Honda CR 125R 2000, Sevice Manual

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Page 3: ...ts of the mOTorcycle grouped according to location Find the section you want on this page then turn to the table of contents on the first page of the section Most sections start with an assembly or system illustration service information and troubleshooting for the section The subsequent pages give detailed procedures If you don t know the source of the trouble go to section 17 Troubleshooting z W...

Page 4: ...disulfide grease containing more than 400 0 molybdenum disulfide NLGI 2 or equivalent Example Molykote BR 2 plus manufactured by Dow Corning U S A Multi purpose M 2 manufactured by Mitsubishi Oil Japan Use molybdenum disulfide grease containing more than 3 molybdenum disulfide NlGI 2 or equivalent i ID Example Molykote BA 2 plus manufactured by Dow Corning U S A Honda Moly 60 U S A only Aocol ASP ...

Page 5: ...d remain hot for some time aher the engine is run Wear insulated glOVBS or wait until the engine and exhaustsystem have cooled belore handling these parts TOOLS 1 16 LUBRICATION SEAL POINTS 1 18 CABLE HARNESS ROUTING 1 20 OPTIONAL PARTS 1 26 USED ENGINE OIL Used engine oil may cause skin cancer if repeatedly left in contact with the skin lor prolonged periods Although this is unlikely unless you h...

Page 6: ... injury The shock absorber contains nitrogen under high pressure Allowing fire or heat near the shock absorber could lead to and explosion that could result in serious injury Failure to release the pressure from a shock absorber before disposing of it may lead to a possible explosion and serious injury if it is hested or pierced To p revent the possibility of an explosion release the nitrogen by p...

Page 7: ...is stamped on the right side of the steering head 2000 2001 CARBURETOR IDENTIFICATION NUMBER 2 The engine serial number is stamped on the left side of the crankcase After 2001 CARBURETOR IDENTIFICATION NUMBER 3 The carburetor identification number is stamped on the engine side After 2001 right side of the carburetor body 1 3 ...

Page 8: ...on Telescopic fork Front wheel axle travel 2000 28 1 9 mm 111 1 in 2001 280 mm 11 0 in After 2001 272 mm 10 7 in Front suspension cushion stroke 2000 200 1 315 mm 12 4 in After 2001 305 mm 12 0 in Rear suspension Swingarm Pro Link Rear wheel axle travel 2000 323 mm 12 7 in 2001 3 19 mm 112 6 in After 2001 318 mm 12 5 in Rear damper Decarbon type with nitrogen gas filled damper Front tire size 80 1...

Page 9: ... from vertical CARBURETOR Carburetor type Piston valve type Venturi diameter 36 mm 1 4 in DRIVE TRAIN Clutch system Multi plate wet Clutch operation system Cable operated Transmission Constant mesh 5 speed Primary reduction 3 150 63 20 Final reduction 2000 2001 4 000 52 13 After 2001 3 923 51 13 Gear ratio st 2000 2001 2 357 33 14 After 2001 2 307 30 13 20d 1 867 28 15 3cd 2000 2001 1 579 30 19 Af...

Page 10: ...001 380 After 2001 400 Slow jet 2000 50 2001 45 After 2001 32 5 Jet needle 2000 6BEG20 69 2001 6BEG20 68 After 2001 BOFY5 74 Jet needle clip position 3rd groove from top Air screw initial opening 2000 1 3 4 turns out 2001 2 1 4 turns out After 2001 2 1 8 turns out Float level 2000 2001 15 0 mm 0 59 in After 2001 7 5 mm 0 30 in Throttle grip free play 3 5 mm 1 8 1 4 in Reed valve clearance service ...

Page 11: ...0 021 0 0001 0 0008 0 03 0 001 Piston ring to ring groove clearance 0 045 0 080 0 002 0 003 0 09 0 004 Piston ring end gap 0 40 0 55 0 016 0 022 0 65 0 026 Cylinder to piston clearance 0 035 0 050 0 0014 0 0020 0 07 0 003 Connecting rod small end I D 19 002 19 014 0 7481 0 7486 19 022 0 7489 Unit mm in r CLUTCH KICKSTARTER GEARSHIFT LINKAGE ITEM STANDARD SERVICE LIMIT Clutch lever free play 10 20 ...

Page 12: ...7782 20 04 0 789 C 17 000 17 01a 0 6693 0 6700 17 03 Q 670 C2 C3 22 000 22 021 0 8661 0 8670 22 04 0 868 Gear to bushing M4 C1 C2 C3 0 020 0 062 0 0008 0 0024 0 11 0 004 clearance MS 0 040 0 082 0 0016 0 0032 0 12 0 005 Mainshaft 0 0 MS 19 959 19 980 0 7858 0 7866 19 94 0 785 Countershaft 0 0 Cl bushing 16 983 16 994 10 6686 0 6691 16 97 0 668 C2 bushing C3 bushing 21 959 21 980 10 8645 0 8654 21 ...

Page 13: ...ube unout 0 2 0 01 Recommended fork fluid Pro Honda HP Fork Oil 5W or equivalent Fluid level 2000 60 12 4 2001 59 2 3 After 2001 98 3 9 Fluid capacity 2000 518 cm3 117 5 US oz 18 2 Imp oz 2001 502 em3 17 0 US OZ 17 7 Imp oz I After 2001 I 475 em3 16 1 US OZ 16 7 Imp Ol Compression damping adjuster 2000 clicks out from full in standard position 2001 9 clicks out from full in After 2001 8 clicks Qut...

Page 14: ...m 2 142 psi Damper compressed gas Nilrogen gas Damper rod compressed force at 18 1 22 1 kg 39 90 48 72 Ibf 10 mm compressed Spring direction Narrow wound end of coil facing down Spring installed 2000 265 10 4 length standard Aher 2000 267 10 5 High speed side compression damping 2000 2001 10 12 1 2 10 turns out from full in adjuster standard position After 2001 1 1 6 1 1 2 turns out from full in l...

Page 15: ...2000 26 861 26 894 1 0575 1 0588 26 85 1 057 Rear Specified brake fluid DOH Brake pad wear indicator 1 0 0 04 Brake disc thickness 4 0 0 16 3 5 0 14 Brake disc run out I 0 15 0 006 Master cylinder 1 0 2000 2001 12 700 12 743 0 4999 0 5016 12 76 0 502 After 2001 9 520 9 563 0 3748 0 3765 9 575 10 3770 Master pisto n 0 0 2000 2001 12 657 12 684 0 4983 0 4993 12 64 0 498 After 2001 9 477 9 504 0 3731...

Page 16: ...2kO 0 Secondary without plug cap 2000 2001 8 kO After 200 1 10 17kO Ignilion coil peak voltage lOa v minimum Ignition pulse generator resistance al 2Q C 68 F 180 2800 Ignition pulse generator peak voltage 0 7 V minimum Alternator exciter coil resistance 2000 2001 9 25 at 20 C 68 Fj After 2001 Yellow Blue 120 180 n Blue White 24 44 n Alternator exciter coil peak voltage 2000 2001 100 V minimum Afte...

Page 17: ...TEM Reed valve mounting screw 6 3 1 0 1 0 7 NOTE 1 Thronle cable holder 1 10 3 0 3 2 21 V Float pin set screw 1 4 2 0 2 1 41 Needle jet holder 2000 2001 1 1 8 310 3 2 21 Main jet 1 5 3 2 0 2 1 4 Slow jet 1 4 1 0 1 0 7 Carburetor top screw 2000 2 4 4 0 4 3 0 Aher 2000 2 4 2 0 2 1 4 Throttle stop screw lock nut 1 5 2 0 2 1 4 Float chamber screw 2000 2001 1 4 2 0 2 1 4 After 2001 3 4 4 0 4 3 0 Carbur...

Page 18: ...brake disc nut Steering stem nut 2000 After 2000 Steering stem adjust nut Fork lube pinch bolt top bottom Fork cap Fork cap lock nut Fork center bolt Fork protector mounting bolt Front brake disc cover bolt Fork air pressure release screw Handlebar upper holder bolt Clutch lever pivot bolt 1 14 Q TV THREAD OIA mml 1 8 1 6 1 18 6 6 1 6 1 8 1 10 2 6 2 6 1 8 24 5 0 5 mm lO 96 0 02 in 1 4 Q TV 2 1 1 2...

Page 19: ...older bolt Front caliper mounting bolt Caliper bleed valve Rear brake disc guard mounting screw Rear master cylinder mounting bolt Front caliper pin bolt Brake caliper pad pin Brake caliper pad pin plug 12000 2001 After 2001 Rear caliper pin bolt Rear caliper bracket pin bolt Brake pedal pivot bolt Rear master cylinder joint nut 2000 2001 After 2001 a TV 2 2 4 4 6 2 2 2 4 2 4 1 2 2 2 2 2 2 2 2 2 2...

Page 20: ...10 Pilot 19 mm 07746 0041400 NOTE 4 12 Bearing remover shaft 07746 0050100 12 Bearing remover head 20 mm 07746 0050600 11 Bearing remover head 25 mm 07746 0050800 12 Driver 07749 0010000 5 10 11 12 Snap ring pliers 07914 SA50001 NOTE 3 07914 3230001 13 Steering stem socket 07916 3710101 NOTE 3 07702 0020001 11 Bearing remover 7 mm 07931 KA30000 NOTE 2 5 8 Bearing remover set 12 mm 07936 1660101 NO...

Page 21: ... 2 12 Peak voltage adapter 07HGJ 0020100 NOTE 2 14 Slider guide 16 mm 07PMG KZ40100 NOTE 2 12 Fork rod holder handle 07TMB 001010A 11 Fork seal driver 46 mm 07TMD MAC0100 NOTE 3 07TMD MAC010A 12 U S A only Taper bearing installer 07VMF KZ30100 11 Installer shaft 07VMF KZ30200 11 Retainer wrench 048 x 15 07YMA KZ40100 NOTE 3 07HMA KS70100 12 U S A only Fork rod holder attachment 32 mm 07YMB KZ40100...

Page 22: ...ling arrea Gearshift spindle spline Gearshift drum guide groove Shift fork claw Shift fork shaft outer surface Right crankcase outside bearing area water pump governor kickstarter Clutch lifter lever cam area Molybdenum paste Governor contact area Transmission oil Transmission gear teeth rolling area and contact area Right and left crankshaft bearing rolling area Main and countershaft bearing roll...

Page 23: ...le cable roller inner and outer surface Kickstarter pedal joint shaft sliding surface Brake pedal pivot shaft sliding surface Gearshift pedal pin sliding surface Brake caliper pin bolt pin bolt A Silicone grease Brake lever pivot bolt sliding surface Brake lever adjust bolt tip Rear master cylinder push rod rounded surface Rear master cylinder boot setting area Rear brake disc bolt threads Honda A...

Page 24: ...L INFORMATION CABLE HARNESS ROUTING 2000 2001 CABLE 2001 ENGINE STOP SWITCH WIRE IGNITION CONTROL MODULE SPARK PLUG WIRE IGNITION COIL FR NT BRAKE HOSE THAOITlE CABLE 1 20 RADIATOR OVERFLOW HOSE CLUTCH CABLE ...

Page 25: ...CABLE GENERAL INFORMATION THIWTTLE CABLE ENGINE STOP SWITCH CORD r IGNIT N CONTROL MODULE IVU 4 f r _ALTERNATOR WIRE IGNITION COIL BRAKE HOSE THROTILE CABLE RADIATOR OVERFLOW HOSE SPARK PLUG WIRE CLUTCH CABLE 1 21 ...

Page 26: ...GENERAL INFORMATION 2000 2001 E ilNE STOP SWITCH CONNECTORS THROTILE CABLE CLUTCH THROTILE CABLE 1 22 ...

Page 27: ...2001 CARBURETOR AIR HOSES GENERAL INFORMATION ENGINE STOP SWITCH CONNECTORS RADIATOR OVERFLOW HOSE THROITLE CABLE CLUTCH CABLE THROITLE CABLE CARB UR iC R AIR VENT OVERFLOW HOSES CRANKCASE BREATHER HOSE 1 23 ...

Page 28: ...GENERAL INFORMATION 2000 2001 CLUTCH ALTERNATOR ALTERNATOR WIRE RADIATOR 1 24 RADIATOR OVERFLOW HOSE REAR BRAKE RESERVOIR HOSE ...

Page 29: ...01 ALTERNATOR WIRE ALTERNATOR WIRE RADIATOR OVERFLOW HOSE CARBURETOR OVERFLOW HOSE THROTTLE CABLE GENERAL INFORMATION CLUTCH CABLE CARBURETOR AIR VENT HOSE CARBURETOR AIR VENT HOSES CRANKCASE BREATHER HOSE 1 25 ...

Page 30: ... 660 Richer only at 1 16 to 1 4 throttle Richer than the 6BEG20 72 needle 6BEG21 72 2 720 Richer only at 1 8 to 3 4 at 1 2 groove of the clip throttle Richer than the 6BEG20 7 1 needle 6BEG21 71 2 710 Richer only at 1 8 to 3 4 at 1 2 groove of the clip throttle Richer than the 6BEG20 70 needle 6BEG21 70 2 700 Richer only at 1 8 to 3 4 at 1 2 groove of the clip throttle Richer than the standard 6BE...

Page 31: ...le lean 6BEG20 71 02 710 mm 6BEG21 7 1 02 7 10 mml 6BEG20 70 102 700 mm 6BEG21 70 02 700 rnm 6BEG20 69 02 690 mm 6BEG21 69 02 690 mm General fl ow characteristics 6BEG20 58 102 680 mm 6BEG2l S8 02 680 mm at 1116 to 1 4 throttle Standard needle 6BEG20 S7 02 670 mml SBEG21 67 02 610 mm BBEG20 56 102 660 mm 6BEG21 66 102 660 mm Rich 6BEG20 65 02 650 mml 6BEG21 65 1 02 650 mm Explanation of the jet ne...

Page 32: ...h 6DFY5 7 1 02 7 10 mm 6DFY6 71 02 71 0 mm 6DFY5 72 02 nO mm 6DFY6 72 02 720 mm U 6DFY5 73 ZI2 730 mm BOFY6 73 11 I2 730 mm General flow characteristics 60FY5 74 02 740 mm BOFY6 74 02 7 40 mm at 1 16 to 1 4 throttle STANDARD BOFY5 75 02 750 mm 6DFY6 75 02 750 mm 6DFY5 76 02 760 mm BOFY6 76 02 760 mm Lean 60FYS 77 02 770 mm SDFY6 77 02 770 mm Explanation of the jet needle numbers Example J DLE NUMB...

Page 33: ... 50 T Aluminiuml 114 53 T Aluminiuml l 6 52 T Aluminiuml 116 Handlebar lower holder Standard 3 mm CO 12 in offset Optional No offset 20 INCH FRONT WHEEL After 2000 Front wheel sub assembly Aim 20 x 1 85 Spoke Hub Distance collar Wheel bearing Dust seal Rim lock 1 85 Tire Dunlop D739FA 90 100 20 Tire flap Tire tube Front wheel assembly see page 11 6 RIM TO HUB DISTANCE STANDARD 23 mm 0 9 in WHEEL R...

