Professional Documents
Culture Documents
NT650
HAWKTMGT
HOW TO USE THIS MANUAL CONTENTS
Follow the Maintenance Schedule (Section 3)
recommendations to ensure that the vehicle is GENERAL INFORMATION
in peak operating condition and the emission
levels are within the standards set by the U.S. LUBRICATION
Environmental Protection Agency and Califor-
nia Air Resources Board. Performing the first MAINTENANCE
scheduled maintenance is very important. It
compensates for the initial wear that occurs FUEL SYSTEM
during the break-in period.
COOLING SYSTEM
Sections 1 through 3 apply to the whole
motorcycle, while sections 4 through 18
ENGINE REMOVAL/INSTALLATION
describe parts of the motorcycle, grouped ac-
cording to location.
w CLUTCH/GEARSHIFT LINKAGE
2
Find the section you want on this page, then
turn to the table of contents on page 1 of that
section.
"w
2 ALTERNATOR/STARTER CLUTCH
CYLINDER HEADIVALVES
Most sections start with an assembly or
system illustration, service information and CYLINDER/PISTON
troubleshooting for the section. The subse-
quent pages give detailed procedures. CRANKSHAFT/TRANSMISSION
If you don't know the source of the trouble,
FRONT WHEEl/SUSPENSION/STEERING
go to section 20, Troubleshooting.
REAR WHEEl/SUSPENSION
All information, illustrations, directions and speci-
fications included in this publication are based on HYDRAULIC BRAKES
the latest product information available at the
time of approval for printing. HONDA MOTOR
BATTERY/CHARGING SYSTEM
CO., LTD. reserves the right to make changes at
any time without notice and without incurring any
...I
obligation whatever. No part of this publication « IGNITION SYSTEM
may be reproduced without written permission. (.)
a:
~
ELECTRIC STARTER
(.)
HONDA MOTOR CO., LTD. W
...I LIGHTS/METERS/SWITCHES
SERVICE PUBLICATIONS OFFICE W
WIRING DIAGRAM
TROUBLESHOOTING
INDEX
21-1
INDEX
21-2 (282)
1. GENERAL INFORMATION
GENERAL SAFETY 1-1 TOOLS 1-7
SERVICE RULES
MODELIDENTIFICATION
SPECIFICATIONS
TORQUE VALUES
1-1
1-2
1-3
1-5
CABLE & HARNESS ROUTING
EMISSION CONTROL SYSTEMS
EMISSION CONTROL INFORMATION
LABElS
1-9
1-16
1-18
•
GENERAL SAFETY
-
I f the engine must be running to do some work, make sure the
area is well-ventilated. Never run the engine in an enclosed
area. The exhaust contains poisonous carbon monoxide gas
that may cause loss of consciousness and lead to death.
Gasoline is extremely flammable and is explosive under cetain
conditions work in a well ventilated area with the engine
stopped. Do not smoke or allow flames or sparks in the work
area or where gasoline is stored.
The battery generates hydrogen gas which can be highly explo- The battery electrolyte contains sulfuric acid. Protect your
sive. Do not smoke or allow flames or sparks near the battery, eyes, skin and clothing. In case of contact, flush thoroughly
especially while charging it. with water and call a doctor if electrolyte gets in your eyes.
Inhaled asbestos fibers have been found to cause respiratory Do not remove the radiator cap when the engine is hot. The
disease and cancer. Never use an air hose or dry brush to clean coolant is under pressure and severe scalding could result. The
brake assemblies. Use an OSHA-approved vacuum cleaner or engine must be cool before servicing the cooling system.
alternate method approved by OSHA designed to minimize
the hazard caused by airborne asbestos fibers. CAUTION:
Used engine oil may cause skin cancer if repeatedly left in con-
tact with the skin for prolonged periods. Although this is un-
The rear shock absorber contains nitrogen under high pres- likely unless you handle used oil on a daily basis, it is still
sure. Do not allow fire or heat near the shock absorber. adviseable to thoroughly wash your hands with soap and
Before disposal of the shock absorber, release the nitrogen. water as soon as possible after handling used oil.
SERVICE RULES
1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that don't meet HONDA's
design specifications may damage to the vehicle.
2. Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only metric tools when servicing the vehicle. Metric bolts, nuts, and screws are not interchangeable with English fas-
teners.
4. Install new gaskets, a-rings, cotter pins, and lock plates when reassembling.
5. When tightening bolts or nuts, begin with the larger-diameter or inner bolts first. Then tighten to the specified torque diag-
onally in 1-5 steps, unless a particular sequence is specified.
6. Clean parts in non-flammable or high flash point solvent upon disassembly. Lubricate any sliding surfaces before re-
assembly.
7. After reassembly, check all parts for proper installation and operation.
8. Route all wires as shown on pages 1-9 through 1-14. Cable and Harness Routing.
1-1
GENERAL INFORMATION
MODEL IDENTIFICATION
'SS SHOWN: After 'SS Similar:
~
Vi::::!
/~ (1) VEHICLE~
IDENTIF·ICATION NUMBER
The frame serial number is stamped on the right side of the The engine serial number is stamped on the right crank-
steering head. case below the rear cylinder.
\
(4) CARBURETOR IDENTIFICATION NUMBER
The carburetor identification numbers are on the carbure- The color label is attached to the rear fender under the
tor body intake side. seat.
When ordering a color coded part, always specify its desig-
nated color code.
1-2
GENERAL INFORMATION
SPECIFICATIONS
ITEM SPECIFICATIONS
[ I: California model
ITEM SPECIFICATIONS
1-4
GENERAL INFORMATION
TORQUE VALUES
The torque specifications listed under "Engine" and "Frame" are for specific tightening points. If a specification is not listed,
follow the standard torque values below.
TYPE TORQUE N'm (kg-m, ft-Ib) TYPE TORQUE N'm (kg-m, ft-Ib)
5 mm bolt, nut 5 (0.50, 3.6) 5 mm screw 4 (0.40, 2.9)
6 mm bolt, nut 10 (1.0, 7.2) 6 mm screw, 6 mm
8 mm bolt, nut 22 (2.2, 16) bolt with 8 mm head 9 (0.9, 6.5)
10 mm bolt, nut 35 (3.5, 25) 6 mm flange bolt, nut 12 (1.2,"9)
12 mm bolt, nut 55 (5.5,40) 8 mm flange bolt, nut 27 (2.7, 20)
10 mm flange bolt, nut 40 (4.0,29)
ENGINE
1-5
GENERAL INFORMATION
FRAME
1-6
GENERAL INFORMATION
TOOLS
SPECIAL
Refer to
Description Tool number Alternate tool Tool number
section
1-7
GENERAL INFORMATION
COMMON
Refer to
Description Tool number Alternate tool Tool number
section
Float level gauge 07401-0010000 trNOTE 1 4
Lock nut wrench, 17 x 27 mm 07716-0020300 7
Gear holder 07724-0010100 f-NOTE 2 7
Flywheel holder 0772 5 - 0040000 p-NOTE 1 8
Torx bit 07703-0010100 8, 18
Rotor puller 07733-0020001 07933-3290001 8
Valve guide remover, 5.5 mm 07742-0010100 9
Valve guide remover, 6.6 mm 07742-0010200 9
Attachment, 24 x 26 mm 07746-0010700 13
Attachment, 32 x 35 mm 07746-0010100 13
Attachment, 42 x 47 mm 07746-0010300 11, 12,
13
Attachment, 52 x 55 mm 07746-0010400 11, 12
Attachment, 62 x 68 mm 07746-0010500 13
Pilot, 15 mm 07746-0040300 13
Pilot, 17 mm 07746-0040400 13
Pilot, 20 mm 07746-0040500 11, 12
Pilot, 25 mm 07746-0040600 11
Extension bar 07716-0020500 rNOTE 1 12
Lock nut wrench, 30 x 32 mm 07716-0020400 12
Pilot, 35 mm 07746-0040800 13
Pilot, 40 mm 07746-0040900 13
Pilot, 22 mm 07746-0041000 11, 13
Bearing remover shaft 07746-0050100 13
Bearing remover head, 20 mm 07746-0050600 12
Driver 07749-0010000 11, 12,
13
Valve spring compressor 07757 -0010000 Valve spring 07957-3290001 9
compressor
NOTE 1: Equivalent commercially available in U.S.A.
NOTE 2: Not available in U.S.A.
1-8
GENERAL INFORMATION
o
Note the following when routing cables and wire harnesses:
• Route harnesses so they are neither pulled taut nor have ex-
cessive slack.
• After routing, check that the wire harnesses are not twisted
or kinked.
0: CORRECT
x: INCORRECT
1-9
GENERAL INFORMATION
.~
~
(2) HEADLIGHT
CONNECTOR
1-10
GENERAL INFORMATION
(1) THROTTLE
CABLES ---::""=~~t1 (4) CRANKCASE BREATHER
TUBE
(5) FUEL TUBE
INLET LINE
(6) FUEL TANK
DRAIN CUP
(7) ALTERNATOR
WIRE
(3) PULSE
(4) RIGHT HANDLEBAR SWITCH GENERATOR
(5) TURN SIGNAL WIRE
6P WHITE CONNECTOR 9P RED CONNECTOR
1-11
GENERAL INFORMATION
(7) REGULATOR/RECTIFIER
4P BLACK CONNECTOR (6) FUEL PUMP WIRE (5) REAR IGNITION COIL
1-12
GENERAL INFORMATION
1-13
GENERAL INFORMATION
NOTE
The hoses shown below are numbered as they appear on the Vacuum Hose Routing Diagram Label (page 1-19).
(4)@TUBE
VIEWZ VIEWY
(8) ® TUBE
(7)@TUBE
(10) PURGE CONTROL VALVE (PCV)
(17)
AIR SUCTION VALVE (ASV)
(20) CD TUBE
1-14
GENERAL INFORMATION
~::::.-:=--'--(11) CANISTER
1-15
GENERAL INFORMATION
SOURCE OF EMISSIONS
The combustion process produces carbon monoxide and hydrocarbons. Control of 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 it is toxic.
Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydro-
carbons.
California only:
The exhaust emission control system consists of a secondary air supply system which introduces filtered air into the exhaust
gases in the exhaust port. No adjustments to this system should be made, although periodic inspection of the components is
recommended. The secondary air supply system helps improve emission performance.
(3) CARBURETOR
(4) INTAKE
MANIFOLD
1-16
GENERAL INFORMATION
The engine is equipped with a closed crankcase system which routes crankcase emissions through the air cleaner into the
combustion chamber.
(1) AIR CLEANER
(2) CARBURETOR
<>:FRESH AIR
_. BLOW-BY GAS
This model complies with California Air Resources Board evaporative emission requirements.
Fuel vapor from the fuel tank and carburetor is directed into the charcoal canister where it is adsorbed and stored while the
engine is stopped. When the engine is running and the purge control diaphragm valve is open, fuel vapor in the charcoal canis-
ter is drawn into the engine through the carburetor. (3) FUEL TANK
I
I
..
I
(8) TO OPEN
(7) AIR VENT CONTROL
VALVE
Co: FRESH AIR (ENGINE STOP)
AIR
_. FUEL VAPOR
1-17
GENERAL INFORMATION
TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Federal law prohibits the following acts or the causing
thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replace-
ment, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is in use; or (2) the use of the vehicle after such device or element of design has
been removed or rendered inoperative by any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:
1. Removal of, or puncturing of the muffler, baffles, header pipes or any other component which conducts exhaust gases.
4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified
by the manufacturer.
A.I v~
1-18
GENERAL INFORMATION
1-19
LUBRICATION
(13) CAMSHAFT--~~---;.@~~~~~~~~
(12) PISTON
2-0
2. LUBRICATION
SERVICE INFORMATION 2-1 OIL PRESSURE CHECK 2-4
TROUBLESHOOTING 2-2 OIL PUMP/RELIEF VALVE 2-5
ENGINE OIL LEVEL 2-3 CONTROL CABLE LUBRICATION 2-10
ENGINE OIL CHANGE 2-3 LUBRICATION POINTS 2-10
OIL FILTER CHANGE 2-4
_l--
SERVICE INFORMATION
If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.
_
CAUTION
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely
unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possi-
ble after handling used oil.
GENERAL
• The oil pump can be serviced after removing the engine from the frame.
SPECIFICATIONS
Engine oil
Oil capacity 2.8 lit (2.94 US qt, 2.46 Imp qt) after disassembly.
2.3 lit (2.43 US qt, 2.02 Imp qt) at oil filter and oil change.
2.2 lit (2.32 US qt, 1.94 Imp qt) after draining.
Oil recommendation HONDA 4 stroke oil or equivalent API
OIL VISCOSITIES
service classification: SE or SF
VISCOSITY: SAE 10W-40
Oil pump
TORQUE VALUES
Oil pressure switch 12 N'm (1.2 kg-m, 9 ft-Ib) Apply sealant to the threads
Engine oil drain bolt 35 N'm (3.5 kg-m, 25 ft-Ib)
Oil filter 10 N'm (1.0 kg-m, 7.2 ft-Ib)
2-1
TROUBLESHOOTING
1. Drain and check fuel flow to carbure- NOT REACHING CARBURETOR----1..... Clogged fuel line or fuel filter/
tor strainer
• Clogged fuel tank breather hole
I
REACHING CARBURETOR Loose or disconnected fuel pump
and relay wire
Faulty fuel pump relay
Faulty fuel pump
Faulty float
Clogged carburetor body
20-2
LUBRICATION
Stop the engine, remove the oil filler cap/dipstick and wipe it
clean.
Check the oil level with the oil filler cap/dipstick by inserting it (2) UPPER--.j.
without screwing it in.
NOTE
(3) LOWER
• Do not screw the cap in when making this check.
If the oil level is below the lower level mark on the dipstick, fill
to the upper level mark with the recommended oil.
Check the O-ring for damage.
OIL CAPACITY:
2.8 lit 12.94 US qt, 2.46 Imp qt) after disassembly
\
(2) SEALING WASHER
2.3 lit 12.43 US qt, 2.02 Imp qt) at oil filter and oil change
2.2 lit (2.32 US qt, 1.94 Imp qt) after draining
Stop the engine and wait a few minutes. then check that the
oil level is at the upper level mark.
2-3
LUBRICATION
CAUTION
• Do not replace the oil filter when the exhaust system is hot.
Remove the drive sprocket cover (page 8-21.
Remove the oil filter with a filter wrench.
TOOL:
Oil filter wrench 07HAA-PJ70100
Apply oil to the new oil filter O-ring and install the new oil filter.
Tighten the oil filter with a filter wrench.
-'-----------
Stop the engine.
Start the engine and check the oil pressure at 6.000 rpm.
Oil PRESSURE: (2) OIL
441 kPa (4.5 kg/cm 2 • 64 psi) at 6.000 rpm (80 0 C/176°Fl PRESSURE
GAUGE
~~.....,~
Stop the engine.
Connect the oil pressure switch wire and start the engine.
Check that the oil pressure warning indicator goes out after
one or two seconds. If the oil pressure warning indicator stays
on. stop the engine immediately and determine the cause.
2-4
LUBRICATION
TOOL:
Snap ring pliers 07914-3230001
Check the spring, O-ring and valve for fatigue, wear or dam- ~ (2) BODY
age.
Check the body for clogging or damage.
o (3) VALVE
Clean all the parts and assemble them in the reverse order of
disassembly.
~
(5) SNAP RING
2-5
LUBRICATION
Remove the oil strainer and oil pipe from the oil pump. (1) OIL STRAINER
Check the a-rings and oil seal for fatigue or damage. (1) OIL SEAL
Clean the oil strainer and oil pipe with non-flammable or high
flash point solvent.
INSPECTION
2-6
LUBRICATION
Remove the oil pump shaft from the oil pump and measure the
pump end clearance.
ASSEMBLY
(1) PUMP BODY
(2) OUTER ROTOR
(10) O-RING
2-7
LUBRICATION
Install the outer rotor in the pump body with the punch mark (1) OUTER ROTOR
facing the cover, then install the inner rotor. (2) PUNCH MARK
Install the drive pin and spacer on the shaft.
Install the shaft in the body, aligning the drive pin with the
inner rotor groove.
(6)
INNER ROTOR
Install the dowel pin and a new gasket on the pump body, then (1) OIL PUMP BODY
install the cover.
Install the O-rings, oil seal, oil strainer and oil pipe on the oil (1) OIL STRAINER
pump.
CAUTION
Install the O-rings on the oil pipe with the tapered side facing
.. ..
out as shown, or the engine will be damaged. (5)
OIL'
SEAL
,
'(2) O-RING
2-8
LUBRICATION
INSTALLATION
Assemble the pressure relief valve and install it in the oil pump.
2-9
LUBRICATION
LUBRICATION POINTS
Use general purpose grease when not otherwise specified
here.
Apply oil or grease to the other sliding surfaces and cables not
shown here .
.,
(1) CLUTCH AND BRAKE
LEVER PIVOTS
(2) THROTTLE
PIPE
J
I
J
I
I "
J
-~
(3) SWINGARM
I PIVOT BALL
J
J AND NEEDLE
,
J
J BEARINGS
-~
J
J
J
(4) FOOT PEG PIVOTS AND
SEAT LOCK STRIKER & LATCH
-~
(11) STEERING
\
\
iii or equivalent
,
(10) FORK
I
I
-~
(9) SPEEDOMETER
_--.:
(7) BRAKE PEDAL
I
2-10
3. MAINTENANCE
SERVICE INFORMATION 3-1 EVAPORATIVE EMISSION
CONTROL SYSTEM
MAINTENANCE SCHEDULE 3-3
(California model only) 3-11
<ENGINE>
<CHASSIS>
FUEL LINE 3-4
DRIVE CHAIN 3-12
THROTTLE OPERATION
CARBURETOR CHOKE
3-4
3-5
BRAKE FLUID 3-13 D
BRAKE PAD WEAR 3-14
AIR CLEANER 3-5
BRAKE SYSTEM 3-14
CRANKCASE BREATHER 3-6
BRAKE LIGHT SWITCH 3-14
SPARK PLUG 3-6
HEADLIGHT AIM 3-15
VALVE CLEARANCE 3-7
CLUTCH SYSTEM 3-15
CARBURETOR SYNCHRONIZATION 3-8
SIDE STAND 3-16
CARBURETOR IDLE SPEED 3-9
SUSPENSION 3-16
RADIATOR COOLANT 3-9
NUTS, BOLTS, FASTENERS 3-17
COOLING SYSTEM 3-10
WHEELS/TIRES 3-17
CYLINDER COMPRESSION 3-10
STEERING HEAD BEARINGS 3-18
SECONDARY AIR SUPPLY SYSTEM
(California model only) 3-11
SERVICE INFORMATION
-'-----------------------
Support the motorcycle on the center stand on a level surface before starting any work.
If the engine must be running to do some work. make sure tlte area is well-ventilated. Never run the engine in an enclosed area.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.
Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area with the engine stopped.
Do not smoke or allow flames or sparks in the work area or where gasoline is stored.
GENERAL
• Engine oil See page 2-3
• Engine oil filter change See page 2-4
SPECIFICATIONS
~ENGINE~
Ignition timing Initial 10 0 BTDC at idle
Full advance 31 0 BTDC at 7,000 ± 200 rpm
Spark plug
NGK NO
Standard DPR8EA-9 X24EPR-U9
For cold climate Ibelow 50 C/41 0F) DPR7EA-9 X22EPR-U9
For extended high speed riding DPR9EA-9 X27EPR-U9
Spark plug gap 0.8-0.9 mm (0.031 -0.035 in)
Valve clearance IN 0.15 ± 0.02 mm (0.006 ± 0.0008 in)
(COLD) EX 0.20 ± 0.02 mm (0.008 ± 00008 in)
Idle speed 1,200 ± 100 rpm
Cylinder compression 1,324 ± 196 kPa 113.5 ± 2.0 kg/em', 192 ± 28 psi)
Throttle grip free play 2-6 mm (1/16-1/4 inl
~CHASSIS~
Clutch lever free play 10-20 mm (3/8-3/4 in)
Drive chain slack 20-30 mm (3/4-1-3/16 in) Refer to page 3-12
Tires
Front Rear
TORQUE VALUES
TOOLS
Special
Valve adjusting wrench 07908-KE90000
Vacuum gauge 07404-0030000 or M937B-021-XXXXX Vacuum gauge set
3-2
MAINTENANCE
* I
* I
* I
(NOTE 2) R R
(NOTE 3) C C C C C C
~ SPARK PLUG R R R R R R 3-6
Lfjl--+------------j----t-----j--t--+---t--t--+---t--t-----j
!::: VALVE CLEARANCE I I I I 3-6
ol---+------------t----+------t--+----+----+--+----+----+--+------t
ENGINE OIL R R R R 2-3
~I__-+------------t----+------t--+---+----+--+----+---+--+------t
<l: ENGINE OIL FILTER R R R R 2-4
uJl--+------------j----t-----j--t--+---t--t--+---t--t-----j
0:: * CARBURETOR-
3-8
Z SYNCHRONIZATION
Q
(/)
I--+------------j----t-----j--t--+---t--t--+---t--t-----j
CARBURETOR-IDLE SPEED 3-9
~f---t------------+----t-----+---+---1f---+--+--+--+--j------+
"" RADIATOR COOLANT (NOTE 5) *R 3-9
wl--+------------j--'-----:....t-----j--t--+---t--t--+---t--t-----j
* COOLING SYSTEM 3-10
SECONDARY AIR SUPPLY
(NOTE 5) 3-11
SYSTEM
* EVAPORATIVE EMISSION
(NOTE 4) 3-11
CONTROL SYSTEM
DRIVE CHAIN 3-12
(/) BRAKE FLUID 3-13
~ BRAKE PAD WEAR 3-14
!:::I--j------------
o BRAKE SYSTEM 3-14
w
~ * BRAKE LIGHT SWITCH 3-14
uJ * HEADLIGHT AIM
0::1--+------ _ 3-15
Z CLUTCH SYSTEM 3-15
a f___t_-----------
Ui SIDE STAND 3-16
(/)1__-+------------
~ * SUSPENSION 3-16
w
Z * NUTS, BOLTS, FASTENERS 3-17
a
Z ** WHEELS/TIRES 3-17
** STEERING HEAD BEARINGS 3-18
* Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is mechanically
qualified.
