Honda CRF110F, Service Manual

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Page 3: ... to the troubleshooting in each section according to the malfunction or symptom Your safety and the safety of others is very important To help you make informed decisions we have provided safety messages and other information throughout this manual Of course It is not practical or possible to wam you about all the hazards associated with servicing this vehicle You must use your own good judgement ...

Page 4: ...Use molybdenum disulfide grease containing more than 3 molybdenum disulfide NLGI 2 or equivalent Example Molykote BR 2 plus manufactured by Dow Corning U S A Multl purpose M 2 manufactured by Mitsublshi Oil Japan Use molybdenum disulfide paste containing more than 40 molybdenum disulfide NlGI 2 or equivalent Example MoIykote G n Paste m nufactured by Dow Coming U SA Honda Moly 60 U S A only Rocol ...

Page 5: ... l l FUEL SYSTEM F LUBRICATION SYSTEM F CYLINDER HEADNALVES F CYLINDER PISTON F CLUTCH GEARSHIFT LINKAGE F iii ALTERNATOR STARTER CLUTCH z CRANKSHAFT TRANSMISSION KICKSTARTER ZF W ENGINE REMOVAUINSTALLATION FRONT WHEEUBRAKE SUSPENSION STEERING REAR WHEEUBRAKE SUSPENSION BATTERY CHARGING SYSTEM F WIRING DIAGRAM INDEX ...

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Page 7: ...SERVICE RULES 1 2 MODEL IDENTIFICATION 1 2 SPECIFICATIONS 1 4 TORQUE VALUES 1 9 1 GENERAL INFORMATION LUBRICATION SEAL POINTS 1 12 CABLE HARNESS ROUTING 1 14 EMISSION CONTROL SYSTEMS 1 18 1 1 ...

Page 8: ...r nuts begin with the larger diameter or inner bolt first Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified 6 Clean parts in cleaning solvent upon disassembly Lubricate any sliding surfaces before reassembly 7 After reassembly check all parts for proper installation and operation 8 Route all electrical wires as shown in the Cable and Har...

Page 9: ...L INFORMATION The carl luretor identification number 1 is stamped on Ihe right side of the carburetor body as shown LABELS The name plale 1 Canada safety certification label is attached on the rc sleering head The Emission Conlrollnformalion Label 1 is attached as shown 11J 1 Canada only 1 3 ...

Page 10: ...GENERAL INFORMATION SPECIFICATIONS GENERAL SPECIFICATIONS 1 4 i I ...

Page 11: ...C al idle ELECTRIC STARTER SYSTEM SPECIFICATIONS FUEL SYSTEM SPECIFICATIONS ITEM Carburetor identification number Carburetor type Main jet Slow jet Air screw opening Float level Engine idle speed Throttle grip freeplay LUBRICATION SYSTEM SPECIFICATIONS iI SPECIFICATIONS PB5PF Piston valve 68 38 See page 6 15 10 7 mm 0 42 in 1 400 100 rpm 3 6mm O 12 0 24 in Canada or equivalent motor oil API servic...

Page 12: ...GENERAL INFORMATION CYLINDER HEADNALVES SPECIFICATIONS ann valve guide CYLINDER PISTON SPECIFICATIONS piston rings piston pin i I CLUTCH GEARSHIFT LINKAGE SPECIFICATIONS clutch 1 6 Ii j i I ...

Page 13: ... STANDARD Starter driven gear boss 0 0 45 660 45 673 1 7976 1 7981 CRANKSHAFTITRANSMISSIONIKICKSTARTER SPECIFICATIONS dcum 14 966 14 984 0 5892 0 5899 FRONT WHEEUBRAKEISUSPENSIONISTEERING SPECIFICATIONS Unit mm in SERVICE LIMIT 45 642 1 7969 14 95 0 589 Unit mm I 1 7 ...

Page 14: ...GENERAL INFORMATION REAR WHEEUBRAKE SUSPENSION SPECIFICATIONS BATTERY CHARGING SYSTEM SPECIFICATIONS I 1 8 ...

Page 15: ...E TORQUE VALUES Torque specifications listed below are for specified fasteners Others should be lightened to standard torque values listed above FRAME BODY PANELS EXHAUST SYSTEM ITEM Q TY MAINTENANCE ITEM Q TY GENERAL INFORMATION FASTENER TYPE N m REMARKS REMARKS 1 9 ...

Page 16: ...N m kgf m lbHI Oil pump cover screw 3 5 5 0 5 3 7 CYLINDER HEADNALVES ITEM C TV CIA REMARKS CYLINDER PISTON ITEM C TV THREAD TORQUE REMARKS DIA mm N m kgf m IbHt Cam chain guide roller pin bolt 1 8 10 1 0 7 Cylinder stud bolt 4 7 6 0 6 4 4 See pa e 9 7 CLUTCH GEARSHIFT LINKAGE ITEM C TY THREAD TORQUE REMARKS DIA mm N m kgf m lbHt Clutch lifter late bolt 4 6 12 1 2 9 Clutch center lock nut 1 14 54 ...

Page 17: ...m N m kgf m lbHt Cam chain guide sprocket spindle 1 6 10 1 0 7 ENGINE REMOVAUINSTALLATION ITEM C TY REMARKS FRONT WHEEUBRAKElSUSPENSION STEERING ITEM Q TY DIA mm N m f Ibf ft REMARKS b QlneS 4 6 4 Fmnl spoke BC2 9 Fmn m pinch bolt U nul 1 0 l Ul f J PPIY I 001t U u lO PP Y locking olhe D bolt T Fo bottorr bridge pinch bolt 2 8 24 g plncl bolt 2 8 16 4 28 ostem Br ke I bolt 3 0 3 2 2 6 REAR WHEEUBR...

Page 18: ...GENERAL INFORMATION LUBRICATION SEAL POINTS ENGINE i i i 1 2 engine oil and 1 2 molybdenum disulfide grease i I 1 12 Ii ...

Page 19: ...II FRAME grease with ext c me pressure agent example Kyodo Yushi EXCEUTE EP2 EP20r Grip Cement U S A GENERAL INFORMATION H 1 13 ...

Page 20: ...GENERAL INFORMATION CABLE HARNESS ROUTING STARTER SWITCH WIRE ENGINE STOP SWITCH WIRE THROTTLE CABLE FRONT BRAKE CABLE IGNITION SWITCH WIRE FRONT BRAKE CABLE 1 14 ...

Page 21: ...NNECTORS MAIN WIRE HARNESS CHOKE CABLE leM 4P CONNECTOR GENERAL INFORMATION FUEL TANK BREATHE R HOSE STARTER SWITCH WIRE THROTTLE CABLE I J IGNITION SWITCH WIRE STARTER SWITCH WIRE THROTTLE CABLE CABLE IGNITION SWITCH WIRE MAIN WIRE HARNESS GROUND CABLE REGULATOR RECTIFIER 4P Black CONNECTOR 1 15 ...

Page 22: ...ENGINE STOP SWITCH WIRE CARBURETOR AIR VENT HOSE CARBURETOR DRAIN HOSE FUEL HOSE 1 16 White tape ENGINE STOP SWITCH WIRE CARBURETOR AIR VENT HOSE MAIN WIRE HARNESS FUEL HOSE CRANKCASE BREATHER HOSE CRANKCASE BREATHER HOSE ...

Page 23: ...PULSE GENERATOR WIRE CONNECTOR NEUTRAL SWITCH WIRE CONNECTOR CRANKCASE BREATHER HOSE STARTER MOTOR CABLE ALTERNATOR WiRE CARBURETOR DRAIN HOSE STARTER MOTOR CABLE BATTERY NEGATIVE H CABLE NEUTRAL SWITCH WIRE FUSE 10A STARTER MOTOR GROUND CABLE STARTER RELAY WIRE BATTERY POSITIVE CABLE 1 17 ...

Page 24: ... in the same way but it is toxic Honda Motor Co Ltd utilizes appropriate carburetor settings as well as other systems to reduce carbon monoxide and hydrocarbons EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control sistem is composed of appropriate carburetor settings no adjustment should be made except for high altitude setting and idle speed adjustment with the throttle stop screw The exh...

Page 25: ...TS 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 2 Removal of or puncturing of any part of the intake system 3 Lack of proper maintenance 4 Replacing any moving parts of the vehicle or parts of the exhaust or intake system with parts other than those specified by the manu...

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Page 27: ...ATION 2 2 TROUBLESHOOTING 2 2 FUEL TANK SHROUD 2 3 LEFT SIDE COVER 2 4 SEAT 2 4 NUMBER PLATE 2 5 FRONT FENDER 2 5 REAR FENDER 2 5 REFLECTOR CANAOA ONLY 2 6 MAIN STEP 2 6 LEFT CRANKCASE REAR COVER 2 7 ORIVE CHAIN COVER 2 7 EXHAUST PIPE MUFFLER 2 8 2 1 ...

Page 28: ...haust pipe from the engine When installing Ihe exhaust system loosely install all of the exhaust pipe fasteners first Always lighten the exhaust clamps first then tighten Ihe mounting fasteners If you tighten the mounting fasteners first Ihe exhaust pipe may not seal proper1y Always inspect Ihe exhaust system for leaks after installation TORQUE VALUES ITEM TROUBLESHOOTING Excessive exhaust noise B...

Page 29: ...ft 161 LEFT SIDE Remove the left side cover page 2 4 Remove the two special bolls 1 and trim clip 2 Remove the left fuel tank shroud 3 by releasing the 2 groove 4 from the hook of the fuel tank Installation Is in the reverse order of removal TORQUE Fuel tank shroud special bolt 10 N m 1 0 kgf m 7lbHt DISASSEMBLY ASSEMBLY 131 111 Remove the screw Ill Remove the fuel tank shroud C 2 from the fuel la...

Page 30: ...gf m 7lbHt DISASSEMBLY ASSEMBLY Remove the screw 1 Remove the battery cover 2 from the left side cover 3 by releasing the tab 4 Assembly is in the reverse order of disassembly REMOVAUINSTALLATION Remove the following left side cover page 2 4 Fuel tank shrouds page 2 3 Remove the seat 1 1 by pulling it backward Align the seat hook 12 with the seat bracket on the fuel tank and seat prong 3J with the...

Page 31: ...NT FENDER REMOVAUINSTALLATION Remove the following Three bolls 1 Front fender 2 Three collars 131 Installation Is in the reverse order of removal Align the bosses 4 of the front fender with holes of the number plate REAR FENDER REMOVAUINSTALLATION Remove the leM page 4 8 Remove the three special bolts 1 Pull the rear fender 2 backward and remove it from the frame pipe Installation is in the revers...

Page 32: ...11 nuts 2 and rear reflector slay 3 Nuts 4 and rear side reflectors 5 Nut 6 and rear reflector 7 Installation is in the reverse order of removal TORQUE Rear side reflector mounting nut 2 5 N m 0 26 kgf m 1 8IbHt Rear reflector mounting nut 1 8 N m 0 18 kgf m 1 3IbHt Rear reflector stay special bolt 10 N m 1 0 kgf m 7 IbUt MAIN STEP 2 6 REMOVAUINSTALLATION Support the motorcycle securely with a hoi...

Page 33: ... set plate 3 Installation is in the reverse order of removal DRIVE CHAIN COVER REMOVAUINSTALLATION Remove the following Three special bolts 1 Two bolts 2 1collars 3 Drive chain cover 4 Drive chain guard 5 Installation is in the reverse order of removal TORQUE Drive chain cover special bolt 10 N m 1 0 kgf m 7 tbHt 131 121 12V13 11 14 2 7 ...

Page 34: ...kgf m 24 IbHt EXHAUST PIPE STUD BOLT Thread two nuts to the stud bolt 1 and tighten them together then use a wrench on them to tum the stud bailout Install and lighten new stud bolls into the cylinder head to the specified torque TORQUE 11 N m 1 1 kgf m 8 IbH t After tightening the stud botts check thai the incomplete threads 2J is buried into the cylinder head DISASSEMBLY ASSEMBLY Replace the gas...

Page 35: ...NCE 3 9 ENGINE OIL 3 10 ENGINE OIL STRAINER SCREEN 3 11 ENGINE OIL CENTRIFUGAL FILTER 3 11 ENGINE IDLE SPEED 3 12 3 MAINTENANCE DRIVE CHAIN 3 12 DRIVE CHAIN SLIDER 3 15 BRAKE SHOE WEAR 3 15 BRAKE SYSTEM 3 15 CLUTCH SYSTEM 3 17 SIDESTAND 3 17 SUSPENSION 3 17 SPARK ARRESTER 3 18 NUTS BOLTS FASTENERS 3 19 WHEELSITIRES 3 19 STEERING HEAD BEARINGS 3 19 3 1 ...

