Introduction ‘This service manual describes the service procedures for and technical festure of the VFR400R. ‘This Model Specific Manual includes every service pro- cedure that is of @ specific nature to this particular model. Basie service procedures that re common 20 ‘other Honda Motorcyclas/Motor ScootersiATVs ore covered in the Common Service Manual. This Model Specific Service Manual should be used together with the Common Service Manual in order to provide com= plete service information on all aspects of this motor. yole. Performing the first scheduled maintenance is very im- portant. It compensates for the intial wear that occurs ‘uring the breakin period. Section 1 and 3 apply to the whole motorcycle. Section, illustrates procedures for removal/instalation of com: __Ranents that may_be required to, perform service de ‘scribed in the following sections. While Sectioh 4 through 19 describe parts of the motor. cycle, grouped according to locations. J+ Find the section you want on this page, then turn to the table of contents on the frst page of the section. “Most sections describe the service procedure through system illustration. Refer to the next page for details on hhow to use this manual. Hf you are not familiar with this motorcycle, read Techni cs Feature in section 20. | it you don’t know the eouree of the trouble, go to section 21 TROUBLESHOOTING, [ AtLinronmarion, 1LusrRanions. omECTIONS | AND SPECIFICATIONS INCLUDED IN THIS PUBL | CATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF AP- PROVAL FOR PRINTING. HONDA MOTOR CO.,LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. NO PART OF THIS PUSLICATION MAY BE REPRO: DUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAIN: ‘TENANCE ON HONDA MOTORCYCLES, MOTOR - HONDA MOTOR CO.,LTD. SCOOTERS OR ATVS. ‘SERVICE PUBLICATION OFFICE Date of leave: Feorvary, 1990 © HONDA MOTOR CO., LTD. € & 6 z Crankshaft/Piston/Transmission E ka Electrical |__| wiring Diagram [19 | Contents i Cooling System Fuel System [_cooten seem SES | Engine Removal/installation Ea a ae Le ¢ | Cylinder Head/Valves Cluteh Gearshift Linkage [10 | Front Wheel/Suspension/Steering E EA Rear Wheel/Suspension E 13 | Brake System }14 | 7 Charging System/Alternator Ha Ignition System Ha Electric Starter/Starter Clutch a Lights/Meters/Switches Ea Technical Feature EQ Troubleshooting Ei a Index E41Important Safety Notice ———————_——___ Indicates 2 strong possibilty of severe personal injury or death if instructions are not followed. Indicates a possibilty of equipment damage if instructions are not followed, Gives heloful information Detailed descriptions of standare workshop procedures, safety sincipies and service operations are not included. I is | importa te note that tis manval contains some warnings an cautions against some specific service methods which Could enuse PERSONAL INJURY to sorvice personnel or could damage & voice or render tunaete Please understand | {hat those warnings could not caver all conceivable woys in which service, whether or not recommended by Honda. might be done or ef the pocily hazardous consequences of each conceivable way, nor could Honda vestigate al uch woys, Anyone using service procedures oF to's, whether or not recommended by Honda, must sasty himself thoroughly that neler personal safety nor vehice safety wil be eopercized by the sevice methods or tools selected ‘Type Codes S ' “+ Throughout this manusl, the following abbreviations are used to identify incividual model Code roars E U.K. ale aa Rasite | Fi Model ot France =a] 1M Model oni “Tammany — = |How to Use This Manual Fi ling Information You Need + This manual is divided into sections which cover each af the major components of the motorcycle. To quickly find the section you are interested in, the first page of each section is marked with a black tab that lines ‘Up with one of the thumb index tabs befare this page “The fist page of each section lists the table of contents within the section Feod the service information and troubleshooting related ‘0 the section before you begin working + Anindex ofthe entire book is provided inthe last chapter 10 directly locate the information you need. Note on the Explanation Method of This Manual + The removal end installation of parts are for the most part Mustrsted by large and clear illustrations that should provide the reader with visual ald ia understending the maior point for servicing + The system ilustrations are augmented by calfoute whose numbers or letters indicate the order in which the parts should be removed oF installd. + The sgquence of steps represented numerically are differentiated from the ones represented alphabetically to natify the teader that they must perform these steps seperately. For exaimpla, ifthe stops prior and up to camshaft removal are performed with the engine inetalied, but the subsequent steps lke cylinder head removal require engine romoval, the callouts are grouped in numerical end alphabetical orders. + Taellustrations may contain symbol marks to indieate necessary service procedures and precautions that need tobe taken, Refer to the next page for the meaning of each symbel mark. + Also in the illustration fsa chart that lists information such as the order in which the partis removediinstalled, the name Of the part, and come extra notes that may be needed, *+ Step by step instructions are provided to supplement the illustrations when detailed explanation ofthe procedure Is naces- sary oF illustrations alone would not sutfice. + Service procedures required before or after the procedure described on that particular page o inspection/adjustment proce: ures required following the installation of parts, are described under the ttle Requisite Service. + Standard workshop procedures and knowledge Covered in the Corman Service Manus! are abbreviated in this manual, Detailed description of the procedure ‘Symbol mark System illustration Step sequence (numerals en ‘or alphabets) ~ Part number ber of Extra notes or precauilon related to the service procedureSymbols ‘The symbols used throughout this manual show specific service procedures. f supplementary information is required pertsin ing to these symbols, I would be explained specifically in the text without the use of the symbols BP | rentace tne paris) with new ones) before assembly Use special toot Use optional tool. These tools are obtained as you order parts. Torque specification, 10 Nem (1.0 kgm, 7.2 feb) 20) Use recommended engine cil, unless otherwise specifies. Use molybdenum oll solution (mixture of the engine cil and molybdenum grease with the ratio 1 : 1 Use muit-purpese grease (Lithium based mut purpose grease NLGI #2 or equivalent) Use molybdenum disulfide grease (containing more then 3% molybdenum disulfide, NLGI #2 or equivalent) Example: Molykote® BR-2 plus manufactured by Dow Corning, US.A, Multipurpose M2 manufactured by Mitsubishi Oil Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NUGI #2 or equivalent) Example: Molykote® G-n Paste manufactured by Dow Corning, US.A, Honda Moly 45 (USA. oniy) Rocol ASP manufactured by Raco! Limited, U.K Rocol Paste manufactured by Sumica Lubricant, Japan Use alicone grease | Apply a locking agent. Use the agent of the middle strength, unless otherwise specified Apply sealant Use brake fluid, DOT 3 or DOT 4. Use the recommended brake. fluid, unless otherwise specifi bleml'si Pik | RI Also Use Fork oF Suspension Fld1. General Information General Safety mW Model Identification 13 Specifications 14 Torque Values 14 General Safety Carbon Monoxide If the engine must be running to do some work, make sure ‘the area is well ventilated. Never run the engine in —— * The exhaust contains poisonous carbon monoxide gas ‘that ean cause loss of consciousness and may lend 10 death. Fun the engine in an open tion system in an enclosed (ea oF with an exhaust evacu: Gasoline Work in @ well ventilated area. Keep cigarettes, flames or sparks away from the work area or where gasoline Is stored * Gasoline fo extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. temain hot for some time after the engine is run, Wear insulated gloves or wait until the engine and exhaust system have cooled before handling these parts, Tools 17 Lubrication & Seal Points 119 Cable & Harness Routing rar | Used Enginertransriission Oi! *+ Used engine ol (or transmission olin two-stiokos) may ‘cause skin cancer if repeatedly Taft in contact withthe -tkin for prolonged poriods. Although this fe unlikely unlass you handle used oll on a dally basic, i is etl advisable to thoroughly wash your hands with soap ‘and water as soan as possible after handling used ol KEEP OUT OF REACH OF CHILDREN. ~ Brake Dust ever use an air hose ot cry