* * In the interest of safety, we recommend these items be serviced only by an authorized Honda dealer.
NOTES: 1. At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Service more frequently when riding in rain or at full throttle.
4. California model only.
5. Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires mechani-
cal skill.
3-3
MAINTENANCE
THROTTLE OPERATION _ i vI \
(1) 2-6 mm
Check for smooth throttle grip full opening and automatic full (1/16-1/14 in)
closing in all steering positions.
Check the throttle cables and replace them if they are deterio-
rated, kinked or damaged.
Adjust the free play by loosening the lock nut and turning the
adjusting nut. Tighten the lock nuts.
3-4
MAINTENANCE
Remove the left and right choke cable boots from the choke
valve nuts.
Loosen each choke valve nut and remove the choke valve from
the carburetor.
Push the choke lever on the handlebar all the way up to fully
closed and measure the distance between the ends of the
choke valve and nut.
It should be 10-11 mm (0.39-0.43 in).
Thread the choke valve in by hand and then tighten the choke
valve nut 1/4 turn with a 14 mm wrench.
AIR CLEANER
Remove the fuel tank (page 4-3).
Remove the air cleaner case cover screws and cover.
3-5
MAINTENANCE
CRANKCASE BREATHER
The crankcase breather drain; air cleaner case drain tube is
I~
behind the side stand.
Remove the drain plug from the tube to empty any deposits.
~
Reinstall the plug securely. (31 CLIP
NOTE
Service more frequently when the motorcycle has been
ridden in rain, at full throttle, or after it is washed or over-
turned. Service if the deposit level can be seen in the trans-
parent section of the drain tube.
SPARK PLUG
(1) DEPOSITS
121 DRAIN
PLUG"
a
Disconnect the spark plug caps and remove the spark plugs. 0.8-0.9 mm
(0.031-0.035 in)
RECOMMENDED SPARK PLUG:
Measure the new spark plug gap with a wire-type feeler gauge.
3-6
MAINTENANCE
VALVE CLEARANCE
NOTE
Inspect and adjust valve clearance while the engine is cold
(below 35°C/95°F).
FRONT CYLINDER
TOOL:
Valve adjusting wrench 07908 - KE90000
3-7
MAINTENANCE
REAR CYLINDER
Inspect and adjust the valve clearance using the same method
as for the front cylinder.
Install the front and rear cylinder head covers.
TORQUE:
Timing hole cap:
10 N'm (1.0 kg-m, 7.2 ft-Ibl
Crankshaft hole cap:
15 N'm (1.5 kg-m. 11 ft-Ibl
CARBURETOR SYNCHRONIZATION
NOTE
Perform this maintenance with the engine at normal operat-
ing temperature. the transmission in neutral. and the motor-
cycle on its center stand.
Remove the rear fuel tank mounting bolt first. then remove the
front side (page 4-3). Carefully raise the tank and support it in
the frame using a suitable base.
~) JOINT PLUG (PIN: 16124-MBO-000)
. ~:---...........
FRONT CYLINDER:
Remove the plug from the front cylinder intake port and install
the vacuum gauge adaptor.
REAR CYLINDER:
Remove the plug from the rear cylinder intake port and install
the joint plug (PIN: 16124- MBO-OOO).
TOOL:
Vacuum gauge 07404-0030000 or
Vacuum gauge set M937B-021-XXXXX
(1) VACUUM GAUGE
Warm up the engine and adjust the idle speed with the throttle
stop screw.
-'-------------
If the engine must be running to do some work, make sure the
area is well-ventilated. Never run the engine in an enclosed
area.
The exhaust contains poisonous carbon monoxide gas that may
cause loss of consciousness and lead to death.
3-8
MAINTENANCE
NOTE
• The rear cylinder carburefor is the base carburetor.
-'--------------
cycle on its center stand.
RADIATOR COOLANT
Check the coolant level of the reserve tank with the engine / /7
-'--------------
running at normal operating temperature. (2) LOWER LEVEL
3-9
MAINTENANCE
COOLING SYSTEM
Remove the radiator shroud and check the radiator air pas-
sages for clogging or damage.
Straighten bent fins or collapsed core tubes with a small flat
blade screwdriver as shown and remove insects, mud or any
obstructions with compressed air or low pressure water.
Replace the radiator if the air flow is restricted over more than
30% of the radiator's surface.
For radiator replacement, refer to page 5-5.
~~ .
(1) SCREWDRIVER
CYLINDER COMPRESSION
-'-----------
Warm up the engine to normal operating temperature.
Stop the engine, disconnect both spark plug caps and remove
one spark plug.
NOTE
To measure the cylinder compression of each individual cyl-
inder and remove only one plug at a time.
Insert the compression gauge. Open the throttle all the way
and crank the engine with the starter motor. Crank the engine
until the gauge reading stops rising. The maximum reading is
usually reached within 4- 7 seconds.
COMPRESSION PRESSURE:
1,324 ± 196 kPa (13.5 ± 2.0 kg/cm 2 , 192 ± 28 psi)
3-10
MAINTENANCE
[~
ro!JE:?~ill'l
(4) DRAIN
(5) CHARCOAL
CANISTER
\':=~~~~=~~~;U'1"'----(6)AIR VENT
I • CONTROL VALVE
~ (7) AIR VENT CONTROL
(8) TO OPEN VALVE
<>: FRESH AIR
AIR (ENGINE STOP)
.....: FUEL VAPOR
3-11
MAINTENANCE
DRIVE CHAIN
-'--------------
CHAIN SLACK INSPECTION
Never inspect or adjust the drive chain while the engine is run-
ning.
Pull the lower run of the drive chain down with your finger and
check slack using the gauge.
A-B: Good.
...£...1
Above A: Too tight.
Below C: Too loose. (1) DRIVE CHAIN SLACK GAUGE (EQUIPMENT TOOL)
CHAIN ADJUSTMENT
~
Tighten the eccentric bearing carrier pinch bolt.
Check the chain wear label on the swingarm. If the red zone on
the label aligns with the driven sprocket teeth after chain has
been adjusted. the chain must be replaced.
3-12
MAINTENANCE
The drive chain on this motorcycle is equipped with small 0- (2) LUBRICATE
rings between the link plates. The a-rings can be damaged by ~ SAE #80 or #90
steam cleaners, high pressure washers and certain solvents. . iii GEAR OIL
Lubricate only with SAE #80 or 90 gear oil.
Commercial chain lubricants may contain solvents which
could damage the rubber a-rings.
NOTE
Never install a new drive chain on worn sprockets or a worn
chain on new sprockets. Both chain and sprockets must be
in good condition, or the new replacement chain or sprock- (2) NORMAL
I
ets will wear repidly.
BRAKE FLUID
FRONT
Check the front brake fluid level with the handlebar turned so
(1) COVER (2) UPPER
that the reservoir is level.
LEVEL
Check the front brake fluid through the sight glass. If the level
is visible, check pad wear first; replace the pads if necessary.
Then remove the cover, set plate and diaphragm. Fill the reser-
voir to the upper level with DOT 4 fluid from a sealed contain-
er. Check the system for leaks.
CAUTION
Do not remove the reservoir cover until the handlebar has been
turned so that the reservoir is level.
Do not mix different types offluid, as they are not compatible
with each other.
• Do not allow foreign material to enter the system when filling
the reservoir.
A void spilling the fluid on painted, plastic or rubber parts.
Place a rag over these parts whenever the system is serviced.
REAR
Check the rear brake fluid level after supporting the motor-
cycle upright on level ground.
Check the rear brake fluid level; if it is near the lower line,
check pad wear first; replace the pads if necessary. Then
remove the cover, set plate and diaphragm. Fill the reservoir to
the upper level with DOT 4 fluid from a sealed container.
Check the system for leaks.
3-13
MAINTENANCE
Check the front brake pads for wear, through from the lower
end of the caliper.
REAR
Check the rear brake pads for wear, through from the rear of
the caliper.
CAUTION
Always replace the brake pads as a sello assure even disc pres-
sure.
BRAKE SYSTEM
Inspect the brake hoses and fittings for deterioration, cracks
and signs of leakage. Tighten any loose fittings.
Replace hoses and fittings as required.
NOTE
Adjust the brake light switch after adjusting the brake pedal
height.
Adjust the brake light switch so that the brake light will come
on when brake engagement begins.
Adjust by turning the adjuster while holding the switch body.
Tighten the adjuster lock nut and recheck the brake light
switch operation.
NOTE
• Do not turn the switch body.
3-14
MAINTENANCE
HEADLIGHT AIM
Adjust vertically by loosing the headlight mounting bolts.
Adjust horizontally by turning the horizontal adjusting screw.
NOTE
Adjust the headlight beam as specified by local laws and
regulations.
-'-----------
An improperly adjusted headlight may blind oncoming dril-eYs,
or it may fail 10 light the road for a safe distance.
CLUTCH SYSTEM
Measure the clutch lever free play at the lever end.
Pull the lever cover back, loosen the lock nut and turn the ad-
juster to obtain the specified free play.
SIDE STAND
Place the motorcycle on its center stand.
Check the rubber pad on the side stand for deterioJation and
wear.
Replace the rubber pad if wear extends to the wear line.
Lubricate the pivot area with clean grease and reassemble the
side stand.
TORQUE:
Side stand pivot bolt: 38 N'm (3.8 kg-m, 27 ft-Ibl
CAUTION
Install the dust seal lip spring is facing out.
Make sure that the dust seal lip spring is seated securely.
SUSPENSION
FRONT
Check the entire fork leg assembly for signs of leaks or dam-
_L- _
age.
Replace any components which are unrepairable.
Tighten all nuts and bolts to the specified torque value.
3-16
MAINTENANCE
REAR
NUTS, BOLTS,FASTENERS
Tighten the bolts, nuts and fasteners at the intervals shown in
the Maintenance Schedule (page 3-3).
Check that all chassis nuts and bolts are tightened to their cor-
rect torque values (page 1-5 and 6).
Check all cotter pins and safety clips.
WHEELS/TI RES
TIRE PRESSURE Front Rear
• Tire pressure should be checked when the tires are COLD. Cold tire Up to
pressures maximum
225 (2.25, 33) 250 (2.50, 36)
kPa weight
(kg/cm 2 , capacity
psi)
Up to 90 kg
(200Ibs) 225 (2.25, 33) 225 (2.25, 33)
load
Tire Bridgestone G547G G548
brand Dunlop K505G K505
3-17
MAINTENANCE
Check the tires for cuts, imbedded nails, or other sharp ob-
jects.
Check the front and rear wheels for trueness (Section 12 and
13).
Measure the tread depth at the center of the tires.
Replace the tires if the tread depth reaches the following limit:
3-18
FUEL SYSTEM
'88 Shown:
4-0
4. FUEL SYSTEM
SERVICE INFORMATION 4-1 CARBURETOR INSTALLATION 4-13
TROUBLESHOOTING 4-2 PILOT SCREW ADJUSTMENT 4-14
FUEL TANK 4-3 HIGH ALTITUDE ADJUSTMENT
(U.S.A. ONLY) 4-14
AIR CLEANER CASE 4-4
PURGE CONTROL VALVE
CARBURETOR REMOVAL 4-5
INSPECTION (California model only) 4-15
CARBURETOR DISASSEMBLY 4-5
AIR VENT CONTROL VALVE
CARBURETOR ASSEMBLY
CARBURETOR
4-9 INSPECTION (California model only)
SECONDARY AIR SUPPLY
4-16 III
SEPARATION/ASSEMBLY 4-12 SYSTEM (California model only) 4-17
SERVICE INFORMATION
-"-------------------------
Gasoline is extremely flammable and is explosive under certain conditions work in a well ventilated area with the engine stopped.
Do not smoke or allow flames or sparks in the work area or where gasoline is stored.
If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.
GENERAL
• Refer to Section 3 for carburetor synchronization, throttle cable and choke cable adjustments.
• When disassembling fuel system parts, note the locations of the a-rings; replace them with new ones on reassembly.
• The carburetor float chambers have drain screws that can be loosened to drain residual gasoline.
• For fuel pump inspection refer to section 18.
• All hoses used in the evaporative emission control system are numbered for identification. When connecting one of these
hoses, compare the hose number with the Vacuum Hose Routing Diagram Label on page 4-15 (California model only), for
its routi ng.
CAUTION
• Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind.
NOTE
If the vehicle is to be stored for more than one month, drain the float chambers. Fuel left in the float chambers may cause
clogged jets resulting in hard starting or poor driveability.
SPECIFICATIONS
4-1
FUEl SYSTEM
TORQUE VALUES
TOOLS
Special
Vacuum/Pressure pump A937X-041-XXXXX or
Pressure pump ST -AH-255-MC7 (U.S.A. only)
Vacuum pump ST -AH-260-MC7 (U.S.A. only)
Common
Float level gauge 07401-0010000
TROUBLESHOOTING
Engine cranks but won't start Misfiring during acceleration
No fuel to carburetor • Faulty ignition system
Engine flooded with fuel
No spark at plug (ignition system faulty) Backfiring
Clogged air cleaner Faulty ignition system
Intake air leak • Faulty carburetor
Improper choke operation
Improper throttle operation Poor performance ldriveability) and poor fuel economy
• Clogged fuel system
Hard starting or stalling after starting Faulty ignition system
Improper choke operation Dirty air cleaner
Ignition malfunction (California model only:)
Faulty carburetor : Faulty air vent control valve
Fuel contaminated : Worn/damaged emission system hoses
Intake air leak
Incorrect idle speed Lean mixture
Incorrect valve clearance (Section 3) Clogged fuel jets
Incorrect carburetor synchronization (Section 3) Stuck vacuum piston
Improper choke valve operation. • Faulty float valve
Low float level
Rough idle Clogged fuel tank breather
Faulty ignition system Clogged fuel strainer
Incorrect idle speed Restricted fuel line
Incorrect valve clearance (Section 3) Intake air leak
Incorrect carburetor synchronization Restricted or faulty fuel pump
Faulty carburetor
Fuel contaminated Rich mixture
Faulty air cut off valve Clogged air jets
(California model only:) Faulty float valve
: Faulty purge control valve Float level too high
: Faulty air vent control valve Dirty air cleaner
: Worn/damaged emission system hoses
4-2
FUEL SYSTEM
FUEL TANK
OFF
REMOVAL
-'----------
Gasoline is extremely flammable and is explosive under certain
conditions. Work in a well ventilated area with the engine
stopped. Do not smoke or allow flames or sparks in the work
area or where gasoline is stored.
Remove the seat (page 13-25) and turn the fuel valve OFF.
Disconnect the fuel tube from the fuel tank.
'88 Only:
California model only:
Disconnect the No.1 fuel breather tube (to canister) from the
fuel tank.
All models:
Remove the rear fuel tank mounting bolt first, then the front
bolt and remove the tank from the frame.
CAUTION
After '88:
Remove the rear fuel tank mounting bolt first, then the front
bolt.
All models:
Remove the fuel tank from the frame.
INSTALLATION
TORQUE:
Front: 12 N'm 11.2 kg-m, 9 ft-Ibl
Rear: 22 N'm 12.2 kg-m, 16 ft-Ibl
NOTE
The air cleaner case can be removed without removing the
case cover removal.
Loosen the air cleaner connecting tube band screws and dis-
connect the crankcase breather and air cleaner case drain
tube.
Remove the air cleaner case.
4-4
FUEL SYSTEM
_L---
CARBURETOR REMOVAL
_
Gasoline is extremely flammable and is explosive under certain
conditions. Work in a well ventilated area with the engine
stopped. Do not smoke or allow flames or sparks in the work
area or where gasoline is stored.
Loosen the drain screws and drain the fuel into a container.
Remove the air cleaner case.
Disconnect the throttle cables from the carburetor.
NOTE
Turn the choke lever fully in to avoid losing the choke
valves.
Remove the choke valves from the carburetor and loosen the
carburetor insulator bands.
CARBURETOR DISASSEMBLY
NOTE
The carburetors can be disassembled without being sepa-
rated.
VACUUM CHAMBER
4-5
FUEL SYSTEM
Make sure the piston moves up and down freely in the cham-
ber.
Then remove the needle holder, spring, jet needle and from the
piston.
Inspect the needle for excessive wear at the tip, bending or
other damge.
Inspect the diaphragm for damage, fatigue or pin holes.
Inspect the vacuum piston for wear or damage.
(1) DIAPHRAGM/
PISTON
4-6
FUEL SYSTEM
Check the float valve and valve seat for scratches, clogging or
damage.
Remove the main jet, needle jet, slow jet and valve seat/filter.
Inspect the float valve seat and filter for grooves, nicks or de-
posits.
'"
(4) VALVE SEAT-- , (3) SLOW JET
NOTE
The pilot screws are factory pre-set and should not be re-
moved unless the carburetors are overhauled.
The pilot screw plugs are factory installed to prevent pilot
screw misadjustment. Do not remove the plugs unless the
pilot screws are being removed.
Cover all openings with tape to keep metal particles out
when the plugs are drilled.
4-7
FUEL SYSTEM
Center punch the pilot screw plug to center the drill point. (1) CARBURETOR (2) DRILL BIT
Drill through the plug with a 4 mm (5/32 in) drill bit. Attach a
drill stop to the bit 3 mm (1/8 in) from the end to prevent drill-
ing into the pilot screw.
CAUTION
Be careful not to drill into the pilot screw.
Both pilot screws must be replaced even if only one requires it,
for proper pilot screw adjustment (page 4-/4).
Force a self-tapping 4 mm screw, PIN 93903-35410) into (1) SELF TAPPING SCREW
the drilled plug and continue turning the screwdriver until the
plug rotates with the screw.
Use compressed air to clean the pilot screw area and remove
metal shavings.
CAUTION
• Damage to the pilot screw seat will occur if the pilot screw is
tightened against the seat.
o
7"'NG
Remove the pilot screws and inspect them. Replace them if
they are worn or damaged. /
(4) WASHER
Remove the two screws, the set plate and the air cut off valve
cover.
NOTE
The air cut off valve cover is under spring pressure. Do not
loose the spring and screws.
4-8
FUEL SYSTEM
CARBURETOR CLEANING
,
(1) CARBURETOR BODY
--
CARBURETOR ASSEMBLY
(6) VACUUM
CHAMBER
COVER
4-9
FUEL SYSTEM
INSTALLATION
If the air tube joint was removed, install a new a-ring onto the
air tube joint.
Install the air cut off valve cover with the joint set plate and
tighten the screws securely.
Be sure the diaphragm and spring are properly seated.
Install the pilot screws and return them to their original posi-
tion as noted during removal.
Perform pilot screw adjustment if new pilot screws are in-
stalled (page 4-1 4).
NOTE
Do not install new plugs on new pilot screw holes until after
adjustment has been made.
If you replace the pilot screw in one carburetor, you must
O. '7
0T
SCREW
CAUTION
Damage to the pilot screw seat will occur if the pilot screw is
tightened against the seat.
Install the valve seat, slow jet, needle jet and main jet.
Install the float with float valve in the carburetor body, then in-
stall the float arm pin through the body and the float.
4-10
FUEL SYSTEM
FLOAT LEVEL
Measure the float level with the float tang just contacting the
float valve.
NOTE
• Install the fuel tube clamps.
VACUUM CHAMBER
Install the washer, jet needle, spring and jet needle holder in
the vacuum piston.
Push the jet needle holder in and turn it in 90 degrees cloc-
kwise.
4-11
FUEL SYSTEM
Install the vacuum piston, aligning the tab of the diaphragm (1) CHAMBER COVER
j
with the groove of the carburetor.
Install the chamber cover with the spring, aligning the cover
with the hole in the carburetor, and secure with at least two
screws before releasing the vacuum piston.
CARBURETOR
SEPARATION/ASSEMBLY
SEPARATION
NOTE
When separating the carburetors, be careful not to lose the
thrust spring and synchronization adjusting spring.
4-12
FUEL SYSTEM
ASSEMBLY
Turn the throttle stop screw to align the rear cylinder carbure-
tor throttle valve with the edge of the by-pass hole.
Align the front cylinder carburetor throttle valve with the by-
pass hole edge by turning the synchronization adjusting
screw.
Make sure the throttle returns smoothly to the fully closed po-
sition.
4-13
FUEL SYSTEM
CARBURETOR INSTALLATION
(1) CARBURETOR
Install the carburetors onto the cylinder heads and tighten the
insulator bands securely.
NOTE
• The pilot screws are factory pre-set and no adjustment is
necessary unless the pilot screws are replaced.
Use a tachometer with graduations of 50 rpm or smaller
that will accurately indicate a 50 rpm change.
INITIAL OPENING:
CAUTION
Damage to the pilot screw seat will occur if the pilot screw is
tightened against the seat.