Page 34: ... US OZ 16 9 Imp oz 2001 TYPE SPRING RATE Oil CAPACITY light 1 scribe mark 0 41 kgf mm Standard 122 96Ibf in 506cm3 17 1 USoz 17 8 Imp oz Maximum 541 cm3 18 3 US OZ 19 0 Imp OZ Minimum 477 cm3 16 1 US OZ 16 8 Imp ozl Standard No mark factory pro 0 43 kgf mm Standard ducts or 2 scribe 24 08Ibf inl 502 cm3 17 0 US oz 17 7 Imp oz marks after market Maximum parts 537 cm3 18 2 US oz 18 9 Imp OZ Minimum ...

Page 35: ... 15 7 Imp oz Heavv 2 t 2 scribe marks 0 46 kgf mm Standard 125 76 tbf in 471 em3 15 9 US OZ 16 6 Imp oz Maximum I 544 em3 I1B 4 US oz 19 1 Imp oz Minimum 440 em3 14 9 US OZ 15 5 Imp oz SHOCK ABSORBER Spring TYPE SPRING RATE IDENTIFICATION MARK Light I 4 5 kgf mm Purple paint 252 0Ibflin Standard 4 7 kgf mm No mark factory products 263 2 lbf in 0 Brown paint aher market pans Heavy 4 9 kgf mm Black ...

Page 36: ...MEMO ...

Page 37: ...stored can cause a fire or explosion This section covers removal and installation of the body panels fuel tank and exhaust system Always replace the exhaust pipe gaskets after removing the exhaust pipe from the engine Always inspect the exhaust system for leaks after installation TORQUE VALUES Seat mounting bolt Sub frame mounting bolt upper Seat bracket screw Front chamber stay bolt Footpeg brack...

Page 38: ...nd tighten the seat mounting bolts to the specified torque TORQUE 26 N m 2 7 kgf m 20 Ibfoftl SIDE COVERS REMOVAL INSTALLATION Remove the seat mounting bolts Remove the flange bolts collars and side cover Be careful not to Install the side cover in the reverse order of removal damage the labs 2 2 Tighten the seat mounting bolts to the specified torque TOROUE 26 N m 2 7 kgf m 20 IbMt BOLT COLLAR J ...

Page 39: ... ere in the upper bolts Inseft the tab inside Installation is in the reverse order of removal the seat NUMBER PLATE REMOVAL INSTALLAnON Remove the number plate tab from the handlebar Remove the bolt collar and number plate Install the number plate aligning its hole and pin on the steering stem Installation is in the reverse order of removal 2 3 ...

Page 40: ...sely attach the upper and lower ends of the sub frame to the main frame while connecting the expansion chamber to the silencer pipe with the sealing rubber and the air cleaner connecting tube to the carburetor Tighten the screw on the connecting tube clamp Snug but do not tighten the three attaching bolts Tighten the sub frame mounting bolts to the specified torque TORQUE Upper 29 N m 13 0 kgf m 2...

Page 41: ...t Check the O ring is in good condition install it onto the fuel valve Aftsr installation Install the fuel valve in the reverse order of removal make sure there are no fue leaks REMOVAL INSTALLATION Remove the seat page 2 2 Remove the radiator shrouds page 2 3 Turn the fuel valve OFF and disconnect the fuel line Remove the fuel tank mounting bolt unhook the band and remove the fuel tank Afterinsra...

Page 42: ... INSTALLATION Remove the right side cover page 2 2 Remove the silencer case mounting bolt silencer case and sealing rubber Check the sealing rubber for wear or damage Replace the sealing rubber if necessary If necessary perform glass wool packing mainte nance page 3 16 Installation is in the reverse order of removal ...

Page 43: ...hamber bracket bolts Always rep ace the Unhook and remove the chamber springs 0 GA SKET expansion chamber Remove the monting bolts and expansion chamber lltiiijjjill gaskets with new ones Installation is in the reverse order of removal TOROUE FRONT CHAMBER STAY BOLT 12 N m 1 2 kgfom 9lbfoft Install the sealing rubber securely 2 7 ...

Page 44: ...MEMO ...

Page 45: ...king or allowing flllmes or sparks in the work life or wher the gasoline is storM elln clluse II fir or explosion If the engine must be running to do some work make sur the ree is well ventilllfed Never run the engine in lin enclosed IIrtt The exhaust cont ins poisonous carbon monoxide gil thet mey clluseloss of consciousness and may le d to deeth Place the motorcycle on a lellel ground before sta...

Page 46: ... pressure release screw Spoke nipple Rim lock 3 2 SPECIFICATIONS 10 20 mm 3 8 3 4 in 25 35 mm 1 3 8 in 25 mm 1 0 in minimum 5 mm 0 2 in minimum Front 80 100 21 51M Rear 100 90 18 57M Front 100 kPa 1 0 kgf cm 14 pSi Rear 100 kPa 1 0 kgf cm 1 14 psi 10 Nom 1 0 kgf m 7 Ibf ft 29 Nom 3 0 kgf m 22 Ibf tt 18 N m 1 8 kgf m 131bHt 128 N m 13 0 kgf m 94 Ibf ft 26 N m 2 7 kgf m 20 Ibf ft 22 N m 12 2 kgf m 1...

Page 47: ...G ROD SMALL END BEARING R 7 10 REED VALVE ONLY R 4 15 TRANSMISSION OIL R 3 9 DRIVE CHAIN I l R 3 10 DRIVE CHAIN SLIDER 1 3 12 DRIVE CHAIN ROLLER 1 3 12 DRIVE SPROCKET 1 3 13 DRIVEN SPROCKET 1 3 13 BRAKE FLUID NOTE 2 1 3 13 BRAKE PADS WEAR 1 3 14 BRAKE SYSTEM 1 3 14 CLUTCH SYSTEM 1 3 15 CONTROL CABLES I l 3 16 EXPANSION CHAMBER SILENCER 1 3 16 SUSPENSION 1 3 17 SWINGARM SHOCK LINKAGE l 3 18 12 27 3...

Page 48: ...eer brake pad Wear Minimum thickness 1 mm 0 04 in Sub frame mounting bolts Fatigue or damage Drive chain guide plate Wear or damage Side cover Damage Front number plate Damage Front reer fender Damage Clutch levar holder Play or damage Brake lever Play or damage Handlebar Bent or cracked Throttle housing Damage Grip rubber Damage Gearshift pedal Damage Brake pedal Damage Drive chain adjuster bolt ...

Page 49: ...ts are made with the upper adjuster Remove the dust cover from the adjuster Adjust the free play by loosening the lock nut and turning the adjuster Tighten the lock nut after making the adjustment Reinstall the dust cover Major adjustments are made with the carburetor end of the cable Pull the carburetor rubber cap up Adjust the free play by loosening the lock nut and turning the adjuster After ad...

Page 50: ...w ith both hands to saturate t he element with oil Gently squeeze out excess oil It is important not to over oil or under oil the element Apply a thin coat of Honda White Lithium Grease or an equivalent to the sealing surface Assemble the air cleaner on to t he holder Slip the air cleaner retaining bolt through the assem bly Align the air cleaner tab with the L mark on the AIR CLEANER _ DRY SQUEEZ...

Page 51: ...LENT NGK DENSO I BR9EG BR9EVJ W27ESR V W27ESR GJ J Optional If necessary adjust the gap by carefully bending the side electrode Then measure the gap again and rein stall SPARK PLUG GAP 0 5 0 6 mm 0 020 0 024 in CAUTION To prevent damage to the cylinder head hand tighten the spark plug before using a wrench to tighten to the specified torque Reinstall the spark plug in the cylinder head and hand ti...

Page 52: ...e up to the filler neck Add coolant as required page 5 3 COOLING SYSTEM Remove the radiator shrouds page 2 3 Check the radiator air passage for clogging or dam age Inspect the hoses for cracks and deterioration Use low pressure water and a soft brush to rinse off any dirt Ihat may be stuck in the radiator core Inspect the hoses for cracks and deterioration Replace if necessary Check the tightness ...

Page 53: ...evel ground 4 Remove the oil filler cap and check bolt from the right crankcase cover A small amount of oil should flow out of the check bolt hole Allow any excess oil to flow out of the check bolt hole S If no oil flows out of the check bolt hole add oil slowly through the oil filler hole until oil starts to flow out of the check bolt hole Install the oil check bolt and filler cap 6 Repeat steps ...

Page 54: ...dle used oil on B daily basis it is still advisable to thoroughly wash your hands with soap and water as soon as possible sher handling used oil 5 After the oil has drained completely install the drain bolt with a new sealing washer TOROUE 29 N m 13 0 kgf m 22 Ibfoft 6 Add the recommended oil Oil CAPACITY 0 57 lit 0 60 US qt 0 50 Imp qt at draining RECOMMENDED TRANSM ISSION Oil Pro Honda HP Transm...

Page 55: ...ll the open end of the master link opposite the direction of chain travel Measure the distance between a span of 17 pins 16 pitches from pin center to pin center SERVICE LIMIT 258 0 mm 10 16 in If the measurement exceeds the service limit replace the chain ADJUSTMENT Raise the rear wheel off the ground by placing a workstand under the engine Measure the chain slack in the upper chain run midway be...

Page 56: ...surface Check the chain guide and chain guide slider for alignment wear or damage Replace the chain guide if it is damaged or worn Replace the chain guide slider if the chain is visible through the wear inspection window DRIVE CHAIN ROLLERS Instal lhe ower After 2001 upper dnve cnain roller with its mark side facing out 3 12 Inspect the drive cham roliers for excessive wear or binding SERVICE LIMI...

Page 57: ... brake pads If the brake pads are worn r c the caliper piston is pushed out and this accounts for a low reservoir level If the brake pads are not worn and the fluid level is low check the entire system for leaks see next pagel FRONT BRAKE Check the front brake fluid reservoir level through the sight glass If the level is near the lower level mark check the brake pad wear page 3 14 REAR BRAKE Place...

Page 58: ...ose and finings for deterioration cracks or signs of leakage Tighten any loose fittings Replace the hose and fittings as required BRAKE PAD WEAR Check the brake pads for wear Replace the brake pads if either pad is worn to the bottom of the wear limit groove Refer to page 13 5 for brake pad replacement BRAKE SYSTEM LEVER POSITION INSPECTION The brake lever position can be adjusted by loosen ing th...

Page 59: ...ck nut CLUTCH SYSTEM Measure the dutch free play at lever end FREE PLAY 10 20 mm 3 8 3 4 in Minor adjustments are made at the adjuster on the lever Pulilhe cover back Loosen the lock nUl and turn the adjuster Tighten the lock nul If the adjuster is threaded out near its limit and the correct free play cannot be obtained lurn the adjuster alilhe way in and back out one lurn Tighten the lock nut ins...

Page 60: ...h cable upper end from the clutch lever II is not necessary Thoroughly lubricate the cable pivot points with a 10 lubricate the commercially available cable lubricant cables If the clutch lever or throttle operation is not smooth replace the cable CAUTION Be sure the throttle returns freely from fully open to fully closed eutometically in all steering pos tions Installation is in the reverse order...

Page 61: ... fasteners Make sure that the fork protectors and dust seals are clean and not packed with mud and dirt Remove any dirt that has accumulated on the bottom of the fork seals Replace damaged components which cannot be repaired Tighten all nuts and bolts Refer to section 11 for fork service Air pressure acts as a progressive spring and affects the entire range of fork travel Air is an unstable gas it...

Page 62: ...d the swingarm and move the rear wheel side ways with force to see if the wheel bearings are worn SWINGARM SHOCK LINKAGE 3 18 Raise the rear wheel off the ground by placing a workstand under the engine Check for worn swingarm bearings by grabbing the rear swingarm and attempting to move the sWing arm side to side Replace the bearings if excessively worn page 12 32 Check that the shock linkage and ...

Page 63: ...a 1 0 kgf cmt 14 psi Inspect the wheel rims and spokes for damage Tighten any loose spokes and rim locks to the speci fied torque TORQUE SPOKES 4 N m 0 4 kgf m 3 0 Ibf ft RIM LOCK 13 N m 11 3 kgf m 9 Ibf ft STEERING HEAD BEARINGS Raise the front wheel off the ground by placing a workstand under the engine Besule thaI the Check that the handlebar moves freely from side to control cables do side nol...

Page 64: ...FUEL SYSTEM 2000 2001 kgf m 4 0 ...

Page 65: ...M CARBURETOR REMOVAL DISASSEMBLY CARBURETOR ASSEMBLY 4 9 CARBURETOR ADJUSTMENT MINOR 4 4 INSTALLATION 4 14 CARBURETOR ADJUSTMENT MAJOR 4 5 REED VALVE 4 21 TUNING FOR SPECIAL CONDITIONS 4 8 AIR CLEANER HOUSING 4 23 19 After 2001 29 N m 3 0 kgfom 22 Ibfoft 4 1 ...

Page 66: ...the engine with a shop towel or cover it with piece of tape to pre vent any foreign material from dropping into the engine NOTE If the vehicle is to be stored for more than one month drain the float bowls Fuel left in the floal bowls may result in clogged jets resulting in hard starting or poor driveabilitY SPECIFICATIONS ITEM SPECIFICATIONS Fuel tank capacity 2000 2001 7 5 liter 2 0 US gal 1 6 Im...

Page 67: ...f ft 2 N m 0 2 kgf m 1 4 Ibfoft 2 N m 0 2 kgf m 1 4 Ibf ftl 2 N m 0 2 kgf m 1 4 Ibf ft 4 Nom 0 4 kgfom 3 0 Ibfoftl 7 N m 0 7 kgfom 5 1 Ibfoft 4 N m 0 4 kgfom 3 0 Ibfo ft 4 N m 0 4 kgfom 3 0 Ibf ft 07 40 1 0010000 Rich mixture Choke valve in ON position Float valve faulty Float level too high Air jets clogged Air cleaner element contaminated Flooded carburetor Worn crankshaft seal clutch side FUELS...

Page 68: ... 59 in AIR SCREW INITIAL OPENING 2 1 4 turns out SLOW JET 45 MAIN JET 380 JET NEEDLE 6BEG20 68 JET NEEDLE CLIP POSITION 3rd groove from top After 2001 FLOAT LEVEL 7 5 mm 0 30 in AIR SCREW INITIAL OPENING 2 1 8 turns out SLOW JET 32 5 MAIN JET 400 JET NEEDLE 6DFV5 74 JET NEEDLE CLIP POSITION 3rd groove from top 2 When the engine is warm enough to run without the choke push the choke knob down to it...

Page 69: ...d tuning information chart for temperature and altitude page 4 6 4 Turn the fuel valve OFF loosen the carburetor instator clamp screw and connecting tube damp screw 5 Drain the gasoline from the carburetor Remove the screws and float chamber and baffle plate 6 Change the jets as required and reinstall the float chamber 7 Remove the jet needle from the throttle valve page 4 9 and change the jet nee...

Page 70: ... 1f 3B I 31 49 9 40 39 60 59 BO 100 99 120 2 1 4 2 1 2 2 3 4 3 2 1 2 50 50 50 50 45 3 d 3 d d d d 340 330 320 310 300 2 1 4 2 1 2 2 3 4 3 50 50 50 50 50 3 d 3 d d d d 350 340 330 320 310 3 4 2 1 4 2 1 2 2 3 4 50 50 50 50 50 3 d 3 d 3 d d d 370 350 340 330 320 1 2 3 4 2 1 4 2 1 2 50 50 50 50 50 3 d 3 d 3 d 3 d 3 d 3BO 360 350 340 330 1 4 1 2 3 4 e 2 1 4 z 50 50 50 50 50 3 d 3 d 3 d 3 d 3 d 390 370 ...