brush to clean brake assemblies. —| + inhaled asbestos fibers have been found to cause respiratory disease and cancer Brake Fluid CAUTION + Spiling fluid on painted, plastic or rubber parts will | | {damage them. Place a clean shop towel over these parts whenever the system s serviced. KEEP OUT OF REACH OF CHILDREN.General Information ee Coolant Under some contitions, the ethylene glycol in engine coolant Is combustible and Its flame is not visible, If the ethylene ‘lycol does ignite, you wil not see any ‘lame, but you can, be burned. ‘Avoid sping engine coolant on the exhaust syatem ‘or engine parts. They may be hot enough to cause the ‘coolant to ignite and burn without a visible flame. + Coolant (ethylene glycol) can cause seme skin ita ton and is poisonous if swallowed. KEEP OUT OF REACH OF CHILOREN. + Donotremove the radiator cap when the engine is hot. ‘The coolant is under pressure and could scald you. * Keep hands and clothing away from the cooling fan, as it starts automatically. It contacts your skin, wash the affected areas immedi- ately with soap and water. If ft contacts your eyes, flush them thoroughly with fresh water and get immediate mect- cal attention. IFit is ewallowed, the vietim must be forced ‘to vomit then rinse mouth and throat with fresh water before cbtaining medical attention. Because of these ‘dangers, always store coolant in a eafe place, away from ‘the reach of children Nitrogen Pressure For shock absorbers with a gas-filed reservoir: * Use only nitrogen to pressurize the shock absorber. “The use ofan unetable gas can cause a fie or explo. sion resulting in serous injury + The shock absorber contains nitrogen under high | pressure. Allowing fie or heat near the shock aby orber could lead to an explosion that could result Serious injury + Failure o release the pressure from a shock absorber | before disposing of ie may feed and serious injury iff is heated or pieroed To prevent the possibilty of an explosion, release the nitrogen by pressing the valve core. Then remave the valve stom from the shock absorber reservoir. Before disposal ofthe shock absorber, release the nitrogen by pressing the valve core. Then remove the valve stem ‘rom the shock absorber Battery Hydrogen Gas & Electrolyte ‘The battery gives off explosive gases: keep sparks, flames and cigarettes away. Provide adequate vert. lation when charging. | + The battery contains sulfuric acid (electrolyte). Con- tact with skin or eyes may cause severe burns. Wear protective clothing and a face shield electrolyte gets on your ekin, flush with water, = electrolyte gets in your eyes, flush with water fo ‘at least 15 minutes and eall a physician. + Electrolyte is poisonous. = If swallowed, drink large quantities of water or milk ‘and follow with milk of magnesia or vegetable oil ‘and call a physician. KEEP OUT OF REACH OF CHILDREN.Model Identification General Information (1) FRAME SERIAL NUMBER ‘The frame serial number is stamped on the right side of ‘the steering head, imbaris stamped on the top of the crank (9) CARBURETOR IDENTIFICATION NUMBER ‘The carburetor identification number is stamped on the _ carburetor body intake side. “The color code label is attached to the the rear seat. When ordering colorGeneral Informations Specifications Uni: man tn — Generat 1 from Specifications | Dimensions Overall length | 1,985 (78.1) ‘Overall length (M Model only) | 2/036 (€0.1, G: 2,070 (81.8) Overs width _| 705 27.81 1,078 142.3) | 11345 (63.0) ‘Ground cloarsnce —| 125449) Dry weight Dry weight (M Model only) Curb weight Maximum weight capacity Maximum weight capacity 178 kg (385.8 1b) 176 kg (388.1 Lo) 192 kg (423.3 Ib} 347 kb (768.0 15} islacement Compression ratio = Valve train Intake valve opens at 1 mm lft lngake valve closes st 1 mm if Exhaust valve open at 1 mm lift Exhaust valve closes at 1 mm lift Lubrication system - | pump type Cooling system Alt fiteation Crankshaft type Fring order Cylinder strangement Gylinder number OUTS son aol (M Mode! only) | $42 kg (754.0 19) Frame Frame type —] Backbone Front suspension Telescopic fork Front wheel travel 120 (4.7) Rear suspension Swingarm Fear whee! travel 120 (4.7) . Rear damper Gas-filled damper with reservoir Front tre size 120/60 VRI7 Rear tie size 150/60 VIB Tire brand (Bridgestone) FRIAR — | — a ‘Tite brand (Dunlop! FRR ~ | ‘KS10A RADIALIKE10 RADIAL Tire brand (Yokohama) FRIAR _| — Tire brand (RC) EB/AR a Front brake Hiydraulle double aise Rear brake Hydraulic single dice Caster angle 25°20" Teall length, 96 (3.8) Fuel tank capacity 15 liters 14.0 US gol. 3.5 Imp gal) Fuel tank reserve capacity | 2.0 ters (0.5 US gal, 0.4 Imp gal Engine Bore and stroke | 35.0x42.0 2.16 «1.68, 998 em? (24.9 cu ia) 3st Gear driven DOHC, 4 valves per cylinder 18° BTDC. 38° ABDC 35°B800 5° ATOC Forced pressure and wet sump Trockois Liquid cooled Paper filter Unittype, 4 main journals i 90° — 4~ 270" ~ 3 — 90° — 2 4 cylinders 20°V> General (Cont'd) General Information eee es Units mm Gi) tem Specifications ‘carburetor Carburetor type ‘Constant velocity, 4 carburetors | Throttle bore 2203) Drive Tain Ciutch system ‘Mutt-plate, wet Clutch operation system Cable operated Transmission 6 speeds Primary reduction 2117 (34/72) Secondary reduction = ‘Third reduction _— Final reduction 2.666 (15/40) Gear ratio tot 2.928 (14ran) Gear ratio 2nd 2.166 (18/39) Gear ratio 3ro 11300 (20/38) Gear ratio ath 1.891 (22/35) Gear ratio Sth 1.435 (23/83) Gear ratio 6th 13te (22/29) Gear ratio reverse a Gearshift pattern left foot operated return system 1-N—2-3~4—5—6 Electrica? Ignition eystom Digitalized ful wansistor ignition Starting system | Electric starter motor Charging system TTiple phase output alternator Regulatorirecifier type ‘SCR Shorteditrple phase ful Lighting system Battery AC rogulator type = 1-5General information Unit: man find 1-6 — twbvicaton kom | Standard |) Service Limit | Engine of copacky a draining 2 Wher 254 US at D4 imp wT = 5 cisassemby 510 tere (217 US qt 266 Imp ath = tol fiter change 2.5 ites (2.68 US ty, 3.20 imp) = | Recommended engine cil Use Honde 4-stoke ol or equivaane Olt viscosmes Viscosity: SAE fOW=a0 | Other viscosity shown in the chart moy be Used when the average temperature in Your fing area fs within she incated range Oil pressure at oi! pressure switch ‘490—588 kPa (5.0—6.0 kg/cm’, 71-85 psi) | 4 5,000 remi@o°cni76¢F) — Oil pump rotor tip clearance @ 0-15 (0.006) _ body clearance @ 0.15-0.22 (0.006—0.009) = tnd clearence @ 0.040.09 (0.0016-0.0035) = [— Fust System pe = Carburetor identification number OE 3A (6), VDE 3C (aR) = ation number (M Model oniy) | VDE SF te 1 = VE 36 (AR) bE ati (6) | atin jot a = (igh sisaced = = a) = = was a = (Front) #22 = ‘Rear #120 = Stow jot #35 = Jet needle clip postion it = Pilot screw inal apering 2 ms out = Pitt screw high altitude acfustment = = Pilot screw final opening 118 turns out = Pilot sorew final opening (M Model ony Turns oot fF) = “2 ene oat AR, G) ‘it screw inital opening “ — ‘ir serew high slttude ediustmont a = Frost level 6.8102 = | Carburetor Vacuum cttoronce Within 40 mmf (1.6 int) = S2se carburetor (For eatburetorsynohronization) | No. 2 carburetor = tele speed 1,200 2 100 min (mi = Throttle grip fre play 256 10.08~0.24) , Accelerator pump clearance = =General information oo Unit: mm fe — oytnder Hood 1 : tem ‘Standard Service Limit ‘Cylinder compression 1,274 © 196 kPa (13.0 £ 2.0 kgiem’®, tae 28 pal200 mir bd = | cylinder compression iterence _ | 0 mami (8 ni = Goi elesrance Iv O13 048 (0,008-0.0071 a \ Ba 0.21027 (0.008-0.0111 = | cyinder need warpage = 20.10 0,008 Stave neh I Ja717-92.987 01.2002—1.2975 sar th2e8) & Seazo—az.e0e (1.2707—1 2860) a2.80 (1278) Comshat unaut = 008 1.00%) Camhalt of larance A 0.040--0.082 (0.0016-0.0032) 0.082 10.0030) 3 eas oa Camshaft jours OD. A 27.889~27.960 (1100013008) 27.88 1.0101 C = jas Combat older 0. & 75.000-28.021 (1.1024~1.1082) 28.03 1.108) : os aay Valve etm 0. 1$a78~4.490 (0.1762-0.1720) 447,0.170) & ees 4.490 (0.1758-0.1760) Gite (01780) valve gue 1. IN @S00=2 812 10.1772-0.1770) 10.100) x Sis00—4612 (01772-01770) 4.5e f.t60) | ‘Stem-to-guide clearance IN _ | 0.010~—0.037 (0.0004-0.0015) 0.08 (0.008) x 0.020-0,047 (0.0008-0.0019) o.12 1.008) | vv aude projection above evindar head Nth) | $00.4 = xin | 1204) = Bator guide neta Fin, eshte ate gen oe wr, eer tection of 9 refigerator FE ter sso anton act a ‘2. Heat the cylinder head to : | Yoo 18080 12-200") | Velve seat width IN 1.70—2.30 (0,067—0.091) _ x 170230 9.067=0.099) _ Valve sping fe length = -_ & = -_ tre Ba .20 202 19) tho Bx gua aa 30.31.18) ure IN aba Gael ss2tian Outer EX bea 381 ga tian | Rocker arn 0. 