4-14
FUEL SYSTEM
5. Turn each pilot screw 1/2 turn out from the initial setting.
6. If the engine speed increases by 50 rpm or more, turn
each pilot screw out by an additional 1/2 turn until engine
speed drops by 50 rpm or less.
7. Adjust the idle speed with the throttle stop screw.
8. Turn the rear cylinder carburetor pilot screw in until the
engine speed drops 50 rpm.
9. Turn the rear cylinder carburetor pilot screw 1 turn out
from the position obtained in step 8.
10. Adjust the idle speed with the throttle stop screw.
11. Perform steps 8, 9 and 10 for the front cylinder carburetor
pilot screw.
12. Drive new pilot screw plugs into the pilot screw bores
with a 7 mm valve guide driver (PIN 07942-8230000).
When fully seated the plug surfaces will be recessed
1 mm.
Drive new pilot screw plugs into the pilot screw bores (page
4-7).
Attach a Vehicle Emission Control Information Update label on
the left sub-frame upper pipe as shown. See SL#132 for infor-
mation on obtaining the label.
NOTE
Do not attach the label to any part that can be easily re-
moved from the vehicle.
-----------
Operation at an altitude lower than 1.500 m (5.000 feet) with
the carburetors adjusted for high altitudes may cause the engine
to idle roughly and stall.
4-15
FUEL SYSTEM
(4) TO CARBURETOR
CANISTER
(2) VACUUM PUMP
NOTE BODY
4-16
FUEL SYSTEM
Connect the vacuum pump to the No.1 0 hose that goes to the
right carburetor body.
Connect the pressure pump to the air vent port of the AVCV.
While applying the vacuum to the AVCV No. 10 hose that
goes to the right carburetor body, pump air through the air
vent port.
Air should flow through the AVCV and out of the hose that
goes to the carburetor air joint pipe.
TOOL:
Vacuum/Pressure pump A937X-041-XXXXX or
Vacuum pump ST-AH-260-MC7
Pressure pump ST -AH-255-MC7
(U.S.A. only)
Plug the hose that goes to the carburetor air joint pipe.
While applying vacuum to the AVCV No.1 0 hose that goes to
the 3-way joint, apply air pressure. It should hold steady.
TOOL:
Vacuum/Pressure pump A937X-041-XXXXX or
Vacuum pump ST -AH-260-MC7
Pressure pump ST-AH-255-MC7
(U.S.A. only)
4-17
FUEL SYSTEM
SECONDARY AIR SUPPLY SYSTEM (2) AIR INTAKE HOSE (3) AIR CLEANER
NOTE
• Do not disconnect the fuel tubes from the tank.
Check that the secondary air intake ports are clean and free of
carbon deposits.
TOOL:
Vacuum/Pressure pump A937X - 041 - XXXXX or
Vacuum pump ST-AH-260-MC7
(U.S.A. only)
Start the engine and open the throttle slightly to be certain that
air is sucked in through the intake hose.
VACUUM HOSE ROUTING DIAGRAM
If air is not drawn in, check the air supply hoses and vacuum
tube for clogging. •,
ENGINE FAMIlY-JHN064742G9
EVAPORATIVE FAMLY-88Z0 CV
TO AIRIC t
CALIFORNIA VEHiClE
With the engine running, gradually apply vacuum to the ASV.
Check that the air intake hose stops drawing air, and that the
vacuum does not bleed off.
SPECIFIED VACUUM:
300-370 mm (11.8-14.6 in) Hg
4-18
FUEL SYSTEM
Disconnect the air supply hoses from the reed valve covers of
(2) REED VALVE
the ASV.
Disconnect the vacuum tube and air intake hose from the
ASV.
Remove the ASV mounting bolts and ASV.
Remove the two screws, the reed valve cover and the reed
valve from the ASV.
(3) REED
Check the reed valve for damage or fatigue, and replace if nec-
(4) REED STOPPER
essary.
CAUTION
Do not disassemble the reed valve assembly or bend the reed
stopper.
• If the stopper, reed or seat is faulty, replace the valve as an as-
sembly.
NOTE
• After installing, make sure the air and vacuum tubes are
correctly connected (page 1-10 to 15.).
4-19
5. COOLI NG SYSTEM
SERVICE INFORMATION 5-1 THERMOSTAT 5-3
TROUBLESHOOTING 5-1 RADIATOR/COOLING FAN 5-5
SYSTEM TESTING 5-2 WATER PUMP 5-7
COOLANT REPLACEMENT 5-3
SERVICE INFORMATION
_L--
GENERAL
_
Do not remove the radiator cap when the engine is hot. The coolant is under pressure and severe scalding could result. The engine
must be cool before servicing the cooling system.
~
If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.
• Use only distilled water and ethylene glycol in the cooling system. A 50- 50 mixture is recommended for maximum corro-
sion protection. Do not use alcohol-based antifreeze.
• Add coolant at the reserve tank. Do not remove the radiator cap except to refill. or drain the system. or to test the coolant
mixture.
• Avoid spilling coolant on painted surfaces.
• After servicing the system, check for leaks with a cooling system tester.
• For temperature sensor and thermostatic switch inspection, refer to section 18.
SPECIFICATIONS
ITEM SPECIFICATIONS
Radiator cap relief pressure 88-127 kPa (0.9-1.3 kg/cm 2 , 13-18 psi)
Freezing point (Hydrometer test): 55% Distilled water + 45% ethylene glycol: -32°C (-25°F)
50% Distilled water + 50% ethylene glycol: -37°C (-34°F)
45% Distilled water + 55% ethylene glycol: -44.5°C (-48°F)
Coolant capacity: Coolant change: 1.60 lit (1.51 US qt, 1.28 Imp qt)
Total system: 2.20 lit (2.32 US qt, 1.94 Imp qt)
Thermostat Begins to open: 80° to 84°C (176° to 183°F)
Valve lift: Minimum of 8 mm at 95°C (0.3 in at 203°F)
Boiling point (with 50- 50 mixture): Unpressurized: 107.7°C (226°F)
Cap on, pressurized: 125.6°C (258°F)
TROUBLESHOOTI NG
Engine temperature too high Engine temperature too low
Faulty temperature gauge or sensor • Thermostat stuck open
Thermostat stuck closed
Faulty radiator cap Coolant leaks
Insufficient coolant or coolant level too low Faulty pump mechanical seal
Passages blocked in radiator, hoses or water jacket • Deteriorated a-rings
Cooling fan motor does not turn
- Burned or loose sub-fuse
- Faulty fan motor
- Faulty thermostatic switch
- Poor connector contact or open circuit in harness
Faulty water pump
5-1
COOLING SYSTEM
SYSTEM TESTI NG
COOLANT MIXTURE
-'------------
Be sure the engine is cool before removing the cap or you may
be severely scalded.
RADIATOR CAP
(1) COOLING SYSTEM TESTER
Wet the radiator cap sealing surface, install the cap on the COMMERCIALLY AVAILABLE
tester, and apply pressure.
CAUTION
Excessive pressure can damage the radiator. Do not exceed /25
kPa (1.25 kglcm 1, /8 psi)
5-2
COOLING SYSTEM
_L-
COOLANT REPLACEMENT
_
The engine must be cool before replacing the coolant or severe
scalding may result.
If the engine must be running to do some work, make sure the
area is well-ventilated. Never run the engine in an enclosed
area.
The exhaust contains poisonous carbon monoxide gas that may
cause loss of consciousness and lead to death. .
Drain the coolant from the system by removing the drain bolt
on the water pump cover.
Reinstall the drain bolt.
Fill the system with 50- 50 mixture of distilled water and eth-
ylene glycol.
Bleed air from the cooling system.
Support the motorcycle on its center stand and shift the
transmission into neutral.
Start the engine and snap the throttle grip, 3-4 times at
4,000- 5,000 rpm. Then add coolant up to the radiator
filler neck.
Reinstall the radiator cap.
Check the level of coolant in the reserve tank and fill to the
correct level if the level is low.
THERMOSTAT
REMOVAL
(1) HOUSING MOUNTING BOLT
Remove the following:
- fuel tank (page 4-3) 18) COVER 80~ ~
- air cleaner case (page 4-3)
5-3
COOLING SYSTEM
INSPECTION
\
Suspend the thermostat in heated water to check its opera-
tion.
Data:
Start to open 80° to 84°C (176-183°F)
Valve lift 8 mm (0.3 in) minimum when
heated to 95°C (203°F) for five
minutes.
INSTALLATION
Assemble the case and filler neck with the new O-ring.
Tighten the bolts.
(1) HOUSING MOUNTING BOLT
Install the thermostat housing case and filler neck onto the
frame.
5-4
COOLING SYSTEM
RADIATOR/COOLING FAN
REMOVAL
5-5
COOLING SYSTEM
Remove the cooling fan motor mounting bolts and cooling fan
motor.
RADIATOR INSPECTION
NOTE
• See section 18 for thermostatic switch inspection.
Slow dirt out from between core fins with compressed air. If
insects, etc., are clogging the radiator, wash them off with
low pressure water.
THERMOSTATIC SWITCH:
TORQUE: 18 N'm (1.8 kg-m, 13 ft-Ib)
WATER PUMP
MECHANICAL SEAL INSPECTION
REMOVAL
Remove the O-ring and dowel pins from the water pump as-
sembly and disconnect the water hose.
5-7
COOLING SYSTEM
Check the water pump for mechanical seal leakage and bear-
ing deterioration. Replace the water pump as an assembly if
necessary.
(4) a-RING
INSTALLATION
Align the water pump shaft groove with the oil pump shaft and
insert the water pump into the crankcase.
Install the water pump cover and tighten the cover mounting
bolts.
5-8
6. ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION 6-2 ENGINE INSTALLATION 6-5
ENGINE REMOVAL 6-3
6-1
ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION
GENERAL
• Support the motorcycle using a hoist, a floor jack or other adjustable support.
• The following parts can be serviced with the engine installed in the frame:
Clutch Alternator
Gearshift linkage Starter motor
Camshafts Carburetors
Cylinder head Water pump
• To service the crankshaft/transmission, oil pump, and cylinder the engine must be removed from the frame.
• When using the lock nut wrench, use a 20 inche long deflecting beam type torque wrench. The lock nut wrench increases
the torque wrench's leverage, so the torque wrench reading will be less than the torque actually applied to the lock nut.
SPECIFICATIONS
TORQUE VALUES
TOOL
Special
Lock nut wrench 07908 - ME90000
6-2
ENGINE REMOVAL/INSTALLATION
ENGINE REMOVAL
Place the motorcycle on its center stand.
Drain the engine oil (page 2-3).
Drain the coolant (page 5-3).
Disconnect the battery negative cable from the battery termi-
nal.
.-- ~
- air cleaner case (page 4-4).
- carburetor (page 4-5l.
- radiator (page 5-5).
- exhaust pipe and muffler (page 13-24). ~ -
---
. . ' (1) EXHAUST PIPE AND MUFFLER
Disconnect the clutch cable from the clutch lifter arm by re-
moving the holder bolt.
6-3
ENGINE REMOVAl/INSTALLATION
CAUTION
The jack heigh1 muSI be conlinually adjusled 10 relieve Slress
for ease of boll removal.
Do nol jack up the engine al lhe oil filler.
TOOL:
Lock Nut wrench 07908-ME90000
Pull the swingarm pivot bolt out to clear the engine mounting
hole, but do not remove it.
ENGINE INSTALLATION
Install the engine into the frame correctly.
CAUTION
Carefully align the mounting points with the jack to prevent •
damage to mounting bolt threads and wire harness and cables.
Insert the swingarm pivot bolt while aligning the serrations of (2) ADJUSTING BOLT
the pivot bolt and adjusting bolt.
~ - \
Turn the pivot bolt with the adjusting bolt clockwise fully to (1) PIVOTIADJUSTING BOLT
seat the swingarm left pivot collar. \
Tighten the bolt to the specified torque.
TORQUE:
Actual: 65 N'm (6.5 kg-m, 47 ft-Ib)
Indicated: 59 N'm 15.9 kg-m, 43 ft-Ibl
TOOL:
Lock nut wrench 07908-ME90000
6-5
ENGINE REMOVAL/INSTALLATION
Install the rear engine upper mounting bolt and tighten it to the
specified torque.
Tighten all the fasteners to the torques given on page 6-1 and
2.
NOTE
Route the wires and cables properly (Section 1).
Fill the crankcase to the proper level with the recommended
oil (page 2-1).
Fill the cooling system (page 5-3l.
Perform the following inspection and adjustments:
Throttle operation (page 3-4l.
Clutch (page 3-15).
6-6
CLUTCH/GEARSHIFT LINKAGE
'SS Shown:
7-0
7. CLUTCH/GEARSHIFT LINKAGE
SERVICE INFORMATION 7-1 PRIMARY DRIVE GEAR 7-10
TROUBLESHOOTING 7-2 CLUTCH INSTALLATION 7-11
RIGHT CRANKCASE COVER REMOVAL 7-3 RIGHT CRANKCASE COVER
INSTALLATION 7-14
CLUTCH REMOVAL 7-4
GEARSHIFT LINKAGE 7-8
SERVICE INFORMATION
GENERAL
• This section covers the removal and installation of the clutch, oil pump drive chain, gearshift linkage and primary drive
gear. All these operations can be done with the engine installed in the frame.
• If the shift fork, drum and transmission require servicing, remove the engine and separate the crankcase (section 11).
• Coat the new clutch discs with clean engine oil before reassembly.
SPECIFICATIONS
Unit: mm (in)
TORQUE VALUES
Shift drum stopper plate bolt 26 N'm (2.6 kg-m, 19 ft-Ib) Apply locking agent to the threads
Primary drive gear bolt 90 N'm (9.0 kg-m, 65 ft-Ib)
Oil pump driven sprocket bolt 15 N'm (1.5 kg-m, 11 ft-Ib) Apply locking agent to the threads
Clutch lock nut 130 N'm (13.0 kg-m, 94 ft-Ibl Staked nut
Oil pass pipe bolt (8 mm) 23 N'm (2.3 kg-m, 17 ft-Ib)
(7 mm) 10 N'm (1.0 kg-m, 7.2 ft-Ib)
TOOLS
Special
Clutch center holder 07923-KE10000 or 07HGB-001000A (U.S.A. only)
Gear holder 07724-0010100 Not available in U.S.A.
Common
Lock nut wrench, 17 x 27 mm 07716-0020300 Equivalent commercially available in U.S.A.
7-1
CLUTCH/GEARSHIFT LINKAGE
TROUBLESHOOTI NG
Faulty clutch operation can usually be corrected by adjusting the clutch lever free play.
7-2
CLUTCH/GEARSHIFT LINKAGE
NOTE
R. crankcase cover can be serviced with rear exhaust pipe
removal only.
CLUTCH LIFTER
Remove the clutch lifter piece. and remove the snap ring and
return spring from the right crankcase cover.
Check the clutch lifter piece and shaft for damage or excessive
scratching.
Check the return spring for fatigue or damage.
(2) L1FTER/
SHAFT
7-3
CLUTCH/GEARSHIFT LINKAGE
Install the clutch lifter shah, snap ring and return spring.
Hook the spring end in the cover tab securely, and turn the
shaft.
Install the clutch lifter piece, aligning the piece end with the
groove in the clutch lifter shaft.
CLUTCH REMOVAL
Remove the following:
- clutch bolts
- clutch lifter plate
- springs
NOTE
• Remove the bolts in a crisscross pattern in 2 or 3 steps.
NOTE •
• Be careful not to damage the shah threads.
7-4
CLUTCH/GEARSHIFT LINKAGE
Hold the clutch center with the special tool and loosen the
clutch lock nut. Remove the tools and the lock nut.
TOOLS:
Clutch center holder 07923-KE10000 or
07HGB-001000A
(U.S.A. only)
Lock nut wrench, 17 x 27 mm 07716 - 0020300 Equiva-
lent commercially available
in U.S.A.
NOTE
If you will remove the oil pump driven sprocket, loosen the
driven sprocket mounting bolt at this time.
7-5
CLUTCH/GEARSHIFT LINKAGE
Remove the drive sprocket and clutch outer guide from the
mainshaft.
SERVICE LIMITS:
Disc A: 2.60 mm (0.102 in)
Disc B: 2.30 mm (0.091 in)
NOTE
Replace the discs and plates as a set if anyone is beyond
the service limit.
\ ( 1 ) CLUTCH DISC
7-6
CLUTCH/GEARSHIFT LINKAGE
NOTE
Replace the discs and plates as a set if anyone is beyond
the service limit.
Check the spring seat and judder spring for distortion, wear or (1) JUOOER SPRING
damage.
Replace them if necessary.
..
•
SERVICE LIMIT:
Clutch outer 1.0. 32.10 mm (1.264 in)
7-7
CLUTCH/GEARSHIFT LINKAGE
Measure 1.0 of the drive sprocket and the 0.0. and 1.0. of the
outer guide.
SERVICE LIMITS:
Oil pump drive sprocket 1.0. 32.10 mm (1.264 in)
Clutch outer guide 0.0. 31.92 mm (1.257 in)
1.0. 22.09 mm (0.870 in)
. I
(2) CLUTCH OUTER GUIDE
__ (1) OIL PUMP DRIVE
SPROCKET
GEARSHIFT LINKAGE
REMOVAL
Loosen the two oil pipe stay mounting bolts and remove the oil
pipe mounting bolt.
Pull the oil pipe out of the stay and oil pump.
7-8
ALTERNATOR/STA RTER CLUTCH
'SS Shown:
30 N·m (3 .0 kg-m,
22 ft-Ibl
8-0
8. ALTERNATOR/STARTER CLUTCH
SERVICE INFORMATION 8-1 FLYWHEEL INSTALLATION 8-5
LEFT CRANKCASE COVER REMOVAL 8-2 LEFT CRANKCASE COVER
INSTALLATION 8-6
FLYWHEEL REMOVAL 8-3
STARTER CLUTCH 8-4
SERVICE INFORMATION
GENERAL
• This section covers the removal and installation of the alternator, starter clutch and starter gears.
• Refer to section 1 5 for troubleshooting and inspection of the alternator.
SPECIFICATIONS
mm (in)
TORQUE VALUES
TOOLS
Common
Rotor puller 07733-0020001 or 07933-3290001
Flywheel holder 07725-0040000}E 0 I 0 II 01 bl 0 USA
Torx bit 07703-0010100 QUiva ent commercia y aval a e In • • •
8-1
ALTERNATOR/STARTER CLUTCH
Remove the gearshift arm pinch bolt and shiftarm from the
spindle.
Remove the eleven left crankcase cover bolts and the cover.
STATOR REPLACEMENT
8-2
ALTERNATOR/STARTER CLUTCH
FLYWHEEL REMOVAL
Remove the starter idle/reduction gear by removing the shaft.
Hold the flywheel with the flywheel holder and remove the fly-
wheel bolt and washer.
TOOL:
Flywheel holder 07725-0040000 Equivalent
commercially available in U.S.A.
NOTE
• The flywheel bolt has left-hand threads.
TOOL:
Rotor puller 07733-0020001 or
07933-3290001
, .
NOTE
• Do not lose the woodruff key.
8-3
ALTERNATOR/STARTER CLUTCH
Hold the flywheel with the flywheel holder and remove the
torx bolts using a torx bit.
TOOLS:
Flywheel holder 07725-0040000 .
Torx bit 07703_0010100}EqUivalent
commercially
available in
U.S.A.
Inspect the oneway clutch for wear or damage and replace if (1) ONEWAY CLUTCH
necessary.
8-4
ALTERNATOR/STARTER CLUTCH
ASSEMBLY
Install the oneway clutch into the clutch outer with the flange
side facing inside.
TOOLS:
Flywheel holder 07725-0040000 .
Torx bit 07703_0010100}EqUlvalen.t
commercially
available
in U.S.A.
FLYWHEEL INSTALLATION
Clean the crankshaft and install the woodruff key.
Install the driven gear and flywheel. aligning the woodruff key
on the crankshaft with the flywheel keyway.
Hold the flywheel with the flywheel holder. install the washer
and flywheel bolt and tighten the bolt.
TOOL:
Flywheel holder 07725-0040000 Equivalent
commercially available in U.S.A.
NOTE
• The flywheel bolt has left hand threads.
8-5
ALTERNATOR/STARTER CLUTCH
Install the starter drive gear with the "OUT" mark facing out
and the shorter shaft, if the gear is removed.
-~~
Install the gearshift arm onto the spindle by aligning the punch (1) DRIVE SPROCKET COVER
--'==
mark on the arm with the punch mark on the spindle.
Check the engine oil level and add the oil if necessary.
8-6
CYLINDER HEADIVALVES
'SS Shown:
9-0
9. CYLINDER HEAD/VALVES
SERVICE INFORMATION 9-1 VALVE SEAT INSPECTION/REFACING 9-12
TROUBLESHOOTING 9-2 CYLINDER HEAD ASSEMBLY 9-14
CYLINDER HEAD COVER REMOVAL 9-3 CYLINDER HEAD INSTALLATION 9-15
CAMSHAFT REMOVAL 9-3 CAMSHAFT INSTALLATION 9-17
CYLINDER HEADS 9-7 CYLINDER HEAD COVER
INSTALLATION 9-20
VALVE GUIDE REPLACEMENT 9-11
SERVICE INFORMATION
GENERAL
SPECIFICATIONS
Unit: mm (in) •
9-1
CYLINDER HEAD/VALVES
TORQUE VALUES
TOOLS
Special
Valve guide reamer (IN) 07984-2000001 or 07984-200000B U.S.A. only
Valve guide reamer (EX) 07984-ZE20001 or 07984-ZE2000B J
Valve guide driver attachment (IN) 07943-MF50100
Valve guide driver attachment (EX) 07943-MF50200
Common
Valve guide driver, 5.5 mm (IN) 07742-0010100
Valve guide driver, 6.6 mm (EX) 07742-0010200 or 07942-6570100 U.S.A. only
Valve spring compressor 07757-0010000 or 07957-3290001
TROUBLESHOOTI NG
Engine top-end problems are usually performance-related and can usually be diagonosed by a compression test.
