. .. .. 17-4
IGNITIONSYSTEM ..19-4
LUBRICATIONSYSTEM .. .. 5-4
POOR HANDLING.. .. .. 23-7
POOR PERFORMANCEATHIGH SPEED 23-6
POOR PERFORMANCEATLOWAND
IDLESPEED 23-5
REARWHEEUBRAKEISUSPENSION.. 16-5
TURNSIGNALLIGHT .. .. ....21-6
TURN SIGNALRELAY .. 21-21
VALVECLEARANCE .. .. .. ...... .. 4-10
VALVE GUIDE REPLACEMENT .. .. 9-18
VALVE SEATINSPECTION/REFACING.. 9-19
WATERPUMP.. .. .. 7-16
WHEELSITIRES .. .. .. .. ..4-25
WIRINGDIAGRAM
49states/Canadatype 22-3
Californiatype .. ........ ...... .. .... 22-4
24-2