8.600 2.516 0.2940-0.99821 e.83 0.220 & £800 a.516 foe46—0.99621 f183 (0.936) Rocker arm shaft O18 8.t00 0.408 (0.0909 0.2240) Bae (0.290) & 8 466—8.488 (0.9889~0,39401 a6 (0398) hocks smtovockr orm chat clomance as i Vote titer Ob a _ Xie ter bore Lo. = — Haru appa acjster assist spring tee natn | — = Ferautclapet acter compression vata wit) | — = ierovene aUnies mae find — Crinderiston tem standard Serve Unt Cynder 1 35.000 65.018 165s 2 18Be) 8607 16a Minder ovt of ound bay 0.10 (0004) | Cylinder taper — 0.10 (0.004) Chine woroge = 10 (0.004) Piston rank section IN mak facing toward the nae side a ton O30! | stvomsaee0 16022 40s s92a.100) | Peston Q. measurement pin | tows) 28 Pieter pi ote a) 14.002 14:008 (0.6513-0.5518) 14.02 10882) oS - ry : * | co | | Cylinder-to-piston clearance: 0,010—0,045 (0.0004—0.0018) 0.10 (0.004) | Piston pin O.D. 13.994 ~14,000 (0,6503—0.5512) 13.98 (0.550) | Pistan-to-piston pin clearance 0.002—0.014 (0,0001—0.0006) 0.04 10.002) | Connostng rod sopiston si clesrance B.o16 0.040 0.00060. 00re) 8.08 (0.002) | torn 8.018 0.080 (0.0006 0.0020) 2:10 (0.008) | | Second 8.018-0.048 (0.0006~0.00"8) 0 f.0os) Tong end gor | St2"0129 oer oor 0.08 (o.02s) Second ng nd gop 048-0128 (0.007=0.019) 2.88 (ooze) Oivng (ed ral rd gap | 2070.00 foooe—o.034) 038 (oar! ‘oo ty ae “mane tacng — Second tng ark : mark tang up = Cranshat = i Connecting rod small end 1.0, 14.016—14.034 {0.5518—0,5525) 14.05 (0.553) | Conestng rod ig end ede searance dri0~0.20 19.008 0.012) xt 1.02) Tada! clooronce = = Crankshaft unout = 0.08 (0.001) ° rh | Craton ot cosrance 0.028-0.082 10.0011 -0.0020) 0.07 (0.003) rankpinbearng sleton See poe 110 a Nain ural of denranee 8.026"0.049(0.0010-0.0010) 0.07 0.003) Bain fourelbaag sletion See page 1140 = [Wotan | Kickstaner pron gear 1. = = Kickstart’ opine OD ae = Kcktarte le gear 1D a a Coumsrehat Oat Nera le gear = = Rcdeater ie gear bushing om = ‘D = =— Tansmission Unit: en nb tem Standard Service Limit “Tanemission gear LD. MS, M6 2, ¢3, ca “Tanemission geer bushing O.D. MS, M6 c2, €3, c& “Tansmission gear bushing LD. MS 2 Gear-to-bushing clearance at MS, M6 gear at C2, C3, C4 gear Mainshaft 0.0. at MS gear bushing Countershaft O.. at C2 gear bushing cz eter _ Gear-to-shatt clearance Gear bushing-to-shaft clearance at MS gear at C2 gear ‘Shift fork clew thickness © R Shift fork LO. L ¢ R Shift fork shaft 0.0. L c 8 728,000~28.021 (1.1024~1.1032) 28,000—28.021 (1.1024~ 1.1032) 27,959-27.980 (1.1007 1.1016) 27:959- 27.980 (1.1007= 1.1018) 24,985~25.006 (0.9837—0.9845) 24,985 25.006 (0.9837-0.9845) 0.020-0.062 (0.0008-0:0026) 0,020-0.062 (0.0008—0.0024) 24.987—-24.978 (0.9830—-0.9824) 24.967—24.978 (0.9830—0.9834) 0.007~-0.039 (0.0003-0.0015) (0.007 0.039 (0.0003—0.0018) 8.93--6.00 (0.283~0.236) 8,936.00 (0.283-0.236) 8,936.00 (0.233-0.236) 12.000—12.021 (0.4724--0.4733) 12,000 12.021 (0.4724—~0.4783) 32.000—12.021 (0.4724—0.4733) 11,969— 11.980 (0.4712-0.4717) 141969— 11/980 (0.4712-0.4717) 11,969— 11.980 (0.4712-0.4717) 28.04 (1.104) 28.04 (1.104) 27.84 (1.100) 27.84 (1.100) 25.03 (0.985) 25.03 (0.985) 10.10 (0.008), 0.10 (0.008) 24.96 (0.983) 24.96 (0.983) 0.08 (0.002) | 0.08 (0.002) 5.8 (0.23) 5.8 (0.23) 5.8 (0.23) 12.04 (0.474) 12.04 (0.474) 12.04 (0.474) 11.98 (0.470) 11.95 (0.470) 11.98 (0.470) 1-9General information eee OI EEeEee—EEEE— Unite ma Gin) [— Clutch system tem Standard Clutch lover free play 10-20 (0.4-0.8) | Recommended clutch fluid — Clutch master cylinder LD. = Giuteh master piston OD, I — Gluten outer 1.0. 28.000—29.021 (11417— 11426) 28.08 (1184) | Clutch outer guide 0.0. 28.967—28.980 (11404— 11408) 28.98 (1339) to. 21.995—22.016 (0.8659—0.8667) 22.05 (0.868) | Mainshatt O.D. st clutch outer guide — — | Oil pump drive sprocket LD. 29.025-29.075 (1.1427~1.1447) 29.11 (1.146) Clutch center B LD (63.964~63.990 (2.5183—2.5183) 64.00 (2.520) One way clutch inner O.. 47.968~47.378 (1.8642—1.8653) 47.36 (7.8846) Clutch spring free height (As a set of Spee) | 8.5 (0.21) 4.8 (0.19) | Clutch spring fee length j— — Clutch dise thickness | 2,92-3.08 0.115-0.121) 2.8 (0.110) Clutch dise thickness A (= — 8 = = Clutch plate warpage a 0.80 (0.012) | Centrifugal clutch drum 10. = _— bushing 0. — — Contrifigal clutch center guide ID. — — | on. — — Centrifugal clutch center guide collar height — — Centsifugal clutch spring free length a = | Clutch tining thickness — — Cranksheft O.D. at clutch center — —_ [7 Contin Svatom Coolant capacity (Radiator and engine} 2.1 ters (2.22 US ft. 1.85 Imp at — M Model | 2.0 tars (2.11 US ft, 1.76 Imp at) — (Reserve tank) 0.2 iter (0.21 US qt, 0.18 Ima at) = Radiator cap refef pressure 108-137 kPe (1.10~1.40 kgfemé, 18-20 psi) — ‘Thermostat begins to open 80—84°C (176—189°F) = Thermostat fully open 85°C (209°F} — ‘Thormostat valve litt 8.0 (0.23) min = = [— Drive Train Recommended final drive ol! Final drive gear oil capacity at disessembly at draining Final drive gear backlash Final drive gear backlash ference between | Ring gear-to-stop pin clearance (A) Stop pin shim 1 Ring gear spacer Pinion spacer i Final drive goar assembly preload Output gear backlash Output gesr 1.0. ‘Output gear bushing OD. 10, Output drive shaft 0.0, Output gear damper spring free length Output shaft adjustment shim Countershatt drive shaft adjustment shim [TTL HH i HILT LI LD 1-10General information eee ost: me ti) — Wheels/Tires ' tem Standard Service Limit j Minimum te tread depth (FR) ARR} Cold the pressure Driver only (FAL Daver only (RA Driver and passenger (FR) ' Driver and passenger (RR) | Front and roar axle runout | Font and rear whee! rim runout (Rady axis) Front west hubsowim distance Front wheal hub standerd surface Fear wheel hub-torim distance | Rear whes! tb standard surface |, Wheel balance weight (Front) (Pear Drive chain slack Deve ehain size line (01D) 228 kPa (2.25 kglem’, 33 psi) 225 kPa (2.25 kglem’, 33 psi) 15-25 (6/8—1) 1.5 10.06) 2.0 (0.08), 0.2 (0.01) 2.0 (0.08) 2.0 (0.08) 160 9 (21 02) max [60 9 (2:1 02) max les x) | RK aBszssmeri04 = Front Suspension Fork spring free length 277.3 (10.91 271.8 (10.70) Fork spring free length A — — 8 = - oe Fork spring direction ‘Tightly wound coil end facing down = Fork tube runout a 0.20 (9.008 | Recommended fork ot Fork hid — Fork a level 122 mm (4.8 in) — [Fork vet i _ = | wu _— — Fork oi eapacity 380 ce (13.2 US 02, 13.7 Imp oz! — | Fork oll capacity (M Model only) 404 ce (13.7 US 02, 14.2 Imp 02) — Fork ofl eapacity (A) — — wu = = Fork air pressure a — Steering bearing preload 1.0=1.8 kg (2.2~3.3 1 — Rear Suspansion Shock absorber spring free length 168.7 (6.2 in} 185.5 (6.12) | | Sheek absorber soring free length (R] : 0 ' Damper gas pressure Damper compressed gas Damper rod compressed force at 10 mm compressed |, Damper driling point | shock absorber spring installed length i (Standard ' ‘Adjustable range) ‘Shock absorber spring adjuster standard position ‘Shock absorber spring direction Recommended shock absorber oll | shock absorber aif capacity sie pressure 98 kPa (10 kglem?, 142 psi Nitrogen, 15—20 kg (3344 Ib) See page 13-13 147.7 16.81) HA LETT 1-11Unit: men tin) With digital type) [— Brakes 1 : tem Standard | Service Limit | Front brake tid Dora = Brake lever fee play _ — Brake ped wea indicator = To the groove 1 | | | | | | broke dise thickness 410.16) 3.5 (0.14) se runout ae 0.30 10012) master cylinder 14,000~14.085 (0.9512 0.5829) 14.06 (0.852) | master piston 0.0. 18.957—13.084 (0.5495—0.5506) 12.98 (0.549) | Caliper ovinder 1D. = — | Caliper evlinder LD. Upper) 30.280-30.280 (1.1902~ 1.1921) 30.29 (1.192) | ftowen 2.40025, 450 (1.0000 —1.0020} 25.46 (1.0024) caliper piston O0. = es Satiper piston 0. (Upper) 30.148-30.198 (1.1869—1.1689) 30.14 (1.1886) : (tower) 25.318 25.366 (0.9986-0.9887) 25.31 (0.9965) | Broke drum Lo. = oe broke fining thickness — a | Rear broke fia | bora = brake pedal height = a brake pedal fre play = — broke bad wear inleator = To the groove 2 ' @ brake dise thickness 6.0 (0.28) 5.0 (0.20) bate ise runout — 0.30 10.012) master oylinder 1. 14.000~14.088 (0.5512 0.6828) 14.06 (0.588) master piston OD. 13.857—13.986 (0.5495 0.8506) 13.98 (0-549) Caliper evlinder 1. 