Page 36: ...evacuation system in an enclosed area SPECIFICATIONS TORQUE VALUES ITEM a TV Aireleaner Air I I guarc 2 I Valve lock nul 2 cap Timing ole cap 1 lter cover bolt 1 3 Clul rlock nul 1 i ivol bolt 1 i Sparl I bolt Fronl spoke 3 2 oiA 5 5 5 f 12 5 9 equivalent motor oil API service classification SG or higher JASO T 903 standard MA SAE 10W 30 N m hr Ibft REMARKS 1 5 1 5 9 O g 0 0 Apply oil 10 e 8 0 10 ...

Page 37: ...TOOLS Valve adjuster B 07908 KE90000 or 07908 KE90200 U S A only Spoke wrench 4 5 x 5 1 mm 07701 0020200 MAINTENANCE 3 3 ...

Page 38: ...00 lBOO 2400 TO km 150 1000 2000 3000 4000 PAGE IITEMS Months IF 3 5 I 3 6 NCTE C C C 3 7 I I lL R R R R R 3 10 O L C I I I I CHA NOTEl I L I Lo 33 5011 km 0 3 12 I IDRIVE I I 3 15 I I I i I I I I 1 17 3 17 I o l U m lb Uh SO 3 18 1 I I I I I I SHOULD BE SERVICED BY A DEALER UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE DATA AND IS MECHANICALLY QUALIFIED IN THE INTEREST OF SAFETY WE RECOMMEND THES...

Page 39: ... hose and turn the fuel valve lever ON to drain the fuel tank After the tank has drained completely remove the two bolts 3 and collars 4 Remove the fuel valve 1 and fuel strainer screen 21 Remove the O ring 3 from the fuel valve Wash the fuel strainer screen in non flammable or high flash point solvent Install a new O ring to the fuel valve Install the removed parts in the reverse order of removal...

Page 40: ...d al Ihe throttle r 1 3 1 housing adjuster 1 Remove the dust cover 2 from the adjuster Adjust the freeplay by loosening the lock nut 3 and tuming the adjuster Recheck the throttle operation Replace any damaged parts if necessary THROTTLE LIMITER ACTIVATION This motorcycle can reduce the throttle grip movement Remove the M5 x 10 screw 1 from the throttle housing Replace the M5 x 10 screw with the M...

Page 41: ... the inside of Ihe air cleaner housing Installation is in the reverse order of removal When installing the air cleaner element apply grease to the element all around TORQUE Air cleaner housing cover screw 1 5 N m 0 15 kgf m 1 1IbHt CRANKCASE BREATHER NOTE Service more frequently when ridden in rain at full throttle or after the motorcycle is washed Service if the deposit level can be seen in the d...

Page 42: ... 10 light brown indicates good condition Excessive lightness indicates malfunctioning ignition system or lean mixture Wet or black sooty deposit indicates over rich mixture RECOMMENDED SPARK PLUG CPR6EA 9S NGK 121 111 131 Clean the span plug electrodes with a wire brush or 3 8 special plug cleaner Check the gap between the center and side electrodes with a wire type feeler gauge If necessary adjus...

Page 43: ... 02 mm 0 004 0 001 in ADJUSTMENT Adjust by loosening the lock nut 111 and turning the adjusting screw 2 until there is a slight drag on the feeler gauge TOOLS 3J 3 Valve adjuster B 07908 KE90000 or 07908 KE90200 U S A only Apply engine oil to the lock nul Hold the adjusting screw and tighten the lock nut to the specified torque TORQUE 9 N m 0 9 kgf m 6 6Ibf ft After tightening the valve adjuster l...

Page 44: ... service classification SG or higher JASO T 903 standard MA Viscosity SAE 10W 30 Check that the a ring is in good condition replace if necessary Reinstall the oil filler capJdipstick ENGINE OIL CHANGE Warm up the engine Stop the engine and remove the oil filler capfdipstick drain bolt 1 and sealing washer 2 Drain the oil completely After the oil has drained completely install the drain bolt with a...

Page 45: ...dge facing up as shown Install the right crankcase cover page 10 8 ENGINE OIL CENTRIFUGAL FILTER CLEANING Remove the right crankcase cover page 10 5 Remove the bolls 1 oil centrifugal filler cover 2 and gaskeI13 Clean the oil centrifugal filter cover and inside of the drive plate using a clean lint free cloth Install a new gasket 1 with its sealed side facing the oil centrifugal filter cover MAINT...

Page 46: ...urate idle speed inspection and adjustment Connect a tachometer Warm up the engine for about 10 minutes Tum the throttle stop screw 1 as required to obtain the specified idle speed IDLE SPEED 1 400 100 rpm DRIVE CHAIN 3 12 Amputation hazard Never inspect or adjust the drive chain while the DRIVE CHAIN SLACK INSPECTION Turn the ignition switch OFF place the motorcycle on its sidestand and shift the...

Page 47: ...in lubricant CLEANING INSPECTION AND LUBRICATION If the drive chain becomes extremely diny it should be removed and cleaned prior to lubrication Remove the left crankcase rear cover page 2 7 Carefully remove the retaining clip 1 with pliers Remove the link plate 2 master link 3 and drive chain Clean the chain with non flammable or high flash point solvent and wipe it dry Be sure the chain has drie...

Page 48: ... II o 0 0 0 0 0 0 0 0 0 SPROCKETS INSPECTION Inspect the drive and driven sprocket teeth for wear or damage replace jf necessary Never use a new drive chain on worn sprockets Bolh chain and sprockets must be in good condition or the new replacement chain will wear rapidly Check the attaching bolts and nuts on the drive and driven sprockets If any are loose torque them Install the drive chain onto ...

Page 49: ...KE SHOES Check Ihe brake shoes and brake drum if the arrow mark 1 on the indicator plate aligns with the triangle mark 2 on the brake panel when the brake leverlbrake pedal is applied Refer to for brake shoe replacement Front brake page 14 14 Rear brake page 15 10 BRAKE SYSTEM FRONT BRAKE MAINTENANCE Front side shown 21 11 Measure the front brake lever freeplay at the tip of the r lever FREEPLAY 1...

Page 50: ...ade with the lower adjuster on the brake panel Loosen the Jock nul 1 and tum the adjusting nut 21 I J untillhe freepJay is within specification I After adjustment tighten the lock nut REAR BRAKE Check the brake pedal freeplay FREEPLAY 15 mm 0 59 In 15 mm 0 59 in Make sure the Adjust the brake pedal freeplay by turning the adjusting cutout on the nut 1 adjusting nut is seated on the brake arm pin a...

Page 51: ...on Check the sidestand assembly 2 for freedom of movement and lubricate the sidestand pivot if necessary Check that the sidestand pivot boll is tightened to the correct torque value Tighten the pivot bolt to the speCified torque TORQUE 10 N m 1 0 kgf m 7lbHt Loosen the pivot bolt 1 8 to 114 turns then tighten the 2 sidestand pivot lock nut to the specified torque L _ _ _________ ____ _ TORQUE 39 N...

Page 52: ...ged components which cannot be repaired Tighten all nuts and bolts Refer to page 15 15 for shock absorber service SPARK ARRESTER INSPECTION CLEANING 3 18 Remove the following Right fuel tank shroud page 2 3 Muffler cover page 2 8 Remove the three bolts 11 spark arrester 2 and 2 gasket 31 from the muffler Check the screen mesh 1 replace if necessary Use a soft brush to remove carbon deposits from t...

Page 53: ...ngs are worn For rear wheel service page 15 6 MAINTENANCE Maintenance of spoke tension and wheel trueness are iiiiiiiDrir ii critical to safe motorcycle operation During the first 150 km 100 miles spokes will loosen more rapidly due to initial seating of parts Excessively loose spokes may result in high speed instability and possible loss of control Inspect the wheel rims and spokes for damage Tig...

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Page 55: ...TEM DIAGRAM 4 2 SERVICE INFORMATION 4 3 TROUBLESHOOTING 4 4 IGNITION SYSTEM INSPECTION 4 5 4 IGNITION SYSTEM IGNITION TIMING 4 7 IGNITION COIL 4 8 ICM IGNITION CONTROL MODULEj 4 8 IGNITION SWITCH 4 9 ENGINE STOP SWITCH 4 10 4 1 ...

Page 56: ... SYSTEM DIAGRAM IGNITION ENGINESTOP FUSE 10 A SWITCH SWITCH RlBI r Bum l BIIY 81 R G RlBI Bu Y BI G BATTERY REGULATOR RECTIFIER IGNITION PULSE GENERATOR IGNITION CONTROL MODULE I eM 4 2 BATTERY G 1 REGULATOR RECTIFIER IGNITION CONTROL MODULE leM G BI Black Y Yellow Bu Blue G Green R Red W White IGNITION COil SPARK PLUG ...

Page 57: ...is often related to poor connections Check those connections before proceeding Make sure the battery is adequately charged Using the starter motor with a weak battery results in a slower engine cranking speed as well as 00 spark at the spark plug SPECIFICATIONS ITEM Spark plug Standard SparkPiUa gap Ignition coil peak voltage Ignition pulse generator ak voltage Ignition timing F mark TORQUE VALUE ...

Page 58: ...d voltage at least once connected connectors or an open circuit in the coil control module eM in case when above I 2 or engine slop switch 3 connected eM connectors 4 No voltage a Black wire of the 1eM S Open circuit or poor connection in the Green wire of the eM voltage adaptor pulse generator Measure the peak voltage above No 1 7 are 2 Cranking speed is slow Battery is undercharged or the operat...

Page 59: ... 2 or use the peak voltage lester TOOL IgniiionMate peak voltage tester Peak voltage adaptor MTP07 0286 U S A only or 07HGJ 002010Q Not available In U S A with commercially available digital multimeter impedance 10 MQ OCV minimum IGNITION COIL PRIMARY PEAK VOLTAGE NOTE Check all system connections before this inspection Poor connected connectors can cause incorrect readings Check the cylinder comp...

Page 60: ... chart page 4 4 IGNITION PULSE GENERATOR PEAK VOLTAGE NOTE Check the cylinder compression and check Ihallhe spark plug is installed correctly in the cylinder head Remove the seat page 2 4 Disconnect the leM 4P connector 1 Connect Ihe peak voltage laster or adaptor probes to the ignition pulse generator wire terminal of the leM 4P connector and body ground TOOL IgniiionMate peak voltage MTP07 0286 ...

Page 61: ..._checks described in the troubleshooting chart page 4 4 Refer to procedure for alternator stator replacement page 11 5 IGNITION TIMING Warm up the engine Stop the engine and remove the timing hole cap from the left crankcase cover Read the Connect a liming light 1 10 Ihe spark plug wire instructions for timing light operation Start Ihe engine and let it idle IDLE SPEED 1 400 100 rpm The ignilion t...

Page 62: ...primary l wire connector 2 and ground wire connector 3J from i the ignition coil 4 Remove the bolts 5 wire clamp and ignition coil Installation is in the reverse order of removal ICM IGNITION CONTROL MODULE REMOVAUINSTALLATION Remove the seal page 2 4 Disconnect the leM 4P connector lJ Remove the leM 2 from Ihe rear fender Instanation is In the reverse order of removal Inslalllhs leM with the UP m...

Page 63: ...y with the ignition switch OFF REMOVAlIlNSTALLATION Release Ihe wire band 1 and disconnect the ignition switch wire connectors 2 Remove the wire band boss 13 and release the ignition switch wire from the wire guide 4 Remove the ignition switch 1 from the top bridge by pushing the two stoppers 2 Install the removed parts in the reverse order of removal Inslalithe ignition switch by aligning the tab...

Page 64: ...nnect the engine stop switch wire connectors 1 Check for continuity between the engine stop switch side connector terminals CONNECTION Blue white Black There should be continuity with the engine stop switch is f and no continuity with the engine stop switch ...

Page 65: ...COMPONENT LOCATlON 5 2 SYSTEM DIAGRAM 5 2 SERVICE INFORMATION 5 3 TROUBLESHOOTlNG 54 5 ELECTRIC STARTER STARTER MOTOR 5 6 STARTER RELAY 5 9 STARTER SWITCH 5 10 NEUTRAL SWITCH 5 11 5 1 ...

Page 66: ...ERY SWITCH STARTER RELAY SYSTEM DIAGRAM FUSE 10 A R Q rO RlBI Vr RlBI BI 5 2 R BATTERY BI RIW STARTER MOTOR STARTER RELAY REGULATORI RECTIFIER L9 R f03 I NEUTRAL SWITCH Y RflSI STARTER SWITCH ENGINE STOP SWITCH 1 BWW BI Black Y Yellow Bu Blue R Red W While Lg light green IGNITION SWITCH ...

Page 67: ...he engine in the frame Always tum the ignition switch to OFF before servicing the starter motor The motor could suddenly start causing serious injury Refer to procedure for starter clutch servicing page 11 5 Refer to information for ignition switch page 4 9 Refer to inspection for engine stop switch page 4 10 SPECIFICATION ITEM Starter motor brush length TORQUE VALUE ITEM Q TY Starter motor cable ...