Page 71: ... 3 d CI 3rd 3 d 2nd Om IN 6DFY5 74 BDFY6 74 BDFY6 74 BDFY5 74 6DFYS 74 IJ j BOFY5 74 BOFY6 74 Sea level MJ 450 440 430 410 Iii 400 390 380 NOTE If you use the chart correctly it shouldn t be necessary to adjust more than one jet size richer or leaner to fine tune your CR If a very large adjust ment is required there may be something wrong elsewhere Check for worn crankshaft seals air leaks blocked...

Page 72: ...e track has a very long straightaway steep climbs a high percentage of sand or the track is muddy Go leaner on the main jet by one number when it is very humid or raining or it is very hot above 45 C 113 F j Jet Needles Under normal circumstances the standard jet needle can be adjusted to fit most situations However a peculiar condition may require replacement of the standard jet needle But before...

Page 73: ...ew and lean the carburetor to the left After 2001 Remove the sub frame page 2 4 l oosen the carburetor insulator band Remove the screws and carburetor top then pull out the throttle valve OISASSEMBLY Compress the spring and remove the collar from the throttle valve Compress the spring and remove the throttle cable from the cable holder FUEL SYSTEM COLLAR THAOITLE CABLE SPRING 4 9 ...

Page 74: ...r damage Check the throttle valve for damage Replsce the these parts jf necessary 2000 2001 Shown THROTTLE VALVE JET NEEDLE CABLE HOLDER After 2001 Shown THROTTLE VALVE 1 CABLE HOLDER JET NEEDLE Disconnect the air vent hoses and over flow hose 2000 _ 2001 Shown AIR HOSES J OVER FLOW HOSE After 2001 Shown OVER FLOW HOSES 4 10 ...

Page 75: ... valve seat contammated valve does not seat properly and will evenrually flood Ifle carburelOl Check the float for damage Check the float valve and valve seat for scoring scratches clogs or damage Check the valve seat O ring for wear or damage Check the tiP of the float valve where it contacts the valve seal for slepped wear or contamination Replace or clean these parts if necessary FUEL SYSTEM 20...

Page 76: ...2001 Remove the main jet and slow jet 4 12 NOTE Before removing the air screw record the number of turns in untit it seats lightly so it can be returned to its original position Remove the air screw and throttle stop screw JET I JET BAFFLE PLATE 2000 2001 Sh o s A THROTIlE AIR SCR EW I SCREW ...

Page 77: ... compressed air AIR Check the air screw for stepped wear or damage Check the spring for damage Replace th ese parts if necessary Unscrew the lock nut and remove the choke knob Check the valve seat for damage or stepped wear Check the O ring for damage After 2001 Shown SLOW MAIN JET FUEL SYSTEM NEEDLEJET HOLDER I SPRING 4 13 ...

Page 78: ...ll air and fuel passages in the carburetor body with compressed air CARBURETOR ASSEMBLYIINSTALLATION 2000 2001 CARBURETOR TOP FLOAT VALVE FLOAT r 6 1 Q 4 14 CHOKE KN OB r THROTILE STOP SCREW J Yl 1 i n SPRI G I COLLAR I VALVE SEAT FLOAT PIN J l JET NEEDLE NEEDLE JET HOLDER J SLOW JET MAIN JET BAFFLE PLATE THROTIl E VALVE ...

Page 79: ...AFflE PLATE l JET NEEDLE CLIP r JET NEEDLE THROTTLE VALVE Install the choke knob and tighten the lock nut to the specified torque TORQUE 4 N m 0 4 kgf m 2 9 Ibf ft 2000 2001 Install the air screw air screw spring throttle stop 2000 2001 S hOW J if screw and lock nut NOTE Install the air screw and return it to its original posi tion as noted during removal THROTTLE 4 15 ...

Page 80: ... kgt m 2 2 IbMt 2 Nom 0 2 kgfem 1 4Ibfoft Ahar 2001 Install the slow jet and main jet 4 16 TOROUE SLOW JET MAIN JET 1 Nom 0 1 kgt m 0 7 Ibfoft 2 N m 0 2 kgt Jn 1 4Ibfoft Install the float valve seat and O ring Tighten the screw to the specified torque TORQUE 1 N m 0 1 kgt m O 7IbMt After 2001 Shown VALVE SEI T O R lG THROTIlE STOP SCREW SCREW JET I JET BAFFLE PLATE JET ...

Page 81: ...e floal valve just contacts the float arm tip Be su re that the float valve tip is securely in con tact with the valve seal Make sure the float level with the float level gauge TOOL Carburetor float level gauge flOAT lEVEL 2000 2001 15 0 mm 10 59 in After 2001 7 5 mm 1 0 30 int 07401 0010000 If the level is out of specification adjust the float level by bending the lip After2001 Install the baffle...

Page 82: ...01 4 N m 0 4 kgf m 3 0 Ibf ft 2000 2001 Inslall and tighten the drain plug 10 the specified torque TORGUE 7 N m 0 7 kgf m 5 1 Ibf ft After 2001 Install the hose guide as shown Connect the air vent hoses and overflow hose 4 18 DRAIN PLUG After 2001 Shown HOSE GUIDE 2000 2001 Shown After 2001 Shown OVER AIR HOSES I O VER FLOW HOSE HOSES ...

Page 83: ... 3 0 3 kgt m 2 2 IbMt Align the throttle valve spring and collar to the throttle cable Compress the throttle valve spring and insert the throttle cable into the cable holder Install the collar bv aligning the tab of the collar with the cut out in the cable holder FUEL SYSTEM NEEDLE CLIP JETNEEDLE 2000 2001 Shown THAOTIl E VALVE JET NEEDLE After 2001 Shown THROTTLE VALVE CABLE HOLDER t r CABLE HOLD...

Page 84: ...bly into the carburetor with the cut out and tab side facing to the air clraner Aft8f 2001 Slide the throttle valve assembly into the carburetor 4 20 Install the carburetor top cover and tighten the screws to the specified torque TORQUE 2000 After 2000 4 N m 0 4 kgf m 2 9 IbMt 2 N m 0 2 kgf m 1 4 IbPft 2000 2001 Shown CARBURETOR TOP ...

Page 85: ... Thronle grip free play page 3 5 Air screw adjustment page 4 4 After installation check the following Secondary air leaks around the insulator and connecting tube Fuel leaks around the fuel hose and carburetor Route the overflow hose air vent hose and fuel hose REED VALVE REMOVAL Remove the carburetor page 4 9 Remove the bolts clutch cable clamp and insulator 2000 2001 Remove the reed valve and ga...

Page 86: ...reed valve Replace the reed valve after 3 races or about 7 5 hours Install the reed valve and reed valve stopper by aligning the cut oul in the reed valve and the cut out of the reed valve stopper Clean the screw threads Apply a small amount of locking agent to the tip of the screw threads Tighten the screws to the specified torque TORQUE 1 N m 10 1 kgPm 0 7 Ibfeft NOTE Do not apply a locking agen...

Page 87: ...all the reed valve with its tab facing up Install the insulator clutch cable holder and bolts Tighten the bolts securely Install the carburetor page 4 20 Aher installation check the following Secondary air leaks around the insulator and con necting hose Fuel leaks around the fuel hose and carburetor AIR CLEANER HOUSING REMOVAL Remove the sub frame page 2 4 Remove the screws and mud guard FUEL SYST...

Page 88: ...the air cleaner housing Check the air cleaner housing for damage Remove the carburetor connecting tube from the air cleaner housing and seal thoroughly if any sign of inadequate sealing is detected INSTALLATION Air cleaner housing installation is in the reverse order of removal CONNECTING BOOT BAND AlA CLEANER HOUSING MUD GUARD 4 24 ELEMENT HOLDER AIR CLEANER ELEMENT AIR REGULATOR PLATE ALIGN ...

Page 89: ...FUELSVSTEM After 2001 CONNECTING BOOT BAND CONNECTING BOOT ELEMENT HOLDER AIR CLEANER ELEMENT AIR CLEANER HOUSING RETAINING BOLT MUD GUARD 4 25 ...

Page 90: ...COOLING SYSTEM 0 2 kgf m kgf m 7 Ibf ft 5 0 ...

Page 91: ...of radiator passages Using tap water may cause engine damage Use only distilled water and ethylene glycol in the cooling system A 50 50 mixture is recommended for maximum corrosion protection Do not use alcohol based antifreeze AU cooling system services can be done with the engine in the frame Avoid spilling coolant on painted surfaces After serviCing the system check for leaks with a cooling sys...

Page 92: ...S A 07936 1660001 Not available in U S A 07741 0010201 or 07936 371020A or 07936 3710200 07936 1660101 or 07936 166010A U S A only 07936 1660110 Not available in U S A 07936 1660120 Not available in U S A 07945 KA30000 or 07965 415000A U S A only or GN AH oS5 415 Coolant leak Passages blocked in radiator hoses or water jacket Radiator air paasages dogged with dirt Faulty water pump oil and water s...

Page 93: ...3 1 042 1 040 30 1 053 1 052 1 051 1 049 1 047 35 1 063 1 062 1 060 1 058 1 056 40 1 072 1 070 1 068 1 066 1 064 45 1 080 1 078 1 076 1 074 1 072 50 1 086 1 084 1 082 1 080 1 017 55 1 095 1 093 1 091 1 088 1 085 50 1 100 1 098 1 095 1 092 1 089 COOLING SYSTEM 25 30 35 40 45 50 77 86 95 104 11 3 122 1 006 1 005 1 003 1 001 0 999 0 997 1 01 4 013 1 011 1 009 1 007 1 005 1 022 1 020 1 018 1 016 1 014...

Page 94: ... them with water and consult a doctor immediately If any coolant in swallowed induce vomiting gargle and consult a physician immediately Ifany coolant gets on your skin or clothes rinse thoroughly with plenty of water KEEP OUT OF REACH OF CHILDREN CAUTION Using coolant with silicate corrosion inhibitors may cause premature wear of water pump seals or blockage ofradiator passages Using tap water ma...

Page 95: ...hers Tighten the drain bolt to the specified torque TOROUE 10 N m 11 0 kgf m 7 IbMtl Fill the system with the recommended coolant through the filler opening up to filler neck CAPACITY 0 90 liter 0 95 US OZ 0 79 Imp oz Lean the machine approximately 20 right and left several times to bleed air trapped in the cooling sys tem If the coolant level drops add more coolant and repeat air bleeding procedu...

Page 96: ... hoses loosen the lower radiator hose clamp and disconnect the lower radiator hose Loosen the upper and lower joint hose clamps and disconnect the upper and lower joint hose Remove the overflow hose from the right side radiator Remove the upper and lower mounting bolts and collars Remove the radiator CAUTION INSTALLATION 5 6 ...

Page 97: ...check the radiator and radiator hoses for leaks Install the radiator shrouds page 2 3 WATER PUMP MECHANICAL SEAL INSPECTION Inspect the telltale hole for signs of coolant leakage If there is leakage the mechanical seal is defective and replace the water pump as an assembly REMOVAL Drain the coolant page 5 5 Remove the four flange bolts and water pump cover Remove the outer gasket and plate COOLING...

Page 98: ...nk case cover Check the water pump shaft and gear to be sure they are not bent or damaged Turn the inner race of the water pump shaft bearing with your finger The bearing should turn the smoothly and quietly Also check that the bearing outer race fits tightly in the right crankcase cover Replace the water pump shaft bearing if necessary page 5 10 WATER PUMP SHAFT 1 WATER PUMP SHAFT ...

Page 99: ... 12 mm Remover head 12 mm Remover shaft 07936 1660101 or 07936 166010A U S A only 07936 1660100 Not available in U S A 07936 1660120 Not available in U S A Drive in the new bearing into the right crankcase cover using the special tools as shown TOOLS Driver Attachment 24 x 26 mm Pilot 12 mm RIGHT CRANKCASE SIDE 07749 0010000 07746 0010700 07746 0040200 Remove the water pump shaft bearing using the...

Page 100: ...eal from the right crankcase cover Install the water seal driver into the right crankcase cover 8S shown Be careful not to Drive in the new water seal damage the water sea lips during TOOLS installation Water seal driver Mechanical seal installer 07945 KA30000 or 07965 41S000A U S A only or GN AH 06s 415 Install the new oil seal into the right crankcase cover 8S shown Install the water pump shaft ...

Page 101: ...ase cover page 9 3 Install the plain washer and impeller onto the water pump shaft Tighten the impeller to the specified torque TORQUE 12 N m 1 2 kgf m 9 Ibf ft Instellths dowel pins and new inner gasket COOLING SYSTEM 12 N m 1 2 kgf m 9 Ibf tt 10 N m 1 0 kgf m 7 Ibf tt WATER PIMPSHAFT NNER 5 11 ...

Page 102: ...he plate and new outer gasket Install the water pump cover and tighten the four flange bolts to the specified torque TOROUE 12 N m 1 2 kgf m 9lbfoft Add the recommend coolant mixture up to the filler neck and bleed the air page 5 5 ...

Page 103: ...MEMO ...

Page 104: ...kgfom 20 Ibf ft 54 Nom 5 5 k l S 1S 40Ibf ft After 2001 12 Nom 11 2 kgf m 9Ibf ft 10 Nom 1 0 kgfom 7 12 Nom 6 0 kgfo m 9 Ibfoft 34 Nom 3 5 kgfom 25lbfoft 0_ After 2000 88 Nom 9 0 kgfom 65 bf tt After 2000 1 0 _ 0 2000 2 N m 0 2 kgfom 1 4 Ibfoft ...

Page 105: ...ent motor oil API service classification SF or SG Viscosity SAE 10W 40 Transmission oil capacity at draining 0 57 liter 0 60 US qt 0 50 Imp qt at disassembly 0 65 liter 0 69 US qt 0 57 Imp qt Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing corrosion protection inhibitors Coolant capacity I at draining 0 881tter 0 930 US qt 0 774 Imp q...

Page 106: ...expansion chamber Remove the bolts and exhaust pipe joint Drain the transmission oil page 3 9 Drain the coolant page 5 5 Remove the fuel tank page 2 5 Disconnect the engine stop switch connectors Remove the number plate page 2 3 Disconnect the ignition control module connector ...

Page 107: ...oses Remove the following Carburetor page 4 9 Wire band Spark plug cap Drive chain Remove the alternator cover and disconnect the clutch cable Remove the bolts nuts washer rear brake reservoir bracket 2000 2001 and engine hanger plates ENGINE REMOVAL INSTALLATION 2000 2001 Shown After 2001 Shown GROUND CABLE CONNECTOR 6 3 ...

Page 108: ...te the wires and cables properly page 1 18 Do not tighten the swingarm pivot nut and engine mounting nuts yet Install the engine to the frame Install the swingarm pivot bolt and nut Install the engine mounting bolts and nuts Install the rear brake reservoir hose guide TORQUE 10 N m 1 0 kgpm 71bHt Install the engine hanger plates bolts and nuts Tighten the engine mounting nuts engine hanger plate n...

Page 109: ...rface Always install a Inslallthe exhaust chamber page 2 7 new gasket and O ring at the Inslall the removed parts in the reverse order of exhaust chamber removal Ins allation Fill the transmission with recommended oil to the correct level page 3 9 Pour radiator coolant mixture into the radiator up to the correct level page 5 4 After installing the engine perform the following inspections and adjus...