Engine noises can usually be traced to the top-end with a sounding rod or stethoscope.
High compression
Excessive carbon build-up on piston crown or combus-
tion chamber
9-2
CYLINDER HEADIVALVES
NOTE
If you will be servicing the inner cylinder head cover compo-
nents, remove the carburetors (page 4-4) at this time.
FRONT:
NOTE
If the cylinder head cover is difficult to remove:
Remove the radiator mounting bolts and release the radiator
from the frame grommets. Suspend the radiator with a
piece of rope or something suitable. (refer to 9-8 page).
~J_
(2) CYLINDER HEAD COVER
CAMSHAFT REMOVAL
Remove the cylinder head covers and carburetors (page 4-4).
Remove the timing hole cap and crankshaft hole cap from the
left crankcase cover.
Align the FT mark (rear: RT mark) on the flywheel with the
index mark on the left crankcase cover timing hole by turning
the crankshaft counterclockwise.
9-3
CYLINDER HEADIVALVES
~-
I
Pull wedge A straight up while holding wedge B down.
Secure wedge A with a 2 mm pin as shown.
NOTE
Be careful not to let the cam sprocket bolts fall into the
crankcase.
Remove the three camshaft holder mounting bolts and the nut,
the oil plate and the holder.
9-4
CYLINDER HEADIVALVES
INSPECTION
Cylinder head
Inspect the camshaft holder and cylinder head journal surfaces
for scoring or evidence of insufficient lubrication.
Camshaft runout
Support both ends of the camshaft with V-blocks and check
the camshaft runout with a dial indicator.
SERVICE LIMIT:
IN: 38.17 mm (1.503 in)
EX: 38.19 mm (1.504 in)
9-5
CYLINDER HEAD/VALVES
NOTE
• Avoid placing plastigauge over the oil hole.
NOTE
• Do not rotate the camshaft when using plastigauge.
TORQUE:
6 mm flange bolt: 12 N'm (1.2 kg-m. 9 ft-Ibl
8 mm flange bolt: 23 N'm (2.3 kg-m. 17 ft-Ibl
8 mm flange nut: 23 N'm (2.3 kg-m. 17 ft-Ibl
9-6
CYLINDER HEADIVALVES
Remove the rocker arms and wave washers from the shafts.
Inspect the rocker arm shafts and rocker arms for wear or
damage.
SERVICE LIMIT:
IN/EX: 11.96 mm (0.471 in) I
Measure the 1.0. of each rocker arm.
NOTE
• The cylinder head can be removed with the engine installed.
Disconnect the clutch cable from the clutch lifter arm by re-
moving the clutch cable holder bolt.
Remove the oil pipe from the engine.
NOTE
• Do not bend the oil pipe during removal.
9-7
CYLINDER HEAD/VALVES
Remove the cam chain tensioner mounting bolts and washers (1) CAM CHAIN TENSIONER BOLTSi'WASHERS
from the cylinder head and cylinder.
FRONT:
REAR:
Remove the gasket, dowel pins and cam chain guide from the
cylinder.
9-8
CYLINDER HEAD/VALVES
DISASSEMBLYIINSPECTION
Cylinder head
CAUTION
• A void damaging the gasket surfaces.
Check the spark plug hole and valve areas for cracks.
Check the cylinder head for warpage with the straight edge
and feeler gauge.
TOOL:
Valve spring .compressor 07757-0010000 or
07957-3290001
CAUTION
To prevent loss of tension, do not compress the valve springs
more than necessary to remove the collers.
NOTE
Mark all parts during disassembly so they can be placed
back in their original locations.
(4) VALVE
r
TIERS
Valve springs
Measure the free length of the inner and outer valve springs.
SERVICE LIMITS:
INNER (IN): 36.47 mm (1.436 in)
(EX): 37.51 mm (1.477 in)
OUTER (IN): 40.58 mm (1.598 in)
(EX): 41.25 mm (1.624 in)
Replace the springs as a set if they are shorter than the service
limits.
9-9
CYLINDER HEAD/VALVES
NOTE
Ream the guides to remove any carbon deposits before
checking clearances.
TOOLS:
Valve guide reamer
IN: 07984-2000001 or 07984-200000B U.S.A. only
EX: 07984-ZE20001 or 07984-ZE2000B J
NOTE
It is important that the reamer always be rotated in the
same direction when it is inserted or removed.
NOTE
Reface the valve seats whenever the valve guides are re-
placed.
9-10
CYLINDER HEADIVALVES
-'-----------
oven. Maximum allowable temperature is 300°F (150°C).
CAUTION
Do not use a torch to heat the cylinder head; it may cause
warping.
Support the cylinder head and drive out the old guides from the
combustion chamber side of the cylinder head.
TOOLS:
Valve guide driver
liN): 07742-0010100
(EX): 07742-0010200 or 07942-6570100 (U.S.A.
only)
NOTE
• Avoid damaging the cylinder head.
TOOLS:
Valve guide driver
5.5 mm (IN): 07742-0010100
6.6 mm (EX): 07742-0010200
Attachment
5.5 mm (IN): 07943-MF50100
6.6 mm (EX): 07943-MF50200
NOTE
Use cutting oil on the reamer during this operation.
It is important that the reamer always be rotated in the
same direction when it is inserted or removed.
TOOLS:
Valve guide reamer
IN: 07984-2000001 or 07984-200000B (U.S.A. only)
EX: 07984-ZE20001 or 07984-ZE2000B (U.S.A. only)
9-11
CYLINDER HEADIVALVES
VALVESEAT INSPECTION/REFACING
Clean the intake and exhaust valves thoroughly to remove
carbon deposits.
CAUTION
The valves cannot be ground. If a valve face is burned or badly
worn or if it contacts the seat unevenly, replace the valve.
If the seat is too wide. too narrow or has low spots, the seat
must be ground.
NOTE
Reface the seat with a 45 degree cutter when a valve guide
is replaced.
9-12
CYLINDER HEAD/VALVES
Install a 45 degree finish cutter and cut the seat to the proper
width. Make sure that all pitting and irregularities are removed.
Refinish if necessary.
NOTE
The location of the valve seat in relation to the valve face is
very important for good sealing.
If the contact area is too high on the valve, the seat must be
lowered using a 32 degree flat cutter.
9-13
CYLINDER HEADIVALVES
If the contact area is too low on the valve, the seat must be
raised using a 60 degree inner cutter. (1 ) CONTACT TOO LOW
NOTE
Install the valve springs with the tightly wound coils facing the
combustion chamber. (1) VALVE
SPRING
Install the spring retainers.
9-14
CYLINDER HEADIVALVES
CAUTION
To prevent loss of tension, do not compress the valve springs
more than necessary to install the valve collers.
TOOL:
Valve spring compressor 07757-0010000 or
07957-3290001
Tap the valve stems gently with a soft hammer to firmly seat
the cotters.
NOTE
Support the cylinder head above the work bench surface to
prevent possible valve damage.
..
Make sure that the cam chain guide bosses are in the grooves
of cylinder.
9-15
CYLINDER HEADIVALVES
TORQUE:
10 mm nut: 48 N'm (4.8 kg-m, 35 ft-Ibl
8 mm bolt: 23 N'm (2.3 kg-m, 17 ft-Ibl
8 mm nut: 23 N'm (2.3 kg-m, 17 ft-Ibl
6 mm bolt: 10 N'm (1.0 kg-m, 7.2 ft-lbJ
Check the oil pass pipe bolts and oil pass pipe for clogging or
bending. •
Install the oil pass pipe, new sealing washers, oil pass pipe
bolts and the pipe holder bolt.
Tighten the bolts.
TORQUE:
Oil pass pipe bolt:
7 mm: 10 N'm (1.0 kg-m, 7.2 ft-Ibl
8 mm: 23 N'm (2.3 kg-m, 17 ft-Ibl
'88 SHOWN:
9-16
CYLINDER HEADIVALVES
NOTE
If the front and rear cylinder camshafts were removed, do
not confuse them. Check the identification mark on the end
of the shaft.
Install the camshaft in the cylinder head through the cam chain - - , (2) INDEX MARK
and install the cam sprocket on the camshaft.
With the cam lobes all facing down, align the timing marks
(index lines) on the cam sprocket with the top of the cylinder
head.
Align the cam sprocket bolt holes in the cam sprocket and
camshaft, install and tighten the cam sprocket bolt.
TORQUE:
8 mm bolt: 23 N'm (2.3 kg-m, 17 ft-Ibl
8 mm nut: 23 N'm (2.3 kg-m, 17 ft-Ib)
6 mm bolt: 10 N'm (1.0 kg-m, 7.2 ft-Ib)
CAUTION
Note the direction of the camshaft end holder, install the flat
surface on the holder facing in.
9-18
CYLINDER HEADIVALVES
NOTE
If the front and rear cylinder camshafts were removed, do
not confuse them, Check the identification mark on the end
of the shaft.
Install the camshaft in the cylinder head through the cam chain . , (2) INDEX MARK
and install the cam sprocket on the camshaft.
With the cam lobes all facing down, align the timing marks
(index lines) on the cam sprocket with the top of the cylinder
head.
Align the cam sprocket bolt holes in the cam sprocket and
camshaft, install and tighten the cam sprocket bolt.
TORQUE:
8 mm bolt: 23 N'm (2.3 kg-m, 17 ft-Ibl
8 mm nut: 23 N'm (2.3 kg-m, 17 ft-Ibl
6 mm bolt: 10 N'm (1.0 kg-m. 7.2 ft-Ibl
CAUTION
Note the direction of the camshaft end holder, install the flat
surface on the holder facing in.
9-18
CYLINDER HEADIVALVES
If the cylinder head was removed with the engine in the frame,
install the following:
- radiator
- exhaust pipe
Place the camshaft into correct position with the cam lobes all
facing down.
Install the cam sprocket and camshaft holders using the same
procedure as for the front cylinder (page 9-17). •
Install the front camshaft with all the cam lobes facing DOWN.
Align the index marks on the cam sprocket with the top of the
cylinder head.
Install the rear camshaft with all the cam lobes facing DOWN.
Align the index lines on the cam sprocket with the top of the
I (1) CAM LOBES
cylinder head.
9-19
CYLINDER HEADIVALVES
NOTE
Be careful not to let the 2 mm pin fall into the crankcase.
Do not forget to remove the 2 mm pin before installing the
cylinder head cover.
(2) HEAD
COVER
Connect the water hose to the water pipe and install the spark
plug caps.
Install the following parts:
- carburetors (page 4-191
- air cleaner case (page 4-4)
- fuel tank (page 4-31
9-20
CYLINDER/PISTON
10-0
10. CYLINDER/PISTON
SERVICE INFORMATION 10-1 PISTON RING INSTALLATION 10-5
TROUBLESHOOTING 10-1 PISTON INSTALLATION 10-5
CYLINDER 10-2 CYLINDER INSTALLATION 10-6
PISTON 10-3
SERVICE INFORMATION
GENERAL
SPECIFICATIONS
Unit: mm (in)
Piston,
Warpage across top
Taper
Out-of-round
Piston ring-to-ring TOP
--
--
--
0.025-0.055 (0.001-0.002)
0.10 (0.004)
0.06 (0.002)
0.06 (0.002)
0.11 (0.004)
m
piston groove clearance 0.10 (0.004)
SECOND 0.015-0.045 (0.0006-0.0018)
rings
and piston Ring end gap TOP 0.20-0.35 (0.008-0.014) 0.65 (0.026)
pin SECOND 0.35-0.50 (0.014-0.020) 0.65 (0.026)
OIL 0.20-0.80 (0.008-0.031) 0.95 (0.037)
Piston 0.0. 78.970- 78.990 (3.1086-3.1098) 78.92 (3.107)
Piston pin bore 20.002-20.008 (0.7874-0.7877) 20.018 (0.7881)
Connecting rod small end 1.0. 20.016-20.034 (0.7880-0.7887) 20.04 (0.789)
Piston pin 0.0. 19.994-20.000 (0.7871-0.7874) 19.984 (0.7867)
Piston-to-piston pin clearance 0.002-0.014 (0.0001-0.0006) 0.034 (0.0013)
Cylinder-to-piston clearance 0.010-0.035 (0.0004-0.0014) 0.13 10.005)
Piston pin-to-connecting rod
0.016-0.040 (0.0006-0.0016) 0.060 10.0024)
small end clearance
TROUBLESHOOTI NG
Low or uneven compression Piston noise
Worn cylinder or piston rings. • Worn cylinder and piston.
Leaking head gasket. • Excessive carbon deposits.
Incorrect valve timing.
Excessive smoke
Worn cylinder and piston rings.
Improperly installed piston rings.
Damaged piston or cylinder.
Overheating
Excessive carbon deposits on piston or combustion
chamber.
Faulty water pump.
10-1
CYLINDER/PISTON
CYLINDER
REMOVAL
Remove the clip and slide the cylinder joint collar toward either
the front or rear cylinder.
INSPECTION
10-2
CYLINDER/PISTON
NOTE
Measure warpage using a straight edge and feeler gauge as
shown.
PISTON
REMOVAL
Place a shop towel into the crankcase and remove the piston
pin clips.
NOTE
• Do not let the clips fall into the crankcase.
INSPECTION
SERVICE LIMITS:
Top: 0.11 mm (0.004 in)
Second: 0.10 mm (0.004 in)
Remove the piston rings and mark them to indicate the correct
cylinder and piston position for reassembly.
NOTE
• Do not damage the piston rings when removing them.
10-3
CYLINDER/PISTON
NOTE
Take measurements 10 mm (OA in) from the bottom, and
90 0 to the piston pin hole.
Measure the top and second piston ring end gaps: using a pis-
ton, push the ring into the cylinder squarely and make the mea-
surement.
SERVICE LIMITS:
Top: 0.65 mm (0.026 in)
Second: 0.65 mm (0.026 in)
Oil: 0.95 mm (0.037 in)
10-4
CYLINDER/PISTON
After installing the rings, check that they rotate freely without
sticking.
PISTON INSTALLATION
Place a shop towel into the crankcase.
Coat the rod small end with molybdenum disulfide grease. As-
semble the piston and connecting rod with the piston' and
piston pin clips as shown.
NOTE
Install the pistons with the mark "IN" facing towards the
intake side.
After installing the piston pin clips, make sure that they are
seated properly and the end gaps are not aligned with the
cut-out in the piston.
Do not let the piston pin clips fall into the crankcase.
CYLINDER INSTALLATION
Clean the cylinder gasket surface.
10-5
CYLINDER/PISTON
Install the piston assembly into the cylinder from the top of the
crankcase while compressing the piston rings with your fin-
gers.
Be sure each assembly is returned to its original position as
noted during removal.
NOTE
Be careful not to damage the piston rings during assembly.
When the cylinder is halfway over the piston. route the cam
chain through the cylinder.
Install a new a-ring onto the cylinder joint and install the cylin-
der joint collar by sliding the collar toward either cylinder.
Install the clips securely.
Install a new a-ring into the connector and install and tighten
the connector mounting bolts, if the connector was removed.
If only the water hose was removed, connect the hose with
the clamp.
NOTE
• Avoid damaging the gasket surface.
NOTE
Align the guide boss with the groove in the cylinder.
Make sure that the end of the guide is inserted into place in
the crankcase.
10-6
CRANKSHAFT/TRANSMISSION
'SS Shown:
11-0
11. CRANKSHAFT/TRANSMISSION
SERVICE INFORMATION 11-1 CRANKCASE 11-11
TROUBLESHOOTING 11-2 TRANSMISSION ASSEMBLY/
INSTALLATION 11-15
CRANKCASE SEPARATION 11-3
CRANKSHAFT/CONNECTING ROD 11-4
CRANKCASE ASSEMBLY 11-16
TRANSMISSION 11-9
SERVICE INFORMATION
GENERAL
• To service the connecting rods, crankshaft, transmission and oil pump, the engine must be removed from the frame (Sec-
tion 6).
• All bearing inserts are select fitted and are identified by color code or code letter. Select replacement bearings from the
code tables.
After installing new bearings, recheck them with plastigauge to verify clearance.
• Apply molybdenum disulfide grease to the main journals and crankpins during assembly.
• Before separating the crankcase, the following parts must be removed.
Cylinder head (Section 9) Flywheel (Section B)
• Cylinder/piston (Section 10) Starter motor (Section 17)
• Clutch/gearshift linkage (Section 7) Water pump (Section 5)
SPECIFICATIONS
mm (in) II]
ITEM STANDARD SERVICE LIMIT
Crankshaft/ Connecting rod big end side clearance 0.05-0.20 (0.002-0.008) 0.3 (0.012)
connecting rod Crankpin oil clearance 0.028-0.052 (0.0011-0.0020) 0.08 (0.003)
Main journal oil clearance 0.025-0.041 (0.0010-0.0016) 0.05 (0.002)
Crankshaft runout -- 0.05 (0.002)
Transmission Gear 1.0. C1 24.000-24.021 (0.9449-0.9457) 24.03 (0.946)
M4, M5, C2, C3 28.000-28.021 (1.1024-1.1032) 28.03 (1.103)
Gear bushing 0.0. C1 23.959-23.980 (0.9433-0.9441) 24.95 (0.982)
M4, M5, C2, C3 27.959-27.980 (1.1007-1.1016) 27.95 (1.100)
Gear bushing I. D. C1 20.016-20.037 (0.7880-0.7889) 20.05 (0.789)
M4, C2, C3 25.000-25.021 (0.9843-0.9851) 25.03 (0.985)
Bushing-to- M4, C3 0.020-0.062 (0.0008-0.0024) 0.08 (0.003)
shaft clearance 0.010-0.049 (0.0004-0.0019) 0.07 (0.003)
C2
Gear-to- M4, M5, C1,
0.020-0.062 (0.0008-0.0024) 0.08 (0.003)
bushing clearance C2, C3
Mainshaft 0.0. M4 bushing 24.959-24.980 (0.9826-0.9835) 24.95 (0.982)
Countershaft 0.0. C1 bushing 19.980-19.993 (0.7866-0.7871) 19.97 (0.786)
C2 bushing 24.972-24.990 (0.9831-0.9839) 24.96 (0.983)
C3 bushing 24.959-24.980 (0.9826-0.9835) 24.95 (0.982)
Shift fork/ Claw thickness 5.93-6.00 (0.233-0.236) 5.83 (0.230)
fork-shaft Right and left shift fork 1.0. 13.000-13.018 (0.5118-0.5125) 13.03 (0.513)
Shaft 0.0. 12.966-12.984 (0.5105-0.5112) 12.96 (0.510)
Shift drum 0.0. (at the left side journal) 11.966-11.984 (0.4711-0.4718) 11.96 (0.471)
11-1
CRANKSHAFT/TRANSMISSION
TORQUE VALUES
TOOLS
Special
Main bearing driver attachment 07HMF-MM90400
Bearing remover set 07936-3710001
- remover handle 07936-3710100
- bearing remover set 07936-3710600
- remover weight 07741-0010201 or 07936-3710200 U.S.A. only
Common
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 20 mm 07746-0040500
Attachment, 52 x 55 mm 07746-0010400
Pilot, 22 mm 07746-0041000
Pilot, 25 mm 07746 - 0040600
TROUBLESHOOTI NG
Excessive noise
• Crankshaft
- Worn main bearing
- Worn crankpin bearing
• Connecting rod
- Worn rod small end
- Worn crankpin bearing
Hard to shift
Shift fork bent
• Shift fork shaft bent
Shift spindle claw bent
Shift drum cam grooves damaged
Shift fork guide pin damaged
11-2
CRANKSHAFT{TRANSMISSION
CRANKCASE SEPARATION
Remove the engine from the frame (Section 6).
Remove the oil filter.
Refer to the service information (page 11-1) for the parts that
must be removed before the separating the crankcase.
Remove the oil pipe stay and cam chain tensioner set plate by
removing the bolts.
Remove the rear cam chain and cam chain drive sprocket.
NOTE
Remove the bolts in a crisscross pattern in 2 or 3 steps.
• Loosen the 6 mm bolts first, then loosen the 8 mm bolts.
'88 Only:
Remove the countershaft set plate bolt and the plate.
After '88:
Remove the counters haft set plate bolts (2 pcs.) and the plate.
NOTE
Remove the bolts in a crisscross pattern in 2 or 3 steps.
• Loosen the 6 mm bolts first, then loosen the 8 mm bolts.
11-3
CRANKSHAFT/TRANSMISSION
Place the left crankcase side down and separate the right
crankcase from the left crankcase while prying where indicat-
ed at the points shown and tapping the cases at several loca-
tions with a soft hammer.
Remove the dowel pins and clean the crankcase halves of any
sealant material.
CRANKSHAFT/CONNECTING ROD
CRANKSHAFT SIDE CLEARANCE INSPECTION
NOTE
• Tap the side of the cap lightly if it is hard to remove.
CAUTION
Do not interchange the crankpin bearings. They must be in-
stalled in their original positions or the correct bearing oil clear-
ance may not be obtained resulting in engine damage.