Page 68: ...erminal and for an open circuit Is the terminal loose or poorly connected YES Loose or poorly connected starter motor cable Open circuit in the starter motor cable NO GO TO STEP 5 5 Starter Relay Operation Inspection Check the operation of the starter relay page 5 9 Does the starter relay click YES GO TO STEP 6 NO GO TO STEP 7 6 Starter Motor Inspection Connect the starter motor terminal to the ba...

Page 69: ...en circuit in Bluefwhite between the engine stop switch and ignition switch 9 Starter Relay Inspection Check the function of the starter relay page 5 10 Does the starier relay function properly YES loose or poor contact of the starter relay connector NO Faulty starter relay Starter motor turns engine slowly Low baltery voltage Poorly connected battery cable Poorly connected starter motor cable Fau...

Page 70: ...nect the starter motor 2P connector and pull out the starter motor wire from the battery case Remove the starter motor mounting bolts 1 J Remove the starter motor 2 from the engine Remove the O ring 1 J Installation is in the reverse order of removal Coat a new D ring 1 with engine oil DISASSEMBLY Pull off the dust cover 1 Remove the screw 2 and starter motor cable terminal 131 Remove the screw 4 ...

Page 71: ... 5 removal Gasket 6 16 Do not use emery or sand paper on the commutator INSPECTION BRUSH Inspect the bruslles for damage and measure the brush length SERVICE LIMIT 3 5 mm 0 14 in ARMATURE Inspect the commutator bars 1 of the armature for discoloration 11 Bars discolored in pairs indicate shorted coils Check for continuity between each pair of commutator C O N T N U TY bars There should be continui...

Page 72: ...n the brush holders 12J NO CONTINUITY 21 Install the armature 1 into the bracket while holding the brushes 2 Install a new gasket 1J onto the bracket 2 The armalUfB S Install the bracket and armature 13 to the motor case magnetically 4 while holding the bracket side armature shaft tlghUy attracted to the motorCSS8 be car fui during instaHstion 5 8 11 ...

Page 73: ...opriate position STARTER RELAY REMOVAL INSTALLATION Remove the left side cover page 2 4 Release the starer relay lJ from the battery case and Disconnect the starter relay 5P connector 2 OPERATION INSPECTION Remove the left side cover page 2 4 Shift the transmission into neutra Turn the ignition switch to ON and engine stop switch to 0 push the starter switch The coil is normal if the starter relay...

Page 74: ...ter switch Is pushed the circuit is normal STARTER RELAY CONTINUITY INSPECTION Remove the starter relay page 5 9 Connect a fully charged 12 V battery positive wire to the relay switch terminal A and negative wire to the terminal B Check for continuity al the terminal C and terminal O There should be continuity between the C and 0 terminals while the battery is connected and no continuity when the ...

Page 75: ...ssion is into gear Connect the neutral switch wire connector REMOVAUINSTALLATION Remove the neutral switch wire connector 1 Remove the bolt 2 and neutral switch 3 Remove O ring 11J from the neutral switch Remove Ihe contact switch cap 2 and spring 3 from the shift drum Install the contact switch cap 1 and spring 2 into the shift drum hole Install the removed parts in the reverse order of removal A...

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Page 77: ...COMPONENT LOCATION 6 2 SERVICE INFORMATION 6 3 TROUBLESHOOTlNG 6 4 AIR CLEANER HOUSING 6 5 6 FUEL SYSTEM FUEL TANK 6 5 INTAKE PIPE 6 6 CARBURETOR 6 6 AIR SCREW ADJUSTMENT 6 15 6 1 ...

Page 78: ...FUEL SYSTEM COMPONENT LOCATION 21 N m 2 1 kgf m 16 IbHI 12 N m 1 2 kgf m 9lbHt 6 2 ...

Page 79: ...fter removing the carburetor wrap the intake port of the engine with a shop lowel or cover it with pieces of tape to prevent any foreign matenal from dropping into the engine If the vehide is to be stored for more than one month drain the float chamber fuel left in the float chamber may cause dogged jets resulting in hard starting or poor driveability_ SPECIFICATIONS TORQUE VALUES ITEM Fuel tank m...

Page 80: ...pression Rich mixture lean mixture Clogged carburetor Backfiring or misfiring during acceleration Ignition system fautty Fuel mixture too lean Afterburn when engine braking Is used Lean mixture in slow circuit Poor performance driveabiUty andlor poor fuel econom y Fuel system clogged Ignition system faulty Air cleaner clogged 40 mm throttle limiter screw installed in the throttle housing replace w...

Page 81: ...rse order of removal Tighten the connecting hose band screw until the band seat on the collar FUEL TANK REMOVAL INSTALLATION Remove the following Seat page 2 4 Fuel tank shrouds page 2 3 Turn the fuel valve 1 OFF Disconnect the fuel hose 2 from the fuel valve Disconnecllhe fuel tank breather hose 3 from the hole on the top bridge Remove the following Bolls 4 Collars 5 Rubber cushions 6 Fuel tank 7...

Page 82: ... bolt 12 N m 1 2 kgf m 9 IbUt CARBURETOR REMOVAL 6 6 Remove the right fuel tank shroud page 2 3 Turn the fuel valve OFF Place an approved gasoline container under the drain hose 1 and toosen the drain screw to drain the fuel Tighten the drain screw to the specified torque TORQUE 1 5 N m 0 15 kgf m 1 1 IbHt Release the drain hose from the hose guide 21 Disconnect the fuel hose 31 from the carbureto...

Page 83: ...nect the air vent hose 1 Remove the two bolts 2 Remove the carburetor 13 from the air cleaner connecting hose 4 Remove the O ring 1 from the carburetor body DISASSEMBLY THROTILE VALVE Remove the throttle cable 1 from the throttle valve 21 while compressing the throttle valve spring 3 FUEL SYSTEM 6 7 ...

Page 84: ...ainer 1 and jet needle 2 Check the throttle valve 11 and jet needle 2 for scratches wear or damage FLOAT AND JETS Disconnect the drain hose 1J Remove the two screws 2 and float chamber 31 Remove the O ring from the float chamber 21 1 21 31 11 ...

Page 85: ...ination Replace the valve if the lip is worn or contaminated Remove the following Throllie slop screw 1 Spring 21 Main jet 3 Needle jet holder 4J Needle jet 51 Slow jet 6 Remove the tamper proof plug 1 Turn the air screw 2J in and record the number of turns it takes before il seals lightly Damage to the air screw seal will occur jf the air screw is lightened against the seat TOOLS Pilot screw wren...

Page 86: ...se parts if necessary 0 0 ASSEMBLY CARBURETOR TOP FLOAT VALVE lIl O RING WASHER SPRING AIR SCREW SPRING PLUG SLOW JET PIN l NEEDLE JET THROTILE STOP SCREW l _ NEEDLE JET HOLDER JET NEEDLE CLIP O RING JET NEEDLE O R G DRAIN DRAIN SC EW FLOAT AND JETS 2 5 N m O 2S kgfm 1 8IbHI FLOAT CHAMBER FLOAT CHAMBER SCREW 2 1 N m O 21 kgf m 1 Slbfoft 1 5 N m 0 15 kgf m 1 11bHt Blow open each air and fuel passag...

Page 87: ... slop screw tt l spring 2 Slow jet 3 Needle jet 4 Needle jet holder 5J Main jet 6J TORQUE Slow main jet Needle jet holder 1 5 N m 0 15 kgf m 1 1IbHt 2 5 N m O 25 kgf m 1 8IbHt InslaUthe float valve 1 into the groove of the float 21 Insla1lthe fioallo the carburetor body while aligning the float valve tip with the valve seal hole FUEL SYSTEM I 5 3 S 2 Install the float pin 1 lhrough the carburetor ...

Page 88: ...e float assembly if the float level is oul of specification Install a new O ring 11 into the float chamber groove Inslall the float chamber 2 onlo the carburetor body Inslall the two float chamber screws 11 and lighten 11111 IIIIIIIIIIIIIII IIIIIIIIII I1111 them to the specified torque TORQUE 2 1 N m 0 21 kgf m 1 5IbHt Connect the drain hose I21 THROTTLE VALVE Instan the jet needle 1 into the thro...

Page 89: ...e spring NSTALLAT ON Install the new D ring into the carburetor body groove Install the carburetor body 1 to the air cleaner connecting hose 2 Install and tighten the bolts 3 Connect the air vent hose 4 Tighten the band screw 1 until the band ends seat on the collar Install the choke cable 2 to the choke lever 31 and cable guide 41 FUEL SYSTEM 6 13 ...

Page 90: ...ighten the carburetor top 1 securely Inslallthe drain hose 1 into Ihe hose guide 2 Connect the fuel hose 3 10 the carburetor After installing the carburetor check the following Tighten the drain screw page 6 6 Choke operation Throttle grip freeplay page 3 6 Engine idle speed page 3 12 Install the right fuel lank shroud page 2 3 ...

Page 91: ...crew wrench 0 type 07KMA MS60102 or 07KMA MN9A100 U S A only 2 Warm up the engine 10 operating temperature Stop and go riding for 10 minutes is sufficient 3 Stop the engine and connect according to the tachometer instructions a tachometer manufacturer s 4 Start the engine and adjust the idle speed to the specified rpm with the throttle stop screw 3 IDLE SPEED 1400 100 rpm 5 Turn the air screw in o...

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Page 93: ...SYSTEM DIAGRAM 7 2 SERVICE INFORMATION 7 3 7 LUBRICATION SYSTEM TROUBLESHOOTING 7 3 OIL PUMP 7 4 7 1 LUBRICATION SYSTEM DIAGRAM 7 2 SERVICE INFORMATION 7 3 7 LUBRICATION SYSTEM TROUBLESHOOTING 7 3 OIL PUMP 7 4 7 1 ...

Page 94: ...LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM CAMSHAFT CRANKSHAFT MAINSHAFT COUNTERSHAFT OIL STRAINER SCREEN 7 2 Oil PUMP OIL CENTRIFUGAL FILTER ...

Page 95: ...oil pump use care not to allow dust or dirt to enter the engine If any portion of the oil pump is wom beyond the specified service limits replace the oil pump as an assembly After the oil pump has been installed check thai there are no oil leaks SPECIFICATIONS pump TORQUE VALUE ITEM Oil pump cover screw TROUBLESHOOTING Engine oil level too low 011 consumption External oil leak Worn piston rings pa...

Page 96: ...nd tighten the three bolls Clean the oil strainer screen page 3 11 Instalilhe right crankcase cover page 10 8 After installation fill the crankcase with recommended engine oil page 3 10 and check that there are no oil leaks OISASSEMBLY ASSEMBLY Remove the following from the oil pump body 1 Three screws 2 Oil pump cover 31 Oil pump shaft 41 Inner rotor 51 Outer rotor 161 Assembly is in the reverse ...

Page 97: ...ll the oll pump shaft Measure the lip clearance between the inner and outer rotors SERVICE LIMIT 0 15 mm 0 006 In LUBRICATION SYSTEM TIP CLEARANCE Measure the pump body clearance between the outer rotor and the oil pump body BODY CLEARANCE SERVICE LIMIT 0 26 mm 0 010 in Measure the side clearance using a straight edge and a feeler gauge SERVICE LIMIT 0 15 mm 0 006 in Assemble the oil pump page 7 4...

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Page 99: ... CYLINDER HEADNALVES COMPONENT LOCATION 8 2 SERVICE INFORMATION 8 3 TROUBLESHOOTING 8 S CYLINDER COMPRESSION TEST 8 6 CYLINDER HEAD COVER 8 6 CAMSHAFT 8 8 CYLINDER HEAD 8 11 CAM CHAIN TENSIONER 8 23 8 1 ...

Page 100: ...CYLINDER HEADNALVES COMPONENT LOCATION 10 N m 1 0 kgf m 7Ibf ft 27 N m 2 B kgf m 20 IbHtj 13 N m 1 3 kgfm 10 IbHt 0 ____ 22 N m 2 2 kgf m 161bHt 16 N m 1 6 kgf m 121bHI 8 2 ...

Page 101: ...tore the disassembled parts to ensure thai they are reinstalled in their original locations Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection Camshaft lubricating oil is fed through oil passages in the cylinder head Clean the oil passages before assembling cylinder head Be careful not to damage the mating surfaces when removin...

Page 102: ...N 07780 0010200 or equivalent commercially available in U S A Valve guide adjusting driver 07743 0020000 Not available in U S A Interior cutter 26 mm 60 IN 07780 0014500 or equivalent commercially available in U S A Valve spring compressor attachment 07959 KM30101 Seat CUtler 24 mm 450 EX 07760 0010600 or equivalent commercially available in U S A Flat cutter 27 mm 320 IN 07780 0013300 or equivale...

Page 103: ...uck open Cylinder head Uneven valve sealing leaking or damaged cylinder head gasket Warped or cracked cylinder head Worn cylinder piston or piston rings page 9 5 Compression too high overheating or knocking Excessive carbon buiid up on piston head or combustion chamber Excessive smoke Cylinder head Worn valve stem or valve guide Damaged stem seal Worn cylinder piston or piston rings page 9 5 Exces...