25.400—28.480 (1.0000 — 1.00201 26.46 (1.0028) alper piston OD. | 25.916-28.368 (0.9060-0.9987) 26.31 0.998) brake drum 10. = — brake fining thickness = a | BattoryiCharging System —aae Alternator charging col resistance (At 20°C/68°F) | 03-100 _ Roguiatorhectiter regulated votiagelamperage | 12.5-~15,6 VIO-8 A at 6,000 min (pm) = Bottery capacity av ~ Gan = {Maintenance Free betery: YTXTA~BS) = Specified current teskage pins 1 mA max Battery specific gravity (Fully chargec) = | (Seeds chargingh a = | Battery charging rate (Normal 0.7 A/S—10 he — | (Ouiek) 20 Art he = | Bortery voltage (Fully charged at 20°C/68°R) | 18.0~18.2 V _ (Needs charging at 20°c/eaem | 12.3 = Alternator lighting col resistance (at 20°C/68°") | —— — ‘AC regulator regulated voltage With anelogue typel| — = ee 1-12General information —_———_—$ ——— —o'_' Units men ind = Ignition System Standerd Serviee limit Spark to Standard NOK (Stands NDI tor cod ctnnaonow S°C/44°F NGKD | fFor cad ciation °C"°F ND) tor ovtrded ah oped ing NEO for entered Pgh sped ing ND) | Spats pos gop | Irion sting “Fark i | Item Advance starts stops Fully advance Alternator exclter coll resistance (At 20°C/68°F) ERSEH, YO7FER EREEH Y2aFER ERIOGH YarrER 0.60.7 (0.024~0.028) 438° BTOC at 1,200 min’ (ror) 1,800 # 200 min (ror) 42,000 200 rin" (eprm) | 372% BTDC at 12,000 mit tom PUTT Ignition coll resistance (Primary: at 20°C/68°F) | 2.63.5 0 (Secondary with plug cap) } 14—26 ko | {Secondary without plug cap! | 11—14 ko | uae generator resistance (At 20°C/63°F) 450-550 9 | ht 8 te we —$@$@— > $m mam $$ Main fuse 30.8 | Fuse 208 K1, 108 x3 Headlight thighviow bear} 12 V 60/50 W x 2 (Ha) Tailforake ight 12V 521 Wx2 | Ucense ight 12V5W Position Hight Front ture signal/running light Front turn signal light Fear tum signal light Inetrument light Oil pressure warning indicator Tailforake light warning indicator Side stand waming indicator Low fuel indicator Coolant temperature indicator Gil temperature Indiestor High beam indicator ‘Turn signal indicator Neutral indicator Reverse indicator ‘Overdrive indicator Olt temperature sensor resistance Fuel unit resistance (At ful evel) (At empty) Fuel pump flow capacity (min.tminute) ‘Thermo sensor resistance (5O°C/122°F) (gorcnn76°r) (120°C/248°F) Fen motor switch Sters t0 close (ON) ‘Stops to open (OFF) | 12V OWE, AR) 12VaWE, G) Seal lll| PPP) HT 98-1029C (208 -218°F} | 98—97°¢ (199-2079) TEEPE TEE stating System $$ $a a$$ i Starter riven gear 0.0. | Starter reduction gear s Starter reduction gear 1.0. Starter motor brush length ft OD. 41,978 ~42.000 (1.6526—1.6535) 8.894~ 10.000 (0.3936-0.3937) 10.070—10.110 (0.3965~-0.3980) 12-13 (047-051) 41.96 (1.852) 9.80 10.380) | 10.18 (0.400) 6.5 (0.26) 1-13General information ——— Torque Values aan Fasteners ype t | Sr hor bot andaat | 808,38) | Smmarew 408.3) Smmbex bot andnut | 1011672 | Simm screw 8109.7 | Smmnex ot andmt 22.82, 16) | Bim fonge bot (© mm nea) | Sean 1Ommnox bot and nat | 354.5, 28) | ammtango bol 10 mm heed aneeut | 32,1. 0) 2mm ex bot ardnst 8846.5, 40) | Simm forge bak and mr | arezz0) | a | 400, a8 + Torauespecitistion ltd blow ae for imporanefesenes + Others shouldbe tighenes fo standard toga aus Reta sbove Notes: 1. Apply lacking agent tothe trends 2 Appy of tothe eae and Nang surface. 4: Apply molyodonum suite ol he treads and lange ste 4 App saat tote tee & sae 6: Appt clean engne oto the Oxing, 4. Ube bot 8 Saftcting nat 'B, Never apply molybdenum disulfide cit, [-Ensine = . Thee = hice Oty | gia. tram) | Nm tkorm, tetby | Remarks Lubrication: ] Oi pump even sprocket bolt Sf . wsasi | Now Ot pump mounting bat oe ata, Oi pump cover bat jo |e 1202.8) | 1 fier i | a toner Note 6 Oil drain bolt, ‘er a 12 | 38138, 27) | Oi preuare sich : 1) ene 12th, 8) Nowe a | Ful ayta | | ‘Carburetor insulator band screw ai 4 10.10.77 | | Cooling system: | Water pump mounting bott 2) 6 10 (1.0, 7) j ‘Thermo sensor ‘ Prve ~ | = 1011.0,7) | Note 4 Cinder nesloindeaton: + am ger case reutig al 2} 6 | asa | now2 am gear cose st batt ae 128, 9) Note 2 Gyiner head cover bot Bele 1910.71 | Camahat holder bat a 1112.8) : Rocker oom chat pg | pn e088 Nowe 4 inde nead pec ot, 8 mm bef TB" | apa | tees | SVindr ead Boe 8 mm 13 c ting a) Spare pg ‘ ° oan | ChthigearsiHnkage: | fagm crankcase cover le) a 1011.0,7) | it ook nt mle 0 sesen | noes | Gear rota eping tu pn ra ¢ Pe | Shit drum centr bolt 1 6 z23 i | nowt | Sit drum set plate ol — 1200 9) Nowe 1 Sit foe shat sot bel i 6 iia. 8) Note 1 Timing hoe ap ifs won | Nowa 1-14General Information er faleteiateahte) ‘Thread “Torque ol ay | aia. (mm | nem tage, tea) | Remarks CGrankcate/crankshattitransmission: Drive sprocket bott 1 10 55 (5.5, 40) Neutral switch 1 10 1211.2, 9) Connecting rod bearing cap nut 8 7 24 2.4, 17) Note 2, 9 Grankcase bolt 6 mm 2 6 12(1.2, 9) a mm 1 8 232.3, 17) 10 mm 1 10 40 (4.0, 28) Lower case oil bolt 1 10 2312.3, 17) Alternator: | Flywheel bolt 1 10 85 18.5, 60) Note 7 Starter clutch: Primary drive gear bolt (starter clutch bolt) 1 10 85 (8.5, 61) Note 7 ‘Starter clutch cover bolt L3 8 28 (2.8, 20) Note 1 [Frame Frame/body panols: Main step holder bolt 4 a 27 (2.7, 20) Note 1 Main step bolt 2 10 45 (4.5, 33) Pilon stop bracket bolt 4 a 27 (2.7, 20) Sub-frame mounting bolt 4 10 27 (2.7, 20) Side stand pivot bolt fa 10 38 (3.8, 27) Side stand bracket bolt 2 8 35 (3.8, 28) Note 1 Exhaust system: Exhaust pipe joint nut 8 6 8 (0.8, 8) Cooling system: Fen motor switch 1 16 2312.3, 17) Note 4 Fuel system: Fuel tank breather check valve 1 18 114-4, 1.8) Foel valve i 18 23123,17) | Engine mount: i Engine mounting bolt 7 10 40 (4.0, 29) Engine mounting adjust bolt 2 2 1100.1, 8) Engine mounting lock rut 2 22 55 15.5,40) | | Engine mounting nut 1 10 40 (4.0, 29) Gearshift pedal bolt 1 6 1211.2, 9) Front suspension: Handlebar holder pinch bolt 4 6 1211.2, 91 Ignition switch mounting bolt 2 8 25 (2.5, 18) Note 1 Fork socket bolt 2 8 20120, 14) | Note | Fork bere 2 7 2312.3, 17) | ‘Upper fork pinch bolt 2 7 itn 8) Lower fork pinch bolt 2 10 40 (8.0, 29) ‘Steering bearing adjustment nut at 35 50 (5.0, 36), Note 2 Stearing stom nut ha 33 140 (14.0, 101) Front axle pinch bolt 4 8 2212.2, 16) Front axle bolt 1 14 6046.0, 43) 1-15General Information [Frame con ree r = ea Torque = : tem eee | pear suspension | | ear weet nut a 18 120 112.0, 87) fee le | nem | ne | Swingarm pivot nut fa re | 9510.5, 6) Swingarm pivot adjust bot \4 3 | isan | Sinton Bet et nue ja to 13.0, 6 | Drive chain ser serew Ia 3 | 404,29) } Driven sprocket nut 6 8 35 (3.8, 25) | Torque tne borne \72 10 35 (3.5, 25) |, Roar shock absorber mounting bolt 2 10 4514.5, 33) Rowe 8 | Rear shock sbsorber spring ashvoter lok nut i | soteo es) Rear shock absorber reservoir holder band ("2 - 4 (0.4, 2.9) Shock linkage boltinut ,3 | w | «sms aa Note 8 | Rear bearing holder pinch bolt J 4 55 (5.5, 40) | Drive pin bolt al 12 18.0.5, 11) Note 1 | Brake/elutch system: | | Master cylinder mounting bott | 4 8 1211.2, 9) Master cyiner of Bolt ja 10 36 (3.5, 25) Front caliper bolt 3 8 | 3313.3, 24) Nowe 1 Front eatper oll bot fea 10 35 G5, 25) Front brake disc bot ji 8 2012.0, 14) Catiper mounting bolt js 8 | 2727.20 Caliper pad pin 3 10 17.07, 12) Caliper ped pin plug 13 10 | 2.8 (0.25, 1.8) Caliper bleed valve \ 3 8 | 606,43) Fear brake reservoir mounting bolt aa 6 | 90.8.7) Fear brake reservoir hose Joint sorew 1 5 1800.15, 1.0 | Now? Far caper pivet pin bale (5 me HEX side) 1 8 1341.3, 9) Note 1 Fear caliper pivot pin batt 4 8 2312.3, 17) Nowe 1 | Rear brake nose joint rut (hose side) ja 10 14 (1-4, 10) | Rear broke Rose joint faliper sie) i 10 35 (3.5, 25) | Roar brake dio ut ke 8 35 (3.8, 25) Note 8 1-16General Information — SS Tools «The newly designed tools are indicated with * mark inthe ls. T Description | Too! Number Apalcation Section | compression gauge attachment, 8 mm | *O7KME-MRSO100 | Cylinder compression measurement 3 | Gi'prossure gauge attachment (07510-4220100 | Engine oll pressure measurement (i iter wrench O7HAA—Ps70100 | Oil fiter replacement | Spark plug wrench, 8 mm s07KMA-MRE0200 | _ Spark plug removal instalation Lock nut wrench OFHMA=¥MR70200 | Engine remevalinstalation 7 Valve spring compressor attachment | O7959-KMSOTO1 | Cylinder Read disassembly/assembly | 8 Valve guise diver O7HIMD—MLO0100 | Valve guide replacement | Valve guide reamer, 4.5 mm O7HMH~MLOO101 Valve guide reaming | | Valve seat cuter, 24 mm (45° IN) {077800010500 -}- Valve seat refacing Valve seat cutter, 22 mm (45° EX) ‘07780-0010701 Valve flat cutter, 24 mm (32° IN) Valve fat cutter 21.5 mm (32° EX) Valve interior cuter, 22 mm (60° IN/EX)| 07780-0014202 Cutter hoger, 4.5 mm 07781 —0010500 + } ot Tock nut wrench, 26%30 mm 077160020208 -[-ciuichanassembiylassembly lee Extension ber 07716-0020500 | Gear holder 07724~0010100 | Primary tive gear removalinstaltaton Fork seal driver 07347 KA80100 -[>- Fork ol seal nation 12 Fork seal diver attachment 07947—Kr00100 -+ Lock nut wrench, 39% 41 mm O7GMA—KS40100 | Steering stem aut removalfinstaliation | Steering stem socket O7HNA-MR70100 | Steering beoring adjustment nut i tightening Steering stom diver attachment o74MD—MR7O100--- Sterng besrng tower nner raze Inner ever C (07746-0030100 1] instalation Diver attachment B (2 pes. required) | 07946—-KM90200 + Stearing bearing outer rave removell Driver assernbly shaft 07946—KM80300-H installation | Bearing