Page 110: ...CYLINDER HEAD CYLINDER PISTON 27 N m 2 8 kgf m 2 0 Ibf h 3 N m 0 3 kgf m 2 2 Ibfoft 12 N m 1 2 kgf m 9lbfoft 7 0 8 N m 1 8 kgf m 13 Ibfoft 12 N m 1 2 kgf m 9Ibf h ...

Page 111: ... servicing Refer to section 8 for RC valve system decarbonizing disassembly and assembly SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT Cylinder head warpage 0 05 0 002 Cylinder 1 0 A 53 916 53 983 2 1250 2 1253 54 013 2 1265 B 53 968 53 976 2 1247 2 1250 54 006 2 1262 Out of round 0 05 0 002 Taper 0 05 0 002 Warpage 0 05 0 002 Piston piston Piston mark direction IN mark facing toward the i...

Page 112: ...nd with a sounding rod stethoscope If the performance is poor at low speeds check for white smoke in the crankcase breather tube If the tube is smoky check for a seized piston ring Compression too low hard starting or poor performance at low speed Blown cylinder head gasket Loose spark plug Worn stuck or broken piston ring Worn or damaged cylinder and piston Faulty reed valve Worn crankshaft seals...

Page 113: ...n the radiator hose clamps and remove the radi of the hose clamp alor hoses from the cylinder head Remove the spark plug cap and spark plug Remove the engine upper hanger plate bolts and hanger plates Remove the five cylinder head nuts CAUTION To avoid warping the cylinder head use II crisscross pettern to loosen 8ach nut about 1 4 turn in two or three steps then remove the nuts Remove the cylinde...

Page 114: ...e in diagonal directions using a straight edge and feeler gauge SERVICE LIMIT 0 05 mm 0 002 in INSTALLATION Install the dowel pins Install the new cylinder head gasket with the UP mark facing up and tab to the rear Place the cylinder head on the cylinder Install the five cylinder head nuts in a crisscross pattern in two or three steps Then tighten the nuts to the specified torque TORQUE 27 N m 12 ...

Page 115: ...mp Add the recommend coolant mixture into the radiator up to the correct level page 5 3 Install the fuel tank and seat page 2 2 5 CYLINDER PISTON CYLINDER REMOVAL Remove the cylinder head page 7 3 Remove the expansion chamber page 2 7 Loosen the water hose clamp screws at the cylinder and remove the hose Remove the following RC valve cover screw and bolts RC valve cover Gasket and grommet Pinion r...

Page 116: ...e the cylinder gasket and dowel pins Remove the AC atye system page 8 4 Remove the exhaust pipe joint page 6 2 PISTON REMOVAL NOTE Do not let the clips fall into the crankcase Always support the piston when pressing out the pin Remove the piston pin clip piston pin and piston NOTE Under racing conditions the piston and piston ring should be replaced according to the maintenance schedule See page 3...

Page 117: ...linder for warpage If warpage is beyond the service limit correct as necessary SERVICE LIMIT 0 05 mm 0 002 inl Check that the cylinder studs are tight If any are loose remove them clean their threads with contact cleaner then install them using Honda Anaerobic Thread lock or equivalent Tighten the stud bolts to the specified torque TORQUE 12 N m 11 2 kgf m 9lbfoft If necessary remove the bolts and...

Page 118: ...S A 54 013 mm 2 1265 in B 54 006 mm 12 1262 in PISTON INSPECTION Measure the piston 0 0 10 mm 0 39 in from the bottom of the skirt and at a right angle to the piston pin hole SERVICE LIMITS A 53 883 mm 2 1214 in B 53 875 mm 2 1211 in If the 0 0 is under the service limit or if nearly 7 5 hours of running time have elapsed replace the pis ton with a new one Calculate the cylinder to piston clearanc...

Page 119: ... m m 0 001 inl Insert the piston ring into the cylinder to distance from the cylinder bottom shown Use the piston to push the ring squarely into the cylinder Measure the piston ring end gaps with the feeler gauge SERVICE LIMIT 0 65 mm 0 026 in CYLINDER PISTON SELECTION The cylinders and pistons are select fitted Record the piston 0 0 code letter A or 8 Record the cylinder t 0 code letter A or 8J U...

Page 120: ... is not over the service limit replace the crankshaft page 10 8 PISTON INSTALLATION Clean the piston ring grooves lubricate the piston ring and piston ring groove with clean Pro Honda HP2 2 s rake oil Install the piston ring on the piston with the mark facing up locate the ring end gap on the pin in the piston ring groove Be careful not to Clean off any gasket malerial from the cylinder sur remove...

Page 121: ...r reuse old clips Do not let the piston pin clips fall into the crankcase CYLINDER INSTALLATION Install the RC valve system to the cylinder page 8 4 Install the exhaust pipe joint to the cylinder Ipage 6 5 Align the ring end gap with the piston ring pin Place the dowel pins and new base gasket on the crankcase lubricate the piston with Pro Honda HP2 2 stroke Oil and slip the cylinder over the pist...

Page 122: ...p Position the gasket on the RC valve cover Install the grommet on the cylinder Install the RC valve cover using the four mounting bolts and one screw Tighten the bolts and screw to the specified torque TORQUE BOLT 12 N m 0 2 kgpm 91bMt SCREW 3 N m 0 3 kgt m 2 2 tbMt Install the water hose and tighten the hose clamp screw securely Install the following Expansion chamber page 2 7 Cylinder head page...

Page 123: ...MEMO ...

Page 124: ...RC VALVE 27 N m 12 8 gt m 2 0 I UII 3 N m 0 3 12 N m kgf m 9 Ibf ft I After I 2001 l I 1 L _______ J 37 N m 3 B kgf m 2 01bfofO 10 N m 1 0 kgf m 7 bf ft 8 0 2 2 Ibfoft 10 N m 1 0 kgf m 7 lbfoft GASKETS ...

Page 125: ... 7 mm TROUBLESHOOTING Poor performance at low speed Exhaust valve does not close fully Faulty governor Bent valve shaft Damaged drive shaft bearing 10 N m 1 0 kgf m 7 rbf h 12 N m 1 2 kgf m 9Ibf ft 3 N m 0 3 kgf m 2 2 Ibfoft 10 N m 1 0 kgf m 7 Ibf ft 9 N m 0 9 kgf m 6 5 Ibfoft 07742 0020200 07931 KA30000 Not available in U S A 07931 KA30100 Not available in U S A Excessive carbon build up on the f...

Page 126: ...11 0 kgf m 71bfoftl EXHAUST VALVE REMOVAL DISASSEMBLY Remove the cylinder page 7 3 Remove the flap valve drive shaft assembly and flap valves from the cylinder Remove the nut and disassemble the flap valve drive shaft assembly DECARBONIZING INSPECTION NOTE Replace the flap valves and flap valve drive shaft as a set Decarbonize the Remove the carbon deposits from the flap valves flap valves each In...

Page 127: ...r Slowly and uniformly heat the cylinder with a heat gun industrial dryer To avoid burns wear insulated globes when handing the heated parts CAUTION Using a torch to heat the cylinder may cause warping Drive in a new bearing into the cylinder TOOL Valve guide driver 22 mm 1 0 07742 0020200 ASSEMBLY INSTALLATION Assemble the flap valve drive shaft and lighten the nut to temporarily RC VALVE VALVE S...

Page 128: ...he 0 5 5 mm hole on the cylinder Lift the flap valve with your finger and until the flap valve arm stops seats against the pin Tighten the drive shaft nut to the specified torque TORQUE 9 N m 10 9 kgf m 6 5 Ibf ft After tighten measure the cylinder upper surface to flap valves lower end clearance is 37 75 0 4 mm 1 48B 0 02 in Install the cylinder page 7 11 PIN 37 5 0 4 mm n 486 0 02 in FLAP VALVES...

Page 129: ...pect the pinion gear teeth for excessive wear or damage Inspect the governor gear teeth for excessive wesr or damage CAUTION Do not d sassemb e the governor GOVERNOR SHAFT BEARING REPLACEMENT RIGHT CRANKCASE SIDE Remove the bearing using the special tooL TOOl Bearing remover 7 mm 07931 KA30000 not available in U S A Orive in the new bearing into the right crankcase TOOL Bearing driver 7 mm 07946 K...

Page 130: ...ing driver 7 mm 01931 KA30100 not available in U S A Apply recommended transmission oil to the pinion gear Install the pinion gear and retaining screw with its washer Apply molybdenum disulfide oil to the pinion rod joint and governor bearing rolling area Install the governor by positioning the pinion lever toward the top of the right crankcase cover When the governor is installed it will spin the...

Page 131: ...ing screw Tighten the screw to the specified torque TORQUE 9 N m 0 9 kgf m 6 5 Ibfoft Install the grommet wi th its tab facing outside as shown Install the following Righi crankcase cover page 9 3 Pinion rod and RC valve cover page 7 12 RCVALVE CRANKCASE TAB GROMMET PINION LEVER JOINT 8 7 ...

Page 132: ...CH KICKSTARTER GEARSHIFT LINKAGE 22 N m 2 2 kgf m 16 Ibfoft r I After 2001 1 L _______ _ r kgf m 9 0 10 N m 11 0 kgf m 7 Ibfoft 12 N m 11 2 kgf m 9 Ibfoft 69 N m 7 0 kgf m 51lbfoft 10 N m 1 0 kgf m 7 Ibf ft ...

Page 133: ...starter pinion gear 1 0 Kickstarter I 0 0 Kickstarter idle gear 1 0 Countershaft 0 0 at kickstarter idle gear TORQUE VALUES Gearshift drum center pin Gearshift drum stopper arm bolt Clutch center lock nut Right crankcase cover bolt Clutch cover bolt Clutch spring bolt Gearshift pedal pinch bolt Kickstarter pedal bolt TOOL Clutch center holder Unit mm in STANDARD SERVICE LIMIT 10 20 3 8 3 4 37 1 1 ...

Page 134: ...n shift arm return spring loose stopper plate bolt Gearshift pedal will not return Weak or broken gearshift spindle return spring Bent gearshift spindle 9 2 Clutch slips when accelerating Incorrect clutch adjustment Worn clutch discs Weak clutch springs Transmission oil mixed with molybdenum or graphite additive Motorcycle creeps with the engine idling Incorrect clutch adjustment Clutch plale warp...

Page 135: ...e rod page 7 5 Remove the kickslarter pedal bolt and kickslarter pedal Remove the bolts and water pump cover page 5 7 Remove the bolts and right crankcase cover and hose clamp After 2001 Remove the gasket and dowel pins Check the starter spindle oil seal for deterioration or damage INSTALLATION Place a new gasket on the right crankcase cover and cut the end of the gasket flush with the end as show...

Page 136: ...valve rod page 7 12 Install the kickstarter pedal and bolt Tighten the kickstarter pedal bolt to the specified torque TORQUE 38 N m 3 9 kgPm 28 IbMt Install the brake pedal page 13 21 Install the expansion chamber page 2 7 Fill the transmission with the recommended oil to the correct level page 3 9 Pour the radiator coolant mixture into the radiator up to the correct level page 5 4 Check and adjus...

Page 137: ...ve the clutch lifter and lifter rod Remove the eight clutch friction discs and seven clutch plates Bend the tabs of the lock washer away from the lock nut Hold the clutch center with the clutch center holder Remove the lock nut lock washer and thrust washer TOOL Clutch center ho lder 07724 0050002 or equivalent commer cially available in U S A Remove the tool and clutch center 9 5 ...

Page 138: ...ator cover page 14 8 Disconnect the clutch cable from the clutch lifter lever by loosening the clutch cable adjuster Remove the flywheel and stator page 14 8 Remove the clutch lifter lever from the left crankcase INSPECTION CLUTCH SPRING Replace the clutch Measure the clutch spring free length springs as II set SERVICE LIMIT 35 2 mm 1 39 in 9 6 ...

Page 139: ...or excessive warpage or discolora tion Rep ace the discs Check the plate warpage on a surface plate using a and plates as a sat feeler gauge SERVICE LIMIT 0 15 mm 0 006 in CLUTCH CENTER Check the clutch center for nicks indentations or abnormal wear made by the clutch plates CLUTCH LIFTER Check the clu tch lifter for wear or damage CLUTCH LIFTER ROD Check the clutch lifter rod for damage and strai...

Page 140: ...or wear or damage CLUTCH OUTER GUIDE Check the clutch outer guide for abnormal wear or damage NEEDLE BEARING Check the needle bearing for wear or damage Check the meinshaft for wear or damage at the sliding surface of the clutch outer guide CLUTCH LIFTER LEVER Check the clutch lifter lever for damage Check the oil seal and needle bearing for wear or damage OUTER NEEDLE E R G CLUTCH LIFTER LEVER ...

Page 141: ...r sliding surface Install the clutch lifter lever to the crankcase Install the stator and flywheel page 14 9 Connect the clutch cable to the clutch lifter lever After installation check the following Ignition timing page 14 10 Clutch operation page 3 15 Apply transmission oil to the clutch outer guide and needle bearing Install the clutch outer guide and needle bearing onlo the mainshaft THRUST WA...

Page 142: ...ith a rib on the clutch center and slip it into place on the main shaft Instatl the clutch center lock nut and tighten the nut to the specified torque while holding the clutch center with the clutch center holder TOOL Clutch center holder 07724 0050002 or equivalent commer ciallv available in U S A TORQUE 69 N m 7 0 kgf m 511bfoftl Bend the tabs of the lock washer up against the clutch center nul ...

Page 143: ...e clutch lifter rod Insert the clutch lifter rod into the mainshaft Install the clutch lifter Instalilhe clutch pressure plale Install the five springs and spring bolts Tighten the bolts in a crisscross pattern in two orthree steps TORQUE 10 N m 1 0 kgf m 7lbfoft Check that the clutch cover O ring is in good condition Apply oil to the O ring and install the clutch cover ClUTCH PLATES FRICTION DISC...

Page 144: ...e and pull the kickstarter spindle assembly out DISASSEMBLY Disassemble the kickstarter spindle by removing the following Thrust washer and collar Return spring Ratchet spring and starter ratchet Snap ring thrust washers and pinion gear INSPECTION Check the return spring and rachel spring for weak ness or damage Check the starter rachel for wear or damage Measure the kickstarter pinion gear I D SE...

Page 145: ...shing for wear or damage Measure the kickstarter idle gear LD SERVICE LIMIT 17 05 mm 0 671 in Measure the countershaft 0 0 at idle gear bushing sliding surface SERVICE LIMIT 16 97 mm 0 668 in STARTER RATCHET THRUST WASHERS KICKST nE R SPINDLE COLLAR PINION GEAR RETURN SPRING RATCHET SPRING 9 13 ...

Page 146: ...st washer RETURN SPRING Apply molybdenum disutifide oil to the kickstarter SNAP RING spindle Install the thrust washer and pinion gear Install the thrust washer Set the sharp edge Install the snap ring in the groove of the spindle of the snap ring facing towards the outside 9 14 Aligning the punch marks and install the starter ratchet Install the ratchet spring STI RT ER RATCHET THRUST WASHER RATC...