Page 104: ... compression is high it indicates that carbon deposits have accumulated on the combustion chamber and or the piston head If compression is low pour 3 5 cm3 0 1 0 2 oz of engine oil into the cylinder through the spark plug hole and recheck the compression If the compression increases from the previous value check the cylinder piston and piston rings for the following leaking cylinder head gasket Wo...

Page 105: ...groove on the cylinder head cover 2 Install the dowel pin 31 Apply liquid sealant Three bond 1215 or equivalent to the semicircular area 111 of rubber seat as shown Set the cylinder head cover 111 onto the cylinder head Install the mounting rubbers 2 with their UP mart 3J facing up Install the special bolts 4 and lighten them to the specified torque TORQUE 10 N m 1 0 kgf m 7lbHt CYLINDER HEADNALVE...

Page 106: ...r 2 Hold the cam sprocket 1 by using the special tool TOOL 2 Universal holder 07725 0030000 Remove the washer boll 3J cam sprocket from the camshaft and cam chain off the cam sprocket Attach a piece of wire to the cam chain to prevent it from falling into the crankcase Remove the bolt l vasher 1 from the cylinder head Remove the camshaft 111 from the cylinder head while holding the rocker arms 2 t...

Page 107: ... Check the cam lobes 1 for excessive wear and damage Measure the height of each cam lobe SERVICE LIMIT IN 32 16 mm 1 266 In EX 31 96 mm 1 258 in DECOMPRESSOR CAM Check the decompressor system that it operates smoothly and that the spring returns the decompressor weight in posilion tf the decompressor weight is faulty replace the camshaft as an assembly INSTALLATION Apply engine oil to the camshaft...

Page 108: ...the r mark 2 on the flywheel is aligned with the index notch 3 on the left crankcase cover Apply engine oil to the cam chain PI and cam sprocket 2J teeth Install the cam chain on the cam sprocket by aligning its lab with the groove of the camshaft making sure that the index lines 3 on the cam sprocket are flush with the top surface of the cylinder head as shown TDC on the compression stroke Instal...

Page 109: ... cap O ring then install them to the caps Install the crankshaft hole cap and timing hole cap to the left crankcase cover TORQUE Crankshaft hole cap Timing hole cap 8 N m 0 8 kgf m 5 9 IbHt 10 N m 1 0 kgf m 7Ibf ft Install the cylinder head cover page 8 7 CYLINDER HEAD REMOVAL Remove the following Cam sprocket page 8 8 Exhaust pipefmuffler page 2 8 Disconnect the spark plug cap 1 Remove the two bo...

Page 110: ...s shown Remove the gasket 1 Jand dowel pins 2 DISASSEMBLY Remove the spark plug page 3 8 ROCKER ARM SHAFT Remove the rocker ann shaft stopper bolls 1 Screw the 6 mm bolt 1 into the threaded hole in the rocker arm shaft 2J and pull it out of the cylinder head Remove the rocker arms 3J ...

Page 111: ...30101 CYLINDER HEADNALVES 1 J Mark all parts during disassembly so they can be pJaced back in their original locations Remove the valve spring compressor and remove the following Valve spring retainers 1 Valve springs 2 Inner valve spring EX side only 3 Valve stem seals 4 Valve spring seats 51 Valves 6J Avoid damaging the Remove the carbon deposits form the combustion ma ingsurfaceand chamber 1J a...

Page 112: ...rollers 1 with your finger The rollers should tum smoothly and quielly Measure the 1 0 of each rocker arm SERVICE LIMIT INfEX 10 10 mm 0 398 in Measure the 0 0 of each rocker arm shaft SERVICE LIMIT INfEX 9 91 mm 0 390 in Calculate Ihe rocker arm to shaft clearance SERVICE LIMIT IN EX 0 044 mm 0 0017 in VALVE SPRING Disassemble the cylinder head page 8 12 Measure the free length of the valve sprin...

Page 113: ... rotate the reamer clockwise TOOL 1J Valve guide reamer 5 0 mm 07984 MA60001or 07984 MA60000 U S A only Inspect and reface Measure each valve guide 1 0 and record it the valve seals whenever the valve guides are replaced page 8 21 SERVICE LIMIT IN EX 5 03 mm 0 198 in Subtract each valve stem O D from the corresponding guide I D to obtain the stem to guide dearance SERVICE LIMIT IN 0 065 mm 0 0026 ...

Page 114: ...R 8 16 CAMSHAFT INTAKE VALVE VALVE Blow through the oil passage In the cylinder head with compressed air Inslall the valve spring seats 1 Apply engine oil to the new valve stem seals 2 and install them Apply engine 01110 the valve stem 3 ouler surface and stem end Insert the valves into the valve guides while turning them slowly to avoid damage to the valve slem seals INTAKE ROCKER ARM ROCKER ARM ...

Page 115: ...ng compressor attachment 07757 010000 07959 KM30101 Support the cylinder Place a suitable tool 1 onto the valve stem 2 head above the wo bench surface Tap the 1 001 genlly to seat the cotters 3 firmly using a plastic hammer to prevent valve damage CAMSHAFT Apply engine oil to the camshaft 1 cam whole surface and bearings Apply molybdenum oil solution to the decompressor cam and arm sliding area In...

Page 116: ...t surface 1 Apply engine oil to the rocker arm shaft 2 whole surface Inslall the rocker arms 1J to the cylinder head Insert the rocker arm shafts 2J into the cylinder head using a screwdriver 3 while aligning the bolt holes of the shafts and cylinder head 121 7 Install and tighten the rocker arm shaft stopper bolts 1 11 Install the spark plug page 3 6 ...

Page 117: ... the cylinder head nuts 1 Install the four washers 2 and tighten the cylinder head nuts to the specified torque in a crisscross pattern TORQUE 13 N m 1 3 kgf m 10 IbUt Install and lighten the cylinder head mounting bolts 3 Install a new gasket 1J onto the cylinder head Set the wire guide 2 to the intake pipe 3 and tighten the two bolts 4 to the specified torque TORQUE 12 N m 1 2 kgf m 9lbHt Connec...

Page 118: ...chamber side TOOL 2 Valve guide driver 5 0 mm 07942 MA60000 Take out new valve guides from the freezer Drive new clips 1 1and valve guides 2 into the cylinder head to the specified height from the cylinder head TOOL 3J Valve guide adjusting driver 07743 0020000 Not available in U S A VALVE GUIDE PROJECTION INfEX 9 1 9 3 mm 0 36 0 37 In Let the cylinder head 0001 to room temperature Ream new valve ...

Page 119: ...russian Blue to the valve seats Tap the valve against the valve seat several times using a hand lapping 1001 without rotating the valve to make a clear pattern Remove the valve and inspect the valve seal face The valve seat contact should be within the specified width and even all around the circumference STANDARD 0 9 1 1 mm 0 035 0 043 In SERVICE LIMIT 1 6 mm 0 06 in If the valve seal width is no...

Page 120: ...bottom 1 4 of the existing valve seal material TOOLS Interior cutter 26 mm 50 IN 07780 0014500 Interior cutter 22 mm 60 EX 07780 0014202 Cutter holder 5 0 mm 07781 0010400 or equivalent commercially available In U S A Using a 45 seat cutter cut the seat to the proper width VALVE SEAT WIDTH O 9 1 1 mm 0 035 0 043 In Make sure thai all pitting and irregularities are removed NOTE Excessive lapping pr...

Page 121: ...er 2 Tensioner spring 3 Push rod 4 Remove the following Pivot bolUwasher 1 Tensioner arm 2J and collar 3 Tensloner roller 4 INSPECTION Measure the tensioner spring free length SERVICE LIMIT 109 mm 4 3 in Check the push rod for wear or damage Measure the push rod O D SERVICE LIMIT 11 94 mm 0 470 in CYLINDER HEADNALVES 8 23 ...

Page 122: ...ed torque TORQUE 16 N m 1 6 kgf m 12 IbHt Install the following Push rod 1J Tensioner spring 2 Install and lighten the sealing bolt 3J with a new sealing washer 4J to the specified torque TORQUE 22 N m 2 2 kgf m 16 IbHt Remove the cam chain lensioner sealing bolt 1 and washer 121 Pour 4 0 em minimum of engine oil into the push rod Install and tighten the sealing bolt with a new sealing washer Inst...

Page 123: ... flywheel page 11 5 Remove the bolt 1 and oil stopper plale 2 Apply locking agent Three Bond 1322 or equivalent to the bolt threads as specified Install the oil stopper plate and lighten the bolt Install the flywheel page 11 9 CYLINDER HEADNALVES 8 25 ...

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Page 125: ...COMPONENT LOCATION 9 2 SERVICE INFORMATION 9 3 9 CYLINDER PISTON TROUBLESHOOTING 9 3 CYLINDERJPISTON 9 4 9 1 ...

Page 126: ...CYLINDERIPISTON COMPONENT LOCATION 0 0 10 N m 1 0 kgf m 7Ibf ft 9 2 ...

Page 127: ...CATIONS piston rings piston pin I TORQUE VALUES ITEM Cam chain guide roller pin bolt Cylinder stud bolt TROUBLESHOOTING OTY THREAD CIA mm 1 8 4 7 Compression too low hard starting or poor performance at low speed Leaking cylinder head gasket Worn stuck or broken piston ring Worn or damaged cylinder and piston Bent connecting rod Compression too high overheating or knocking Excessive carbon built u...

Page 128: ... the crankcase Cam chain guide roller pin boll 11 and sealing washer 2 Guide roller 3 Be careful not 10 Remove the cylinder 1 damage the mating surface Remove the gasket 11 and dowel pins 2J PISTON REMOVAL Place 8 clean shop Remove the piston pin clip 1 with pliers towel over the Push the piston pin 2 out of the piston crsnkcsse to prevent the clip from falling into the cronkcaSIt 9 4 connecting r...

Page 129: ...nd wear Measure and record the cylinder 1 0 al three levels in both the X and Y axis Take the maximum reading to determine the cylinder wear SERVICE LIMIT 50 05 mm 1 970 in Calculate the cylinder to piston clearance For measurement of the piston 0 0 page 9 6 SERVICE LIMIT 0 10 mm 0 004 In Calculate the cylinder for taper and out of round at l three levels in an X and Y axis Take the maximum y read...

Page 130: ...f the piston ring is near1y flush with the piston and measure the clearance using a feeler gauge SERVICE LIMITS Top 0 08 mm 0 003 In Second 0 08 mm 0 003 in Insert the piston ring 1 into the bottom of the cylinder squarely using the piston crown Measure the ring end gap SERVICE LIMITS Top Second 011 0 5 mm 0 02 In 0 5 mm 0 02 In 1 1 mm 0 0410 Measure the piston 0 0 at a point 10 mm 0 4 in from the...

Page 131: ...CE LIMIT 13 05 mm 0 514 in Calculate the connecting rod to piston pin clearance SERVICE LIMIT 0 07 mm 0 003 In CYLINDER STUD BOLT REPLACEMENT CYLINDERJPISTON If replacing the cylinder stud bolts be sure to instatl them as shown Thread two nuts onto the stud bolt 11 and tighten them together then use a wrench on them to turn the stud bolt out Install and tighten new stud bolts to the specified torq...

Page 132: ... as shown side rails Stagger the side rails gaps as shown Be careful not to damage the gasket mating surfaces 9 8 After installation the piston rings should be free to rolate in the groove Place a clean shop towel over the crankcase to prevent the dirt dust or piston pin clips from entering the crankcase Clean the gasket mating surfaces of the crankcase and cylinder thoroughly Apply oil to the con...

Page 133: ...g area piston ring grooves and piston rings whole surface Route the cam chain 1 through the cylinder 2 86 careful not to Instatt the cylinder over the piston while compressing damage tM piston the piston rings with your fingers rings and cylinder bora Be careful not to Instatt the cam chain guide rotter 1 new sealing drop the guide rollar washer 2 and cam chain guide rotter pin bolt 3 into the cra...

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Page 135: ...10 CLUTCH GEARSHIFT LINKAGE COMPONENT LOCATION 10 2 SERVICE INFORMATION 10 3 TROUBLESHOOTlNG 10 4 RIGHT CRANKCASE COVER 10 5 CLUTCH 10 9 GEARSHIFT LlNKAGE 10 26 10 1 ...

Page 136: ...CLUTCH GEARSHIFT LINKAGE COMPONENT LOCATION 17 N m 1 7 n 131bHt 10 N m 1 0 kgf m 7Ibf ft 54 N m 5 5 kgf m 40 Ibf ft 54 N m 5 5 kgf m 40 IbHt 5 N m 0 5 kgf m 3 7 Ibf ft 10 2 ...