remover 8 07946—KM390500 | Assembly base 07946-KM80600 Driver (0749-0010000 | _Beerng instalation 8 Attachment, 4247 mm 07748 -0010200 -}-~ Bearing holder needle bearing | ‘attachment, 6269 mm 07746-0010800 +} repiecement | Pilot, 40 mm 07746 -0040900 1) ' Shock ebsorber compressor attachment | 07959~MB10000 -|-- Shock absorber disassembly/essembly | | ‘Shock absorber compressor 07GME—0010000 ~~ ' | Bushing diver B O7HIAF =n1n190200 | Shock absorber upper mounting | bushing replacoment |_ Pivot adjust wrench 07908- 4690001 | Swingarm oivet bolt removalfinstallation Driver shaft (07946-M4J00100 -}--Fight swingarm pivot bearing | Attachment, 97540 mm 0746~0610200 -[ inetlstion | Pilot, 20 mm | 07746 - 0040500 — i Bearing remover sat 607936~3710001 -L—-Fight swingarm pivot bearing removal | “Remover handle 07936-3710100 + = = Beating remover (078363710600 = siging weight (077410010201 ‘Needle bearing remover O7KIMC—MR70100-}-Lete swingarm pivot bearing | Diver shore (07346 -ms00100 | replacement ‘on, 38 rm ao [Pon 28 07748 -0081100 =) 1-17General Information ee... Description | Tool Number ‘Application | Section | o7EMD-x780100 | shock om neaae beving emavel | 18 Boag remover 27998-3710900 Shock in noad Bening omaeat_ «|| Remover hen Graae—a7tor00 1] Stang weight O7zat-ootozor —L) Diver {7249=0010000 -H7- Shock arm and ink needle beeing \ Attachment, 26228 mm 87746 -c010700 -L) iatatacon Pot 1 ren G7ras—oconn0 | "Soap ng pee |" erase.z2000% | take monercynae aoomanon? | a tesenbiy Peak voltage adaptor 07HGJ-0020100 ate ‘Peak voltage measurement | a6 Biot mutieser @rav1 -0020000 + Univeral tcer 077260080000 -}-Fiywhnee emovaliastafanon 7 motor pul ee 1-18a Lubrication & Seal Points General Information —— ei aaaeaomv—' [Engine Location Valve stor (valve guide sliding surface) Connecting rod small end baring “Transmission gearshift fork groove Timing hole eap thveads Connecting rod beating Crankshaft main bearing Material Molybdenum isutide oi! Remarks J Ciguia seatane Cylinder head bolt threads Connecting red bearing cap nut Rocker arm sliding surtace _ ‘Camshatt journal, cam lobe Other sliding surface CAUTION Never apply motykidenum sulfide el, Grrkce aig ware = Be vet asy eae wr mance Rocker arm shaft plug Sealant | Seer Ch Bes be nt aay ssa othe Sete els ee tn ™ en ae | ro maar trots Eo Eom _| oi er Ors Trae | Peon ‘Clutoh lifter rod lifter eam contacting areal ‘Multipurpose grease Cylinder head sealing bolt threads ‘Shift drum center bolt threads Gearshift return spring stud pin ‘Shift drum set plate bolt threads ‘Shift fork shaft act bolt threacs Oil pump driven sprocket bolt treads 55:75 mm (0220.80 m Locking agent 1-19General information —oo—$ [Frame Location Material Remarks Drive chain Gear ol! #80—30 1 || Axle holder bearing Multipurpose grease Side stand pivot ‘Shock linkage bearing collar | Shock linkage bearing ‘Seat lock hook Gearshift pedal pivot ‘Shock absorber upper mounting collar ‘Swingarm pivot bearing Steering head bearing - Step pivot Speedometer gearbox | ‘Throttle pipe tlange Rear brake pedal pivot Dust cea! lip Pad pin threads Pad pin plug threads Caliper piston DOT 4 brake thud Caliner piston seal Caliper dust seo! Master cylinder piston ‘Master cylinder piston eup ‘Steering bearing adjustment nut threads Engine oi Fan motor switch threads Seslant Handlebar grip rubber Honda Bond A or equivalent Caliper pivat pin T"sttcone grease Caliper pivot pin boot { Side wand bracket bl reds Toakng oon | Drv chan ance actow onoeos Drie pr toe oes Font etic bat trends Teton smc runes ble eae ces for cape por bok tree | Borba avec hee sew tds 1-20General Information Cable & Harness Routing (2) CLUTCH CABLE (7) LEFT FRONT TURN SIGNAL WIRE CONNECTORS (9) Right FRONT. ‘TURN SIGNAL, WIRE CONNECTORS 10) RIGHT FRONT BRAKE HOSE 1-21General Information (2) HEADLIGHTS, (9) LEFT FRONT TURN SIGNAL WIRE CONNECTORS \ (6) RIGHT FRONT TURN SIGNAL aI WIRE CONNECTORS: (4) POSMON LIGHTS (7) SEAT LOCK CABLE (8) SPARK UNIT (6) FUSE BOX (10) BRAKE/TAILLIGHT WIRE CONNECTORGeneral Information (1) THROTTLE CABLES. a sue AIR CLEANER TUBES: (4) CRANKCASE BREATHER HOSE (6) REAR IGNITION com 7 ® eatery (9) AUTO FUEL Valve Vacuum Tug — (10) THROTTLE STOP CONTROL CABLE (@) REAR SHOCK ABSORBER DRAIN TUBE’ I) SPEEDOMETER CABLE (12) CLUTCH CABLE = (13) FRONT IGNITION Com. (18) THROTTLE STOP CONTROL KNOB (17) FAN MOTOR swiTcH 116) FUEL TANK DRAIN TUBE 1-23General Information (2) STARTER RELAY SWITCH 15) FUEL TANK (Main FUSE) (4) AUTO FUEL VALVE BREATHER TUBE VACUUM TUBE (1) RESERVE TANK OVERFLOW TUBE (3) FUEL LINE (6 RADIATOR OVERFLOW TUBE (8) HL BEAM RELAY (7) stARTER MoTOR CABLE SS 03) (0) RIGHT CONNECTOR BRACKET A: IGNITION SWITCH WIRE CONNECTOR (SP-BLACK) B: PULSE GENERATOR WIRE CONNECTOR [4P-BLACK) : OIL PRESSURE SWITCH/NEUTRAL SWITCH WIRE CONNECTOR (2P-BLACK) ©: RIGHT HANDLEBAR SWITCH WIRE ‘CONNECTOR (6°-RED) E: ATERNATOR WIRE CONNECTOR (aPvHITe) 04) VEw® 1-242. Frame/Body Panels/Exhaust System Service Information 24 Fuel Tank Removal/Installation | Seat Cowling Removai/installation 2-2 Windshield Removal/Installation 26 | Upper Fairing Removaliinstallation 2-2 ‘Muffler Removal/Installation 28 Side Fairing Removal/installation 23 Exhaust Pipe Removal/installation 2-10, Lower Fairing Removal/installation 2-4 ‘Sub-Frame Removal/installation 242 | Service Information is extremely flammable and explosive under certain conditions. si 1us bums may result ifthe exhaust system is not allowed to cool before components are removed or serviced. + Work in a woll ventilated area. Smoking or allowing flames or sparks in the working area or where gasoline is stored can ‘cause a fire oF explosion. ‘This section cover removal and installation of the frame.body panels, fusl tank and exhaust system. Frame body panel installation sin the reverse order of removal, unless noted otherwise. ‘When removing the cover, be careful not to damage any tab of groove of tho cover Be careful not to bind the wire harnesses when installing the sub-frame.Frame/Body panels/Exhaust System Seat Cowling Removal/Installation Unlock the rear seat by turning the ignition Key clockwise. Remove the rear seat. Remove the six attaching screws. Raise the rear of the seat cowling and release the two boss: 26 from the grommets. Disconnect the brake/teltight wite connector and ernove the seat cowling rearward, Nore + Be careful not to damage the front of the cowting Install the seat cowling, while inserting the hook of the ‘cowling under the frame. Insert the bosses into the grommet by pushing the rear of the cowling, Install the rear ses, aligning the hook with the cowling, and push the seat down to lock the sest. Nore + Be careful not to bind the wire harness etc. (3) REAR SEAT (4) Bosses (5) BRAKE TAILUGHT (6) GRomMers Upper Fairing Removal/Installation DDisconneet the loft and right turn signal wire connectors. Remove the following: = both side feirings (page 2-3) = front panel (page 2-4), = both rearview mirror mounting nuts. = both rearview micro. = both rearview mirror mounting rubbers = both turn signal lights, = upper fairing, Install the upper fairing in the reverse order of removal ‘CAUTION *+ Be careful not to bind the mounting rubber. (1) REARVIEW MIRROR (2) MOUNTING RUBBER (3) MOUNTING NUT (e) screw (4) TURN SIGNAL LIGHT (5) UPPER FAIRINGFrame/Body panels/Exhaust System Side Fairing Removal/Installation ®, ‘Align the tabs with the slots propety. CAUTION + Be careful not to damage the tabs. + Make sure that the clip nut for the tapping sorew is installed properly I itis missing, install it securely with the threaded side L_ facing down. Procedure ary Remarks Removal Order Installation ion the reverse order of removal an | Quick serew (2) | Screw (2) | Tapping screw (4) | Lett sce faving 15) | Right ade faringFrame/Body panels/Exhaust System Lower Fairing Removal/Installation . a ‘CAUTION + Moke sure thatthe ofp nut for the tapping sorew fs installed property. If tis missing, install securely with he threaded ede facing down. Procedure ay Remarks Removal Order Installation isn the reverse order of removal, 1 | im clip sorewiout 4 (2) | Front pane! screw 3 (3) | Front panel 1 | wore ‘Atinatalstion, inser the tep ends under the tab of the upper faring property a shown, (2) | Mounting serew 2 (6) | Mounting bottwasher 2 (6) | Mounting colar 2 (7) | Lower faring assembly 1 2-4 aFrame/Body panels/Exhaust System Fuel Tank Removal/installation 7 Gasoline fs extremely flammable and is explosive under eer tain conditions. Workin a well ventlated area, Smoking or at towing flames oF spats inthe work area or where gasoline Giese cavcuaro te wagosn (1 BREATHER TUBE (2 MOUNTING BOLT Remove the seat cowling (page 2:2), “umm the fuel valve OF Disconnect the fuel tank breather tube from the tank FRemave the fuol tank mounting bolt. ‘Raise the rear ofthe tank and disconnect the fue tine and vacuum tube from the fuel valve. Install the fue tank inthe reverse order of removal Note 7 Moke sure that the fuel tank mounting rubber is inetalad Cont the frame properly before instaling the tank. ‘Aftor connecting the fut fine, connect a vacuum pump to the auto fuel valve vacuum joint and apply vacuum. “Tum the fuel valve ON and check the feline for leakage, (G}FUEL TANK 2-5Frame/Body panels/Exhaust System Windshield Removal/Installation 3. Install wth using new pins, LeFrame/Body panels/Exhaust System +_ Be catoful not to damage the windshiol oo Procedure oy Remarks ‘Removal Order . 