11-4
CRANKSHAFT/TRANSMISSION
NOTE
The crankshaft cannot be repaired. Replace it if the journals
or crankpins are burnt, cracked, or if the run out is beyond
limits.
Install the bearing caps and rods on the correct crankpins, and
tighten them evenly.
NOTE
• Do not rotate the crankshaft during inspection.
11-5
CRANKSHAFT{TRANSMISSION
1
CONNECTING
ROD 1.0. CODE
43.000-43.008 mm
\ (1.5741-
1.5744 in)
C
(1.5738-
1.5741 in)
B
(1.6929-1.6932 in) (BROWN) (BLACK)
43.008-43.016 mm B A
2
(1.6932-1.6935 in) (BLACK) (BLUE)
11-6
CRANKSHAFT/TRANSMISSION
Measure the main journal bearing 1.0. and record it. (1) CRANKCASE
•
Calculate the clearance between the main journal and the main
bearing.
Determine the corresponding main bearing 1.0. code. The code (2) MAIN BEARING
will be either a letter A or B on the crankcase.
~~~
~
[\ F
'r
-----0,
. beanngs
Choose rep acemen t main In accor d ance WI'th th e
table below. MAIN JOURNAL 0.0. CODE [on crank weightl
1 2
44.992-45.000 mm 44.984-44.992 mm
(1.7713-1.7717 in) (1.7710-1.7713 in)
MAIN 8EARING 48.990-49.000 mm C 8
A
1.0. CODE (1.9287-1.9291 in) (BROWN) (BLACK)
[on crankcasel 49.000-49.010 mm B A
B
(1.9291-1.9295 in) (BLACK) (BLUE)
11-7
CRANKSHAFT/TRANSMISSION
NOTE
• Always use a press to remove the main bearing.
TOOLS:
Driver 07749-0010000
Main bearing remover attachment 07HMF-MM90400
Align the marks on the bearing with the groove in the bearing
hole, and press the main bearing into the crankcase.
(2) MARKS
CAUTION (3) GROOVE
NOTE
The "0" mark in the table indicates that the matching is
possible in the crossed codes.
m~'9
SELECTION TABLE
NOTE
Align the boss on the bearing with the groove in the rod or
cap.
Apply molybdenum disulfide grease to the bearing.
NOTE
Align the 1.0. code on the cap and rod.
Tighten the nuts in two or more steps. After tightening,
check that the rods move freely without binding.
TRANSM ISSION
REMOVAL
Bend down the lock washer tabs and remove the bolt and lock
washer from the center shift fork.
Remove the shift fork shaft.
11-9
CRANKSHAFT/TRANSMISSION
Check the shift fork shaft for scratches, scoring or evidence of (2) SHIFT FORK
insufficient lubrication.
Measure the shift fork shaft 0.0.
Measure the 1.0. of each shift fork and the fork claw thickness.
--------
SERVICE LIMITS:
1.0.: 13.03 mm (0.513 in)
CLAW THICKNESS: 5.83 mm (0.230 in)
Inspect the shift drum and shift fork shaft journals for exessive
wear or damage.
SERVICE LIMITS:
A: M4 bushing 24.95 mm (0.982 in)
B: C1 bushing 19.97 mm (0.786 in)
C: C2 bushing 24.96 mm (0.983 in)
0: C3 bushing 24.95 mm (0.982 in)
\ b
(2) COUNTERSHAFT
11-10
CRANKSHAFT/TRANSMISSION
Replace if necessary.
"
(2) SNAP RING
GROOVE
SERVICE LIMITS:
M4, M5, C2, C3 gears: 28.03 mm (1.103 in)
C1 gear: 24.03 mm (0.946 in)
SERVICE LIMITS:
M4, M5, C2, C3 bushings 0.0.: 27.95 mm 11.100 in)
C1 bushing 0.0.: 24.95 mm 10.982 in)
M4, C2, C3 bushing I.D.: 25.03 mm 10.985 in)
C1 bushing 1.0.: 20.05 mm 10.789 in)
SERVICE LIMITS:
bushing-to-shaft (M4, C3):
0.08 mm (0.003 in)
(C2):
0.07 mm (0.03 in)
gear-to-bushing (M4, M5, C1, C2, C3):
0.08 mm (0.003 in)
BEARING REPLACEMENT
Turn the inner race of each bearing with your finger. The bear-
ings should turn smoothly and quietly. Also check that the
bearing outer race fits tightly in the crankcase.
11-11
CRANKSHAFT/TRANSMISSION
Left crankcase
Remove the left mainshaft bearing using the special tools.
TOOLS:
Bearing remover set 07936-3710001
- remover handle 07936-3710100
- bearing remover set 07936 - 371 0600
- remover weight 07741-0010201 or
07936-3710200 U.S.A.
only
Drive the countershaft bearing and oil seal out of the crank-
case.
Install the new mainshaft bearing set plate on the left crank-
case.
NOTE
Apply fresh engine oil to the new crankcase bearings before
installation.
TOOLS:
Left mainshaft bearing:
Driver 07749-0010000
Attachment. 42 x 47 mm 07746-0010300
Left countershaft bearing:
Driver 07749-0010000
Attachment. 52 x 55 mm 07746-0010400
Pilot. 25 mm 07746-0040600
11-12
CRANKSHAFT/TRANSMISSION
TOOLS:
Right mainshaft bearing
Driver 07749-0010000
Attachment, 52 x 55 mm 07746-0010400
Pilot, 22 mm 07746-0041000
Right countershaft bearing
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 20 mm 07746-0040500
Install the set plate aligning the edge of the set plate with the
slot on the bearing outer and tighten the bolt securely.
Crankcase studs
Check that the studs are tight. If any are loose, remove them,
clean their threads with contact cleaner, then reinstall tn~m
using Honda Anaerobic Thread Lock, or equivalent.
After installing, be sure to measure the distance from the top (1) 8 mm STUD BOLT (2) 10 mm STUD BOLT
of each stud to the crankcase surface.
11-13
CRANKSHAFT/TRANSMISSION
Oil jet
Remove the oil jets from the front cylinder bore of the right and
left crankcase.
TRANSMISSION ASSEMBLY/
INSTALLATION
Apply MOS2 grease to the shift fork journals of M3, C4 and C5
gears.
Clean all parts in solvent and dip them in clean engine oil.
CAUTION
Align the oil holes in the bushings and gears with the oil holes in
the shaft.
Mainshaft
o0q)(()OO 00
M5 M3
11-14
CRANKSHAFT{TRANSMISSION
Countershaft
(1) COUNTERSHAFT
Apply molybdenum disulfide grease to the following.
o~®o ~~©
- shift fork grooves
- inside and outside of the bushings
- outside of the spline bushings
C2 r - - - - - ' - : : . . - - - - - - - - - - - l
Tighten the bolt with the lock washer and bend up the tabs of
the lock washer.
Assemble the mainshaft, countershaft, shift fork shaft and (1) TRANSMISSION ASSEMBLY
shift drum.
Install them into the left crankcase as an assembly.
\
11-15
CRANKSHAFT/TRANSMISSION
CRANKCASE ASSEMBLY
Apply sealant to the crankcase mating surfaces.
Install the dowel pins.
Assemble the right and left crankcases being careful to align (2) RIGHT CRANKCASE
the dowel pins and ~hafts. 1
CAUTION
Do not force the crankcase halves together; if exessive force is
required, something is wrong. Remove the right crankcase and
check for misaligned parts.
NOTE
• Tighten the 8 mm bolts first, then tighten the 6 mm bolts.
NOTE
• Tighten the 8 mm bolts first, then tighten the 6 mm bolts.
'88 Only:
Install the counters haft set plate with the attaching bolt.
After '88:
Install the countershaft set plate with the attaching bolts (2
pes).
11-16
CRANKSHAFT/TRANSMISSION
Install the oil pipe stay and cam chain tensioner set plate.
Tighten the bolt sercurely.
Install the front cam chain over the front cam chain drive
sprocket.
Install the cam chain tensioner set plate and tighten the bolt
securely.
11-17
FRONT WHEEl/SUSPENSION/STEERING
~
22 N'm (2.2 kg-m. 16 ft-Ib)
12-0
12. FRONT WHEEL/SUSPENSION/STEERING
SERVICE INFORMATION 12-1 FORK 12-12
TROUBLESHOOTING 12-2 HEADLIGHT BRACKET 12-19
HANDLEBARS 12-3 STEERING STEM 12-20
FRONT WHEEL 12-7
SERVICE INFROMATION
-'------------------------
Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to clean brake
assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA designed to minimize the hazard
caused by airborne asbestos fibers.
GENERAL
• A jack or other support is required to support the motorcycle during front end service.
• For front brake service, refer to section 14.
• For headlight, instrument and ignition switch services and inspections, refer to section 18.
SPECIFICATIONS
Unit: mm (in)
ITEM STANDARD SERVICE LIMIT
m
Axle runout -- 0.2 (0.01)
Front wheel rim runout Radial -- 2.0 (0.08)
Axial -- 2.0 (0.08)
Fork spring free length -- 336.4 (13.2)
Fork tube runout -- 0.2 (0.01)
Fork fluid capacity '88: 497 cc (16.8 US OZ, 17.4 Imp oz)
--
After '88: 502 cc (16.9 US OZ, 17.6 Imp OZ)
TORQUE VALUES
12-1
FRONT WHEEL/SUSPENSION/STEERING
TOOLS
Special
Steering stem socket 07916-3710100
Ball race remover set 07946-KM90001 orTAdjustable bearing puller 07736-A01000A
[Attachment, 42 x 47 mm 07746-0010300
Attachment, 52 x 55 mm 07746-0010400
- Driver attachment A 47 mm 07946-KM90100
- Driver attachment B 55 mm 07946-KM90200
- Driver assembly shaft 07946-KM90300
- Bearing remover A 47 mm 07946-KM90401
- Bearing remover B 55 mm 07946-KM90500
- Assembly base 07946-KM90600
Steering stem socket 07916-3710100
Snap ring pliers 07914-323000 -Equivalent commercially available in U.S.A.
Steering stem driver 07946-MBOOOOO
Common
Lock nut wrench, 30 x 32 mm 07716-0020400,Equivalent commercially available in U.S.A.
Extension bar 07716-0020500...J
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Attachment, 52 x 55 mm 07746-0010400
Pilot, 20 mm 07746-0040500
Fork seal driver 07947-KA50100
- Driver attachment 07947-KF00100
Bearing remover shaft 07746-0050100 Equivalent commercially available in U.S.A.
Bearing remover head, 20 mm 07746-0050600 T
TROUBLESHOOTING
Hard Steering Soft Suspension
• Steering bearing adjustment nut too tight Weak fork springs
• Faulty steering stem bearings • Insufficient fluid in fork legs
Insufficient air in front tire , . Hard Suspension
Steers to One Side or Does Not Track Straight Fork oil level too high
Bent fork legs • Fork tube(s) bent or fork slider(s) damaged
Bent front axle, wheel installed incorrectly
Unequal oil quantity in each fork tube Front Suspension Noise
Slider binding
Front Wheel Wobbling Insufficient fluid in fork legs
Distorted rim Loose fork leg fasteners
Worn front wheel bearings
Faulty tire
Axle or axle holder not tightened properly
12-2
FRONT WHEEL/SUSPENSION/STEERING
HANDLEBARS
REMOVAL
Disconnect the front brake light switch wires from the switch.
Remove the following:
- rear view mirror from the master cylinder
- master cylinder holder mounting bolts and holder (2) HANDLEBAR SWITCH
- right handlebar switch screws and switch
- the right handlebar retainer ring and loosen the handlebar
pinch bolt.
- the right handlebar from the fork tube.
Remove the left handlebar retainer ring and loosen the left (1) RETAINER
handlebar pinch bolt. RING
12-3
FRONT WHEEL/SUSPENSION/STEERING
NOTE
• Apply lubricant spray (CRC 5-56 or equivalent) through the
tab hooking hole to the rubber suspension in order to easy
removal.
(3) HOOKING HOLE
(5) GRIP END WEIGHT
Remove the grip end weight by removing the mounting screw
from the handlebar weight.
Discard the used retainer. (1) GRIP END WEIGHT
(3) HANDLEBAR
WEIGHT
NOTE
• Allow the adhesive to dry for an hour before using. (1) GRIP
12-4
FRONT WHEEL/SUSPENSION/STEERING
INSTALLATION
Install the right handlebar onto the fork tube, aligning the pin
on the bottom of the handlebar holder with the cut-out in the
fork bridge. Install the retainer ring. Tighten the handlebar
pinch bolt.
Align the locating pin on the right handlebar switch with the
hole in the handlebar.
Apply clean grease to the throttle cables and apply clean oil to
the throttle pipe sliding surface and connect the throttle cables
to the throttle pipe.
(6) PINCH
BOLT
------.~~.((
Place the front brake master cylinder on the handlebar and in-
stall the master cylinder holder with the "UP" mark facing up.
Align the end of the holder with the punch mark on the handle-
bar. Tighten the upper holder bolt first, then tighten the lower
bolt.
Install the right rear-view mirror into the master cylinder hold-
er.
12-5
FRONT WHEEL/SUSPENSION/STEERING
Install the left handlebar onto the fork tube in the same manner
as a right handlebar.
Connect the choke cable to the choke lever.
Install the left handlebar switch by aligning the locating pin
with the hole in the handlebar.
Tighten the front screw first, then tighten the rear screw.
Install the clutch lever and holder with the "UP" mark facing
up.
Align the end of the holder with the punch mark on the handle-
bar and tighten the upper bolt first then tighten the lower bolt.
12-6
FRONT WHEEl/SUSPENSION/STEERING
FRONT WHEEL
REMOVAL
Raise the front wheel off the ground.
CAUTION
Support the caliper assembly so that it does not hang on the
brake hose. Do not twist the brake hose.
NOTE
If you squeeze the front brake lever after the caliper is re-
moved, the caliper piston will move out and make assembly
difficult.
Loosen the right and left front axle pinch bolts, and remove the
axle bolt.
Remove the side collar from the right side and remove the
speedometer gear box from the left side.
12-7
FRONT WHEEL/SUSPENSION/STEERING
INSPECTION
Axle
Set the axle in V blocks and measure the runout.
(1) AXLE
SERVICE LIMITS:
RADIAL RUNOUT: 2.0 mm (0.08 in)
AXIAL RUNOUT: 2.0 mm (0.08 in)
Wheel Balance
CAUTION
Wheel balance directly affects the stability, handling and over-
all safety of the motorcycle. Always check balance when the
tire has been removed from the rim.
NOTE
For optimum balance, the tire balance mark (a paint dot on
the side wall) must be located next to the valve stem.
Remount the tire if necessary.
Mount the wheel, tire and brake disc assembly in an inspection (1) INSPECTION
stand. STAND
Spin the wheel, allow it to stop, and mark the lowest
(heaviest) part of the wheel with chalk.
Do this two or three times to verify the heaviest area. If the
wheel is balanced, it will not stop consistently in the same po-
sition.
12-8
FRONT WHEEL/SUSPENSION/STEERING
Wheel bearing
Turn the inner race of each bearing with your finger. The bear-
ings should turn smoothly and quietly. Also check that the
bearing outer race fits tightly in the hub.
NOTE
• Replace hub bearings in pairs.
BEARING REPLACEMENT
NOTE
If the bearings are removed, they must be replaced with
new ones.
TOOLS:
Bearing remover shaft 07746-0050100
Bearing remover head, 20 mm 07746-0050600
12-9
FRONT WHEEL/SUSPENSION/STEERING
Drive a new right bearing into the wheel until it is fully seated
first.
TOOLS:
Driver 07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 20 mm 07746-0040500
NOTE
• Do not allow the bearings to tilt while driving them in.
Never install an old bearing, once a bearing is removed, it
must be replaced with a new one.
ASSEMBLY
NOTE ,-
• The front wheel has no rim band.
-'-----------
• Do not get grease on the brake disc or stopping power will be
reduced.
(3) SPEEDOMETER
RETAINER (5) BRAKE DISC
12-10
FRONT WHEEL/SUSPENSION/STEERING
Install the brake disc onto the wheel hub with the minimum
thickness marking (MIN TH 4.0 mm) facing out.
Clean and apply locking agent to the mounting bolt threads.
Tighten the bolts to the specified torque in a crisscross pattern
in 2 or 3 steps.
-'-------------
Do not get grease on the brake disc or stopping power will be
reduced.
Coat the speedometer gear retainer with clean grease and in-
stall the retainer into the wheel hub. aligning the tangs with
the slots in the hub.
Apply clean grease to the dust seal lip and install the dust seal
over the gear retainer.
Fill the speedometer gear box with clean grease and install the
drive gear.
Apply clean grease to the right dust seal lip and install the seal
into the wheel.
Install the side collar.
12-11
FRONT WHEEl/SUSPENSION/STEERING
INSTALLATION
(1) CALIPER
_ _;.:M.OllliL1NG SOLTS
FORK
REMOVAL
12-12
FRONT WHEEL/SUSPENSION/STEERING
Loosen the fork bottom pinch bolts and remove the fork legs
from the fork top bridge and steering stem.
DISASSEMBLY
-'------------
Remove the fork tube cap and the spring.
Drain the oil by pumping the tube up and down several times.
Hold the fork slider in a vise with soft jaws or use a shop towel.
NOTE
Temporarily reinstall the spring and cap if the bolt is difficult
to remove.
12-13
FRONT WHEEL/SUSPENSION/STEERING
Remove the dust seal and the stop ring with a screwdriver. (2) STOPPER RING
CAUTION
• Do not scratch the fork lube sliding surface.
Pull the fork tube out until resistance from the slider bushing is
felt. Then move it in and out, tapping the bushing lightly until
the fork tube separates from the slider. The slider bushing will
be forced out by the fork tube bushing.
Remove the oil lock piece from the piston. (1) PISTON
/
Remove the piston and rebound spring from the fork tube.
/
(2) OIL LOCK PIECE
Remove the oil seal, back-up ring and slider bushing from the (2) BACK-UP RING
fork tube. I
NOTE
Do not remove the fork tube bushing unless it is necessary
to replace it with a new one. See bushing inspection, page
12-15.
7
(4) FORK TUBE BUSHING
12-14
FRONT WHEEL/SUSPENSION/STEERING
INSPECTION
Fork spring
Measure the fork spring free length.
Fork tube/slider/piston
Check the fork tube, fork slider and piston for score marks and
excessive or abnormal wear.
7' PISTON RING
Bushings
Visually inspect the slider and fork tube bushings.
(1) BUSHING
Replace the bushings if there is excessive scoring or scratch-
ing, or if the teflon is worn so that the copper surface appears
on more than 3/4 of the entire surface. (2) BACK-UP RING
(5) TEFLON
SURFACE
12-15
FRONT WHEEL/SUSPENSION/STEERING
ASSEMBLY
Before assembly, wash all parts with a high flash point or non-
flammable solvent and wipe them off completely.
~
(2) FORK TUBE CAP
1141 OIL SEAL /
~
1131 BACK-UP RING ~
1121 SUOER BUSHIN~
I
(2) OIL LOCK PIECE
Place the fork slider in a vise with soft jaws or use a shop towel
to avoid damaging the slider.
Clean and apply a locking agent to the socket bolt threads and
screw the bolt into the piston.
Temporarily install the fork spring and cap to tighten the
socket bolt.
Tighten the bolt with a 6 mm hex wrench.
12-16
FRONT WHEEL/SUSPENSION/STEERING
Place the slider bushing over the fork tube and rest it on the
slider.
Coat a new oil seal with ATF or equivalent and install it with
the seal markings facing up. Drive the seal in with the seal driv-
er.
TOOLS:
Fork seal driver 07947-KA50100
- driver attachment 07947-KF00100
Install the stop ring securely into the groove in the fork slider.
CAUTION
• Do not scratch the fork tube sliding surface.
Compress the fork tube and pour in the recommended fork oil
to the specified level.
Gently install the fork spring in the fork tube then install the 11IFORKSP~
spring seat and spacer.
NOTE
I 1
Note the spring direction; the tapered end must face toward
the bottom.
I I
CAUTION
~
• Do not damage the fork tube sliding surface.
!
12-17
REAR WHEEL/SUSPENSION
w
Tiro
120 N'm (12.0 kg-m, 87 ft-Ibl
SERVICE INFORMATION
GENERAL
_l-- _
• Never ride on the rim .
• When using a lock nut wrench, use a 20 inch long deflecting beam type torque wrench. The lock nut wrench increases the
torque wrench's leverage, so the torque wrench reading will be less than the torque actually applied to the lock nut.
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high
quality brake degreasing agent.
Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to clean brake
assemblies. Use an OSHA-approved vacuum cleaner ot alternate method approved by OSHA designed to minimize the hazard
caused by airborne asbestos fibers.
The shock absorber contains nitrogen gas under high pressure. Do not allow fire or heat near the shock absorber.
Before disposal of the shock absorber, release the nitrogen. (see page 13-16). IIIE"I::l
~---=--------------~=--------~
SPECI FICATIONS
Unit: mm (in)
TORQUE VALUES
13-1
REAR WHEEL/SUSPENSION
TOOLS
Special
Snap ring pliers 07914-323000-Equivalent commercially available in U.S.A.
Shock absorber compressor attachment 07967-KE10000
Driver shaft 07946-MJ00100
Bearing remover set 07946 - MJOOOOO
- Driver head 07946-MJ00200
Spherical bearing driver 07946-KA30200 Not available in U.S.A.