Page 147: ... starter idle gear and washer to the countershaft Install the kickstarter spindle and hook the return spring end to the crankcase InSl all the following Clutch page 9 9 Right crankcase cover page 9 3 GEARSHIFT LINKAGE REMOVAL Remove the right crankcase cover page 9 3 Remove the clutch page 9 4 Remove the bolt and gearshift pedal Remove the gearshift spindle and washer from the crankcase 9 15 ...

Page 148: ...fall assembly when removing the guide plale and drum shifter 9 16 Remove the shift drum center pin and shift drum center Remove the bolt stopper arm return spring and washer Remove the drum pin from the shift drum INSPECTION GEARSHIFT SPINDLE Check the gearshift spindle for wear or damage Check the return spring for fatigue or damage GEARSHIFT SPINDLE ...

Page 149: ...he shift drum Install the return spring washer and stopper arm and tighten the stopper arm bolt to the specified torque TORQUE 12 N m 1 2 kgf m 9 Ibf h Check the stopper arm for proper operation Move the stopper arm out ofthe way using a screwdriver Align the shift drum center hole with the dowel pin and slip it into place Clean and apply a locking agent to the gearshift drum center pin threads In...

Page 150: ...te bolts securely Install the shifter collar onto the drum shifter Donorforgetto Assemble and install the washer to the gearshift ins al the washer spindle onto the gearshift spindle 9 18 Install the gearshift pedal and bolt Tighten the bolt to the specified torque TORQUE 12 N m 11 2 kgf m 9lbf ftl Move the gearshift pedal and check the shift mecha nism for smooth operation Install the clutch page...

Page 151: ...MEMO ...

Page 152: ...CRANKCASE CRANKSHAFT TRANSMISSION 64 N m 6 5 kgf m 47 Ibl ft 10 0 10 N m 1 0 kgf m 7 Ibl ftl 29 N m 3 0 kgf m 22 fbl tt 10 N m 1 0 kgf m 7 Ibl tO ...

Page 153: ...CRANKCASE ASSEMBLY This section covers crankcase separation for service of the crankshaft transmission and kickstarter The crankcase must be separated to service the crankshaft and transmission The engine must be out of the frame for this service The following parts must be removed before separating the crankcase Alternator section 14 Clutch kickstarter gearshift linkage section 9 Cylinder head cy...

Page 154: ...82 20 04 0 789 Cl 11 000 17 01S O 6693 0 6700 17 03 0 670 C2 C3 22 000 22 021 0 8661 0 8670 22 04 0 868 Gear ta bushing M4 Cl C2 C3 0 020 0 062 O OOOS 0 0024 0 11 0 004 clearance M5 0 040 0 OS2 0 0016 0 0032 0 12 0 005 Mainshaft 0 0 M5 19 959 19 980 0 7858 0 7866 19 94 0 785 Countershaft 0 0 Cl bushing 16 983 16 994 0 6686 0 6691 16 97 0 668 C2 bushing C3 busing 21 959 21 980 0 8645 0 8654 21 94 0...

Page 155: ... Nom 1 0 kgf m 7 Ibf ft 10 Nom 1 0 kgf m 7 Ibfoft 26 Nom 2 7 kgf m 20 Ibfoft Apply a locking agent to the threads Apply a locking agent to the threads 07631 0010000 07724 0010200 Not available in U S A 07725 0030000 07746 0010200 07746 0010300 07746 00 10400 07746 0040400 07746 0040500 07746 0040600 07746 0041100 07749 0010000 07936 3710300 07741 00 10201 07936 3710100 07937 4300001 07965 1660102 ...

Page 156: ...OOL Universal holder 07725 0030000 Remove the cone spring washer and drive sprocket Temporarily install the clutch outer guide needle bearing and clutch outer onto the mainshaft Insert the gear holder between the primary drive and driven gear Remove the primary drive gear bolt then remove the washer and drive gear TOOL Gear holder 07724 0010200 Not available in U S A Check the primary drive gear f...

Page 157: ...kcase and separate the crankcase halves NOTE Separate the right and left crankcase from each other while tapping them at selleral locations with a soft hammer r BOLTS BREATHER HOSE 0 b v 0 ml ch W O CR NKCA PULLER CAUTION i I Do not pry the crankcase halves apart with a screw driver TOOLS Crankcase puller 07937 4300001 or 07937 4300000 or 07631 0010000 use with 6 x 100 mm bohs and large washers Re...

Page 158: ... instead expand the snap ring and pull it off using the gear behind it Disassemble the mainshett and countershaft INSPECTION GEAR Check the gear dogs dog holders and teeth for damage or excessive wear Measure the 1 0 of each gear SERVICE LIMITS BUSHING M4 M5 C1 C2 Cl 23 06 mm 0 908 inl 20 06 mm 0 190 inl 25 06 mm 0 987 inl Check the bushings for damage or excessive wear Measure the 0 0 of each bus...

Page 159: ... in Starter idle gear 16 97 mm 0 668 in SHIFT FORK Check the shift fork for abnormal wear or deforma tion Measure the shift fork I D and claw thickness SERVICE LIMITS 1 0 Claw thickness SHIFT FORK SHAFT 11 065 mm 0 4356 in 4 8 mm 0 19 in Check the shift fork shaft for abnormal wear or defor mation Measure the shift fork shaft 0 0 SERVICE LIMIT 10 973 mrn 0 4320 in SHIFT DRUM Inspect the shift drum...

Page 160: ...mage or nick the hollow crank weight Separate the crankcase page 10 4 Remove the transmission page 10 6 Remove the crankshaft from the right crankcase using a hydraulic press as shown If the crankshaft bearing is removed with the crank shaft remove the bearing using the bearing puller and discard the bearing TOOL Uniyersal bearing puller INSPECTION 07631 0010000 or equivalent commer ciallv availab...

Page 161: ...ing rod big end side clearance I FEELER GAUGE SERVICE LIMIT 0 9 mm 0 04 in CRANKCASE BEARING REPLACEMENT CRANKCASE BEARING OIL SEAL LOCATION CRANKSHAFT Oil SEAL CRANKSHAFT BEARINGS RIGHT CRANKCASE SIDE MAIN SHAFT BEARINGS COUNTEASHAFT BEARINGS CLUTCH LEVER CRANKSAHFT OIL SEAL Oil SEAL COUNTEASHAFT CLUTCH LEVER Oil SEAL NEEDLE BEARING LEFT CRANKCASE SIDE SHIFT DRUM BEARINGS SHIFT SPINDLE OIL SEAL n...

Page 162: ...nkshaft bearings into both bearings squarely crankcase using Ihe special tools as shown 10 10 TOOLS Driver Anachment 52 x 55 mm Pilot 22 mm 07149 0010000 07746 0010400 07746 0041000 TRANSMISSION BEARINGS LEFT CRANKCASE Remove the countershaft oil seal Remove the screws and countershaft bearing set plates Remove the countershaft bearing and shift drum bearing ...

Page 163: ...hown TOOLS Shift drum bearing Oriver Attachment 37 x 40 mm Mainshaft bearing Driver Attachment 37 x 40 mm Pilot 17 mm Countershaft bearing Driver Attachment 42 x 47 mm Pilot 20 mm 07749 0010000 07746 0010200 07749 0010000 07746 0010200 07746 0040400 07749 0010000 07746 0010300 07746 0040500 MAllNSIHAfT BEARING COUNTEASHAFT I ATTACHMENTtplLOT MAINSHAFT I Clean and apply a locking agent to the count...

Page 164: ...plates Remove the shift drum bearing Drive in rile new Drive in new bearings into the right crankcase OBsrfngs squarely 10 12 TOOLS Shift drum bearing Driver Attachment 37 x 40 mm Pilot 25 mm Mainshaft bearing Driver Attachment 42 x 7 mm Pilot 20 mm Countershaft bearing Driver Attachment 37 x 40 mm Pilot 17 mm 07749 0010000 07746 0010200 07746 0040600 07749 0010000 07746 0010300 07746 0040500 0774...

Page 165: ...rankcase mating surfaces dress them with an oil stone After cleaning lubricate the crankshaft bearings with recommended clean 2 stroke oil Install the threaded adapter on to the crankshaft TOOL Threaded adapter 07965 KA30000 Install the crankshaft into the right crankcase using the special tools TOOLS Crankcase assembly tool set 07965 1660102 Not available in U S A or 07965 1660101 or 07965 166010...

Page 166: ...e grooves Align their end gaps with the grooves of the spline Clean all parts in solvent Assemble all parts into original positions MAINSHAFT Ml 14T After 2001 M5 23Tj 13T COUNTERSHAFT 10 14 I l o JI lll JJ J M4 BUSIH ING RING MS BUSHING M2 15T M4 21T After 2001 17T M5 23T Ml 14T After 2001 13T C3 JOT C3 BUSHING C5 26T C1 BUSHING P SPLINE SNAP C2 BUiH NG WASHER RING m Q O E C4 28T After 2001 COUNT...

Page 167: ...rk uL is the left shift fork and uCn is for the center shift fork Face the sh ift fork marks as toward the left crankcase All marks face left crankcase Apply transmission oil to the following parts Shift drum guide grooves Shift fork claws and guide pins Shift fork sliding surfaces Shift fork shaft Install the shift forks to the grooves of the shifter gear Install the shift drum by aligning the gu...

Page 168: ...lush with the case as shown TOOLS Left crankshaft oil seal Crankcase assembly tool set Assembly tool shaft Assembly collar Right crankshaft oil seal 07965 1660102 Not available in U S A or 07965 1660101 or 07965 1660100 07965 1660200 07965 1660302 or 07965 1660301 or 07965 1660300 or 07965 166030A U S A only Threaded adapter 07965 KA30000 or Threaded adapter 10 x 12 5 x 16 x 15 Assembly collar Thr...

Page 169: ...elow CAUTION Insta t he drille sprocket with its flat sid facing the outside Install the cone washer with the OUT SIDE mark facing oul Hold the drive sprocket with the universal holder and install and tighten the sprocket bolt to the specified torque TOOL Universal holder 07725 0030000 TOROUE 26 N m 1 2 7 kgf m 20 Ibf ftl Install the drive sprocket guard and tighten the bolts FLAT SIDE DRive SPROC...

Page 170: ...he primary drive and driven gear TOOL Gear holder 01124 001 0200 Not available in U S A Tighten the primary drive gear bolt to the specified torque TORQUE 64 N m S 5 kgf m 47 Ibf ftl Install the remaining parts in the reverse order of removal NOTE Refer to Service Information page 10 11for installa tion of parts removed to perform crankcase trans mission service Start the engine and check for leak...

Page 171: ...MEMO ...

Page 172: ...kgf m 16Ibf ft 4 co co n 22 N m 2 2 kgf m 108 N m 111 0 kgf m 80 Ibfo ft I 7 N m 0 7 kgf m 5 Ibf tt 11 0 1 161bf J20 N m 2 0 kgf m 14 1bf o _ 0 54 N m 5 5 kgf m 40 IbHt 88 N m 9 0 kgf m 65 IbHt 29 N m 3 0 kgf m 22 Ibf tt 028N m 12 9 kgl m 21 Ibf h I I I I I i i I II l N m 3 1 kgf m 22 Ihf ft 13 N m 1 3 kgf m 9 Ibf ftl ...

Page 173: ...hould be disassembled and cleaned on a regular basis to ensure maximum performance and service life from the internal parts Refer to section 13 for brake system information m SPECIFICATIONS Unit mm in ITEM STANDARD SERVICE LIMIT tire pressure 100 kPa 1 0 kgf cm1 14 psi Axle runout 0 20 0 008 Wheel rim runout Radial 2 0 0 08 Axial 2 0 0 08 Wheel hub to rim distance 21 25 1 013 Fork Spring free leng...

Page 174: ... 0 kgf m 65 Ibf ft 20 N m 2 0 kgf m 14 Ibf ft 4 Nom 0 4 kgf m 3 0 Ibf ft 13 N m 1 3 kgf m 9Ibf ft 16 No m 0 6 kgf m 12 Ibfoft 147 N m 15 0 kgf m 108Ibf ft 108 Nom 11 0 kgf m 80 lbf ft 7 N m 0 7 kgf m 5 1 Ibf ftl 5 N m 10 5 kgf m 3 6 Ibf ft 22 Nom 2 2 kgf m 16 Ibf ftl 20 Nom 2 0 kgf m 14 Ibf ftl 29 N m 3 0 kgf m 22 Ibf ft 28 N m 2 9 kgf m 21Ibf ft 54 N m 5 5 kgf m 40 Ibf ft 7 N m 0 7 kgfom 5 1 Ibfo...

Page 175: ...nly adjusted right and left fork legs Front wheel wobbling Bent rim Worn front wheel bearings Bent spokes Faulty tire Axle not tightened properly Unbalanced tire and wheel FRONT WHEEL SUSPENSION STEERING Wheel turn hard Faulty wheel bearing Bent front axle Brake drag Soft suspension Insufficient fluid fork Fork oil viscosity too high Weak fork springs Tire pressure too low Hard suspension Excess f...

Page 176: ...Remove the front brake disc cover bolts Support the motorcycle using the safety stand or hoist under the engine Remove the axle nut loosen the axle holder bolts and pull out the axle Remove the front wheel assembly INSPECTION AXLE Set the 8xle in V blocks and measure the unout Turn the axle and measure the runout using a dial indicator Actual runout is 1 2 the total indicator reading SERVICE LIMIT...

Page 177: ... they fit loosely in the hub WHEEL RIM Check the rim runcut by placing the wheelan a turning stand Then rotate the wheel by hand and read the runout using a dial indicator Actual unout is 1 2 the total indicator reading SERVICE UMlTS Radial 2 0 mm 10 08 inl Axial 2 0 mm 10 08 inl Check the spokes and tighten any distance collar DISASSEMBLY Remove the right side collar and dust seal Remove the left...

Page 178: ...w ones Replace the bearing in pairs 16 N m lUi kg m 12 Ibf tt RIGHT DUST SEAL RIGHT WHEEL BEARING DrSTANCE COLLAR BEARING RE OIIER WHEEl BEARING lEFT DUST SEAL 13 N m 1 3 kgf m 9Ibf ft 11 6 Place the rim on the work bench Place the hub with the disc side down and begin lacing with new spokes Adjust the hub position so that the distance from the hub left end surface to the side of rim is as shown S...

Page 179: ...ied torque TORQUE 13 N m 1 1 3 kgf m 9 IbMt Pack all bearing cavities with grease Drive in the left wheel bearing into the hub using the special tools as shown TOOLS Driver Attachment 37 40 mm Pilot 20 mm 07749 0010000 07746 0010200 07746 0040500 Install the distance collar into place then drive t he right wheel bearing using the same special tools SPOKE II b kLlrO Y SPOKE W RENCH RUBBER Pack the ...

Page 180: ...he right and left wheel collars for wear or damage Install the right and left wheel collars to the wheel as shown INSTALLATION Clean the clamping surface aftha axle shaft and axle holders Install the front wheel between the fork legs Fit the caliper over the disc taking care not to damage the brake pads Apply a thin layer of grease to the axle and insert the axle from the right side Install and ti...

Page 181: ... front brake disc cover Install and tighten the front brake disc cover bolts to the specified torque TORQUE 13 N m 1 3 kgf m 9lbf ftl REMOVAL Remove the front wheel page 11 4 Remove the brake caliper page 13 14 CAUTION Do nor suspend the brake caliper rom the brake hose 00 not twist the brake hos NOTE Do not operete the brake lever after removing the caliper and front wheel To do so will cause dif...