Page 137: ... disengaged inspect the engine oil and oil level before servicing the clutch system SPECIFICATIONS clutch TORQUE VALUES ITEM Clutch lifter plate boll Clutch center lock nut Centrifugal dutch lock nul Gearshift cam plate bolt Shift drum stopper arm bolt Gearshift pedal pinch bolt Shift return spring pin I Q TY 4 1 1 1 1 1 1 THREAD TORQUE REMARKS DIA mm N m kgf m IbUt 6 12 1 2 9 14 54 5 5 40 Apply o...

Page 138: ... graphite additive Motorcycle creeps with clutch disengaged Incorrect clutch adjustment Clutch plale warped Faulty clutch lifter Faulty clutch weight Hard to shift Damaged gearshift spindle Damaged stopper plale and pin loose stopper plate bolt Incorrect clutch adjustment Loose gearshift cam piate boll Transmission jumps out of gear Damaged stopper arm Damaged gearshift cam plale Loose gearshift c...

Page 139: ...pedal marl the pedal position to ensure the origins location Remove the bolts 1J in a crisscross pattern in several steps Be careful not to Remove the right crankcase cover 2 damage the mating surface Remove the following Clutch lever 1 Clutch lifter cam plate 2 Gasket 3 Dowel pins 4 DISASSEMBLY Remove the following Clutch adjuster lock nut 1 Washer 2 O ring 31 Clutch adjuster lifter boss 4 CLUTCH...

Page 140: ...pring 3 KICKSTARTER SPINDLE OIL SEAL 11 11 13 Check thai the kickstarter spindle oil seal 1 is in good condition replace it if necessary If replacing the oil seal install it until it is fully sealed OIL PASSAGES Blow open the oil passage of the right crankcase cover with compressed air Check the oil passage for any clogs ...

Page 141: ... the clutch adjusterllifter boss 1 into the right crankcase cover aligning its boss with Ihe hole in Ihe crankcase cover Apply oil to a new O ring 2 Inslall the D ring onto the clutch adjuster lifter boss Install the washer 11 and clutch adjuster lock nut 121 Adjusllhe clutch system page 3 17 after installing Ihe right crankcase cover CLUTCH GEARSHIFT LINKAGE 121 11 13 10 7 ...

Page 142: ... onto the gearshift spindle white aligning the punch mark of the lever with Index line of the gearshift spindle Apply engine oil to the gearshift spindle Journal area Install the right crankcase cover 11 and tighten the right r crankcase cover bolls 2 In a crisscross pattern in several sleps Install the kickstarter pedal 1 to its original position as marked during removal Install and tighten the b...

Page 143: ...e lock nut 2 groove Install the special tool using proper bolts or screws TOOL 1 Clutch center holder 07HMB HB70100 or 07923 HB3000B U S A only Remove the centrifugal clutch lock nut 2J using the special tools TOOLS 3 lock nut wrench 20 x 24 mm 07716 020100 4 Extension bar 07716 0020500 or equivalent commercially available In U S A Remove the washer 1J and lock washer 2 Remove the clutch weight as...

Page 144: ...utch center lock nul 2 using the special tools TOOLS 3 Universal holder 07725 0030000 4 lock nut wrench 20 x 24 mm 07716 0020100 5 Extension bar 07716 0020500 or equivalent commercially available in U S A Remove the washer 1 J Loosen the clutch lifter plale bolls 2 Remove the two all separator plate mounting bolls 1 ...

Page 145: ...AL CLUTCH DISASSEMBLY INSPECTION ONE WAY CLUTCH Temporarily install the centrifugal clutch outer to the crankshaft Hold the crankshaft and tum the centrifugal clutch outer by hand Make sure that the centrifugal clutch outer only turns counterclockwise as shown and does not turn clockwise Remove the centrifugal clutch outer from the crankshaft Remove the snap ring 1J and retainer 2 CLUTCH GEARSHIFT...

Page 146: ...for excessive wear or damage roil9rs as a set Measure the one way clutch roiler 0 0 SERVICE LIMIT 4 97 mm 0 196 In Replace the clutch Check the springs 2 for fatigue or damage springs as a set Check the one way clutch inner 1 for wear or damage CLUTCH OUTERISUB GEAR III 2 1 Remove the spring retainer 1 and spring 21 by r ll I 12 1 carefully prying up on the retainer Be careful not to lose the pin ...

Page 147: ...y dutch drum 1 0 SERVICE LIMIT 42 04 mm 1 655 in Check the inside of the centrifugal clutch drum for scratches or excessive wear Measure the centrifugal clutch drum I D SERVICE LIMIT 104 3 mm 4 11 In CLUTCH WEIGHT Check the clutch weight assembly for damage Measure the clutch weight lining thickness SERVICE LIMIT 1 0 mm 0 04 in Remove the E clips 111 CLUTCH GEARSHIFT LINKAGE 11 1 J 10 13 ...

Page 148: ...ring seal 3 131 111 Altemately lift the clutch weights 1J then remove the 11 1 clutch weights and springs 2 10 14 Remove the damper rubbers 1 Jfrom the drive plate 2 Check the drive plate bosses 1 for wear or damage Check each dutch weight 21 for wear or damage 111 1 21 111 ...

Page 149: ...AFT Measure the crankshaft 1 0 0 SERVICE LIMIT 18 92 mm 0 745 in CENTRIFUGAL CLUTCH ASSEMBLY CLUTCH GEARSHIFT LINKAGE I I f 1 I E CLIP SPRING SEAT CLUTCH WEIGHT SPRING SIDE PLATE SPRING RETAINER FRICTION SPRING SPRING PIN SNAP RING SUB GEAR CLUTCH ROLLER CLUTCH INNER CENTRIFUGAL CLUTCH OUTER 10 15 ...

Page 150: ... their open ends facing the drive plale side 10 16 Install the clutch weights and springs onto the drive plate as shown Install the spring seat 1 friction spring 2 and side plale 3 to the clutch weight assembly 4J as shown Inslall the new E dips 1 while compressing the side plate 2 Align the open end of the E clips and bosses 3J of the side plale 4 ...

Page 151: ...e spring 1 Jinto the hole on the olII iII spring retainer 2J Coil the spring into the spring retainer making sure that the spring is set between the retainer and tab 3 Install the spring retainer spring 1 to the clutch outer 1 1 while aligning the straight end of spring into the hole on Align the sub gear 2 and aligning the retainer groove with GROOVE and PIN the pin Check the sub gear 11 operatio...

Page 152: ...tall the snap ring 2 into the groove of the one way ring is seated in Ihe clutch Quter securely groove 10 18 Temporarily install the centrifugal clutch outer to the i iiii crankshaft I Hold the crankshaft and turn the centrifugal clutch outer by hand Make sure that the centrifugal clutch outer only turns counterclockwise as shown and does not tum clockwise Remove the centrifugal clutch outer from ...

Page 153: ...e slols 3 on the clutch lifter plale 4 then remove it CHANGE CLUTCH INSPECTION CLUTCH LIFTER BEARING 111 21 141 Temporarily install the clutch lifter bearing 1 to the r clutch lifter plate 2 Turn the inner race of the clutch lifter bearing with your finger The bearing should turn smoothly and quieUy Also check that the bearing outer race of the bearing fits tighlly in the clutch lifter plate Repla...

Page 154: ... CENTER 111 Check the grooves 1 of the clutch center 121 for damage or wear caused by the clutch plates Replace if necessary 111 121 CLUTCH DISC Replace the clutch discs if they show signs of scoring or discoloration Measure the thickness of each clutch disc SERVICE LIMIT 1 82 mm 0 072 in CLUTCH PLATE Replace the clutch Check each clutch plale for warpage on a surface plate discs and plales 8S usi...

Page 155: ...he clutch outer for damage or wear caused by the clutch discs Measure the primary driven gear 1 0 SERVICE LIMIT 23 07 mm 0 908 In Measure the clutch outer guide 1 0 and 0 0 SERVICE LIMITS 1 0 17 049 mm 0 6712 in 0 0 22 940 mm 0 9031 in MAINSHAFT Measure the mainshaft 1 0 0 al clutch outer guide SERVICE LIMIT 16 87 mm 0 664 in 10 21 ...

Page 156: ...he following sequence Clutch spring Clutch center Clutch disc A Clutch plate Clutch disc B 10 mark Blue paint on a lab Clutch plate Clutch disc A Pressure plale CLUTCH CENTER PRESSURE PLATE r _ CLUTCH DISC B 7J 10 MARK BLUE PAINT CLUTCH OUTER Set the spring seat 1 with its chamfered edge 12 r AJ 9 0 c facing the clutch lifter plale 31 as shown while aligning 1 3J its lab with the sial on the plate...

Page 157: ...lutch center assembly 3 into the clutch outer INSTALLATION Install the collar 1 onto the mainshaft Apply oil to the clutch outer guide 2 outer surface Install the clutch outer guide onto the mainshaft Install the collar 3 onto the crankshaft CLUTCH GEARSHIFT LINKAGE Align 131 111 Apply molybdenum disulfide oil to the primary drive 1111 gear inner surface 10 23 ...

Page 158: ... onto the mainshaft Tighten the clutch lifter plate bolts 2 10 the specified torque TORQUE 12 N m 1 2 kgf m 9lbHt Apply oil to the clutch center lock nut 1 threads and seating surface Install the clutch center lock nut Hold the clutch lifter plate and tighten the clutch center lock nut to the specified torque using the special tools TOOLS 2 Universal holder 07725 0030000 3 Lock nut wrench 20 x 24 ...

Page 159: ...utch outer while aligning the splines of the clutch weight assembly and crankshaft Install a new lock washer 1 onto the crankshaft aligning its inner tab with the groove of the dutch weight assembly Install the washer 1 with its OUT SIDE mark 2 faCing out CLUTCH GEARSHIFT LINKAGE 10 25 ...

Page 160: ...Ht If any of the centrifugal clutch lock nut 1 groove is not iO aligned with the lock washer tab 21 further tighten the centrifugal clutch lock nul and align the centrifugal clutch lock nut groove with the lock washer tab Bend the lock washer lab against the centrifugal clutch lock nut groove Install the following Engine oil centrifugal filter cover page 3 11 Right crankcase cover page 10 8 GEARSH...

Page 161: ...per armlbolt 1 Return spring 2 Remove the bolt 1 gearshift cam plale 2J and shift drum side plale 3 Remove the gearshift spindle 1 by holding down the gearshift arm 2 as shown Remove the side plate pins 1 and gearshift drum pins 2 from the gearshift drum 3 10 27 ...

Page 162: ... 4 for wear or damage 21 31 Inspect the gearshift spindle oil seal 1 for deterioration 7 u _iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii a or damage replace if necessary If replacing the oil seal install it until it is fully seated INSTALLATION Apply grease to the gearshift spindle oil seal 1 lips Install the five gearshift drum pins 1 and two side plate pins 2 to the holes on the gearshift drum 3 ...

Page 163: ...quivalent to the gearshift cam plate bolt 3J as specified then install and tighten it to the specified torque TORQUE 17 N m 1 7 kgf m 131bHt Apply locking agent Three Bond 1322 or equivalent to the shift drum stopper armlbolt 1J as specified Set the return spring end 2 along the crankcase wall as shown Install the stopper armlbolt then tighten it to the 1 1 specified torque TORQUE 10 N m 1 0 kgf m...

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Page 165: ...11 ALTERNATORISTARTER CLUTCH COMPONENT LOCATION 11 2 STATOR 11 5 SERVICE INFORMATION 11 3 FLYWHEEUSTARTER CLUTCH 11 5 LEFT CRANKCASE COVER 11 4 11 1 ...

Page 166: ... ALTERNATORISTARTER CLUTCH COMPONENT LOCATION 40N m 4 1 30Ibf ft 11 2 ...

Page 167: ...ignition pulse generator Inspection page 4 6 SPECIFICATION TORQUE VALUES ITEM Flywheel nut Starter clutch mounting lorx bolt TOOLS Flywheel holder 07725 0040001 Q TV THREAD OIA mm 1 10 6 6 Flywheel puller 30 mm 07KMC HE00100 ALTERNATORISTARTER CLUTCH TORQUE REMARKS N m kgf m IbHt 40 4 1 30 Apply oil to the threads and sealing surface 16 1 6 12 Apply locking agent 1 0 the threads See page 11 8 11 3...

Page 168: ...ove the bolls and hose guide 4 Remove the left crankcase cover 5 Remove the dowel pins 1 and gasket 2 INSTALLATION Clean any gasket material from the left crankcase cover and crankcase mating surface Install the dowel pins 1 and a new gasket 2 Apply engine oil to the reduction gear journal of the left crankcase cover InsleUthe left crankcase cover 1J Install the hose guide 2 and bolts 3 then tight...

Page 169: ...H Remove the stator mounting bolts 1 then remove the stator 21 from the left crankcase cover Installation is in the reverse order of removal Apply liquid sealant THREE BONO 1215 or 12078 or equivalent to the wire grommet sealing surface and inSlali lhe grommet into the cover groove FLYWHEELISTARTER CLUTCH REMOVAL Remove the left crankcase cover page 11 4 Remove the shaft 1 and starter reduction ge...