Lock nut wrench 07908-ME90000
Oil seal driver 07965-KE80100
Common
Driver 07749-0010000
Attachment, 24 x 26 mm 07746-0010700
Attachment, 32 x 35 mm 07746-0010100
Attachment, 42 x 47 mm 07746-0010300
Attachment, 52 x 55 mm 07746-0010400
Attachment, 62 x 68 mm 07746-0010500
Pilot, 15 mm 07746-0040300
Pilot, 17 mm 07746-0040400
Pilot, 20 mm 07746-0040500
Pilot, 22 mm 07746-0041000
Pilot, 35 mm 07746 - 0040800
Pilot, 40 mm 07746-0040900
Driver handle 07949-3710001
TROUBLESHOOTI NG
Wobble or vibration in motorcycle
• Bent rim
Loose wheel hub bearing(s)
Damaged tire
Axle not tightened properly
• Swingarm pivot bearing worn
Bent frame or swingarm
Damaged drive pin and pin hole
Soft suspension
Weak spring
Improper shock absorber spring preload
Leaking damper
Hard suspension
Improper shock absorber spring preload
Bent shock absorber rod
Swingarm pivot bearings damaged
Bent frame or swingarm
Suspension noise
Faulty rear damper
• Loose fasteners
13-2
REAR WHEel/SUSPENSION
REAR WHEEL
-'------------
REMOVAL
CAUTION
Cover the left rim edge, spindle edge and brake caliper with
tape to avoid damaging the wheel.
NOTE
The sprocket and driven flange dampers can be removed
without removing the wheel (see page 13-6).
Loosen the eccentric bearing carrier pinch bolt and turn the
carrier counterclockwise until it stops to obtain maximum
chain slack.
Remove the chain from the rear sprocket and place it on the
outside of the sprocket.
Rotate the eccentric bearing carrier to its rearward most (maxi-
mum chain slack) position.
Attach tape to the wheel rim, edge of the spindle and brake
caliper to avoid damaging the wheel.
Remove the wheel from the drive pins, then angle it to the right
and pull it backward to go between the brake disc and muffler.
CAUTION
Be careful not to damage the wheel rim and brake disc when re-
moving the wheel.
Then, as the wheel reaches the hub, angle it to the left and pull
it out backward as shown.
CAUTION
Be careful not to damage the wheel rim and brake caliper when
removing the wheel.
13-3
REAR WHEEL/SUSPENSION
INSPECTION
SERVICE LIMITS:
RADIAL RUN OUT: 2.0 mm (0.08 in)
AXIAL RUNOUT: 2.0 mm (0.08 in)
NOTE
The wheel cannot be repaired and must be replaced with a
new one if the service limits are exceeded.
Wheel Balance
CAUTION
Wheel balance directly affects the stability, handling and over-
all safety of the motorcycle. Always check balance when the
tire has been removed from the rim.
NOTE
For optimum balance, the tire balance mark (a paint dot on
the side wall) must be located next to the valve stem.
~~
Remount the tire if necessary. (2) TIRE BALANCE MARK
13-4
REAR WHEEL/SUSPENSION
INSTALLATION
L-- _
CAUTION
Cover the left rim edge, spindle edge and brake caliper with
tape to avoid damaging the wheel.
Use care not to damage the wheel rim and brake disc when re-
moving the wheel.
Insert the axle in the wheel hub, making sure the splines are
correctly aligned.
Tap the axle with soft hammer to seat the axle securely.
CAUTION 3) DRIVE
CHAIN
• Make sure that the axle threads are applied clean grease to
obtain the specified torque.
,A'\~ i I fh-'l/lit 1/
Install the axle center collar, shim and wheel nut. (1) AXLE CENTER COLLAR
Tighten the wheel nut to the specified torque.
---- - \ ""
/,
TORQUE: 120 N'm (12.0 kg-m, 87 ft-Ibl
Apply the rear brake several times and check for free wheel ro-
tation when released.
13-5
REAR WHEEL/SUSPENSION
SPROCKET
REMOVAL
Turn the eccentric bearing carrier to loose the drive chain, then
remove the chain from the sprocket.
INSTALLATION
Reinstall the drive chain and adjust the slack (page 3-12).
(1) SPROCKET
\\
(1) REAR WHEEL '.
Tap the axle with a soft hammer until the splines clear the
driven flange cover.
13-6
REAR WHEEl/SUSPENSION
Unstake the eccentric bearing carrier lock nut and remove the
nut.
Remove the lock washer and side collar.
Remove the snap ring and brake disc guard plate. p:::iBAKE DISC GUARD PLATE
Remove the eccentric bearing carrier from the swingarm.
\
13-7
REAR WHEEL/SUSPENSION
INSPECTION
(1) BEARING
Bearing
Turn the inner races of the ball bearings with your finger.
The bearing should turn smoothly and quietly.
Also check that the bearing outer races fits tightly in the
eccentric bearing carrier.
Check the right bearing needle rollers for obvious signs of
wear.
NOTE
• Replace the bearings in pairs.
Damper
Separate the driven flange cover with the sprocket from the
flange.
(4) DAMPER
13-8
REAR WHEEL/SUSPENSION
BEARING REPLACEMENT
Eccentric bearing carrier
,
(1) DUST SEAL
Press the ball bearings out of the carrier first with the special (2) ECCENTRIC BEARING CARRIER
tools.
TOOLS:
Driver 07749-0010000 ....._ - - ( 1 ) DRIVER
Attachment, 42 x 47 mm 07746-0010300
Pilot 40 mm 07746-0040900
Press the needle bearing out of the carrier with the special
tools.
TOOLS:
Driver 07749-0010000 (2) ECCENTRIC
Attachment 52 x 55 mm 07746-0010400 BEARING
CARRIER
NOTE
• Install the bearing with marks facing out.
TOOLS: (3)
Driver 07749-0010000 ECCENTRIC
Attachement 62 x 68 mm 07746-0010500 BEARING CARRIER
13-9
REAR WHEEL/SUSPENSION
Carefully press the new ball bearings in with the special tools.
NOTE
(3) ATTACHMENT/PILOT
• Install the bearing with sealed end facing out.
TOOLS:
Driver 07749-0010000
Attachment 62 x 68 mm 07746-0010500
(2) ECCENTRIC
BEARING CARRIER
, .
Driven flange
Separate the cover and the flange.
Remove the dampers and the a-ring.
()8i~3) DAMPER
~
(4) O-RING
(2) FLANGE
13-10
REAR WHEEL/SUSPENSION
Press the bearing and dust seal out of the cover with the spe-
cial tools.
TOOLS:
Driver 07749-0010000
Attachment 52 x 55 mm 07746-0010400
Pilot 35 mm 07746-0040800
SPINDLE
INSPECTION
(1 ) RETAINING BOLTS
Apply a locking agent to the drive pin bolt threads and tighten
the drive pin bolts to the drive pin if replaced them.
Install the brake disc to the spindle and tighten the disc retain-
ing bolts and nuts.
Install the disc retaining bolt lock nut onto the anywhere bolt.
TORQUE: 9 N'm (0.9 kg-m. 7 ft-Ib) (2) BRAKE DISC (3) SPINDLE (5) DRIVE PIN/BOLT
13-11
REAR WHEEl/SUSPENSION
(11) ECCENTRIC
BEARING CARRIER ----:::::.::.....-.I!I
(10) ECCENTRIC BEARING CARRIER
PINCH BOLT
Install the eccentric bearing carrier onto the swingarm. (2) PINCH BOLT
Loosely install the eccentric bearing carrier pinch bolt.
Install the brake disc guard plate onto the eccentric bearing
carrier by using the snap ring.
13-12
REAR WHEEL/SUSPENSION
Install the drive chain on the sprocket and position the flange (31 DRIVEN FLANGEI (1) SPINDLE
against the eccentric bearing carrier. SPROCKET
Insert the spindle through the bearing carrier and driven flange.
Engage the driven flange and the spindle, making sure the
splines are correctly mated. "
(4) SPLINES
(2) ECCENTRIC BEARING CARRIER
~
• Use care not to damage the pads when installing the caliper.
Install the eccentric bearing carrier lock nut and stake it.
13-13
REAR WHEEl/SUSPENSION
Operate the brake pedal to seat the caliper piston against the
pads.
SHOCK ABSORBER
_
The rear shock absorber contains nitrogen under high pressure.
Do not allow fire or heat near the shock absorber.
Before disposal of the shock absorber, release the nitrogen.
NOTE
• If you plan to disassemble the shock absorber. set the
spring adjuster to the softest position at this time.
REMOVAL
Raise the rear wheel off the ground by placing the motorcycle
on its center stand. (2) LOWER MOUNTING COLLAR
Loosen the sub-frame lower mounting bolts and lower the sub-
frame.
Pull the shock absorber out from the frame through the upper
sub-frame pipes.
13-14
REAR WHEEL/SUSPENSION
TOOL:
Shock absorber compressor attachement 07967 - KE 10000
Compress the spring until the stop ring can be removed, and
remove the stop ring from the shock absorber.
(12) DAMPER-_ _~
13-15
REAR WHEEL/SUSPENSION
(2) ALIGN
NOTE (1 )
SHOCK ABSORBER
• Make sure the spring adjuster is set to the softest position. COMPRESSOR I
ATTACHEMENT
Set the shock absorber in the hydraulic press with the special
tool.
TOOL:
Shock absorber compressor attachment 07967-KE10000
Compress the spring until the stop ring can be installed, and in-
stall the stop ring.
13-17
REAR WHEEL/SUSPENSION
TOOL:
Spherical bearing driver 07946 - KA30200
Not available in U.S.A.
Apply clean grease to a new needle bearing and drive it into (1) DRIVER
the shock absorber until it is flush with lower mount surface.
TOOLS:
Driver 07749-0010000
/
Attachment 24 x 26 mm 07746-0010700
Pilot 17 mm 07746-0040400
Apply clean grease to the dust seal lips and install them onto
the lower mount.
INSTALLATION
(1) SHOCK ABSORBER
Install the lower mounting collar into the mount.
(2) LOWER MOUNTING
Install the shock absorber in the frame with the drain tube
COLLAR
facing forward.
Tighten the shock absorber upper mounting bolt.
(4) FUEL FILTER
TORQUE: 65 N'm (6.5 kg-m, 47 ft-Ibl BASE MOUNTING BOLT
13-18
REAR WHEEL/SUSPENSION
SWINGARM
REMOVAL
.
;
/
Raise the rear wheel off the ground by placing the motorcycle
on its center stand.
Remove the rear wheel (page 13-3) and eccentric bearing car-
rier (page 13-6).
Unhook the rear brake hose and remove the rear brake caliper
(page 14-15).
TOOL:
lock nut wrench 07908 - ME90000
Using a hex wrench, turn the pivot bolt and adjusting bolt
counterclockwise together.
13-19
REAR WHEEL/SUSPENSION
Pull the pivot bolt out the frame while supporting the swing-
arm.
Remove the swingarm from the frame.
Remove the pivot collars and bushing.
DISASSEMBLY
(2) SWINGARM
13-20
REAR WHEEL/SUSPENSION
Press the right pivot bearings out of the swingarm using a hy-
draulic press and the driver shaft.
TOOL:
Driver shaft 07746-MJ00100 or
Driver handle 07949-3710001
Press the left pivot needle bearing out of the swingarm using a (1) DRIVER
hydraulic press and the special tool. SHAFT SET
TOOL:
Driver shaft set 07746-MJOOOOO
TOOLS: Ii
Driver 07749-0010000
Attachment. 32 x 35 mm 07746-0010100
Pilot. 15 mm 07746-0040300
TOOLS:
Driver 07749-0010000
Attachment. 32 x 35 mm 07746-0010100
Pilot. 22 mm 07746-0041000
13-21
REAR WHEEl/SUSPENSION
Install the snap ring into the groove in the swingarm. (2) SWINGARM
Apply clean grease to the dust seal lips and install the dust
seals in the swingarm pivots.
ASSEMBLY
INSTALLATION
13-22
REAR WHEEl/SUSPENSION
Turn the pivot bolt and adjusting bolt together clockwise until
they touch the left pivot collar.
Tighten the adjusting bolt.
TORQUE:
Actual: 65 N·m (6.5 kg-m, 47 ft-Ib)
Indicated: 59 N·m (5.9 kg-m, 43 ft-Ib)
TOOL:
Lock nut wrench 07908 - ME90000
13-23
REAR WHEEL/SUSPENSION
MUFFLER/EXHAUST PIPE
_L-
REMOVAL
Loosen the exhaust pipe band bolt and separate the muffler
and exhaust pipes.
(1 I EXHAUST PIPE
GASKET
INSTALLATION
TORQUE:
Exhaust pipe joint nut: 27 N'm (2.7 kg-m. 20 ft-Ibl
Muffler mounting bolt: 27 N'm (2.7 kg-m. 20 ft-Ibl
Muffler band bolt: 27 N·m (2.7 kg-m. 20 ft-Ibl
CAUTION
Be sure the new exhaust pipe gaskets are correctly seated on the
pipe flange before installing the pipes.
13-24
REAR WHEEL/SUSPENSION
SEAT
REMOVAL/INSTALLATION
Insert the ignition key into the helmet holder and turn it cloc-
kwise.
REAR COWLI NG
REMOVAL/INSTALLATION
13-25
HYDRAULIC BRAKE
I
12 N·m
(1.2 kg-m,
9 ft-Ib)
14-0
14. HYDRAULIC BRAKE
SERVICE INFORMATION 14-1 FRONT BRAKE CALIPER 14-11
TROUBLESHOOTING 14-2 REAR BRAKE MASTER CYLINDER 14-13
BRAKE FLUID REPLACEMENT/ REAR BRAKE CALIPER 14-15
BLEEDING 14-3
BRAKE PEDAL 14-17
BRAKE PADS/DISCS 14-5
FRONT MASTER CYLINDER 14-8
SERVICE INFORMATION
GENERAL
-'-----------------------
A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high
quality brake degreasing agent.
Use only DOT 4 brake fluid.
The brake caliper and brake pads can be removed without disconnecting the hydraulic system.
Once the hydraulic system has been disassembled, or if the brakes feel spongy, the system must be bled.
Do not allow foreign material to enter the system when filling the reservoir.
Brake fluid will damage painted, plastic, and rubber parts. Whenever handling brake fluid, protect the painted, plastic and rubber
parts by covering them with a shop towel. If fluid does get on these parts, wipe it off immediately with a clean cloth.
Always check brake operation before riding the motorcycle.
Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to clean brake
assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA, designed to minimize the hazard
caused by airborne asbestos fibers.
SPECIFICATIONS
Unit: mm (in)
14-1
HYDRAULIC BRAKE
TORQUE VALUES
TOOL
Special
Snap ring pliers 07914-3230001
TROUBLESHOOTING
Brake lever/pedal soft or spongy Brakes grab
Air in hydraulic system Pads contaminated
• Low fluid level • Disc or wheel misaligned
Hydraulic system leaking
Brake chatter or squeal
Brake lever/pedal too hard Pads contaminated
Sticking piston(sl Excessive disc runout
Clogged hydraulic system Caliper installed incorrectly
Pads glazed or worn excessively
Brake drag
Hydraulic system sticking
Sticking piston(s)
Clogged hydraulic system
Incorrect pedal adjustment
Caliper slide pins sticking
• Disc or wheel misaligned
14-2
HYDRAULIC BRAKE
Check the fluid level with the reservoir parallel to the ground.
Remove the reservoir cover, set plate and diaphragm.
Loosen the caliper bleed valve and pump the brake lever. Stop
operating the lever when fluid stops flowing out of the bleed
valve.
, .
Close the bleed valve, fill the reservoir with DOT 4 brake fluid
to the upper level.
Install the diaphragm and reservoir cover.
14-3
HYDRAULIC BRAKE
Connect a Brake Bleeder or equivalent to the bleed valve. (2) BLEED VALVE.\
Pump the brake bleeder and loosen the bleed valve. Add fluid I
when the fluid level in the master cylinder reservoir is low.
Repeat above procedures until no air bubbles appear in the
plastic hose. .
•
NOTE
AIR BLEEDING
NOTE
Do not release the brake lever (or pedal) until the bleed
valve has been closed.
3) Release the brake lever (or pedal) slowly and wait several
seconds after it reaches the end of its travel.
Repeat steps 2 and 3 until bubbles cease to appear in the fluid
at the end of the hose.
Tighten the bleed valve.
Close the bleed valve, fill the reservoir with DOT 4 brake fluid
to the upper level.
-----------
A contaminated brake disc or pad reduces stopping power. Dis-
card contaminated pads and clean a contaminated disc with a
high quality brake degreasing agent.
14-4
HYDRAULIC BRAKE
BRAKE PADS/DISCS
-'------------
FRONT BRAKE PAD REPLACEMENT
NOTE
Always replace the brake pads in pairs to assure even disc
pressure.
'88 Only:
Remove the cotter pin.
NOTE
Check the brake fluid level in the reservoir as this operation
causes the level to rise.
Pull the pad pin out of the caliper and remove the brake pads.
14-5
HYDRAULIC BRAKE
'88 Only:
Install the new cotter pin onto the pad pin.
NOTE
Operate the brake lever to seat the caliper pistons against
the pads.
NOTE
Always replace the brake pads in pairs to assure even disc
p·ressure.
14-6
HYDRAULIC BRAKE
Push the piston all the way in to allow installation of new brake
pads.
NOTE
Check the brake fluid level in the reservoir as this operation
causes the level to rise.
Install the caliper onto the brake disc so the disc is positioned
between the pads. being careful not to damage the pads.
Operate the brake pedal to seat the caliper piston against the
pads.
14-7
HYDRAULIC BRAKE
DISC THICKNESS
CAUTION
A void spilling brake fluid on painted surfaces. Place a rag over
the fuel tank whenever the brake system is serviced.
When removing the oil hose bolt, cover the end of the hose
to prevent contamination. Secure the hose to prevent fluid
I
from leaking out.
DISASSEMBLY
14-8
HYDRAULIC BRAKE
TOOL:
Snap ring pliers 07914-3230001
or equivalent commercially
available in U. S. A.
~
(3)PISTON~
(2) SPRING
INSPECTION
Check the primary and secondary cups for damage before as-
sembly.
ASSEMBLY
CAUTION
• Handle the master cylinder piston, cylinder and spring as a set. A (4) SNAP RING
CAUTION
When installing the piston, do not allow the cup lips to turn
(1) MASTER CYLINDER
inside out.
14-9
HYDRAULIC BRAKE
Install the snap ring using a snap ring pliers. (1) SNAP RING
Install the boot.
CAUTION
• Be certain that the snap ring is seated firmly in the groove.
TOOL:
Snap ring pliers 07914-3230001
or equivalent commercially
available in U.S.A.
INSTALLATION
Set the master cylinder onto the handlebar with the holder
"UP" mark facing up.
Temporarily install the holder bolts. Align the slit of the master
cylinder with the punch mark on the handlebar.
Tighten the upper bolt first. then the lower bolt.
Connect the brake light switch wires to the switch terminals.
Install the rear view mirror.
Connect the brake hose with the oil bolt and two sealing wash-
ers and tighten the oil bolt.
Fill the reservoir with DOT 4 brake fluid to the casting ledge
and bleed the brake system (page 14-3).
Operate the brake lever to seat the caliper pistons against the
pads.
14-10
HYDRAULIC BRAKE
CAUTION
• A void spilling brake fluid on painted surfaces.
DISASSEMBLY
-----------
spurts.
Do not use high pressure air or bring the nozzle too close to the
inlet.
Push the dust seals and piston seals in, lift them out and dis-
card them.
NOTE
• The seals must be replaced whenever they are removed.
CAUTION
• Be careful not to damage the piston sliding surfaces.
INSPECTION
14-11
HYDRAULIC BRAKE
ASSEMBLY
Coat new piston seals and dust seals with clean brake fluid
and install them in the caliper.
Install the pistons with the dished ends toward the pads.
Install the caliper assembly over the brake disc so that the disc
is positioned between the pads.
CAUTION
• Be careful nol 1o damage rhe pads.
Tighten the pad pins and install and tighten the pad pin plug
(page 14-5).
Connect the brake hose to the caliper with the oil bolt and two
new sealing washers.
14-12
HYDRAULIC BRAKE
\
(2) MASTER CYLINDER
Remove the cotter pin and joint pin, and disconnect the brake
actuating arm from the master cylinder push rod.
Remove the rear master cylinder from the foot peg bracket.
DISASSEMBLY
Remove the snap ring and push rod from the master cylinder
body.
CAUTION
• The push rod will pop out when the snap ring is removed.
TOOL:
Snap ring pliers 07914-3230001
Equivalent commercially
available in U.S.A.
14-13
HYDRAULIC BRAKE
(3) PISTON
INSPECTION
(2) MASTER CYLINDER
Check the piston and piston cups for damage. wear or deterio-
ration.
NOTE
The master cylinder piston, cups and spring must be in-
stalled as a set.
CAUTION
When installing the cups, do not allow the lips to turn inside
out and be certain the snap ring is seated firmly in the groove.
Adjust the push rod standard length so that the distance from
the center of the master cylinder lower mount hole to the
center of the joint pin hole is 80 mm (3.15 in).
Tighten the lock nut. (3) JOINT PIN
14-14
HYDRAULIC BRAKE
Connect the rear brake actuating arm to the master cylinder (5) MOUNTING BOLi-s::'"
"
push rod with the joint pin, and secure the joint pin with the
washer and new cotter pin.
Hook the rear brake pedal return spring and brake light switch
spring to the actuating arm.