1) | Rearview miror mounting nut 4 | Nove Loosen until the clearance is made. (2) | Set pining 6 | note (Cut the pin to remove, (3)_| Windshield 1 Installation Order (3) | Windshield 1 (2) | Sat pining 6 | Nove. ‘Temporarily instal the sot rings, position the windshiets propery and fit the pins Rearview mitror mounting ut 4 27System Muffler Removal/Installation Frame/Body panels/ExhaustFrame/Body panels/Exhaust System Do not service the exhaust system while Rishon. CAUTION [Be not bond or twist the brake hose. Support the removed fight step assembly oo that R does not hang from the brake hose Requisite Service + Seat cowting removalinstallation page 2-2) 2 Lower faiing removalinstaliation (page 2-4) Proceoire Tew] Femerks Removal Order Tratalotion she reverse order oF eo «| Heat guard mounting bots 1 (2) | lone step bot 2 {81 | eon step + | note Remove togter with he het guard Never hang fom the brats hove | (a) | Exhaust pipe band bot 2 | Nore lesen the bot. (5) | Exhaust pipe mat | 3 (8) | Motegmoming boivnut | v2 | nove [Ainstalaion, loosely instal he board nuttin the | ‘vhost pipe nuts and band bats frat then ight tem. «71 | Lat ion stp 1 (8) | Hutter assembiy 1 1 | Gasket 2 2-9Frame/Body panels/Exhaust System Exhaust Pipe Removal/Installation - WAN 4 | OMAY 7) = 2-10iS Frame/Body panels/Exhaust System ee casTon [Fe core tor isto revo them om danagin when sing te ont emul bs. Requisite Service «Muffler removalnstaaton(pege 2:8) Procedire ow Tenens Removal Order Train sin te rovers order of omar «| oor exhaust pipe joint nut 4 | Roar exaust pipe i 63) | Lower radiator mounting bok 2 | nore Fomove the bolts nove te radiator forward and old it ‘wat srg. | Front exhaust pipe ent nut 4 {8 | Front exhaust pipe 3 [16 | caster 4 2-11Frame/Body panels/Exhaust System ‘Sub-Frame Removal/installation ( 2-12Frame/Body panels/Exhaust System ee CAUTION Requisite Service + Seat cowling removalnstaliation page 2-2) Tum the ignition switch OFF and disconnect the batery negative cable from the battery terminal. 1 Bo cartul not to bind the wie harness when stating to subframe 1 Route the wie hamess able, et page 121) 1 Fuel tank removalfnstallation (page 2-5) 1 Battery romovalinstalation (pege 15-8) Procedure oy Remarks Removal Order Tnotalation fen the reverse order of rmoval. 0) | Spark plug caplimary wire connector 2 (2) | Regulatortectiier connector 1 (@) | Tur signal relay connector 1 (a) | Spark unit wire connector 2 (6) | Rae turn signal wire connector 4 (6) | License tight wie connector 2 7) | Fuse box i {@) | Right grab rat i (9) | Shack absorber reservorvbracket 1 {10) | Rear brake reservoir 4 | cauTion: Koop the reservoir lvel to prevont ai from entering the system. (11) | Radiator reserve tank (12) | Mutter mounting botdnat Ww (13) | Sub-trame mounting bort 4 | nove Fomnove the main wire hamess from the clamp. 1149 | Rear fender bot 1 2-13—_————— 3. Maintenance Service Information 31 _ Valve Clearance 37 Service Access Guide 3:2 Carburetor Synchronization 3-10 Maintenance Schedule 3-4 Drive Chain att Air Cleaner 35 Sido Stand 312 : Spark Plug 35 Service Information «Refer to Common Service Manus! for service procedures on items nat included in this manual tothe specifications (Section 1} for maintenance service data 3-1Maintenance eS Service Access Guide + The fllowing shows the locations ofthe pars that must he removed forthe maintenance items listed below: Refer to the Common Service Manual for tems not included in this manuel + Refer to section 2 (Frame/body panelslexhaust system), forthe part that must be removed for service For example: AIR CLEANER (Contamination, clogging, replacement] — Maintenance part lservice tems) + Fuel tank ~ The parts that must be removed for service. (1 SPARK PLUG (Weer, damage, color page 35) + Side fating - () ACLEANER (Contamination, clooging replacement: page 3-5) + Fuel tank (2) BRAKE HOSE (Meakage, degradation, damage) (12) THROTTLE GRIP (Operation, fee play) (13), BRAKE LEVER, (Air bubbles in eystern) (3) RESERVE TANK (Coolant level (4) BRAKE RESERVOIR (level check, fluid replacement) (5) BRAKE CALIPER, (ed wear) (6) TRE ‘Wear, damage, pressure) 7) WHEEL @arage, snout, corrosion) (8) BRAKE LIGHT SWITCH (Operation {14)_BRAKE CALIPER (Pad weer) (15) TIRE (Wear, damase, pressure} (16), wees (Damage, runout, corrosion) (9) BRAKE PEDAL (Air bubbles in system) (10) OWL FILER CAP/OIPSTICK (evel check, replacement) 3-2(3)_CARBURETOR CHOKE (Operation) _— (2) BRAKE MASTER CYLINDER ol check, flid replacement) (3) HEADLIGHT J (4) BRAKE CALIPER (Pad wear) (5) OILFIETER (Replacement) + Front pa (6) O1L DRAIN BOLT (il eplacement) + Lawerfaitng TIT) VALVE CLEARANCE (page 37h ‘Maintenance (8) THROTTLE STOP CONTROL KNOB Ae speed adjustment) (9) BRAKE HOSE (1) SIDE STAND (Operation: page 9:12) (Leakage, dogradation, damage) (Qo) DRIVE CHAIN (Free pay, tbrcation, replacement: pags 3-1) 3-3‘Maintenance Sam Maintenance Schedule Perform the PRE-RIDE INSPECTION in the Owner's Manual a ach e@heduled maintenance period, Ic inspect and clean, adjust, lubricate, or rplace if necessary. Fi Replace C:Clean L: Lubricate A: Adjust The folowing items requier some mechanical knowledge. Certain items (particuletly those marked * and **) may require more techn. ‘al information and tools. Consult thet authorized Honda dealer. - Frequency | Whichever Odometer Reading (Note 1) gone ap[xio00mm] 1 | 6 [2 | 18] ] 1 a6 ["y [tooom foo] «|e [12] 16120) 24 | perry em Note Months [12 [16 | 24 | 30 | 96 | pace + [Feet tine 1 1 | Note @ =| Trrente Operation 1 1 | Note 4 =| Carburetor Choke 1 1 | Note Air Cleaner Now 2 ® R35 7 [Wave Cearancs i 1 27, Spark Pu theti [ey [else Epaine OF ® R a R_| Nowa Engine OW Fiter R R ® R_| Nowa = oxburtor Syverson 1 1 1 | 310 + [ Cerourter le Sosed 1 i Redietor Coolant News 1 ta R | Nowa =| Coating Systern 1 Th 1 Noe 4 Deve Chain Tr: Every 4.000 km (1600 ri 344 Broke Fd Nowe s ‘Ti pali [ta | vows Brake Pade Wes se Brake Systm 1 1 1 (| Now 4 = [ke Ligh Saitoh i 1 1 [Now =| Hesdiohe Aim i 1 1 [Nowe {hutch System i valet 1 Nowe Side Sand 1 1 32 =| Sespension 1 1 1 [Nowe @ =| ts, Gos, Fasteners 7 i 1 1 | Now =| WiheotrTies 1 1 1 [Nowe Scsoing Heed Basra i 1 1 1 | Nowe * Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is mechanically qualifies * + Inthe interest of safety, we recommend these items be serviced only by an authorized Honda deater. Notes: ‘At higher odometer readings, repeat atthe frequency interval established here, 2. Service more frequently when riding in unusually wet or dusty areas. [3 Replace every 2 year, or at indicated edometerintorval, whichever comes first. Replacement requies mechanical sil. 4. Refer to Common Service ManualMaintenance Air Cleaner (2) COVER Scr tain cucaner case cover ew Remove the following: = seat cowling (page 2-2). = fuol tank (page 2-5). = sir cleaner case cover screws. = sub air cleaner tubes. = sir cleaner case cover Femove the ar cleaner element, and replace it with anew one. Install the removed parts inthe reverse order of removal () FRONT (4) SPARK PLUG WRENCH + Do not touch the exhaust pipe while itis hot. Rear Cynder ‘Remove the No, 1 and No, $ cylinder spark plug caps, and remove ‘he spark plugs with the spark plug wrench, Front Cylinder: Remove the folowing: T tad ates nce 2 (2) SPARIK PLUG WRENCH (5) UPPER RADIATOR Move the upper radiator forward, remove the No. 2 and Ne. 4, tylinder sparkplug caps and remove the spark plugs withthe spark. plug wrench, ‘CAUTION +_ Be careful not to damage the radiator fine while serving] Note ~ or spect, refer to aaton 2 ofthe Garnmen Seni] a Manual + For recommended spark plug and specified spark piva gop, | refer to section 1 {Specifications}. 