Page 170: ...move the woodruff key 2J removal be careful nor 0 damege the kay groove and crankshaft Do not lose the woodruff kay 11 6 STARTER CLUTCH DISASSEMBLY Remove the flywheeUstarter clutch page 11 5 Check the operation of the one way clutch by turning the driven gear 1J You should be able to tum the driven gear counterclockwise smoothly but the gear should not tum clockwise Remove the starter driven gear...

Page 171: ...ction gear 1 or wear or damage Check the starter driven gear 1 for wear or damage Measure the driven gear boss 0 0 SERVICE LIMIT 45 642 mm 1 7969 in Remove the starter sprag dutch 1 from the dutch ouler 2 Starter clutch Check the starter sprag clutch for abnormal wear or should be rep aced damage as an assembly if Check the sprag clutch sliding surface of the clutch any parts am outer for abnormal...

Page 172: ...er _ 2 2 Install the starter clutch assembly 1J onto the flywheel 2 _ Apply a locking agent Three Bond 1322 or equivalent c o at i g W th 6 _5 _ 0 m m to the starter clutch mounting tOD bot 1 threads as 0 26 0 04 in from tip specified Hold the flywheel using Ihe special 1001 and tighten the bolts to the specified torque TOOL 2J Flywheel holder 07725 0040001 TORQUE 16 No m 1 6 kgf m 12 IbHt 2 11 8 ...

Page 173: ...nterclockwise 1 Make sure that the starter driven gear turns counterclockwise smoothly and does not tum clockwise Inslallthe flywheel starter clutch page 11 9 INSTALLATION Install the woodruff key 1J in the crankshaft key groove Apply engine oil to the needle bearing 2 and install it to the crankshaft Wipe any oil off the mating surface of the crankshaft and flywheel Install the flywheel starter c...

Page 174: ...specified torque TOOL 3 Flywheel holder 07725 040001 TORQUE 40 N m 4 1 kgf m 30 IbHt Apply engine oil 10 the starter reduction gear 1 joumal area and gear teeth Install the starter reduction gear with aligning the starter drive gear 2Jand starter driven gear 3 Apply engine oil to the starter reduction gear shaft 1 whole surface Install the shaft into the reduction gear Install the left crankcase c...

Page 175: ...ION KICKSTARTER COMPONENT LOCATION 12 2 SERVICE INFORMATION 12 3 TROUBLESHOOTING 12 5 CRANKCASE SEPARATION 12 6 CRANKSHAFT 12 7 TRANSMISSION 12 9 CAM CHAIN GUIDE SPROCKET 12 16 CRANKCASE ASSEMBLY 12 17 KICKSTARTER 12 19 12 1 ...

Page 176: ...CRANKSHAFTITRANSMISSION KICKSTARTER COMPONENT LOCATION I 10 N m 1 0 kgf m 7 IbHt 12 2 ...

Page 177: ...Cylinder head page 8 11 Cylinder piston page 9 4 Oil pump page 7 4 Starter motor page 5 6 Neutral switch page 5 11 Be careful not to damage the crankcase mating surfaces when servicing Prior to assembling the crankcase halves apply sealant to the mating surface Wipe off excess sealant thoroughly Clean all disassembled parts with clean solvent and dry them using compressed air before inspection SPE...

Page 178: ...nut U S A only 07931 HB3020A Bearing remover shaft 12 mm 07936 1660120 12 4 Driver 07749 0010000 Assembly collar 07YMF KPB0100 Assembly set 14 mm 07JMF KW70100 Bearing remover head 12 mm 07936 1660110 Attachment 52 x 55 mm 07746 0010400 Assembly shaft U S A only 07931 ME4010B Bearing remover set 12 mm 07936 1660101 Bearing remover 12 mm 07936 166010A U S A only ...

Page 179: ...ion Jumps out of gear Worn gear dogs and dog holes Broken shift drum stopper arm Remover weight 07741 0010201 or 07936 371020A U SA only Attachment 32 x 35 mm 07746 0010100 Broken drum stopper arm spring page 10 28 Broken gearshift spindle return spring page 10 28 Worn or bent shift forks Worn gear shifter groove Excessive noise Worn connecting rod big end bearing Worn crankshaft bearing Worn tran...

Page 180: ...en and remove the crankcase bolts 1J in a IIIIIIIIIIIIIIIIIIIIIIII I11111 crisscross pattern in several steps 1J Place the left crankcase up Carefully separate the left crankcase 1 from the right crankcase 2 while tapping them at several locations with a soft hammer Remove the dowel pins 1 Be careful not fo Clean off the sealant from the left and right crankcase damage the mating mating surfaces s...

Page 181: ...ove it using a special tool as shown TOOL 2 Universal bearing puller 07631 0010000 or equivalent commercially available in U S A 121 If the bearing remains in the crankcase drive it out from Z z Ji iiiii i the outside I Do not reuse the Discard the crankshaft bearing 111 crankshaft bearing INSPECTION SIDE CLEARANCE Measure the side clearance by inserting the feeler gauge 1 between the crankshaft a...

Page 182: ...a stand or V blocks and measure the runout using a dial gauge The measuring locations are shown in the illustration SERVICE LIMIT 0 10 mm 0 004 in 30mm 1 2 in Tum the outer race of the left crankshaft bearing with your finger The bearing should tum smoothly and quietly Also check that the bearing inner race fils tighlly on the crankshaft Replace the crankshaft if the outer race does nol turn smoot...

Page 183: ...46 0010400 07746 0041000 For transmission bearing replacement page 12 14 INSTALLATION Apply 1 2 cm3 of oil to the connecting rod 1 big end Draw the crankshaft 2 into the right crankcase 3 bearing inner race using the special tool TOOLS 4 Assembly set 14 mm U S A TOOLS Threaded adapter 16 x 15 x 14 x 1 0 mm Assembly collar Assembly shaft Special nut 07JMF KW70100 07AMF KYKA100 07YMF KPB0100 07931 M...

Page 184: ...ts in solvent thoroughly NOTE Keep track of the disassembled parts gears bushings washers and snap rings by sliding them onlo a 1001 or slipping them onto a piece of wire Remove the following from shift drum 1 Guide pin clips 2 Guide pins 3J Shift forks 4J INSPECTION SHIFT FORK Check the shift fon for deformation or abnormal wear Measure each shift fork claw thickness SERVICE LIMIT 4 60 mm 0 181 i...

Page 185: ...ve 11 for abnormal wear or 12 J damage Check the gear dogs 21 and teeth for abnormal wear or lack of lubrication I J Check the dog holes 1 for abnormal wear or lack of lubrication Measure the 1 0 of each gear SERVICE LIMITS M2 M3 C1 C4 17 04 mrn 0 671 in 18 04 mm 0 710 in 20 04 mm 0 789 In Check the C1 gear bushing for wear or damage Measure the gear bushing 0 0 and I D SERVICE LIMITS 0 0 17 94 mm...

Page 186: ...the outer race fils loosely in the crankcase OIL PASSAGES Blow open the oil passages of the right crankcase with compressed air Check the oil passages for clog wear or damage ASSEMBLY Clean all parts in solvent and dry them thoroughly Apply molybdenum disulfide oil to the each rotating gear inner surface and Cl bushing whole surface to ensure inilial lubricalion Assemble all parts into their origi...

Page 187: ... WASHER M2 GEAR 18T SPLINE WASHER Washer and snap ring direction COUNTERSHAFT ClIC4 inner surface I I C3 shift fork groove C2 GEAR 28T THRUST WASHER COLLAR C1 BUSHING SPECIAL WASHER SPLINE WASHER SNAP RING THRUST WASHER C1 GEAR 13 IT LOCK WASHER SPLINE WASHER Insert the lock washer labs into the slots of the spline washer Washer and snap ring direction 12 13 ...

Page 188: ...M 12 14 GUIDE PINS TRANSMISSION BEARING REPLACEMENT Remove the crankshaft page 12 7 Remove the bolls 1 and mainshaft bearing set plates 2 Drive out the mainshaft bearing 3 and countershaft bearing 4 from the right crankcase Drive out the counlershaft bearing 1 from the left crankcase I ...

Page 189: ...ankcase mainshaft bearing Driver 07749 0010000 Attachment 37 x 40 mm 07746 0010200 Pilot 17 mm 07746 0040400 Right crankcase countershaft bearing Driver 07749 0010000 Attachment 32 x 35 mm 07746 0010100 Pilot 12 mm 07746 0040200 1 Left crankcase mainshaft bearing 2 Driver 07749 0010000 3 Attachment 28 x 30 mm 07946 1870100 4 Pilot 12 mm 07746 0040200 Left crankcase countershaft bearing Driver 0774...

Page 190: ...gears counlershaft 3 gears and shift drum assembly 13 Install the mainshaft 1 counlershaft 2 and shift drum 3 into the right crankcase Rotate the shift drum to check the transmission operation Assemble the crankcase page 12 17 CAM CHAIN GUIDE SPROCKET REMOVAL 12 16 Separate the crankcase page 12 6 Hold the cam chain guide sprocket 1 j tum the cam chain guide sprocket spindle 12 counterclockwise an...

Page 191: ...amage INSTALLATION Apply engine oil to the cam chain guide sprocket spindle 11 sliding surface Install the spindle to the left crankcase hold the sprocket 12J and lighten the spindle to the specified torque TORQUE 10 N m 1 0 kgf m 7lbHt Assemble the crankcase page 12 17 CRANKCASE ASSEMBLY Clean off the sealant from the left and right crankcase mating surfaces Inslallths dowel pins 111 onlo the rig...

Page 192: ... except the oil passage area as shown Install the left crankcase IIIonto the right crankcase 21 r 7ii ii l Install and lighten the crankcase bolls 1 in a crisscross I I pattern in saveral steps Apply oil 10 the cam chain 11 whole suriace Install the cam chain over the timing sprocket 2 Install the removed parts in the reverse order of removal page 12 3 ...

Page 193: ...ve the snap ring 1 and retainer 2 from the kickstarter spindle Separate the crankcase page 12 6 Remove the kickstarter spindle 1 from the right crankcase OISASSEMBLYIINSPECTION Remove the following Special washer 1 Collar 2 Return spring 3 Snap ring 1 Starter ratchet 2 Ralchel spring 3 21 2 3 11 12 19 ...

Page 194: ... 1 for bend wear or 12 20 damage Measure the klckstarter spindle 0 0 SERVICE LIMIT 19 94 mm 0 785 in Check the starter pinion gear 2 for abnormal wear or damage Measure the starter pinion gear lD SERVICE LIMIT 20 08 mm 0 791 in Check the kickstarter spindle journals 11 of the left and right crankcase for excessive wear or damage ...

Page 195: ...orn snap ring which could easily spin in the groove Check Ihat the snap rings are seated in the grooves and align their end gaps with Ihe grooves of the spline Check Ihal the special washer is sealed in the groove o KICKSTARTER SPINDLE RETURN SPRING COLLAR SPECIAL WASHER View from inner side Install the ratchet spring and friction spring as shown x STARTER PINION GEAR Washer and snap ring directio...

Page 196: ...Inslall the ratchet spring 1 10 the starter ratchet 2 Make sure that the Install the starter ratchet and snap ring 3 to the snap ring is firmly kicksiarter spindle seated in the groove 3 2 2 3 Install the return spring 1 to the kickstarter spindle 12 22 while aligning the spring end with the hole on the spindle Install the collar 1 to the kickstarter spindle while lIIIIIiIIIIII aligning jls groove...

Page 197: ... shown tnsert the return spring end into the hole on the right 1 crankcase as shown Assemble the crankcase page 12 17 Set the retainer 1 to the kickstarter spindle Temporarily install the kickstarter pedal 2 and bolt 3 Turn the kickstarter pedal and completely install the retainer while aligning its wide tooth with Ihe wide spline on the spindle Release Ihe kickslarter pedal Remove the bolt and ki...

Page 198: ...MEMO ...

Page 199: ...13 ENGINE REMOVAUINSTALLATION COMPONENT LOCATION 13 2 SERVICE INFORMATION 13 3 ENGINE REMOVAL 13 4 ENGINE INSTALLATION 13 5 13 1 ...

Page 200: ...ENGINE REMOVAUINSTALLATION COMPONENT LOCATION 54 N m 5 4 kgf m 40 lbHt 12 N m 1 2 kgf m 9Ibf ft 2 N m 0 2 kgf m 1 5 IbHt 12 N m 1 2 kgf m 91bf ft 13 2 ...

Page 201: ...al for selVice Crankshaft page 12 7 Transmission page 12 9 Kickslarter page 12 19 Cam chain guide sprocket page 12 16 Other components can be serviced with the engine installed in the frame SPECIFICATIONS Engine oil capacity En ine dry weight TORQUE VALUES ITEM ITEM After draining After disassembly a TV SPECIFICATIONS 1 0Iiler 1 1 USqt 0 9 1m t 1 15Iiler 1 22US 1 1 011rn 22 3 kg 49 2 Ibs REMARKS 1...