Install the brake light switch, switch stay and rear brake
master cylinder. Tighten the master cylinder mounting bolts
securely.
Install the right foot peg bracket. Tighten the mounting bolts.
Connect the rear brake hose with the oil bolt and two new
sealing washers.
Operate the brake pedal to seat the caliper piston against the
pads.
14-15
HYDRAULIC BRAKE
DISASSEMBLY
Remove the pad spring, boots and collar from the rear brake
caliper.
Place a shop towel over the piston, position the caliper with
the piston down and apply small squirts of air pressure to the
fluid inlet to remove the piston.
------------
Do not use high pressure air or bring the nozzle too close to the
inlet.
Push the dust and piston seals in and lift them out.
Wash the caliper cylinder, seal gooves and caliper piston with
clean brake fluid.
CAUTION
INSPECTION
14-16
HYDRAULIC BRAKE
ASSEMBLY / ( 3 ) COLLAR
The piston and dust seals must be replaced whenever they are
removed. ,
Check the boot and replace it if it is hardened or deteriorated.
USTSEAl
?3
Coat the piston and dust seals with clean brake fluid and install
them with the small diameter facing in.
Lubricate the caliper cylinder and piston with clean brake fluid
and install the piston into the caliper cylinder with the piston
dished end facing toward the pads.
(4) PISTON /'
Apply silicone grease to the collar and the insides of the boots SEAL (6) PISTON
and install them into the caliper.
Make sure that the boot is seated in the collar and caliper
grooves properly.
Install the pad spring.
Install the brake hose with the oil bolt and the new sealing
washers. Tighten the oil bolt.
Operate the brake pedal to seat the caliper piston against the
pads.
BRAKE PEDAL
REMOVAL/INSTALLATION
Remove the right foot peg bracket bolts and the muffler
mounting bolt and nut.
14-17
HYDRAULIC BRAKE
Remove the cotter pin and joint pin, and disconnect the brake
actuating arm from the master cylinder push rod.
Apply clean grease to the brake pedal pivot and install the
pedal into the bracket with the snap ring.
Install the right foot peg bracket. Tighten the mounting bolts.
14-18
BATTERY/CHARGING SYSTEM
(6) R: Red
(7) W: White
(8) G: Green
(9) Y: Yellow
L- y _ _...... •
ilnl1l1'l1f'..:.1-----y---.....1
----y---_.. . .
(5) ALTERNATOR
G G
j
.&...
~
(2)
BATTERY
12VBAh
11
-= ~
15-0
15. BATTERY/CHARGING SYSTEM
SERVICE INFORMATION 15-1 CHARGING SYSTEM 15-7
TROUBLESHOOTING 15-3 REGULATOR/RECTIFIER 15-8
BATTERY 15-4 ALTERNATOR 15-10
SERVICE INFORMATION
GENERAL
• Battery charging
NOTE
Refer to the instructions in the Operation Manual for the Honda Battery Tester and Christie Battery Charger for detailed
battery charging steps.
After activation, the maintenance-free battery must be charged at the appropriate ampere-hour rating for the proper length of
time.
Set the Battery Amp. Hr. Selector Switch on the Christie Charger (#MC 1012/2) for the size of the battery being charged. Set
the Timer to the NEW BATT position and connect the battery clamps. When the timer reaches the "trickle" position, the
charging cycle is complete.
After charging, test the condition of the new battery using the Honda Battery Tester (#BM-21 0) refer to the Operation
m
-------------------------
The battery generates hydorogen gas which can be highly explosive. Do not smoke or allow flames or sparks near the battery,
expecially while charging it.
If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area.
The exhaust contains posisonous carbon monoxide gas that may cause loss of consciousness and, lead to death.
15-1
BATTERY/CHARGING SYSTEM
SPECIFICATIONS
ITEM STANDARD
Battery Capacity 12V-8Ah
Voltage at 20°C (68°F) Fully cahrged 13.0-13.2 V
Needs charging 12.3 V
Leakage ampere at 20°C (68°F) 0.1 A max.
Charging current 0.9 amperes
Charging time 5 Hr
Regulator/rectifier Type Three-phase/full-wave
Regulated voltage/Amperage 13.5-15.5 V/0.5 A (3,000 rpm)
Alternator Charging coil resistance at 20°C (68°F) 0.1-1.0 n
Output 0.24 kw/5,OOO rpm
Charging start rpm 1,200 ± 100 rpm
TOOLS
MULT1TESTER:
07411-0020000 (KOWA Digital type)
KS-AHM-32-003 (KOWA Digital type; U.S.A. only)
07308-0020001 (SANWA Analogue type)
TH-5H (KOWA Analogue type)
15-2
BATTERY/CHARGING SYSTEM
TROUBLESHOOTI NG
ABNORMAL
I Measure the battery leakage (page 1 5-7). I
I
Check the regulator/rectifier resistances be
tween each regulator/rectifier terminals (page
15-9)
NORMAL
NORMAL .
Short circuit in wire
harness
ABNORMAL ~. Faulty ignition
Faulty regulator/
rectifier
NOT OVE~CHARGED I REGULATED
. Fault y batter y
ABNORMAL
l- ---l~.Faulty stator coil
NORMAL
..
- - - - - - - - - - - - - - - - - - i..~.
,-I Faulty battery
15-3
BATTERY/CHARGING SYSTEM
BATTERY
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ '88 Shown:
The battery gives off explosive gases; keep sparks. flames and (1) COVER BOLTS
cigarettes away. Provide adequate ventilation when charging.
• The battery contains sulfuric acid (electrolyte). Contact with
skin or eyes may cause severe burns. Wear protective clothing
and a face shield.
- If electrolyte gets on your skin, flush with water.
- If electrolyte gets in your eyes, flush with water for at least
15 minutes and call a physician.
Electrolyte is poisonous.
- If swallowed, drink large quantities of water or milk and
follow with milk of magnessia or vegetable oil and call a
physician.
REMOVAL
Remove the seat and turn OFF the ignition switch.
Remove the battery case cover bolts and cover.
Disconnect the negative (-) terminal cable first, then
positive (+) terminal cable at the battery.
Pull the battery out of the battery holder.
INSTALLATION
(4) POSITIVE TERMINAL
Install the battery in the reverse order of the removal.
After installing the battery, coat the terminals with (5) BATTERY
clean grease.
VOLTAGE INSPECTION
Remove the seat.
Remove the battery case cover.
Measure the battery voltage.
NOTE
For accurate test results, be sure the tester's cables and
clamps are in good working condition and that a secure
connection can be made at the battery.
15-4
BATTERY/CHARGING SYSTEM
Push in the "5.5 Ah-9 Ah" test button for threee seconds and
read the condition of the battery on the meter. HIGH
Q@@@@@@@O
LOW
NOTE
• Be sure to push the correct test button.
For the first check. DO NOT charge the battery before test-
ing.
First check:
Green : OK
Yellow, Red: Charge
YELLOW
(-1)
Second check:
First check Yellow:
Green : OK
Yellow : Replace
First check Red:
Green : OK
Yellow : Recharge
Red: Replace
Third check:
Green : OK
Yellow Replace
---
CHARGING
NOTE
Standard Quick
Refer to the instructions in the Operation Manual for the Charging current 0.9 A 4.0 A
Honda Battery Tester and Christy Battery Charger for de-
tails on battery charging steps. Charging time 5 hours 1 hour
Specified voltage 12 V min.
Remove the battery.
Connect the charger positive (+) cable to the battery positive
(+) terminal.
Connect the charger negative (-) cable to the battery negative
(-) terminal.
15-5
BATIERY/CHARGING SYSTEM
-'-------------
• Keep flames and sparks away from a charging battery.
Turn power ON/OFF at the charger, not at the battery termi-
nals.
(1) BATTERY
CAUTION
Quick-charging should only be done in an emergency; slow
charging is preferred.
For battery charging, do not exceed the charging current and
time specified on the battery. Using excessive current or extend-
ing the charging time may damage the battery.
NOTE
Use the CHRISTIE Battery Charger (MC 1012/2) to charge
the battery.
DOD
-'-------------
air vents are not blocked.
Set the Battery Amp. Hr. Selector Switch to the "5.5 to 9.0"
position.
When the timer reaches the "Trickle" position, the charging YELLOW --II-I.."'}
-1
cycle is complete. Turn the Power Switch OFF and disconnect
the clamps.
15-6
BATTERY/CHARGING SYSTEM
NOTE
The charger will automatically switch to the Trickle mode
after the set charging time has elapsed.
Re-test the battery using the Honda Battery Tester and re-
charge if necessary using the previous steps.
NOTE
For accurate test results, let the battery cool for at least ten
minutes or until gassing subsides after charging.
CHARGING SYSTEM
NOTE
• When inspecting the charging system, check the system
components and lines step-by-step according to the
troubleshooting on page 15-3.
• With large capacity circuits that exceed the ratings of the
fuse contained in the tester, measuring errors can cause
damage to testing equipment.
Before starting each test, set the tester at the high capacity
range first, then adjust it to the small capacity circuits range
in order that you have the correct range.
LEAKAGE INSPECTION
CAUTION
(1) BATTERY
When measuring small capacity circuits, keep the ignition NEGATIVE TERMINAL
switch off. If the switch is suddenly turned on during a test, the
tester fuse may blow. ,•
-~---------
• If the engine must be running to do some work, make sure the
area is well-ventilated. Never run the engine in an enclosed
area.
The exhaust contains poisonous carbon monoxide gas that may
cause loss of consciousness and lead to death.
15-7
BATTERY/CHARGING SYSTEM
CAUTION
Be careful not to let the battery positive cable contact the frame
while testing.
Restart the engine and allow it to idle, then increase the engine
speed gradually.
The voltage and amperage should be controlled as specified
below:
ES:J
(3) STARTER
A
STANDARD: 13.5-15.5 V/0.5 A (3,000 rpm) (20 0 C/68°Fl
RELAY
REGULATOR/RECTI FI ER
SYSTEM INSPECTION
NOTE
The regulator/rectifier is semiconductorized unit; the speci-
fied tester. If a different tester is used the test results will
be out of specification.
You'll get a false reading if your finger touches the tester
probes.
If the pointer of the tester fails to swing to zero when the
adjusting knob is turned fully clockwise or counter-
clockwise, replace the tester dry battery.
15-8
BATTERY/CHARGING SYSTEM
Tester:
07411-0020000 (KOWA Digital type) Tester Range
KS-AHM-32-003 (KOWA Digital type; U.S.A. only) SANWA kO
07308-0020001 (SANWA Analogue type)
TH-5H (KOWA Analogue type) KOWA RX100
UNIT INSPECTION
Unit: k{l
Provided the circuit on the wire harness side are normal and
there are no loose connections at the connector, inspect the I'" EB Probe Red/ Yellow Yellow Yellow
Green
White 1 2 3
regulator/rectifier unit by measuring the resistance between 8 Probe ' "
the termi.nals. Red/White 20-100 20-100 20-100 10-50
NOTE
Yellow 1 ---------
0.5-10 ~ 30-500 30-500 20-200
Use the specified multitesters. Using other equipment may Yellow 3 0.5-10 30-500 30-500 ~ 20-200
not allow you to obtain the correct results. Green 1-20 0.5-10 0.5-10 0.5-10
This is due to the characteristic of semiconductors, which
have different resistance values depending on the applied ---------
Manufacture Range
voltage.
SANWA kO
SPECIFIC MULTITESTER: KOWA RX100
- 07411-0020000 (KOWA Digital type)
- KS-AHM-32-003 (KOWA Digital type; U.S.A. only)
- 07308-0020001 (SANWA Analogue type)
- TH-5H (KOWA Analogue type)
15-9
BATTERY/CHARGING SYSTEM
NOTE
It is not necessary to remove the stator coil to make this
test.
15-10
IGNITION SYSTEM
(2) FRONT
IGNITION
COIL
(8) PULSE
GENERATORS
\ \
(6) MAIN
FUSE
~I---~~
(10) W:
(11) G:
(12) Y:
White
Green
Yellow
+--+....-BIIW--... 1
-= (5) BATTERY
(13) Bu: Blue
(14) BI: Black
I
(7) SPARK UNIT
(9)
FRONT
IGNITION
tt it ~8JAR
-=- -:::- - - IGNITION
COIL COIL
16-0
16. IGNITION SYSTEM
SERVICE INFORMATION 16-1 IGNITION COIL 16-3
TROUBLESHOOTING 16-2 PULSE GENERATOR 16-4
IGNITION SYSTEM INSPECTION 16-3 IGNITION TIMING 16-4
SERVICE INFORMATION
DL-- _
If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in on enclosed area.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.
GENERAL
• Ignition timing cannot be adjusted since the spark unit is non-adjustable. If ignition timing is incorrect, check the system
components and replace any faulty parts.
• For spark plug gap inspection and adjustment procedure, see page 3-6.
• For alternator removal and installation, see section 8.
• For pulse generator removal and installation, see section 7.
• When inspecting the ignition system, check the system components and lines step-by-step according to the troubleshoot-
ing on next page.
• Each pair of spark plugs (Front and Rear) has its own ignition circuit.
• To test the neutral switch, refer to section 18.
SPECIFICATIONS
Spark plug
Ignition system
ITEM STANDARDS
TOOLS
Tester
07411 -0020000 (KOWA Digital type)
KS-AHM-32-003 (KOWA Digital type; U.S.A. only)
07308-0020001 (SANWA Analogue type)
TH-5H (KOWA Analogue type)
16-1
IGNITION SYSTEM
TROUBLESHOOTI NG
B _
When performing a spark test, keep open flames or sparks away from the work area.
NORMAL
- Faulty
• Neutral switch (page 18-8)
• Short circuit in wire harness
ABNORMAL
1. Check the ignition secondary coil resistance 'f-r-_A_B_N_O_R_M_A_L_ _ .• Faulty ignition coil
1
(page 16-3). I • Faulty spark plug wire
NORMAL
16-2
IGNITION SYSTEM
NOTE
Check the system components and lines step-by-step ac-
cording to the troubleshooting chart on page 16-2.
<6P CONNECTOR>
Ignition primary coil Y and BI/W (Rear) Bu/Y and BI/W (Front) 2.2-2.6 fl
DC power supply circuit line BI (+) and G H, Bu/Y (+) and G H, Y (+) and G Battery voltage should come.
(-) with the ignition switch "ON" and engine stop
switch "RUN"
<4P CONNECTOR>
Pulse generator coil W/Y and Y (Front) W/Bu and Bu (Rear) 450-550 fl
Each terminal and body ground NO CONTINUITY
IGNITION COIL
INSPECTION
NOTE
• The rear ignition coil is behind the swingarm pivot nut.
Disconnect the spark plug caps from the plugs and measure
the secondary coil resistance with the spark plug caps in place.
16-3
IGNITION SYSTEM
PULSE GENERATOR
INSPECTION
NOTE
It is not necessary to remove the pulse generator to make
this inspection.
IGNITION TIMING
NOTE
The spark unit system is factory pre-set and cannot be ad-
justed. Ignition timing inspection procedures are given to in-
spect the function of the spark unit components.
Connect the timing light to the other spark plug wire if you
see that the ignition timing is incorrect, and you might be
able to see the timing is correct.
-'-----------
Warm up the engine to operating temperature.
(2) INDEX
MARK
If the engine must be running to do some work, make sure the
area is well-ventilated. Never run the engine in an. enclosed
area.
The exhaust contains poisonous carbon monoxide gas that may
cause loss of consciousness and lead to death.
Connect the timing light to the front spark plug wire. (1) "F" MARK
The timing is correct if the "F" mark aligns with the index
mark on the right crankcase cover at idle for each cylinder.
Raise the engine rpm and the "F" mark should begin to rotate
counterclockwise for each cylinder.
16-4
ELECTRIC STARTER
(7) CLUTCH
SWITCH
(1) STARTER
SWITCH
(3) CLUTCH
DIODE
(4) STARTER
RELAY SWITCH
(2) STARTER
MOTOR
=- (3)G~D'~~/~~EUTRALTCH
(10) MAIN FUSE L..--------G/R--- (5) ~LUTCH SWITCH I
30 A
G G
Y/R,-------J '*" +
(9)
R/W-+ TO REGULATOR/RECTIFIER
R~I------C1'"'-O~---O"'1:
(8) IGNITION SWITCH (7) SUB FUSE (6) STARTER SWITCH
15 A
17-0
17. ELECTRIC STARTER
SERVICE INFORMATION 17-1 STARTER RELAY SWITCH 17-6
TROUBLESHOOTING 17-1 CLUTCH DIODE 17-7
STARTER MOTOR 17-3
SERVICE INFORMATION
GENERAL
• The starter motor and pulse generator can be removed with the engine in the frame.
• To inspect the pulse generator, refer to Section 16.
• Refer to section 8 for starter clutch removal and installation.
SPECIFICATION
Unit: mm (in)
TROUBLESHOOTI NG
NOTE
The starter motor should turn when the transmission is in neutral and the clutch is disengaged.
Check for the following before troubleshooting the system.
- Blown main (30A) or sub (1 OAl fuse.
- Loose battery and starter motor cables.
- Discharged battery.
ABNORMAL
2. Check the neutral indicator function.
· Faulty neutral switch (page 18-1)
· Loose neutral switch connectors
NORMAL
· Faulty ignition switch (page 18-4)
BATTERY
·· Faulty starter relay switch (page 17-6)
Faulty clutch diode (page 17-7)
VOLTAGE COMES · Open or short circuit in wire harness
NORMAL
· Loose starter relay switch connector
17-1
ELECTRIC STARTER
Starter motor and engine turns, but engine does not start
Faulty ignition system
Engine problems
- Low compression
- Fouled spark plugs
17-2
ELECTRIC STARTER
STARTER MOTOR
REMOVAL
B _
With the ignition switch OFF, remove the negative cable at the
battery before servicing the starter motor.
DISASSEMBLY
NOTE
• Record the location and number of shims.
(2) CASE
INSPECTION
Check for continuity from the cable terminal to the motor case (1) CONTINUITY
and from the cable terminal to the brush wire (black).
17-3
ELECTRIC STARTER
Check the front cover oil seal for wear or fatigue. (1) OIL SEAL
17-4
ELECTRIC STARTER
ASSEMBLY
(2) CASE
(4) SHIMS
(7) a-RING
(4) SHIMS ~?~
(4) SHIMS
(1) FRONT COVER
17-5
ELECTRIC STARTER
Align index marks of the front cover, case and rear cover as (1) ALIGN
shown.
Install and tighten the starter motor case screws and apply oil
to the a-ring and install it on the front cover.
(2) a-RING
INSTALLATION
NOTE
• Install the ground cable with one mounting bolt as shown.
Connect the motor cable to the motor terminal and install the
rubber cap over the terminal.
Depress the starter switch button with the ignition switch ON.
The coil is normal if the starter relay switch clicks.
VOLTAGE INSPECTION
17-6
ELECTRIC STARTER
CONTINUITY INSPECTION
CLUTCH DIODE
REMOVAL
Connect the positive probe to the (+) terminal and the negative
probe to the (-) terminal of the diode.
NOTE
The test results shown above are for a positive ground ohm-
meter and the opposite results will be obtained when a neg-
ative ground ohmmeter is used.
17-7
18. LIGHTS/METERS/SWITCHES
SERVICE INFORMATION 18-1 TEMPERATURE SENSOR 18-7
TROUBLESHOOTING 18-2 TEMPERATURE GAUGE 18-8
SWITCHES LOCATION 18-2 FUEL PUMP RELAY 18-8
HEADLIGHT 18-3 FUEL PUMP 18-9
IGNITION SWITCH/METER 18-4 OIL PRESSURE SWITCH 18-9
HANDLEBAR SWITCHES 18-6 NEUTRAL SWITCH 18-9
THERMOSTATIC SWITCH 18-7 TURN SIGNAL RELAY 18-10
SERVICE INFORMATION
_
If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area.
The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death.
Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area with the engine stopped.
Do not smoke or allow flames or sparks in the work area or where gasoline is stored.
GENERAL
• Some wires have different colored bands around them near the connector. These are connected to other wires which cor-
respond to the band color.
• All plastic connectors have locking tabs that must be released before disconnecting, and must be aligned when
reconnecting.
• To isolate an electrical failure, check the continuity of the electrical path through the part. A continuity check can usually
be made without removing the part from the motorcycle. Simply disconnect the wires and connect a continuity tester or
volt-ohmmeter to the terminals or connections.
• A continuity tester is useful when checking to find out whether or not there is an electrical connection between the two
points. An ohmmeter is needed to measure the resistance of a circuit, such as when there is a specific coil resistance in-
volved, or when checking for high resistance caused by corroded connections.
SPECIFICATIONS
Headlight 12 V 60 W/55 W
Brake/taillight 12 V 32/3 cp (27/8 W) x 2
Turn signal lights Front 12 V 32/3 cp (23/8 W) x 2
Rear 12 V 32 cp (23 W)
License light 12 V 4 cp
Indicator lights Turn signal 12 V 3 W
Neutral 12 V 3 W
High beem 12 V 3 W
Meter light 12 V 3.4 W x 1. 1.7 W x 2
Main fuse 30 A
Sub-fuse
10 A x 6. 15A x 1 (brake/turn/horn)
(fan, ignition, headlight, oil/neutral, brake/turn/horn, parking)
Fuel pump flow capacity/min 600 cc (0.630 US qt, 0.528 Imp qt)
TORQUE VALUES
Radiator thermostatic switch 18 N·m (1.8 kg-m, 13 ft-Ibl - Apply sealant to the threads
Oil pressure switch 12 N·m (1.2 kg-m, 9 ft-Ibl - Apply sealant to the threads
Ignition switch mounting bolt 25 N·m (2.5 kg-m, 18 ft-Ibl
18-1
LIGHTS/METERS/SWITCHES
TOOL
Common
Torx bit 07703-0010100 -Equivalent commercially available in U.S.A.