Page 182: ...juster and compression adjuster counterclockwise to the softest position to prevent damage the needle Loosen the fork bottom pinch bolts and pull the fork leg down and out DISASSEMBLY Clean the fork assembly especially the sliding surface of the fork slider and bottom of the slider around the center bolt before disassembling the fork CAUTION 8e careful not to scratch the slider and not to damage t...

Page 183: ...er rod the slider can move up lind down freely on the outer tube Always hold both the outer tube lind slider with your hands sfter removing the fork csp or the guide lind slider bushings might be damaged Remove the distance collar lock nut spring guide and O ring FORK _ r LOCK NUT SPRING SEAT NO GOOD X h X 1 1 lltl L NO GOOD DISTANCE COLLAR LOCK NUT _ II ii O r SPRING GUIDE 11 11 ...

Page 184: ...nter bolt aligning it index line to the fork outer tube end Set the lower end axle holder of the slider in a vise with a piece of wood or soft jaws to avoid damage CAUTION Do not overtighten the axle holder Loosen the center bolt using the special tool as shown TOOLS Fork rod holder handle 07TMB 001010A Fork rod holder attachment 32 mm 07YMB KZ40100 Remove the center bolt and sealing washer Remove...

Page 185: ...essive motions pull the slider out of the outer tube Carefully remove the slider bushing by prying the DUST slot with a screwdriver until the bushing can be pulled off by hand CAUTION Do not damage the slider bushing especially the sliding surface To prevent loss of tension do not open the bushing more than necessary Remove the following from the slider Guide bushing Back up ring Oil seal Stop rin...

Page 186: ...y in the of the protector guide prol9Ctor guide grooVtJ CAUTION The outflr tube can move up lind down fr y on the slider Always hold the slider and fork tube with your hands or the guide and slider bushings might be damaged Set the slider in V blocks and measure the fork tube runcut by roteting it with a dial indicator Actual runcut is 112 the total indicator reading SERVICE UMIT 0 20 mm 10 008 in...

Page 187: ...excessive wear or scratches If copper appears on the entire surface replace the bushings Replace the back up ring if there is distonion al the points shown Remove any metal powder from the slider and guide bushings with a nylon brush and fork oil SPRING GUIDE BUSHING 1 f T r BACK UP RING FORK DAMPER STOP RINGS Check the damper rod of the damper for bend wear or damage Check the bladder and stop ri...

Page 188: ...flammable or high flash point solvent before assembly DISTANCE COLLAR FORK CAP 1 2 N m 10 12kgf m 0 87 Ibf 29 N m 3 0 kgfom 22lbf ftJ OUTER TUBE OIL SEAL r l STOP RING DUST SEAL CENTER BOLT 54 N m 5 5 kgf m 40 Ibfoft FORK DAMPER CUua 11 16 I O_RING SPRING SEAT LOCK NUT 28 Nom 2 9 kgfom 21lbf ftl _ SPRING GUIDE i I I I i I SPRING DISTANCE COLLAR PARTITION PLATE ...

Page 189: ...ack up ring Guide bushing Slider bushing NOTE Remove the burrs from the bushing taking care not to peel of its coating Coat the slider and guide bushings with the recommended fork oil and ins1all the slider into the outer tube Drive in the guide bushing together with the back up ring and oil seal into the outer tube using the special tool TOOL Fork 1driver 46 mm 07TMD MAC01DO or 07TMD MAC010A U S ...

Page 190: ... damaging the dust seal lower the outer tube gently onto the axle holder If you removed the bladder from the fork damper measure the full length of bladder If the fu ll length is under the service limit replace with a new one SERVICE LIMIT 387 mm 15 2 in Apply fo rk oil to the bladder lips Install the bladder aligning the lips on the bladder with the grooves on the fork damper Check the bladder is...

Page 191: ... the center bolt with a new sealing washer Scribe the index line to the fork rod holder handle page 11 12 Attach the fork rod holder assembly to the center bolt aligning it index line to the fork outer tube end Tighten the bolt using the special tools as shown TOOLS Fork rod holder handle 07TMB 001010A Fork rod holder attachment 32 mm 07YMB KZ40100 TORQUE 54 N m 5 5 kg m 40 IbMt FORK TUBE FORK DAM...

Page 192: ...od until a little flows out of the end rod 3 Pumpthe outerlUbe and rod slowly eight orten times 4 Add additional oil up to the specified capacity and repeat step 3 NOTE Be sure the oil level is the same in both fork legs Support the fork leg vertically and the fork is compressed fully whenever measuring the oil level 2000 Maximum oil 35 mm 1 4 in Slightly stiffer as level capacity 548 cm 18 5 US t...

Page 193: ...s wire to the lock nut on the damper rod Wipe off any excessive oil from fork spring then install it overlhe wire and into the slider with tapered side facing up Pull the mechanic s wire up and hold the damper rod at the damper rod Remove the mechanic s wire from the damper rod Turn the lock nut by hand until it bottoms on the damper rod Install the spring seat onto the fork spring PARTlTlO MECHAN...

Page 194: ...ten the fork cap to the specified torque TORQUE 28 N m 12 9 kgf m 21 IbMt Temporarily install the fork cap in the outer tube INSTALLATION Install the fork leg Tighten the bonom bridge pinch bolts to the speci fied torque TORQUE 20 N m 1 2 0 kgf m 14 IbMt Tighten the fork cap to the specified torque TORQUE 29 N m 13 0 kgf m 22 Ibf ft A LOCKNUT B FORK CAP FORK CAP ...

Page 195: ...to the specified torque TOROUE 22 N m 2 2 kgf m 16 Ibfoft CAUTION Overtightening the pinch bolts can deform the outer tubes A deformed outer tube must be replaced Turn the wear ring with the end gap facing rearward Tighten the brake hose guide bolts to the specified torque TORQUE 5 N m 10 5 kgf m 3 6 Ibf ft Clean and apply a locking agent to the fork protector mounting bolt threads Install the for...

Page 196: ...tors Unhook the holding tab of the number plate page 2 3 Remove the wire bands securing the engine stop CLUTCH button wire and remove the engine stop button Disconnect the clutch cable and remove the clutch lever bracket BRACKET Remove the front brake master cylinder with its MASTER CYLINIDER holder keeping it upright to prevent air from enter ing the hydraulic system CAUTION Do not disc onnf JCt ...

Page 197: ...rottle housing dust cover Remove the throttle housing cover by removing the screws Slide the rubber protector off the throttle cable end loosen the lock nut and adjuster Remove the throttle cable roller and collar Disconnect the throttle cable end from the throttle drum remove the cable from the housing by remov ing the lock nut and adjuster Loosen the throttle housing mounting bolts and remove th...

Page 198: ... drum Align Ie H 6 mark on the left handlebar grip ftange with the punch mark on the handlebar INSTALLATION Inslall the bushings lower holders washers and handlebar holder nuts as shown standard position NOTE By turning the lower holder 1aO degrees you can install it 6 mm forward of the standard position By installing the optional lower holder you can set it 3 mm 0 12 in forward of the standard po...

Page 199: ...emble the throttle housing place the dust cover over the throttle housing Align the 6 mark on the dust cover with the punch mark on the handlebar Tighten the throttle housing upper bolt first then the lower bolt TOROUE 9 N m 10 9 kgf m 6 5 Ibf tt If you disassembled the throttle housing install the throttle housing as follows Apply thin coat of oil to the sliding surface of the throttle grip and t...

Page 200: ...1 4Ibf ft Place the dust cover over the throttle housing Align the L mark on the dust cover with the punch mark on the handlebar Tighten the throttle housing upper bolt fi rst then the lower bolt TORQUE 9 N m 0 9 kgf m 6 5 Ibfoftl Adjust the throttle grip free play page 3 5 Position the brake master cylinder on the handlebar Install the master cylinder holder with the UP mark up and align the end ...

Page 201: ...the engine stop bunon on the handlebar and align the end of engine stop button holder wit h the punch mark on the handlebar Install and lighten the engine stop button screw with the ground wire TOROUE 2 N m 0 2 kgfom 1 41bf hl Attach the engine stop button wire to the handlebar using the wire bands Route the number plate tab around the handlebar cross bar as shown STEERING STEM REMOVAL Remove the ...

Page 202: ... Steering stem socket 07916 3710101 or Adjustable pin spanner wrench 07702 0020001 Remove the steering stem UPPER SEAL Remove the dust seal upper tapered roller bearing Check the head bearings outer races for wear or damage BEARING REPLACEMENT Remove the upper and low er bearing ouler races from the head pipe TOOL Ball race remover Driver handle Attachment 28 x 30 mm 07946 3710500 or 07949 3710001...

Page 203: ...ller 2 required 07VMF KZ30100 Installer shaft 07VMF KZ30200 Install a new upper outer race bearing race installer and install shaft as shown Hold the shaft with a wrench turn the installer to install the upper outer race TOOLS Bearing face installer 2 required 07VMF K230100 Installer shaft 07VMF KZ30200 INS TALL R SHAFT LOW ROUTER RACE I ALL H SHAFT BEARING RACE INSTALLER UPPER OUTER RACE BEARING ...

Page 204: ...lic press and special tool as shown TOOL Attachment 30 mm 1 0 07746 0030300 INSTALLATION Apply grease to all of the bearing area Install the upper tapered roller bearing in the steering head Slide the steering stem into the steering head from the bottom Install the dust seal Install the steering head adjusting nut Tighten the steering head adjusting nut with the steering stem socket TORQUE 7 N m 0...

Page 205: ...torque TORQUE 2000 147 N m 15 0 kgf m 10Blbf ft After 2000 108 N m 11 0 kgf m 80 IbHtl Recheck the steering stem adjustment Turning the bridge side la side and check for smoothness and no binding Install the brake hose guide and lighten the bolt to the specified torque TORQUE 5 N m 0 5 kgf m 3 6 Ibfoft Install the front fender washers collars and tighten the botts Install the following Number plat...

Page 206: ...00 22 N m 2 2 kgf m 16 Ibf ft After 2000 12 N m 1 2 kgf m 9lbf hj 44 N m 4 5 kgf m 33 Ibf ft 78 N m 8 0 kgf m og 5 58 Ibf h 78 N m 8 0 kgf m 58Ibf ft 127 N m 13 0 kgf m j J 94 Ibf h 12 0 r I After 2001 I i L _______ J 1 N m 0 1 kgf m O 1Ibfoft N m 8 0 kgf m 58Ibf h ...

Page 207: ...educlIs stopping power Discard c ontamimJted p lJds and clean a contam nat d disc with high quality brake degrelJsing agent When servicing the rear w heel support the motorcycle using a safety stand or hoist For optimum suspension performance and linkage component service life the swingarm and shock linkage pivot bearings along with related seals and bushings should be disassembled cleaned inspect...

Page 208: ...8 22 clicks out from full in TORQUE VALUES Rear axle nut Rear spoke nipple Rear rim lock 127 N m 13 0 kgf m 94 Ibfoft 4 Nom 0 4 kgf m 3 0 Ibfoft U nut 13 N m 1 3 kgf m 9 Ibfoft Unit mm On SERVICE LIMIT 0 20 0 008 2 0 0 08 2 0 0 08 5 0 2 25 1 0 Rear brake disc bolt 2000 2001 Rear brake disc bolt nut After 2001 Final driven sprocket nut 42 N m 4 3 kgf m 31 Ibfoft Apply a locking agent to the threads...

Page 209: ... pivot Bent swingarm pivot Incorrect suspension adjustment Tire pressure too high REAR WHEEL SUSPENSION 07701 0020400 or equivalent commercially available in U S A 070MA KZ30100 07710 0010401 07716 0020100 077 46 0010300 07746 0010700 07746 0030300 07746 0040400 07746 0040500 07746 0040600 07746 004 1000 077 46 0041400 07746 0050100 07749 0010000 07946 1870100 07946 KA30200 Not available in U S A ...

Page 210: ...er and adjusting block Push the rear wheel forward Oerail the drive chain from the driven sprocket Remove the axle from the left side and remove the rear wheel Remove the side collars INSPECTION AXLE Place the axle in V blocks and measure the runout Actual runout is 1 2 the total indicator reading SERVICE LIMIT 0 20 mm O OOS inl AXLE ...

Page 211: ...by placing the wheel in a turning stand Spin the wheel slowly and read the runout using a dial indicator Actual runout is 1 2 the total indicator reading SERVICE LIMITS Radial 2 0 mm 0 08 in Axial 2 0 mm 0 08 in Check the spokes and tighten any that are loose DISASSEMBLY Remove the bolts After 2001 bolts and nuts and brake disc Remove t he right dust seal Remove the driven sprocket bolts nuts and ...

Page 212: ...mm Bearing remoYer shaft CAunON 07746 0050800 07746 0050100 Never install the old bearings once the bearings have blHln removed the bearing must be replaced with a new one Replace the bearings In pairs RIGHT WHEEL BEARING BRAKE DISC BOLT 42 N m 4 3 kgf m 31 Ibf ft I RETAINER WRENCH 32 N m 3 3 kgf m 24 Ibf tt RETAINER 44 N m 14 5 kgf m 33 Ibfoft _ After 2001 i o o i i oC i 0 Il tiC J L 1 BAAKE DISC...

Page 213: ...all the rim lock rim band tube and tire Torque the rim lock to the specified torque TORQUE 13 N m 11 3 kgf m 9 Ibf ft Pack the all bearing cavities with grease Drive in the new left inner and outer bearings using the speciallools as shown TOOLS Driver Attachment 42 x 47 mm Pilot 25 mm 07749 0010000 07746 0010300 07746 0040600 Install the distance collar then drive in the new right side bearing usi...

Page 214: ... with its DRIVE mark facing out 2 2001 Clean the brake disk bolt and apply Honda Anaerobic Thread lock or equivalent to the threads 12 8 Install and tighten the bolts Aher 2001 boilS and nuts to the specified torque TORQUE 12000 2001 42 N 4 3 kgfem 31 IbMt After 2001 16 N m 1 6 k9J m 121bMt Apply grease to the new right dust seal lips then install it INSTALLATION Apply grease to the inside of the ...

Page 215: ...r the driven sprocket If the master link retaining clip was removed install it on the drive chain with the closed end of the clip in the direction of wheel rotation Install the adjusting block washer and loosely install the axle nut Adjust the drive chain slack page 3 11 Tighten the axle nut to the specified torque TORQUE 127 N m 113 0 kgf m 941bfoft Snug the adjusting bolts against the chain adju...

Page 216: ... under the engine Remove the seat page 2 2 Remove the sub frame page 2 4 NOTE If you plan to disassemble the shock absorber loosen the spring lock nut and adjusting nut Remove the upper mounting bolt nut Remove the shock absorber lower mounting bolt nut and shock absorber DISASSEMBLY ADJUSTING NUT NOTE Measure the spring length for installation later Hold the shock absorber in a vise by the upper ...

Page 217: ...in by r lightly tapping on the tool with a plastic hammer until you have good access to the stop ring CAUTION To avoiddamage the threads ofthe gas valve Install the cap before depressing the chamber cap NOTE Depress the chamber cap just the minimum amount necessary fo r stop ring access SUITABLE TOOL VALVE CAP Two small screwdrivers and a shop towel are L __________ _________ required to remove th...