Page 202: ...Crankcase breather hose 4 Release the carburetor drain hose 5 from the hose guide 16 Remove the starter molor cable screw 1 and disconnect the starter motor cable 2 from the starter molor Remove the screw 3 and disconnect the ground cable 4 from the starter motor Oisconnect the spark plug cap 1 Remove the two bolls 2 and wire guide 3J then release the intake pipe 14 from the cylinder head Remove t...

Page 203: ...foreign malerial from dropping into the engine ENGINE INSTALLATION During engine installation hold the engine securely and be careful not to damage the frame and engine NOTE Note the direction of the hanger bolts Use a floor jack or other adjustable support carefully place the engine Into the frame and maneuver it into place Route the wires and hoses properly page 1 14 Place the engine into the fr...

Page 204: ...1 2 kgf m 9lbHt Connect the spark plug cap 4 Set the ground cable terminal 1 against the starter molor case and tighten the screw 2 Connect the starter motor cable 3 to the starter motor and tighten the screw 4 to the specified torque TORQUE 2 N m O 2 kgf m 1 5 IbHt Connect the following Alternator 2P connector 1 Ignition pulse generator wire connector 2 Neutral switch wire connector 3 Crankcase b...

Page 205: ...14 FRONT WHEEUBRAKEISUSPENSION STEERING COMPONENT LOCATION 14 2 SERVICE INFORMATION 14 3 TROUBLESHOOTING 14 5 HANDLEBAR 14 6 FRONT WHEEL 14 9 FRONT BRAKE 14 14 FORK 14 18 STEERING STEM 14 26 14 1 ...

Page 206: ...FRONT WHEEUBRAKE SUSPENSION STEERING COMPONENT LOCATION 7 5 kgf m 54 IbHt g _____22 N m 2 2 kgf m 161bHt l _____ 32 N m 3 3 kgf m 24 lbf ft 59 N m 6 0 kgf m 44 IbHt 14 2 ...

Page 207: ...roved vacuum cleaner Riding on damaged rims impairs safe operation of the motorcycle When servicing the front wheel brake fork or steering slem support the motorcycle using a safely sland or hoist SPECIFICATIONS I I 6 3 0 09 TORQUE VALUES ITeM T DIA mm N m JI f ftL I I bolt 4 E 0 9 J 7 Be2 9 F poke Fm axle Fm beake a m pi IlOIt 1 b 9 9 1 01 7 3 oe g Forl socke boll L 0 20 2 0 15 I d f bottom bridg...

Page 208: ...7916 3710100 U S A only 14 4 Bearing remover shaft 07746 0050100 Driver 07749 0010000 Fori seal driver weight 07747 0010100 or 07947 KA50100 U S A only Ball race remover 07GMD KS40100 Attachment 32 x 35 mm 07746 0010100 Spoke wrench 4 5 x 5 1 mm 07701 0020200 Fori seal driver attachment 31 mm 07747 0010400 or 07AMD GFMA100 U S A only Steering stem driver 28 mm 07946 4300101 or 07946 MBOOOOO and 07...

Page 209: ...ingarm pivot components Uneven fork oil quantity in each fork Front wheel wobbling Bent rim Worn or damaged front wheel bearings Faulty fronllire Unbalanced tire and wheel Bent spokes Front wheel hard to turn Faulty wheel bearings Bent front axle Brake drag Soft suspension Weak fork springs Insufficient fluid in fork Tire pressure too low Stiff suspension Incorrect fork fluid viscosity Bent fork p...

Page 210: ...ds 1 and handlebar pad 21 Remove the two screws 1 and throttle housing cover 121 121 Disconnect the throttle cable end 1 from the throttle 14 1 pipe flange and remove the throttle pipe 2 Remove the throttle cable slider 31 and throttle housing 141 Remove the two screws 11 holder 2 and front brake lever bracket 3J ...

Page 211: ...he handlebar upper holder bolts 1 and holders 2 Remove the handlebar 3J INSTALLATION Place the handlebar 1 onto the lower holders aligning cc c the punch mark on the handlebar with the mating surface of the lower holder Place the upper holders 21 with the punch marks 3 facing forward Install the upper holder bolls 4 lighten the forward bolts first then the rear bolts TORQUE 12 N m 1 2 kgf m 9lbHt ...

Page 212: ...lign the edge of the engine stop switch with the punch mark on the handlebar then lighten the two screws 1 3 to the specified torque TORQUE 0 9 N m 0 09 kgf m O 7 IbHt Install the starter switch 1 onlo the handlebar Align the mating surface of the starter switch with the punch mark on the handlebar then lighten the two screws 2J to the specified torque TORQUE 0 9 N m 0 09 kgf m 0 7IbHt Place the f...

Page 213: ...nstall the throttle housing cover I Align the mating surface of the throttle housing with the punch mark on the handlebar Tighten the upper screw 2 first then the lower screw 13 Secure the handlebar switch wires with the wire bands 1 Install the handlebar pad 2 Instalilhe number plate page 2 5 FRONT WHEEL REMOVAL Supportlhe motorcycle securely using a safety stand or r c c a hoist and raise the fr...

Page 214: ...ight wheel hub INSPECTION Axle runout Set the axle 1 in V blocks and measure the runout Actual runout is 1 2 of the lotal indicalor reading SERVICE LIMIT 0 20 mm 0 008 In Wheel rim Check the rim runout by placing the wheel in a trueing 14 10 stand Spin the wheel by hand and read the runout using a dial indicator SERVICE LIMITS Radial 1 0 mm 0 04 In Axial 1 0 mm 0 04 In e ...

Page 215: ...rs smoothly quietly or if they filloosely in the hub Inslall the new bearings into the hub using the special tools page 14 12 DISASSEMBLY Remove the dust seal 1 from the right wheel hub Install the bearing remover head 1 lnto the bearing From the oPPOsite side install the bearing remover shaft 2 and drive the bearing out of the wheel hub Remove the distance collar and drive Qut the other bearing T...

Page 216: ... necess81 wtten new spokes 8re installed 14 12 TOOLS 2J Driver 3 Attachment 32 x 35 mm 4J Pilot 12 mm Wheel center adjustment 07749 0010000 07746 0010100 07746 0040200 Place the rim on the work bench and begin lacing with new spokes Tighten the spokes In 2 or 3 progressive steps to the specified torque TOOL Spoke wrench 4 5 x 5 1 mm 07701 0020200 TORQUE 3 2 N m 0 33 kgf m 2 4lbHt Adjust the hub po...

Page 217: ...t wheel hub Install the brake panel 111 into the front wheel Install the front wheel between the fork legs while aligning the brake panel groove with the boss on the left fork slider Apply a thin coat of grease to the front axle 2 suriace then inslall the front axle from right side Inslall and tighten the axle nut 1 to the specified cg torque TORQUE 59 N m 6 0 kgf m 44 lbHt 14 13 ...

Page 218: ...14 14 Remove Ihe front wheel page 14 9 Puilihe dust cover 1 off loosen the lever side lock nut 2 and adjuster 3 then disconnect Ihe brake cable from the front brake lever loosen the brake panel side lock nul 1 J and adjusting nut 2 Oisconnect the brake cable from the brake arm 3 and brake panel then remove Ihe spring 4 INSPECTION Measure the front brake drum J D SERVICE LIMIT 96 0 mm 3 78 In ...

Page 219: ...re the brake lining thickness SERVICE LIMIT 2 0 mm 0 08 in DISASSEMBLY Remove the brake shoes 1 and springs 2 Remove the brake arm pinch bolt 1 nut 2J and brake arm 3 Remove the indicator plate 1 J brake cam 2 and dust iiP iiiiiii seal 3 14 15 ...

Page 220: ...NEL DUST SEAL 1tI u NUT BRAKE ARM Apply grease to the dust seal 1 and install it onto the brake panel Apply 0 03 O OB 9 of grease to the brake cam 2 sliding surface Install the brake cam into the brake panel Install the wear indicator plale 1 on the brake cam 2 by aligning its wide tooth with the wide groove on the brake cam 12J 14 16 ...

Page 221: ...mJ 2 Apply 0 1 02 9 of grease to the brake cam brake shoe 21 1II contact area and anchor pin Assemble the brake shoes 1 and springs 2 in the direction as shown InslaUthe shoe assembly onto Ihe brake panel Wipe any excess grease from the brake cam and anchor pin INSTALLATION Set the spring 1 to the brake cable 21 Connect the brake cable to the brake arm 31 and brake panel Connect the brake cable 11...

Page 222: ...tom bridge pinch boll 1 Remove the fork leg 2 When the fork Is to be disassembled lower the forX leg and lighten the bottom pinch bolt 1 loosen the fork cap bolt 2J but do not remove it yet Loosen the fork bottom pinch bolt and remove the fork leg DISASSEMBLY Hold the Iorio slider in a vice with soft Jaws or a shop r towel 1 Loosen the fork socket bolt 1 but do nol remove it yet ...

Page 223: ...r spring O ring 21 pressure Use care Collar 3J when removing it Spring seat 4 Fork spring 51 Pour out the fork fluid by pumping the fork pipe up and down several times 11 c 2 3 4 Remove the dust seat 1 and stopper ring 2J from the fork slider Remove the sockel bolt 1 and sealing washer 2 2 11 14 19 ...

Page 224: ...ck piece 3 121 131 Remove the fork piston 1 and rebound spring 21from I I the fork pipe 3 Remove the fork oil seal 1 from the fork slider TOOL 2 011 seal remover 07748 010001 or equivalent commercially available In U S A 131 121 111 Remove the back up ring 1 and guide bushing 2 from the fork slider 3 1 121 31 ...

Page 225: ...ut Actual runoul is 1 2 the total indicator reading SERVICE LIMIT 0 20 mm 0 008 In Check the fork piston ring 3 for wear or damage Check the rebound spring 4 for fatigue or damage Replace the components if necessary Fork pipe bushing back up ring Visually inspect the guide bushing 1 Replace the guide bushing if there is excessive scoring or scratching or if Ihe teflon is worn so that the copper su...

Page 226: ...m c 2 gf m_16 Ibfft D RING II COLLAR SPRING SEAT SPRING Before assembly wash alt parts with high flash point or non fla mmable solvent and wipe them dry 2 14 22 11 Install the guide bushing 1 and back up ring 2 into the fork slider 3 31 c J Install the rebound spring 1 Jand fork piston 211nlo the 2 for pipe 13 Inslall the oil lock piece 4J to the end of the fork piston Install the fork pipe into t...

Page 227: ...e around the fork top end to avoid damaging the fork oil seal lips Coal a new fork oil seal 1 lips with fork fluid and install it over the fork pipe with the marking side facing up Drive the fork oil seal into the fork slider using the speciatlools TOOLS 2J Fork seal driver weight 31 Fork seal driver aUachment 31 mm U S A TOOLS Driver weight Fork seal driver attachment 31 mm 07747 0010100 07747 00...

Page 228: ... the lower portion of the fork pipe Be sure the oil level Compress the fork leg fuUy and measure Ihe oil level i Is the same in both from the top of the fork pipe fork pipes 14 24 FORK FLUID lEVEL 96 0 mm 3 78 in 96 0 mm 3 78 in Pull the fork pipe up and inslaUthe fork spring 11 with Ihe lightly wound coil end facing down DOWN Coat a new O ring 1 with fork fluid and install it into the fork cap bo...

Page 229: ...E 22 N m 2 2 kgf m 161bHt l oosen the bottom bridge pinch bolts and pull up the fork pipe to the lop bridge Align the lOp end of the fork pipe with the upper surface of the lop bridge as shown Tighten the bottom bridge pinch bolt 1 10 the specified torque TORQUE 32 N m 3 3 kgf m 24 IbHt Tighten the lop bridge pinch bolt to the specified torque TORQUE 22 N m 2 2 kgf m 161bHt InslaU the following Fr...

Page 230: ...lock nul washer 2 and lop bridge 3J U S A Remove tne left bottom bridge pinch bolt 1 and cable guide 2 Canada Remove the front reflectors page 2 6 111 Remove the steering stem lOP thread lJ using the 14 26 special tool TOOL 2 Lock nut wrench 07916 3710101 or 07916 3710100 U S A only Hold the bottom of steering stem to prevent it from falling oul of the steering head then remove the adjustment nut ...

Page 231: ... 1 and lower has baen involved bearing outer race 2 using the special tool in an accident examine the area TOOLS around 11 6 steering 3 Driver head for Clacks 4 Attachment 42 x 47 mm 07749 010000 07746 J010300 Temporarily install the steering stem lock nut PJ onto the stem to prevent the threads from being damaged when removing the lower bearing inner race 2 from the stem Remove the lower bearing ...