TROUBLESHOOTI NG
No Lights Come On When Ignition Switch Is Turned ON: All Lights Come On. but Dimly, when Ignition Switch Is
Bulb at fault or burned out Turned ON:
Faulty switch • Battery voltage low
Wiring to that component has open circuit • Faulty bulb
Fuse blown
Wiring loose, broken. or at fault Headlight Beam Does Not Shift When HI-LO Switch Is Op-
Battery dead or disconnected erated:
Faulty dimmer switch
• Wiring loose, broken, or at fault
SWITCHES LOCATION
(1) METERS
, (2) IGNITION SWITCH
HEADLIGHT
REMOVAL/INSTALLATION
Disconnect the headlight connector and remove the rubber (1) HEADLIGHT CONNECTOR
protector.
~"~\.
Remove the headlight retainer clip and replace the headlight (1) RETAINE
bulb.
CAUTION
This motorcycle is equipped with a halogen headlight bulb.
Do not put finger prints on the headlight bulb, they may create
hot spots on the hulb.
If you touch the bulb with your bare hands, clean it with a cloth
moistened with alcohol to prevent its early failure.
Do not try to replace the bulb or clean the headlight with the
light ON.
After replacing the bulb, instal/the rubber boot tightly against
the unit.
\p
(2) RUBBER PROTECTOR
18-3
LIGHTS/METERS/SWITCHES
IGNITION SWITCH/METER
IGNITION SWITCH INSPECTION
METER
OFF HARNESS
P
COLOR R RIBI BulO Br/W Br Y/BI (1) SPEEDOMETER
(2) 6P BLACK::;J\
CABLE
CONNECTOR
REMOVAL
After'S8:
Remove the (torx) mounting bolts using the special tool and
the ignition switch.
TOOL:
Torx bit 07703-0010100
or equivalent commercially
available in U.S.A.
18-4
LIGHTS/METERS/SWITCHES
. ~' 0
_
~ []
• ~ 0
(6) TRIP-METER'
KNOB ~
0-0'
~~ ~
'\
Assemble the removed parts in the reverse order of disassem-
•
\ e.
(5) COVER (4) MOUNTING
SCREWS
bly.
INSTALLATION
'88 only:
Install the meters and ignition switch in the reverse order of re-
moval.
TOOL:
Torx bit 07703-0010100
or equivalent commercially
available in U.S.A.
18-5
LIGHTS/METERS/SWITCHES
Dimmer Switch
-----
Lo
HL2
~
~
Hi Lo
~
~
(1) RIGHT HANDLEBAR
SWITCH
I
~ ~ ~
(N) ~ ~ ~
Hi
Color code Bu/W Bu W
-------.
RIGHT
W
~
~
R
~
~
L TL2 PR PL
~
N
LEFT (). .()
Horn Button
-------.
Released
HOl H02
, .
~ ~
Depressed
Color code WIG Lg
Starter Switch
-----
Released
Pushed
IGl
~
~
ST
~
~
HL
~
~
HLl
~
~
-------.
RUN
IG,
~
~
IG2
~
OFF
Color code BI BI/W
18-6
LIGHTS/METERS/SWITCHES
THERMOSTATIC SWITCH
The cooling fan motor is actuated by the thermostatic switch
located in the bottom of the radiator.
If the fan motor does not start, disconnect the Black/Blue lead
from the thermostatic switch and ground it with a jumper wire
as shown.
Turn the ignition switch ON. The cooling fan motor should
start running. If it does not start, check for battery voltage
from the Black/Blue lead of the fan motor connector and
ground with ignition switch ON.
If there is no voltage, check for a blown fuse, loose terminals
or connectors, or an open circuit.
If there is voltage, inspect the thermostatic switch as follows:
Remove the switch.
Connect one lead of an ohmmeter to the connector of the
thermostatic switch and the other to the body.
NOTE
• Do not over tighten the switch.
TEMPERATURE SENSOR
Remove the seat and fuel tank.
Disconnect the Green/Blue wire from the temperature sensor.
Check for continuity between the sensor body and ground.
There should be continuity.
If there is no continuity, check the thermostat housing for
looseness and recheck. If there is still no continuity, remove.
The temperature sensor from the thermostat housing.
18-7
LIGHTS/METERS/SWITCHES
50°C 100°C
Temperature
(122°F) (212°F)
Resistance 130-180 {} 25-30 {}
-'--------------
Wear gloves and eye protection.
NOTE
(2) THERMOMETER
TEMPERATURE GAUGE
Disconnect the wire from the temperature sensor and short it
to ground.
CAUTION
Do not leave the temperature sensor wire grounded for longer
than a Jew seconds or the temperature gauge will be damaged.
-'------------
• Gasoline is extremely flammable and is explosive under certain
conditions. Work in a well ventilated area. Do not smoke or
allow flames or sparks in the your work area or where gasoline
is stored.
Inspect as follows:
Disconnect the connector and test the wires on the main har-
ness side.
ITEM STANDARD
Between BI (+) and body ground (-) Battery voltage
with the ignition switch "ON" should come.
Y/Bu wire between the pump
CONTINUITY
relay and spark unit
BI/Bu wire between the pump
CONTINUITY
relay' and fuel pump
18-8
LIGHTS/METERS/SWITCHES
FUEL PUMP
SYSTEM INSPECTION
Turn the ignition switch OFF. Remove the seat and disconnect
the fuel pump relay wire connectors. Short the black and
black/blue wire teminals with a jumper wire.
Disconnect the fuel tube from the T-joint near the carburetor
and hold a graduated beaker under the fuel tube.
-'-------------
Gasoline is extremely flammable and is explosive under certain
conditions. Work in a well ventilated area with the engine
stopped. Do not smoke or allow flames or sparks in the work
area or where gasoline is stored.
Turn the ignition switch ON and let fuel flow into the beaker
for 5 seconds, then turn the ignition switch OFF.
Multiply the amount in the beaker by 12 to determine the fuel
pump flow capacity per minute.
NEUTRAL SWITCH
INSPECTION
18-9
LIGHTS/METERS/SWITCHES
18-10
19. WIRING DIAGRAM
~
~,~,.,~ "~~~
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GENfAATOR
IlE"'UTOIlIfl£C1FU
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CD=L--"I
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-=-
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-................
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r---------------------S~'Qol C(JI(TMITY ·, ..""'"
• ....
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~ " ~
,n
10f0IC ..... .' .....
0030Z - MN8 - 6700
20. TROUBLESHOOTING
ENGINE DOES NOT START 20-1 POOR ENGINE PERFORMANCE AT
LOW AND IDLE SPEEDS 20-5
ENGINE IS HARD TO START OR
SOON STOPS 20-2 POOR ENGINE PERFORMANCE AT
HIGH SPEEDS 20-6
ENGINE LACKS POWER WITH
NORMAL LOADING 20-3
1. Drain float chamber and check flow NOT REACHING CARBURETOR---....-· Clogged fuel line or fuel filter/
to carburetor. strainer
I Clogged fuel tank breather hole
REACHING CARBURETOR Loose or disconnected fuel pump
and relay wire
Faulty fuel pump relay
Faulty fuel pump
Sticking float valve
Faulty float
Clogged carburetor body
2. Check spark plug WET PLUG - - - - - - - - - - _ " ' . Mixture too rich
I Carburetor flooded
NO PROBLEM Choke valve stuck open
I
Cylinder flooded
Dirty air cleaner
~
4. Pour 1-2 cc (0.03-0.06 US OZ, ENGINE STA R T S . _ - - - - - - - -....• Faulty choke system
0.04-0.07 Imp OZ) fuel into Fuel contaminated
cylinders through the spark plug Carburetor incorrectly adjusted
hole, reinstall spark plugs and try Intake pipe leaking
to start engine without choke Clogged carburetor passage or jets
applied, with full-throttle.
I
ENGINE DOES NOT START
•
5. Test cylinder compression using
compression gauge
LOW COMPRESSION----------l..~· Valve stuck open
Damaged cylinder head gasket
I Improper valve timing ~
COMPRESSION NORMAL Improper valve and seat contact ~
Worn cylinder and piston rings
Damaged piston
20-1
TROUBLESHOOTING
1. Drain and check fuel flow to carbure- NOT REACHING CARBURETOR------t...• Clogged fuel line or fuel filter/
tor strainer
• Clogged fuel tank breather hole
I
REACHING CARBURETOR • Loose or disconnected fuel pump
and relay wire
Faulty fuel pump relay
Faulty fuel pump
Faulty float
Clogged carburetor body
20-2
TROUBLESHOOTING
POSSIBLE CAUSE
1. Check exhaust smoke at half-throttle B L U E - - - - - - - - - - - - - - <...• Engine oil leaking; refer to sections
I
NO PROBLEM
(OIL IN FUEL) 9, 10
3. chLk spark plug condition WET PLUG - - - - - - - - - - - . . . . . Loose connection between spark
I plug caps and wire
NORMAL Dirty air cleaner element
Improper float level
Rich mixture
4. Check the specified fuel flow UNDER THE SPECIFIED------••• Dirty fuel filter
capacity Clogged fuel lines
I Faulty fuel pump
NO PLOBLEM
20-3
TROUBLESHOOTING
[Continued)
I . .. .. . ..
6 . Ch ec k Ignition timing uSing timing
light
ABNORMAL - - - - - - - - - - _ . .•
POSSIBLE CAUSE
20-4
TROUBLESHOOTING
POSSIBLE CAUSE
1. Check engine condition with choke BETTER CONDITION--------.· Intake pipe leaking
applied • Improper carburetor adjustment
I
DO NOT IMPROVE
Clogged carburetor slow jet
Improper float level
2. chick engine condition without air 'BETTER CONDITION--------<.~· Dirty air cleaner element
cleaner element Improper carburetor adjustment
I
DO NOT IMPROVE
Clogged carburetor air passages
Improper float level
3. chIck spark plugs on both cylinders WEAK OR NO S P A R K - - - - - -••• Refer to page 16-2
I
NO PROBLEM
~
5 . T est cy I'Inder compression
.. uSing LOW COMPRESSION-------....~·· Improper valve and seat contact
compression gauge Valve stuck open
I • Improper valve timing
COMPRESSION NORMAL • Damaged cylinder head gasket
!
• Worn cylinder and piston rings
k'" .. . ..
6 . Ch ec Ignition timing uSing timing ABNORMAL - - - - - - - - - - - . . Improper ignition timing
light with "F" mark. (Faulty spark unit, pulse rotor, or
I generator)
NORMAL
~
Worn cam chain
.
8. Clean the carburetors: air passages BETTER -------------<.~. Clogged air passages
and jets Clogged jets
I
DOES NOT IMPROVE
....-------------------------------<.~.
1 Seized cylinder and piston
Seized connecting rod bearing
Damaged main bearing
20-5
TROUBLESHOOTING
POSSIBLE CAUSE
DISCOLOURED----------
.. • Improper heat range
(Light gray, White) Lean mixture
Improper float level
Intake pipe leaking
2. Check exhaust smoke at half-throttle BLUE - - - - - - - - - - - - -......~. Engine oil leaking; refer to sections
I
NO PROBLEM
9, 10
4.
!.
Check
.
engine performance without
air cleaner element
BETTER CONDITION-------...,...... •
Improper float level
t cy
6 . Test l 'Inder compression
.. uSing LOW COMPRESSION --------1...~. Improper valve and seat contact
compression gauge Valve stuck open
I Damaged cylinder head gasket
COMPRESSION NORMAL Worn cylinder and piston rings
! k' .. .. . ..
7 . Ch ec Ignition timing uSing timing
light with full-advanced
ABNORMAL----------_
.. • Improper ignition timing
(Faulty pulse rotor or generator with
I ferrous burrs)
NORMAL
20-6
TROUBLESHOOTING
[Continued]
I
8. Test ride check valve train
I
VALVE SURGING----------·
POSSIBLE CAUSE
9. Ch!Ck for clutch slippage CLUTCH S L l P S - - - - - - - - - -... • Improper clutch lever free play
II
NO PROBLEM
• Faulty clutch lifter system
Worn or warped clutch disc/plate
Weak clutch spring
10. Clean the carburetors: air passages BETTER-------------l_~· Clogged air passages
and jets • Clogged jets
I
DOES NOT IMPROVE
1
.... ----<..~. Seized cylinder and piston
Seized connecting rod bearing
Damaged main bearing
20-7
Technische Daten Honda NT650 HAWK GT
Abmessungen
Länge über alles 2.085 mm
Breite über alles 750 mm
Höhe über alles 1.075 mm
Radstand 1.430 mm
Sitzhöhe 778 mm
Fußrastenhöhe 355 mm
Bodenfreiheit 155 mm
Trockengewicht 168 kg
Leergewicht, fahrfertig 184 kg
Rahmen
Typ Aluminium-Kastenprofilrahmen (Twin tube diamond)
Vorderradaufhängung Teleskopgabel
Federweg 130 mm
Hinterradaufhängung Schwingarm
Federweg 120 mm
Fahrzeuggesamtgewicht 291 kg
Maximale Zuladung 156 kg
Reifengröße vorne 110/80 - 17 57H, schlauchlos
Reifengröße hinten 150/70 - 17 69H, schlauchlos
Reifenluftdruck, (Reifen kalt) bis 90 kg Zuladung:
vorne: 225 kPa / 2,25 bar
hinten: 225 kPa / 2,25 bar
bis zur maximale Zuladung:
vorne: 225 kPa / 2,25 bar
hinten: 250 kPa / 2,50 bar
Vorderradbremse Hydraulische Einscheibenbremse
Bremsscheibenfläche 262 x 2 cm²
Hinterradbremse Hydraulische Einscheibenbremse
Bremsscheibenfläche 200 x 2 cm²
Kapazität des Kraftstofftanks 12,0 Liter
Reservemenge des Kraftstofftanks 2,0 Liter
Nachlaufwinkel 27 °
Nachlauf 111 mm
Füllmenge Gabelöl bis Baujahr 1988: 497 ccm
ab Baujahr 1988: 502 ccm
Füllstand Gabelöl: bis Baujahr 1988: 133 mm
ab Baujahr 1988: 128 mm
Motor
Typ wassergekühlter Zweizylinder, Viertaktmotor, SOHC
Zylinderanordnung 2 Zylinder, 52 ° V
Bohrung und Hub 79,0 x 66,0 mm
Hubraum 647 ccm
Verdichtungsverhältnis 9,4 : 1
Ventiltrieb leiser Mehrglieder-Kettenantrieb mit obenliegender
Nockenwelle und Kipphebeln
Schmiersystem Druckumlaufschmierung mit Ölsumpf
1/4
Technische Daten Honda NT650 HAWK GT
Luftfilter Papierfilter
Verdichtungsdruck 1,324 kPa ± 196 kPa (13,5 bar ± 2 bar)
Einlaßventil öffnet sich bei einem Hub von 1 mm: 10 ° vor OT
schließt sich bei einem Hub von 1 mm: 40 ° vor UT
Auslaßventil öffnet sich bei einem Hub von 1 mm:: 40 vor UT
schließt sich bei einem Hub von 1 mm:10 ° nach OT
Ventilspiel, Motor kalt Einlaß: 0,15 ± 0,02 mm
Auslaß: 0,20 ± 0,02 mm
Motorgewicht (trocken) 80 kg
Leerlaufdrehzahl 1.200 ± 100 U/min
Vergaser Vergasertyp: Gleichdruckvergaser
Bezeichnung VDGKA [VDGLA]
Schwimmerstand 9,2 mm
Antriebsstrang
Kupplung Mehrscheiben-Ölbadkupplung mit Seilzug
Getriebe 5-Gang-Getriebe
Primäruntersetzung 1,888 (36/68)
Getriebübersetzung 1. Gang 2,769 (13/36)
Getriebübersetzung 2. Gang 1,882 (17/32)
Getriebübersetzung 3. Gang 1,450 (20/29)
Getriebübersetzung 4. Gang 1,174 (23/27)
Getriebübersetzung 5. Gang 0,965 (29/28)
Schaltschema Fußschaltung links, mit Rückführsystem
1-N-2-3-4-5
Eektrik
Zündung Digitale Transistorzündung
Zündzeitpunktmarkierung » F « 10 ° vor OT im Leerlauf
Frühzündung, voll 31 ° vor OT bei 7.000 U/min ± 200 U/min
Anlaßsystem Elektrischer Anlasser
Wechselstromlichtmaschine 240 W / 5.000 U/min
Batteriekapazität 12 V / 8 Ah, MF Batterie
Zündkerzen Standard:
NGK: DPR8EA-9 Nippon Denso: X24EPR-U9
für kaltes Wetter (unter 5°C)
NGK: DPR7EA-9 Nippon Denso: X22EPR-U9
für längere Hochgeschwindigkeitsfahrten:
NGK: DPR9EA-9 Nippon Denso: X27EPR-U9
Elektrodenabstand 0,80 - 0,90 mm
Zündfolge vorderer Zylinder (232 °) - hinterer Zylinder (488 °)
Sicherungen / Hauptsicherung 6 x 10 A , 1 x 15 A / 30 A
Beleuchtung
Scheinwerfer (Fernlicht/Abblendlicht) 12 V - 60/55 W
Rücklicht / Bremslicht 12 V - 21/5 W
Blinker vorne / hinten 12 V - 21 W
Instrumentenbeleuchtung 12 V - 1 x 3,4 W, 2 x 1,7 W
Öldruckwarnleuchte 12 V - 3,0 W
Fernlichtanzeige 12 V - 3,0 W
Blinkeranzeige 2 x 12 V - 3,0 W
Leerlaufanzeige 12 V - 3,0 W
2/4
Drehmomentanzugswerte Honda NT650 HAWK GT
Gegenstand Anzahl Gewinde-Ø Drehmoment
mm Nm (kg/m)
Motor
Zündkerze 4 12 14 (1,4)
Zylinderkopfdeckel-Schraube 4 6 10 (1,0)
Nockenwellenhalterungs-Schraube 6 8 23 (2,3)
Nockenwellenhalterungs-Mutter 2 8 23 (2,3)
Nockenwellenhalterungs-Schraube / 6mm 4 6 10 (1,0)
Mutter Zylinderkopf 8 10 48 (4,8)
Schraube Zylinderkopf 4 8 23 (2,3)
Mutter Zylinderkopf / 8 mm 4 8 23 (2,3)
Schraube Zylinderkopf / 6 mm 2 6 10 (1,0)
Schraube Nockenwellenantriebsrad 4 7 23 (2,3)
Sicherungsmutter der Kupplungsnabe 1 18 130 (13,0)
Schraube des Kurbelgehäusedeckels, rechts 15 6 10 (1,0)
Schraube des Kurbelgehäusedeckels, links 9 6 10 (1,0)
Ölfilter 1 20 10 (1,0)
Ölablaßschraube 1 14 35 (3,5)
Leerlaufschalter 1 10 12 (1,2)
Öldruckschalter 1 -- 12 (1,2)
Schraube des Primärantriebszahnrads 1 12 90 (9,0)
Schwungscheibenschraube 1 12 130 (13,0)
Schrauben des Anlaßerfreilaufs 6 8 30 (3,0)
Ölkontrollschraube 1 10 23 (2,3)
Befestigungsschraube der Ölleitung 2 7 10 (1,0)
Mutter des Pleuellagerdeckels 4 8 34 (3,4)
Kurbelgehäuseschraube 14 8 27 (2,7)
Kurbelgehäuseschraube 6 6 12 (1,2)
Schraube der Schaltwalzen-Anschlagplatte 1 6 26 (2,6)
Zündzeitpunkt-Prüflochkappe 1 14 10 (1,0)
Kurbelwellenabdeckappe 1 30 15 (1,5)
Schraube des Ölpumpen-Antriebsrads 1 6 15 (1,5)
Sicherungsmutter Einstellschraube Ventile 6 7 23 (2,3)
Zylinderstehbolze / 8 mm 2 8 20 - 30 (2,0 - 3,0)
Zylinderstehbolzen / 10 mm 8 10 30 - 50 (3,0 - 5,0)
Halteschraube der vorderen Motoraufhängung 4 8 28 (2,8)
Befestigungsschraube der Motoraufhängung 1 10 40 (4,0)
Schraube der Motoraufhängung, hinten, oben 1 10 40 (4,0)
Sicherungsmutter der Motoraufhängung 1 22 55 (5,5)
Einstellschraube der Motoraufhängung 1 22 11 (1,1)
Schraube des Schalthebels 1 6 12 (1,2)
Thermostatschalter 1 16 18 (1,8)
Befestigungsschraube Zündunterbrechungsschalter Seitenständer 2 6 25 (2,5)
Auspuff / Benzintank
Mutter der Krümmerrohrbefestigung am Zylinderkopf 4 8 27 (2,7)
Schraube der Auspuff-Klemmschelle 2 8 27 (2,7)
Schalldämpfer Halteschraube zu Fußrsten 1 8 27 (2,7)
Schraube Benzintankbefestigung /vorn: 1 6 12 (1,2)
Schraube Benzintankbefestigung / hinten: 1 8 22 (2,2)
Benzinfilter Befestigungs-Schraube 1 6 22 (2,2)
3/4
Drehmomentanzugswerte Honda NT650 HAWK GT
4/4