3-5Maintenance Using the spark plug wrench, hand tighten the spark plug untiitis | {l) INDEX PLATE ‘Seated, then tighton it tothe specified torque: “Torque: 9 Nim (0.9 kgm, 7 feb) When the spark plug wrench (07KMA—MR80200) i used: Hand tighten the sparkplug uni itis seated, using the spark plug wrench, “Turn the index plat to align the starting ne of the tightening, 3 install the handle onto the sparkplug wrench, ‘When 3 new spat plug is used {the sealing washer is not com ‘pressed tighton the plug fromthe stating ine to the "9" mark of the index plata, When the speck plug is teusod {the sealing washers compressed, Lighten the plug from the stetig ine to the @”" mark ofthe index. plate. cauTIONMaintenance Valve Clearance NOTE = « Inepest and adjust valve clearance wile the engine fs cold below 35°C/95°). Cylinder Head Cover Removal Front Cylinder Remove the lower faring (page 2-4) Remove the upper and lawer radiator mounting bolts and move the radiators forward. Remove the folowing: = fuel rank (page 2-5) = sir eloaner case (page 6-41. = sir cleaner cage base = heat protector. eS — front sparkplug caps. ‘cover bolts. servicing. Be careful not to damage the front fender ‘ear Cylinder Femave the folowing: ~ seat cowling (page 22) = fue tank (page 2-8), — rear cylinder head cover bolts. = rear cylinder head cover Inspection Remove the timing hole cap. “umn the crankshaft clockwise and align the 7" mark front: 72, — ‘war: TI) onthe starter clutch cover wit the index mark on the ight ‘cankesse cover. (6) MOUNTING. oir (2) MOUNTING BOLT (4) MOUNTING BOUT (5) LOWER RADIATOR (0) REAR CYLINDER HEAD COVERMaintenance ‘Wher the edge marks on the right sides of the cam shatts are face ing on, the piston of the following cyinder is at TDC (Top Dead Center) on the compression stroka. Rear (7): No. 1 cylinder Whe the 8896 mats ate feoing dew he Tol ‘TDC'on the compression stroke. Front (12k: No.2 cyindor Rear (i: No. 3 eylindor Relation between the timing mark and edge marks: (1) EDGE MARK Timing mark | Eagemarke | Piston at TDC on the ‘compression stroke Faciog up Net eyinder a Fae We Teri xs oo 1) EDGE MARK we Facing up Na eying | Facing down No 2evinger_|_ Make sure that the piston is at TDC on the Gompitéeion stTke, ‘Measure the valve clearance by inserting the feeler gauge between the rocker arm and adjustment shim. Valve clearance: Intake valve: 0.12—0.18 mm (0.005—0.007 in) Exhaust valve: 0.21—0.27 mm (0.080.011 in} ‘Shim Removal ‘Make sure thatthe piston is at TDC on the compression stoke, race teh shop tawels inthe spark plughole and cam gear cesehole ‘and place the magnet near the shim to prevent the shimn fromm tating. Move the rocker arm inward by pushing i CAUTION + Wthe valve clearance i too small, the shim may kump out when moving the rocker arm NOTE c (7) CAMSHAFT HOLOER (2) EDGE MARK 1) CAMSHAFT (G) FEELER GAUGE i vatve stem a i) CAMSHAFT HOLDER (2) SHIM (3) ROCKER ARM “fo hold the moved rocker arm, lis convenient toMaintenance ‘Shim Selection NOTE ‘Sixy-ive shims are available in thickness intone Clean the shim with a clean shop tel ‘Measure the shim thickness with a micrometer and record i. “o select the shim needed to bring the valve clearance within specification, use the fllowing formula: a=b-c+d '& now shim thickness recorded valve clearance ©: specified vale clearance ‘old hin thickness Example: Rocorded valve clearance = 0.20 mn fb) ‘Specified valve clearance = 0.15 mm Ic) (Old shim thiekness = 2.200 mm (4) 2 = 0.20 ~ 018 + 2.200 2-225 "Now shim sitokness 2.250 mm Nove — : +f the required thickness ofthe new shim is move than 2.800 mm, the valve seat Is probable heauilycarboned. Reface the seat, recheck valve clearance and reselect the shim, | ‘Make sure thatthe piston is at TOC on the compression stroke Installation Apply molybdenum disulfide oto the shim and racker arm shipper Place tha chop tawelsin the spark plughole and eam gear case hole land place the magnet neat the valve to pravent the shim from faling, ‘Move the rocker arm inward by pushing "W hold the moved rocker arm, it fe eanveniont to use the install the shim with the tweezers. (2) CAMSHAFT (@) SHIM (a) TWEEZERS. (1) MICROMETER 2 suingMaintenance Carefaly slide The rodker drm jginat postion. “Make sure thatthe shim contacting surface ofthe rocker arm is positioned in the center of the shim and the shim ie completely seated CAUTION + Be careful not to bound the shims out when siding the rocker Turn the crankshatt clockwise several times: Recheck the valve clearance - ‘Apply Honda bond A or equivalent to the gasket groove in the cylinder head cover Install the cover gasket withthe “IN” mark facing toward the in ‘ake side. Install the cylinder head cover withthe "IN" mark facing toward the intake side. Install the cover bolt washers with the “UP” mark facing up Install the cover bolts and tighten them, Torque: 10 Nem (1.0 kg, 7 40) Install the removed parts in the reverse order of removal Carburetor Synchronization Nore “+ Refer to section 2 of Common Service Manual for carburetor ‘synchronization procedure. + Synchronize the carburetor withthe engine at normal oper- ating temperature, transmission in neutral and motorevele supported upright Disconnect the vacuum tube from the No. 3 oylinder intake "manifold, eppiy vacuum to the auto fuel valve and pinch the tube ‘with a lip. Remove the plugs from the Na. 1,2 and 4 eylinder intake manifold ‘and incall the vacuum gauge adaptors, (1) ROCKER ARM (2 guia (3) VALVE RETAINER (a) Vatve STEM (0) COVER GASKET (3) "IN" MARK (2) CYLINDER HEAD COVER (1) COVER BOLT WASHER, 3-10Maintenance Connect the vacuum gauge adaptor tothe auto ful valve vacuum tube joint ofthe No.3 cylinder intake manifold Note “The bast tors the No.2 carburetor ‘Adjust the cerburetor synchronization by turning the synchronize: tion adjusting screw Drive Chain + Never inspect or adhust the dive chain while the engine le running, Place the motoroycle on its sie stand and shift the transmission Into neutral CCheck slack in the dive chain lower run midway between the — sprockets, ‘Stack: 15-25 mm (5/8—1 in) ‘Adjust the chain slack as flows: Loosen the bearing holder pinch bolt. “umn the axle bearing holder with the pin spanner providedin thetall, IN (2) GEARING HOLDER, ‘Kit unt the correct deve chain slack is obtained, {Nl DRIVE CHA PINCH BOT NoTE ~ Tanase the adjustment aie the rear wheel with an optional stand end tum the whi the ame ciection asthe bearing holder rotationMaintenance ‘After adjustront, check the chain weer label If the red zane onthe label reaches the outside diameter ef the driven sprocket, replace the drive chain with a new one. Replacement chain: RK GBS25SMa Tighten the besring holder pinch bolt Torque: BS Nem (5.5 kg-m, 40 feb) Side Stand (Check the side stand rubber for wear. Replace the rubber if wear extends to the wear mark, Check the side stand operation ‘The side stand should lower easily to its fst stop then lock ‘after moving farther forward to support the motorcycle as the rub- ber touches the ground, ‘When the motoreyele is ited upright, the stand should automat cally move the frst position, and rewaet when Kicked Ups If the side stand does not mave freely, disassomile itt ‘Remove the return spring at the retracted position. Remove the pivot bolt and remeve the side etand assembly from the fame, : = ZA, oH 0 nermacre Postmon Ff Lf (2) FIRST STOP POSITION, (G) WEAR MARC Wt (4) SIDE STAND RUBBER Check the folowing parts for wear or damage: — inside of the pivot and pivot colar pivot dust seals. Lubricate the pivot area with clean grease and ‘stand ‘CAUTION + install the dust seal with the epring side facing out. “+ Make sure that the dust seal sping is nat removed, then i ‘tal the side stand {_stah ihe se en Torque: ‘Side stand bracket bot: 96 Nem (3.5 kg-m, 25 4b) Recheck the side stand operation, (1) RETURN SPRING y (2) waster oe ‘SPRING AX (a) oust seat Vs) PIVOT COLLAR 3-12Service Information 41 Oil Cooler Removallinstallation 43 Troubleshooting 41 Oil Pump Removal/tnstailation 44 Lubrication System Diagram 42 Oil Pump Disassembly/Assembly 46 Service Information + The sevice procedures inthis section can be performed withthe engine ol dain, + Wen removing and instaling the ol pump use care not to alow dust orci to enter the engine | If ay portion ofthe el pump is wor beyond the speced service lis replace the ol puma as an assembly 2 Aft the oll pump has been installed, check hat here ae no of tak and that ol pressure covect. 4. Lubrication System | Troubleshooting it Level Low Low Oil Pressure Ol consumption. + esaure reli! vale stuck open. + Exteel ea + Clogged cil fiter sreen {Worn piston ing or incorrect piston tng intallation. + Oi!purnp wom or dameged. 