Page 232: ...IIIIIIIIIII II recommended EXCEUGHT EP2 manufactured by KYODO YUSHI Japan or Shell ALVANIA EP2 or equivalent to the lip of a new dust seal 1 then install I to the lower bearing inner race INSTALLATION Grease with extreme pressure agent recommended EXCEUGHT EP2 manufactured by KYODO YUSH1 japan or Shell ALVANIA EP2 or equivalent Apply 3 5 9 minimum each to lower upper races STEERING STEM 14 28 TOP ...

Page 233: ...ces 1 and upper bearing IIIIIIIIIIIIIIIIII 2 then install the upper bearing and upper bearing inner race Hold the steering stem and tighten the top thread 1 to 1I l 1 2 1 the initial torque using the speciatloo TOOL 2 Lock nut wrench 07916 3710101 or 07916 3710100 U S A only TORQUE 25 N m 2 5 kgf m 18 IbHt Move the steering stem 1 to the right and teft lock to lock five times to seat the bearings ...

Page 234: ...lths fork legs Install the washer 2J and stem lock nut 3 Tighten the steering stem lock nut to the specified torque TQRQUE 14 N m 7 5 kgf rn 54lbHt Recheck that the steering stem moves smoothly without play or binding U SA Install the bottom bridge pinch bolt 1 and cable guide 121_ CsnlKla Instalilhe front reflectors page 2 6 Install the following Fork legs page 14 25 Front fender page 2 5 Front w...

Page 235: ...15 REAR WHEEUBRAKEISUSPENSION COMPONENT LOCATiON 15 2 SERVICE INFORMATION 15 3 TROUBLESHOOTING 15 5 REAR WHEEL 15 6 REAR BRAKE 15 10 BRAKE PEDAL 15 13 SHOCK ABSORBER 15 15 SWINGARM 15 16 15 1 ...

Page 236: ...REAR WHEEUBRAKEfSUSPENSION COMPONENT LOCATION 50 N m 1 kgf m 371bHI kgf m 47 Ibf ft 59 N m Ibf tt 15 2 ...

Page 237: ...nd is required to support the motorcycle A contaminated brake drum or shoe reduces stopping power Discard contaminated shoes and clean a contaminated drum with a high quality brake degreasing agent Use only genuine Honda replacement bolts and nuts for all suspension linkage and swingarrn pivot mounting points ordinary bons lack adequate strength for these application Also take note of the installa...

Page 238: ...ing remover head 12 mm 07746 0050300 Attachment 32 x 35 mm 07746 0010100 Spoke wrench 4 5 x 5 1 mm 07701 0020200 15 4 Bearing remover shaft 07746 0050100 Pilot 12 mm 07746 0040200 Driver 07749 0010000 Attachment 37 x 40 mm 07746 0010200 i ...

Page 239: ...re and wheel Tire pressure too low Rear wheel hard to turn Brake drag Faulty wheel bearings Bent rear axle Drive chain too light See page 3 12 Soft suspension Weak shock absorber springs Oit leakage from damper unit Tire pressure too low Stiff suspension Bent shock absorber damper rod Damaged suspension Damaged swingarm pivot bushings Bent swingarm pivot or frame Tire pressure too high Rear suspen...

Page 240: ...nul 1 Support the motorcycle securely and raise the rear wheel off Ihe ground with a hoist or equivalent Loosen both lock nuts 2 and adjusting nuts 3 Push the rear wheel forward and release Ihe drive chain Remove the following Axle nul Rear axle 4 Adjuster plates 51 Rear wheel Remove the brake panel assembly 1 from the right wheel hub Remove the left side collar 1 1and dust seal 2 from the left wh...

Page 241: ... aCfJ the wheel Remove and discard the bearings if the races do not bearings in pairs lurn smoothly and quietly or if they fit loosely in the hub Install Ihe new bearings into the hub using the special lools page 15 8 Wheel rim runout REAR WHEEUBRAKE SUSPENSION Check the rim runou by placing the wheel in a trueing stand Spin the wheel by hand and read the runou using a dial indicator SERVICE LIMIT...

Page 242: ...RING 6201UU DISTANCE COLLAR DRIVEN SPROCKET NUTS 32 N m 3 3 kgf m 24 Ibf ft Wheel bearing installation DRIVEN SPROCKET C LEFT WHEEL BEARING 6301UU DUST SEAL Rep ace the wheel Drive in a new right brake panel side wheel bearing 1 bearings in pairs squarely Do not reuse old bearings TOOLS 2 Driver 3 Attachment 32 x 35 mm 4 Pilot 12 mm 07749 0010000 07746 0010100 07746 0040200 Inslall the distance co...

Page 243: ...e steps to the specified torque TOOL Spoke wrench 4 5 x 5 1 mm 07701 l020200 TORQUE 3 2 N m 0 33 kgf m 2 4 IbHt Check the wheel rim runout page 15 7 Instalilhe driven sprocket 1 j bolts 2 and nuts 3 Tighten the nuts to the specified torque while holding the bolls TORQUE 32 N m 3 3 kgf m 24 IbUt INSTALLATION REAR WHEEL BRAKE SUSPENSION 11 0 1 0mm 0 43 0 04 in Apply grease to a new dust seal 1 lips ...

Page 244: ...ter plate 2 Axle nut 3 Adjust the drive chain slack page 3 13 Tighten the axle nul to the specified torque TORQUE 64 N m 6 5 kgf m 47 IbHt Install the washer 1 Jand spring 2 onto the brake rod 1 31 Connect the brake rod to the brake arm with the jOint pin 4 Install the brake adjusting nut 5J loosely Adjust the rear brake pedal freeplay page 3 16 REAR BRAKE 15 10 BRAKE PANEL REMOVAL Remove the rear...

Page 245: ...SASSEMBLY Mark the side of he Pull the brake shoes 1 apart and remove them from brake shoes to the brake panel indicate their Remove the springs 2J from the brake shoes original position before removing them Remove the brake arm cover 1J Remove the nut 2 bolt 3 and brake arm 4 Remove the following Indicator plate 1 Brake cam 2 Dust seal 3 REAR WHEEUBRAKE SUSPENSION 15 11 ...

Page 246: ...IbHt INDICATOR PLATE DUST SEAL fI s m Apply grease to the new dust seal 1 lips Install a dust seal with the nat surface facing out until it Is fully seated BRAKE SHOES BRAKE PANEl Apply 0 03 0 08 9 of grease to the brake cam 1 sliding surface _ 11 Install the brake cam into the brake panel 15 12 ...

Page 247: ...1 01 kgf m 7 3 lbHt Instalilhe brake arm cover 4 Apply 0 1 0 2 9 of grease to the brake cam and brake 12 1 shoe contact area and anchor pin Assemble the brake shoes 11 and springs 2 in the direction as shown Install the shoe assembly onto the brake panel Wipe any excess grease from the brake cam and anchor pin Instalilhe rear wheel page 15 9 BRAKE PEDAL REMOVAUDISASSEMBLY Remove the brake pedal ad...

Page 248: ... pin 1 and joint pin 2 Ihen separate the brake rod 3 and brake pedal 4 ASSEMBLY INSTALLATION 141 Set the brake rod 1 and brake pedal 2J instal the joint pin 31 and new cotter pin 4 4 Apply grease to Ihe brake pedal pivot sliding surface Install Ihe relum spring 1 and brake pedal 2J to the pivot Hook the return spring end to Ihe cut out of the frame Inslallthe washer 3 and new cotter pin 4 121 ...

Page 249: ...nt Remove the shock absorber lower mounting nut 1 and bolt 121 Remove the shock absorber upper mounting nut 3 bolt 4 and shock absorber 5 Installation is in the reverse order of removal TORQUE Shock absorber upper mounting nut 50 N m 5 1 kgf m 37Ibf ft Shock absorber lower mounting nut 50 N m 5 1 kgf m 37 1bHtl INSPECTION REAR WHEEUBRAKE SUSPENSION Do not disassemble Visually inspect the shock abs...

Page 250: ...s Hold the bag around the drill molor and briefly run the drill motor inside the bag this will inflate the bag with air from the motor and help keep the bag from getting caught in the bit when you start SWINGARM REMOVAL 15 16 Support the motorcycle securely and raise the rear wheel off the ground with a hoist or equivalent Remove the following Drive chain cover page 2 7 Drive chain page 3 13 Rear ...

Page 251: ...nut 131 but do nut tighten it yet Align the holes of the swingarm and shock absorber lower mount then install the bolt 1 and nut 21 Tighten the shock absorber iower mounting nut and swingarm pivot nut to the specified torque TORQUE Shock absorber lower mounting nut 50 N m 5 1 kgf m 37 IbHt Swingarm pivot nut 59 N m 6_ 0 kgf m 44 IbUt Inslan the following Rear wheel page 15 9 Drive chain page 3 14 ...

Page 252: ...MEMO ...

Page 253: ... CHARGING SYSTEM COMPONENT LOCATION 16 2 SYSTEM DIAGRAM 16 2 SERVICE INFORMATlON 16 3 TROUBLESHOOTING 16 5 BATTERy 16 6 CHARGING SYSTEM INSPECTION 16 7 REGULATOR RECTIFIER 16 8 ALTERNATOR CHARGING COIL 16 8 16 1 ...

Page 254: ...BATTERY CHARGING SYSTEM COMPONENT LOCATION SYSTEM DIAGRAM w I ALTERNATOR G L 16 2 I FUSE 10 A BATTERY FUSE10A r Cf J G W RlBI R REGULATOR RECTIFIER 81 BATTERY 1 1 BI Black G Green R Red W White ...

Page 255: ...Battery voltage may recover after battery charging but under heavy load battery voltage will drop quickly and eventually die out For this reason the charging system is often suspected as the problem Battery overcharge often results from problems in the battery itself which may appear to be an overcharging symptom If one of the battery cells is shorted and battery voltage does nol increase the regu...

Page 256: ...BATTERY CHARGING SYSTEM TOOLS Motorcycle battery analyzer Micro 404XL 16 4 Christie battery charger MC1012J2T U S A only ...

Page 257: ...y currenlleakage Is the current leakage below 0 1 mA YES Faulty regulator rectifier NO _ Shorted wire hamess Faulty ignition switch 4 CHARGING VOLTAGE INSPECTION Measure and record the battery voltage using a digital multimeter page 16 6 Start the engine Measure the charging voltage page 16 7 Compare the measurements to the results of the following calculation STANDARD Measured BV Measured CV 15 5...

Page 258: ... H cable VOLTAGE INSPECTION Measure the battery vollage using a digital mullimeter VOLTAGE Fully charged 13 0 13 2 V Under charged Below 12 4 V BATTERY TESTING Refer to the instructions that are appropriate to the battery testing equipment available to you TOOL Battery tester Micro 404Xl U S A only BATTERY CHARGING U S A only Remove the battery page 16 6 Refer to the instructions that are appropri...

Page 259: ...eakage exceeds the specified value a shorted circuil is likely Locate the short by disconnecting connections one by one and measuring the current CHARGING VOLTAGE INSPECTION Remove the left side cover page 2 4 Be sure the battery is in good condition before performing this test Warm up the engine to normal operating temperature Connect the multimeter between the battery positive and negative termi...

Page 260: ...ator rectifier connector replace the regulatorlrectifier REMOVAUINSTALLATION Remove the seat page 2 4 Disconnect the regulator rectifier 4P Black connector 111 Remove the bolt 2 ground cable 31 and regulatorl rectifier 4 Installation is in the reverse order of removal ALTERNATOR CHARGING COIL INSPECTION Disconnect the alternator 2P connector 1 Measure the resistance between the White wire terminal...

Page 261: ...17 WIRING DIAGRAM WIRING DIAGRAM 17 2 17 1 ...

Page 262: ...WIRING DIAGRAM WIRING DIAGRAM I CJ b I o v lI I 0 o oCD 0 I M S 0 i O m 0 J dll 8 ru I C J 17 2 ...

Page 263: ...IGNITION SYSTEM INSPECTION 4 5 IGNITION TIMING 4 7 INTAKE PIPE 6 6 KICKSTARTER 2 19 LEFT CRANKCASE COVER 11 4 INDEX LEFT CRANKCASE REAR COVER 2 7 LEFT SIDE COVER 2 4 LUBRICATION SEAl POINTS 1 1 2 LUBRICATION SYSTEM DIAGRAM 7 2 MAIN STEP 2 6 MAINTENANCE SCHEDULE 3 4 MODEL IDENTIFICATION 1 2 NEUTRAL SWITCH 5 11 NUMBER PLATE 2 5 NUTS BOLTS FASTENERS 3 19 OIL PUMP 7 4 REAR BRAKE 15 10 REAR FENDER 2 5 ...

Page 264: ...INDEX REAR WHEEUBRAKE SUSPENSJON 15 5 WHEELSfTlRES 3 1 9 VALVE CLEARANCE 3 9 WIRING DIAGRAM 17 2 ...