Page 218: ...e damper rod slowly to force the chamber cap out CAUTION The chamber cap will 1M removed with hydraulic pteSSUrll 0 its forctl un be signmuntconsidflring the air in the bladder Wear protective clothing and a face guard to protect your eyes and face in case the chamber cap pops out quickly and forcibly 2 Place the damper in a vise with soft jaws with the damping adjuster facing up being careful not...

Page 219: ...r to about 1 2 mm 0 04 0 08 in below the stop ring groove Install the stop ring in the groove of the reservoir securely Temporarilyfill the reservoir with air slowly until the chamber cap seats against the stop ring Be sure the stop ring is seated in the ring groove all the way around or the chamber cap can come apart when riding the motorcycfe Then make sure that chamber cap face is level with th...

Page 220: ...020100 Drain most of the shock oil from the damper and reservoir by pumping the damper rod in and out several times If END PLATE Clamp the shock absorber in a vise by the damper case protected on both sides by pieces of wood Remove the end plate and tape or tie it to the rubber stopper so it won t get in the way 12 14 Push in the damper seal until you have good access STOP to the stop ring Two sma...

Page 221: ...he dampe rod piston ring Carefully pull the damper rod assembly out of the damper case DAMPER ASSEMBLY DAI P R CASE PISTON RING REPLACEMENT Inspect the piston ring If the piston ring is damaged cut the piston ring and replace the piston ring and O ring under the piston ring with a new one Place the slider guide attachment over the piston All and install a new O ring and piston ring onto place S O ...

Page 222: ... thoroughly with solvent If the threads cannot be repaired replace the rod Hold the lower shock mount in a vise with soft jaws a piece of wood or shop towel Remove the burrs from the damper rod end with a file and correct the threads with a die DIE 12 x 1 5 mm Clean the damper rod with solvent after correcting the threads NOTE Make sure that filings are not stuck in the damper rod 1 0 Remove the v...

Page 223: ...end plate rubber stopper and rubber seat from the damper rod ROD GUIDE INSPECTION Inspect the rebound rubber and dust seal lips for wear or damage and replace the rod guide case with a new one if necessary Visuallv inspect the rod guide case metal If the metal is worn so that the copper surface appears replace the rod guide case with a new one Remove the a ring from the rod guide case and replace ...

Page 224: ...cess Disassemble them thoroughly clean them with solvent and blow t hem dry with compressed air before assembly CAUTION Use eddttd car to avoid getting solvent on the piston ring lind O ring The valve e lng ment andnumber of lIa tIS may differ from those shown DAMPING ADJUSTER END NUT OCKNUT WASHERS VALVE STOPPER ADJUSTING NUT CHAMBER CAP 8 mm 0 3 in 8 mm 0 3 in 11 jf 4 10 I SLIDING SURFACE WASHER...

Page 225: ...ES l Install the rubber seal rubber stopper and end plate Install the special tool onto the damper rod TOOL Slider guide 16 mm 07PMG KZ40100 not available In U S A Carefullv install l he rod guide case with the rebound rubber facing up over the damper rod NOTE The rod guide case oil seal is filled with grease Be careful not 10 remove grease from the seal Be careful not to damage the dust seal lip ...

Page 226: ... stopper NOTE Note the installation direction of the piston valves Be careful not to bind the valves when installing the piston onto the damper rod Also check that they are concentric with the damper rod Hold the lower shock mount in a vise with soft jaws piece of wood or shop lowel Install and tighten a new end nut to the specified torque TORQUE 37 N m 3 8 kgpm 27 IbMt Slake the end of damper rod...

Page 227: ...the damper case Hold the shock absorber gently in a vise by the damper case protected on both sides by pieces of wood CAUTION Do nof overtighten the vise and distort the damper case Drive the end plate squarely and evenly into the damper case with a plastic hammer FiU the damper case and reservoir with Pro Honda HP Fork Oil 5W through the damping adjuster hole_ RECOMMENDED SHOCK Oil Pro Honda HP F...

Page 228: ...te the bladder inside CAUTION Check or any oil that m ay leak out of the valve while pressurizing Replenish oil liS necessary Be sure that the reservoir pressure is correct with an accurate pressure glJuge Fill the damper with the Pro Honda HP Fork Oil 5W up to the damping adjuster hole neck Apply oil 10 the new a rings and install them to the damping adjuster Dip the damping adjuster in clean sho...

Page 229: ...ing nut and lock nut Turn the shock absorber lower mount so that the rebound adjuster screw is on the same side of the shock as the reservoir as shown Turn the spring adjusting nut until the spring length measurement recorded al disassembly is reached or until the spring length is as specified below NOTE One turn of the adjusting nut changes the spring length by 1 5 mm 0 06 in STANDARD SPRING LENG...

Page 230: ...al bearing driver 07946 1 A30200 Not available in U S A Press the spherical bearing out of the upper mount TOOL Spherical bearing driver 07946 KAJ0200 Apply multi purpose grease NLGI No 2 Molybdeum disufide MOS2 additive to the new spherical bearing DrIVe he beanng Press a new spherical bearing into the upper mount in evenly do nor allow it to tlk TOOL Spherical bearing driver 12 24 07946 KA30200 ...

Page 231: ...nstall them oorrecl dust seal in each side INSTALLATION Set the shock absorber onto the shock arm with the rebound adjuster faci ng to the right Install the lower mounting bolt by aligning the cut Qut of the bolt with the stopper on the shock absorber Install and tighten the lower mounting nut TORQUE 44 N m 4 5 kgf m 33 IbMt Install and tighten the shock absorber upper mounting REAR WHEEL SUSPENSI...

Page 232: ...oller Remove the following SH CK LINK BOLT NUT Shock absorber lower mounting bolt nut I SIDE Shock arm bolt nut shock link side Shock arm bolt nut swingarm side Shock arm Shock link bolt nut frame side Shock link Remove the side coliars pivot collar and dust seals SIDE COLLAR DUST SEAL from the shock link 0 PIVOT WILLA H 12 26 ...

Page 233: ...e INSPECTION Check the dust seals and collars for wear damage or fatigue Check the needle bearings for damage or loose fit Check the shock arm and shock link for cracks or damage REAR WHEEL SUSPENSION SIDE COLLARS PIVOT COLLARS 0jNffl j DUST PIVOT COLLAR SIDE COLLAR SEALS 0 oo I 0 o II 0 0 WASHER DUST SEALS I r i o PIVOT COLLARS If the needle bearings are damaged replace them SIDE COLLAR DUST SEAL...

Page 234: ...urpose grease Press haMedle Press the new needle bearings into the shock link bearings into the side pivot so that the needle bearing surface is lower sflockarmwith 6 5 7 0 mm 0 26 0 28 in from the end of the the marked side shock arm surface lacing out Press the Medle bearings into the shock arm with the marked side facing out 12 28 TOOLS Driver Attachment 24 l 26 mm Pilot 20 mm 07749 0010000 077...

Page 235: ...urface is lower 4 4 4 7 mm 0 17 0 19 in from the end of the shock link surface TOOLS Driver Attachment 28 x 30 mm Pilot 20 mm INSTALLATION 07749 0010000 07946 1870100 07746 0040500 Apply multi purpose grease NLGI No 2 molybdenum disulfide additive to the shock arm shock link dust seal lips collars and bearings NOTE Make sure that the needle bearing railers are in position before installing Number ...

Page 236: ...f the bolt with the stopper on the shock ab sorber Tighten all nuts to the specified torque TORQUE Shock link nut 78 8 0 kgf m 58 IbMt Shock arm nut swingarm side 78 N m 8 0 kgfem 58 IbMt Shock arm nut shock link side 18 N m 8 0 kgt m 58 IbMt Shock absorber lower mounting nut 44 N m 4 5 kgt m 33 IbMt 2 2001 Install the drive chain roller and tighten the bolt Install tile drive to the specified tor...

Page 237: ...ve the shock arm bolt and nut swingarm side 2000 2 1 Remove the screws and brake hose guides After 2001 Remove the screw and brake hose guide REAR WHEEL SUSPENSION BOLT NUT S VINIGA RM SiDE Remove the rear brake caliper from the slide rail on CALIPER RAC KET the swingarm CAUTION Do not disconnect the hydraulic line Do not suspend the brake caliper from the brake hose 12 31 ...

Page 238: ...olt and swingarm Check the chain slider and chain guide for wear or damage page 3 12 OISASSEMBLV Remove the bolts nuts and chain guide Remove the screws and chain slider Remove the following Side collars Dust seals Washers Thrust needle bearings Collars PIVOT COLLAR CHAIN GUIDE BEARING ...

Page 239: ...ss the needle bearings out of the swingarm using special tools and a hydraulic press TOOLS Driver Attachment 24 x 26 mm Pilot 22 mm Attachment 30 mm 1 0 07949 3710001 07746 0010700 07746 0041000 07746 0030300 Pack the new needle bearings with multi purpose grease Press t he new needle bearings into the wingarm using the special tools as shown TOOLS Driver Attachment 28 x 30 mm Pilot 22 rnm 07749 0...

Page 240: ...SUSPENSION ASSEMBLY 12 34 Install the following Washers Thrust needle bearings Dust seals Collars Side collars Install the chain slider with its hole and tab on the swingarm After 2001 i DUST SEALS WASHERS BEARING ...

Page 241: ... bolts and nuts to the specified torque TORQUE 12 N m 1 2 kgfem 91bMt INSlALLAlION Apply thin coat of grease to the swingarm pivot bolt sliding surface InSlalithe swingarm onto the frame Install theswingarm pivot bottto the frame and swing arm pivot Install and tighten the swingarm pivot nut to the specified torque TORQUE 88 N m 9 0 kgf m 65 IbHtJ SWINGARM REAR WHEEl SUSPENSION CHAIN GUIDE _ 12 35...

Page 242: ...screws to the specified torque TORQUE 1 2 N m 0 12 kgf m O 87Ibfoft After 2001 InSlaUthe brake hose guide 12 36 Tighten the screw to the specified torque TORQUE 1 2 N m 10 12 kgfom O 87Ibf tt Apply oil to t he shock arm nut swingarm side threads and seating surface Install the shock arm bolt and nut Tighten the nut to the specified torque TORQUE 78 N m 8 0 kgf m 58 IbMt Install the rear wheel page...

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Page 244: ...ft r I 2 N m 0 2 kgf m 1 4 Ibf ft I I I lil 30 N m 3 1 kgf m 22 Ibf tt I ___________________________________________ I I 2000 2001 I I 34 N m 3 5 kgf m 25 Ibf ft I I 6 N m 0 6 kgf m 4 3 bf tt I I I a I 0 I I 18 N m 1 8 kgf m 13Ibf ft I I I I I I I I I I I I 2 N m 0 2 kgf m 1 4 Ibf h 7 N m 0 7 kgf m 5 1Ibf ftl 34 N m 3 5 kgf m 25 bf tt 26 N m 12 6 kgf m 19Ibf ft 13 0 13 N m 1 3 kgf m 9 Ibf tt ...

Page 245: ...YLINDER FRONT BRAKE CALIPER REAR BRAKE CALIPER BRAKE PEDAL FRONT MASTER CYLINDER 13 9 After 2001 6 N m 0 6 kgf m 4 3 Ibf ft 34 N m 3 5 kgf m 25lbfoft 1 N m 0 1 kgf m 0 7 Ibf ftl 6 N m 0 6 kgf m 4 3Ibfoft 7 N m 0 7 kgf m 5 Ibfoft 26 N m 2 6 kgf m 19 Ibfoft 13 12 13 16 13 19 13 22 34 N m 1 3 5 kgf m 25 bfo tt OJ 13 N m 1 3 kgf m 9 Ibfoft 13 1 ...

Page 246: ...NDARD SERVICE UMIT Front Specified brake fluid DOT 4 Brake pad wear indicator 1 0 0 04 Brake disc thickness 3 0 0 12 2 5 0 10 Brake disc runout 0 15 0 006 Master cylinder 1 0 11 000 1 043 0 4330 0 4347 11 05 0 435 Master piston 0 0 10 957 10 984 0 431 4 0 4324 10 84 0 427 Caliper cylinder 1 0 27 000 27 050 1 0630 1 0650 27 06 1 065 Caliper piston 0 0 2000 26 900 26 950 1 0590 1 0610 26 89 1 059 Ah...

Page 247: ...ster cylinder piston Contaminated master cylinder Bent brake lever pedal HYDRAULIC BRAKE 34 N m 3 5 kgf m 25 Ibfoft 6 N m D 6 kgf m 4 3 Ibfoft 6 N m 0 6 kgf m 4 3 Ibfoft 1 N m 0 kgf m 0 7 Ibfoft 10 N m 1 0 kgf m 7 Ibfoft 30 N m 3 1 kgf m 22 Ibfoft 6 N m 10 6 kgf m 4 3 Ibf ft 7 N m 10 7 kgf m 5 1 Ibf ft 13 N m 1 3 kgf m 9Ibf ft 23 N m 2 3 kgf m 17 Ibf ft 18 N m 1 8 kgf m 13 Ibf ft 2 N m 0 2 kgf m 1...

Page 248: ... air bleeding procedure is per formed in the same manner as in the lever brake line air bleeding procedure Once the hydraulic system has been opened or if the brake feels spongy the system must be bled When using a commercially available brake bleeder follow the manufacturer s operating instructions BRAKE FLUID DRAINING Make sure that the master cylinder is parallel to the ground before removing t...

Page 249: ...r from being pumped into the system When using a brake bleeding tool foUowthe manu facture s operating instructions Pump the brake bleeder and loosen the bleed valve Add fluid when the fluid level in the master cylinder is low to prevent drawing air into the system If air enters the Repeat the above procedures until no air bubbles bleeder from appear in the plastic hose around tile bleed valVe thr...

Page 250: ...e After bleeding air completely tighten the bleed valves 10 the specified torque TORQUE 6 Nom to S kgf m 4 3 Ibf ftl Fill the reservoir to the casting ledge with DOT 4 brake fluid to the upper level FRONT Install the diaphragm and reservoir cover Tighten the reservoir cover screws to the specified torque TORQUE 1 N m 0 1 kgf m 0 7Ibf ft REAR 2000 2001 Install the diaphragm set plate and reservoir ...

Page 251: ...w ays replace tflB Push the caliper pistons all the way in to allow instal brake pads In pairs lation of new brake pads 10 assure even disc pressure NOTE Check the brake fluid level in the brake master cylinder reservoir as this operation causes the level to rise Remove the pad pin plug and remove the pad pin Afrer2001 REAR Remove the pad pin Remove the O ring from the pad pin Remove the brake pad...

Page 252: ...ear 13 8 Sel the new O ring in the grouve of the pad pin Push the brake pads against the pad spring then install the pad pin plug Tighten the pad pin to the specified torque TORQUE 18 N m 1 8 kgf m 13 IbMt Install and tighten the pad pin plug TORQUE 2 N m 0 2 kgf m 1 4Ibfoft fter2001Sh ...

Page 253: ...page exceeds the service limit Replace the brake disc if the w heel bearings are normal FRONT MASTER CYLINDER REMOVAL CAUTION Avoid spilling fluid on painted plastic or rubber parts Place If rag 01l8r these parts whenever the system is serviced NOTE When removing the brake hose bolt cover the end of the hose to prevent contamination Secure the hose to prevent fluid from leaking out Drain the brake...

Page 254: ...own TOOL Snap ring pliers 07914 SA50001 Remove the master piston and spring Clean the inside of the cylinder and reservoir with brake fluid INSPECTION Check the piston boot primary cup and secondary cup for fatigue or damage Check the master cylinder and piston for abnormal scratches Measure the master cylinder t O SERVICE LIMIT 11 05 mm 0 435 in DUST CO R BOLT NUT LEVER SNAP I PLIERS RING BOOT PI...

Page 255: ...iing the cups do not allow the lips to turn inside out Install the snap ring using the special tool CAUTION Be certain the snap ring is firmly seated in the groove TOOL Snap ring pliers 07914 SASOOOl Apply silicone grease to the inside of the boot Install the boot Install the brake lever Install and tighten the pivot bolt to the specified torque TORQUE 6 Nom 0 6 kgfom 4 3 Ibfoft Hold the pivot nut...

Page 256: ...ighten the oil bolt to the specified torque TOROUE 34 N m 3 5 kgf m 25 Ibf ftl Fill the reservoir to the upper level and bleed the brake system page 13 4 REAR MASTER CYLINDER 13 12 REMOVAL CAUTION Avoid spilling fluid on painted plastic or rubber parts PllJcfI II rag over these parts whenevBr the system s serviced NOTE When removing the brake hose bolt cover the end of the hose to prevent contamin...

Page 257: ...om the master cylinder body using the special tool as shown TOOL Snap ring pliers 07914 SA50001 Remove the push rod master piston and spring Clean the inside of the cylinder with brake fluid INSPECTION Check the piston boot primary cup and secondary cup for fatigue or damage Check the master cylinder and piston for abnormal scratches Measure the master cylinder 1 0 SERVICE LIMIT 2000 2001 12 76 mm...

Page 258: ...sembly Dip the piston in brake fluid Install the spring to the piston Instellthe piston assembly Apply grease to the piston contact area of the push rod CAUTION When installing the cups do not allow the lips to turn inside out Install the push rod into the master cylinder Install the snap ring using the special tool CAUTION Be certain the snap ring firmly se ted in the groove TOOL Snap ring pliers...

Page 259: ...p ring using the special tool CAUTION Be certain the snap ring is firmly seated in the groove TOOL Snap ring pliers 07914 S ASOOOl Connect the brake pedal to the push rod lower joint Install t he jOint pin and secure it with a new cotter pin Install th e rea r mast er cylinder and tighten the mounting bolts to the specified torque TOROUE 13 N m 11 3 kgf m 9 Ibfoft HYDRAULIC BRAKE 13 15 ...

Page 260: ...tic or rubber parts Place rag over these parts whenevtt the system is serviced Drain the brake hydraulic system page 13 3 Remove the brake pads page 13 5 Remove the oil bolt sealing washers and brake hose eyelet joints Remove the caliper mounting bolts and then remove the caliper and bracket as an assembly DISASSEMBLY Remove the caliper bracket from the caliper body Remove the brake pad spring fro...

Page 261: ...uld cause injury Push the dust seals and piston seals in and lift them out CAUTION Be careful not to damage the piston sliding surlace Clean the seal grooves caliper pistons and caliper piston sliding surfaces with clean brake fluid INSPECTION Check the caliper cylinder and pistons for scoring scratches or damage Measure the caliper cylinder 1 0 SERVICE LIMIT 27 06 mm 1 065 inl Measure the caliper...

Page 262: ...cylinder with their closed ends facing the pad NOTE Install the each piston seal dust seal and caliper piston in their proper locations Install the brake pad retainer onto the caliper bracket Note the Installation Install the pad spring into the caliper body direction of the pad spring Apply silicone grease to the boot inside then install them WhBn assembling Assemble the caliper and bracket 11 16...

Page 263: ...1 9 REAR BRAKE CALIPER REMOVAL CAUTION Avoid spilling fluid on painted plastic or rubber parts Place a rag over these parts whenev the system is serviced Drain the brake hydraulic system page 13 3 Remove the brake pad page 13 5 Remove the rear wheel page 12 4 Slide the brake caliper backward and pull it off of the slide rail on the swingarm Remove the oil bolts sealing washers and brake hose eyele...

Page 264: ... is expelled Use the air in shon spuns Do not bring the air nozzle too close to the infet or the pistons may be forced out with excessive force thet could cause injury Push the dust seal and piston seal in and lift them out CAUTION Be careful not to damage the piston sliding surlace Clean the seal groov8S caliper piston and caliper piston sliding surface with clean brake fluid INSPECTION Check the...

Page 265: ...grease Install the piston and dust seals into the groove of the caliper body Coat the caliper piston with clean brake fl uid and install it into the caliper cylinder with its closed end facing the pad NOTE Install the piston seal dust seal and caliper piston in their proper locations Install the brake pad retainer onto the caliper bracket Note the installation Install the pad spring into the calip...

Page 266: ...sealing washers and oil bolts Push the brake hose eyelet to the stopper on the caliper then tighten the oil bolt to the specified torque TOROUE 34 N m 3 5 kgf m 25 Ibfoftl Install the caliper bracket assembly onto the swingarm by aligning the bracket tab with the slide rail on the swingarm Install the rear wheel page 12 8 Install the brake pad page 13 6 Fill and bleed the hydraulic system page 13 ...

Page 267: ... Install the brake pedal joint and secure it with a new cotter pin Apply grease to the sliding surface of the brake pedal and pivot bolt Install and tighten the rear brake pedal pivot bolt to the specified torque TORQUE 25 N m 2 6 kgf m 19 Ihlott Install the return spring HYDRAULIC BRAKE 13 23 ...

Page 268: ...IGNITION SYSTEMIALTERNATOR ENGINE STOP BunON _I NITION CONTROL MODULE IGNITION COIL IGNITICIN PULSE GENERATOR AH 2 _ N m 5 5 kgf m 40 Ibfoftl 2 N m 0 2 kgf m 1 4 Ibf ft 14 0 ...

Page 269: ...N Some electrical components mey be dameged if terminals or connectors are connected or disconnected while the ignition switch is ON and cur ent is present When servicing the ignition system always follow th e steps in th e troubleshooting sequence on page 14 2 The ignition timing does not normally need to be adjusted since the ignition Control Module lCM is factory preset The leM m ay be damaged ...

Page 270: ...coil peak voltage Ignition timing FH mark TORQUE VALUES Flywheel nut Allernator cover screw 2000 TOOLS Peak vollage adapter Flywheel puller Universal holder TROUBLESHOOTING 0 7 V minimum 2000 2001 9 25 0 After 2001 Yellow Blue 120 1S0 0 Blue White 24 44 0 2000 2001 100 V minimum After 2001 20 V minimum Yellow Blue and Blue White 2000 2001 After 2001 54 N m 5 5 kgf m 40 Ibf ft 2 N m 0 2 kgf m 1 4 I...

Page 271: ...ectors 5 An open circuit or loose connection in Green wire 6 Faulty exciter coil measure the peak voltage 7 Faulty ignition pulse generator measure the peak voltage 8 Faulty ICM when above No 1 7 are normal Peak voltage is normal but no spark 1 Faulty spark plug or leaking ignition coil secondary jumps at plug current ampere 2 Faulty ignition coil Exciter coil Low peak voltage 1 The multimeter imp...

Page 272: ...0020100 not available in U S A with Commercially available digital multimeter impedance 10 MnfDCV minimum IGNITION COil PRIMARY PEAK VOLT AGE Avoid touching the sp8rk plug 8nd tester probes to prevent electric shock NOTE PEAK VOLTAGE ADAPTER DIGITAL MULTIMETER Check all system connections before jnspectjon l d If the system is disconnected incorrect peak voltage might be measured Check cylinder co...

Page 273: ...umber plate page 2 3 Disconnect the leM connector Connect the peak voltage adapter probes to the connector terminals of the wife harness side TOOLS Peak voltage adapter 07HGJ 0020100 not available in U S A with commercially available digital multimeter impedance 10 MW DCV minimum CONNECTION 2000 2001 Blue White H After 2001 Yellow Blue H Blue White H Crank the engine with the kickstarter and read ...

Page 274: ...m I CONNECTION BluefYeliow 1 1 Green White H Crank the engine with the kickstarter and read the peak voltage PEAK VOLTAGE 0 7 V minimum If the peak voltage measured is abnormal check the wire harness for open circuit or loose connection If the wire harness is normal check each item in the PEAK VOLTAGE ADAPTER troubleshooting chart If all items are normal the ignition pulse generator is faulty See ...

Page 275: ...ooil resistance between the primary terminal and plug cap STANDARD 2000 2001 9 16 kO 20 C 68 F After 2001 1 15 22 kO 20 C 68 FI If the resistance is oul of range remove the spark 2000 _ 2001 Shown plug cap and measure the ignition secondary coil resis Iance between the primary terminal and spark plug wire STANDARD 2000 2001 1 4 8 kO 20 C 68 F After 2001 10 17 kO 20 C 68 F If resistance is out of r...

Page 276: ...If the resistance is out of range replace the stator see below IGNITION PULSE GENERATOR INSPECTION Remove the number plate page 2 3 Disconnect the leM connector Measure the resistance between the BlueNeUow and GreenNJhite terminals of the wire harness side STANDARD 180 280 n 120 C 6SOF If resistance is out of range replace the stator see bellow ALTERNATOR REMOVAL Remove the number plate page 2 3 D...

Page 277: ...ud page 2 3 Disconnect the ignition coil connector and ground cable eyelet 2000 Aemove the screws alternator cover and rubber gasket After 2000 Remove the bolts and alternator cover Remove the gasket IGNITION SYSTEM ALTERNATOR 14 9 ...

Page 278: ...ruff key to the groove on the crank shaft Install the stator and tighten the bolts securely Install the grommet to the groove on the left crankcase Install the flywheel to the crankshaft by aligning the groove on the flywheel and woodruff key Install the washer and nut Hold the flywheel wit h the special tool and tighten the nut to the specified torque TOOL Universal holder 07725 0030000 TORQUE 54...

Page 279: ...al the alternator cover and tighten the screws to the specified torque TORQUE 2 0 2 kgfem 1 4IbMt After 2000 Install the new gasket Install the alternator cover and tighten the bolts Connect the ignition coil connector and ground cable eyelet Install the left radiator shroud page 2 3 IGNITION SYSTEM ALTERNATOR 14 11 ...

Page 280: ...s carbon monoxide gas that m y cause foss of consciousnsssllnd may lead to death NOTE The ignition timing is factory preset and need only be checked when an electrical system component is replaced Warm up the engine to normal operating tempera ture Stop the engine Remove the alternator cover Check that the stator index mark is aligned with the index mark on the crankcase Attach the timing light an...

Page 281: ...is procedure Remove the stator mounting bolts setting plate screw and setting plate Elongate the setting plate mounting bolt hole then reinstall it with its temporary index mark aligned with the index mark on the crankcase Install and tighten the stator mounting bolts and setting plate screw Recheck the ignition timing The stator setting plate index mark should now align between the F marks on the...

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Page 283: ...OONE STOP SWITCH CONTINUITY IG E FREE PUSH COLOR IIW G J 15 WIRING DIAGRAMS ENGINe STeP SWITCH IGHln COL Y W l S1 AR PU BLACK YillOW 0 Ll L GREEN EO P WI HE BROWN ORANGE LlOO BLUE LIGHT GREEN PIN GRl Y 0030Z KZ 4 J200 15 1 ...

Page 284: ... EXT lOW EXT G ENGINE STOP SWITCH IG E FREE PUSH 0 COlOR BIIW ENGINE STOP SWITCH BI BLACK B BROWN Y YELLOW 0 ORANGE B BLUE Lb LIGHT BLUE G GREEN L LIGHT GREEN R RED P PINK W WHITE G GRAY COLOR COMB GROUNDIMAAKING IGNITION PULSE GENERATOR ALTERNATOR IGNITION COIL 1SPARK PLUG ...

Page 285: ...xhaust gas as it passes through the exhaust chamber To obtain an extensive increase in output from 2 cycle engines it is necessary to change the exhaust timing according to the low and high speeds of the engine In this engine a valve is provided at the upper end of the exhaust port in the cylinder The valve adjusts the exhaust timing according to engine speed providing greater power output RIGHT F...

Page 286: ...eed and its speed exceeds the operating speed of the governor the steel ball is flung radially outward compressing the governor spring As this takes place the ring rack moves causing the pinion gear to rotate Rotation of the pinion gear is then conveyed to the flap valve through the pinion rod flap valve arm and flap valve drive shaft there by opening the flap valve 16 2 VAl V SHAFT ARM GOVERNOR P...

Page 287: ...plug wire Broken or shorted ignition coil Faulty ignition pulse generator Faulty exciter coil Faulty engine stop swich loose or disconnected ignition system wires 3 Test cylinder compression low Compression _ Stuck piston ring Worn cylinder and piston ring Compression Normal Damaged cylinder head gasket Faulty reed valve Cylinder head flaw Compression leak past crankcase I 4 Start by following nor...

Page 288: ...Does Not Increase Carburetor choke is on Clogged air cleaner Engine Speed Increase Restricted fuel flow Clogged exhaust chamber Pinched fuel fill cap breather Excessive carbon build up on the exhaust valve 5 Check ignition timing Incorrect Faulty Ignition Control Module OCM Correct I Faulty ignition pulse generator 6 Test cylinder compression Incorrect Faulty reed valve using kickstarter Worn cyli...

Page 289: ...heck ignition timing Incorrect Improper ignition timing faulty Ignition Control Module teM Correct Faulty alternator 2 Check carburetor air screw _ Incorrect See page section 4 adjustment Correct j 3 Check for leaking intake pipe leaking loose insulator clamp No leak gasket j Damaged insulator and reed valve 4 Perform spark test Weak or Intermittent Spark Carbon or wet fouled spark plug Good Spark...

Page 290: ...arburetor and check Clogged Contaminants in the fuel for clogged jets Not Clogged I 5 Check RC valve system Incorrect _ Exhaust pipe Correct 6 Install a farge carburetor main jet _ Condition Worse _ Jet size wrong rejet in the opposite direction POOR HANDLING POSSIBLE CAUSE 1 If steering is heavy _ Steering stem adjusting nut too tight Damaged steering heed bearings 2 If either wheel is wobbling E...

Page 291: ...in sand j POSSIBLE CAUSE Increase the fork oil capacity Use stiffer fork spring 5 Front end understeers it washes out or pushes Lower fork oil level such as on at tight track with hard ground Use softer fork spring j 6 Front end hunts at high speed it wanders under power Increase the fork oil capacity Increase shock preload 7 Front end shakes under heavy braking Decrease shock preload Increase the...

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Page 293: ... MODEL IDENTIFICATION 3 NUMBER PLATE 2 3 NUTS BOLTS FASTENERS 3 19 OPTIONAL PARTS 1 26 18 INDEX POOR HANDLING 17 4 POOR PERFORMANCE AT HIGH SPEED 17 4 POOR PERFORMANCE AT lOW AND IDLE SPEEDS 17 3 RADIATOR 5 5 RADIATOR COOLANT 3 8 SHROUD 2 3 REAR BRAKE CALIPER 13 22 REAR MASTER CYLINDER 13 12 REAR WHEEL 12 4 REED VALVE 4 21 RIGHT CRANKCASE COVER 9 3 SEAT 2 2 SERVICE INFORMATION ClUTCt VK ICKSTAATER...