2 Worn valve guide o seal 2 enema ak. + Incorect ol being sed. 01 Contamination 2 towea evel = From coolant mixing with ol — Faulty water pump mechanical sel High OW Prescure = Faulty head gasket. _+ Pressure reef valve stuck closed. — Water leak in crankcase + Plugged oi iter, galley or metering office, + Incarece ol being used. No OW Pressure + Oil level t00 low. Seized Engine + Oil pump drive chain or dive sprocket broken, + Noor ow ol pressure + Oi pump damaged {pump shaft. + Clogged ol erfcaipassage + Interna ot leaks. + Oil leakage inside the engine, Use of ol not recommended.Lubrication System Lubrication System Diagram 1) Ou PIPE (2) CONNECTING ROD OL JET (3) o'cooLeR (6) OL PRESSURE. RELIEF VALVE. (4) ou PUMP. (6) OL STRAINER» Lubrication System il Cooler Removal/installation Requisite Service + Lower fang removalinstalation (page 2-4) 1 Engine ot draining Vocation: page 3-3, step: section 2 of the Common Service Manual) Procedure oy Remark Removal Order Tnatalaton isn the reverse order of removal. 11 | Oit cooler boi 5 12) | Oitcooler 1 (3) | Oxing a (4) | Tube 2 a3Lubrication System Oil Pump Removal/Installatione Lubrication System ~-norE. oped te ive sree bak belo emavng th pana outing bt + emove te ci pump drive sprocket bot wih care ae coated with tread locking agent. “a - Requisite Service Engine oll ding Vocation: poge 2-3, step: section 2 ofthe Common Service Manu Lower fering ramovatinstalaion (page 2-1) 1 Gipump driven sprocket removalinstalition [pages 9-4 and 8-6) Front exhaust system (page 210), Fight erankease cover removalinstalation (page 9-2. : Procedure ay Femants Removal oder ~T intalaton in the Teves cide of removal «n | Oipan bok 2 (2) | open 1 | Nore Loosely tighten the bolts frst te set the ol pan in conect potion. (2) | Pressure elit vate 1 | Rove ‘Agn th cutout inthe stopper with the pipe. (2) | ot stainenO-ing an | Note Install th ol strainer aging the boss in the trainer with . the ait on the ol strain. | (5) | Ot pipeio-ing 218 | (6) | of pipe bate 2 | 1) | ipipetO-ing in| nove Femove the dive sprocket bot before removing the ol pamp mounting bls. «21 | Oi pump bot : (8) | Ol pump assemy 1 | Nore When instaling the of pump assembly, align the projection ton the pump shafr withthe cutout inthe water pump shaft Sy rotating the pomp anafe Disassembly: see page 4.8. 120) | Dowel pn 2 «1 | Ot ertee!0ing vn | Nore Ifthe ofice is removed, check it for clogging beore rin. stalation 4-5Lubrication System Oil Pump Disassembly/Assembly — meena amNOTE, 7 Clean each part with cleaning solvent and coat with clean engine ol before assembly. Requisite Service «+ Gil pump rerovalinstallation (page 4-<). Procedure ay Farmar Disassembly Order “Assembly isi the veverve order of disassembly. (1) | Ot pump body bolt a {2} | Cooter purnp cover i {3} | Dowel pin 2 {4} | Cooter outer rotor 4 | nore : 1+ Install the outer rotor with ts punch mark facing cooler pump cover. 18) | Cooter inner roter ‘l 46) | Drive pin 1 (7) | Thrust washer 1 (@) | On pump body 1 (2) | Dowel pin 2 (10) | Feed pum outer roter 1 | Note ‘Install the outer rotor with ts punch mark facing foed x pump cover, 1) | Feed pump inner roter 1 102} | Deve pin 1 (43) | 0 pum shaft 1 | nore + Install with the tab side facing the cover (water pump side). (14) | Feed pump cover 1 (45) | Cotter pin 1 (16) | Spring retainer 1 (7) | Spring 1 118) | Piston : {19) | Cotter pin 1 (20)| OF strainer pipelO~ing n 475. Cooling System Service Information 5-1 Water Pump Disassembly/Assembly 55 ‘Troubleshooting 51 Radiator Removat/installation 56 ‘System Flow Pattern 52 Radiator Disessembly/Assembly 58 Coolant Draining 53 |_| Thermostat Removaliinstallation 54 Service Information + Wait until the engine fe cool before slowly remaving the radiator cap. Removing the cap wile the engine fs Hot afd the coolant {is under prossure may cause serious scalding. + Radiator coolant is toxic. Keep it away from eyes. mouth, skin and clothes. if any coolant gets in your eyes, nce them with water and consulta doctor immediately. = 1 any-pootant ie ewllowed, induce vomiting, gargle and consulta physician immediatly. = tf any coolant gets on your skin or clothes, rinse thoroughly with plenty of water. + KEEP OUT OF REACH OF CHILDREN. + Aad coolant atthe reserve tank. Do nat remove the radiator cap except to refill or drain the system, {Alf cooling systam service can be made with the engine in the frame. + Avoid spilling coolant on painted surfaces. + After servicing the system, check for leaks witha coating system tester. 1 Reler to section 18 for fan moter switch and thermo sensor inspections. Troubleshooting Engine Ternperature Too High + Faulty radiator cap. * Inoutfeiant coolant {Passages blocked in radiator, hoses, or water jacket. + Alvin systar. Faulty water pump. + Thermostat stuck closed, a + Faulty temporature gauge or thermo sensor + Faulty cooling fan motos, + Faulty fan motor switch, + Fan shround installed impropesiy. Engine Temperature Too Low + Faulty temperature gouge or gauge sensor. + Thermostat stuck open. 1 Faulty cooling fan motor switch (see section 18) ‘Coolant Leaks Faulty pump mechanical sea Deteriorated O-rings. Faulty radiator cap. Damaged or deteriorated gasket, Loose hose connection or clamp, Damaged or deteriorated hoses,Cooling System System Flow Pattern (4) WATER PUMPCooling System Coolant Draining ~The radiator caps under high pressure and radiator coolant could spurt out, resulting in scalds on your hands etc. Ifthe apis removed while the radiators hot. Wait unt the radia: toe coals down and remove the cap. remove the side faving and the lower faring (pages 2-3 and 2-4 Remove the radiator eap. ‘Remove the drain bolt on which a copper washer attached) from the water pump and drain the coolant. Remove the two rains from the cylinder and drain the eoolsnt.Cooling System Thermostat Removal/Installation Requisite Service + Fuel tank removalnstallation (page 2-5) + Lower faring removalinstaltion (page 2-4). + Coolant draining page 6:21 + Coolant refill (section 5 of the Common Service Manual. Procedure ay Remarks Removal Order Installation isin the reverse order of removal. (0) | Bandiwater hose 22 | nove Loosen the hose band. (2) | Thermostat cover bolt 2 (@) | Thermostat cover 1 (@) | Ong 1 (6) | Thermostat 1 (@) | Thermo sensor connector 1 (0) | Thermo sensor |} | Note + At reassembly, apply a sealing agent tothe threads (8) | Thermostat housing bolt 2 (2) | Oving 1Cooling System Water Pump Disassembly/Assembly i a ae 10000,7) Nore =a ae = 7 Before removing the water pura plage an oll pan under the engine to catch the leaked engine: Requisite Service + Lower faring removalinstalation (page 2-41 + Coolant draining (page 5-3). Coolant refi (ezction § of the Common Service Manu Procedure oy Femars Removal Order installation isn the reverse order of removal. (0) | Hose banaiweter hose: 2m | Nove + Loosen the band and pull eut the water hose. 2) | Bore 2 | NOTE + Before removing bolts, loosen the pump cover bolts (3) | Water pump assembly a | nore +A installation, align the pump shaft slot with the cil pump] shaft, (2) | Housing cover bolt 2 (8) | Cover 1 1) | O-rng 2 17) | Dowel pin 1 1 caution + Avoid further disassembly. 1) | Water pump‘Cooling System Radiator Removal/installation 5-6Cooling System CAUTION. not to break the fins. + Take care not to damage the front fond Requisite Service + Lower faking removalinstalation (page 2-4) + Coolant draining ipage 5-3). {Coolant refil (section § ofthe Common Service Mana). Protect the radiator fine by attaching a place of adhesive tape or equivalent and removelinstall the radiator with care Procedure Lew 1 Remarks Removal Order (1) | Upper radiator hose (2) | Radiator breather tube (2) | Fan motor connestarfan motor switch con- sector n (4) | Lower radiator hose 1 18) | Upper radiator bott 2 (6) | Lower rector bot 2 nm (7) | Uppertowerr Installation fen the reverse order of removal. Nore + Remove the two bolts, pul the upper raciator to the flywhee! side, and eisconnact at the upper connection (of tha radiator mount NOTE + Remove the two bolts, pull the lower radiator to the clitch sie, and disconnect atthe Upper connection of the radiator mount. NoTE + Romove as an assembly. 5-7Cooling System Radiator Disassembly/Assembly GROUNDCooling System cAUTION 7 Protect the radiator fins by attaching a pace of adhesive tape or equivalent and femoverinstall the radiator with care not to break the fins. nore 7_ Set the fan motor wire in the fan shround clamp propery to ave interference betwen the fan and the Cbd Roquisite Service + Radiator romovalinstalstion [age 5:6) Procedure Lew] Remares Disassembly Order 1 “Resembly isin the reverse order of disassembly. «| Radiator grite 1 (2) | Fight radiator hose 3 (3) | Lett raiator 1 14) | Fan motor swich 1 | Nore + At instalation, spoly sealant tothe toads, ‘CAUTION + Do not oversighten the fan motor switch, othe radiator tay be damaged. (61 | Fan motor boke 3 | nore + On reassembly tighten the ground wire together with the upper bot. (6) | Fan motor assombly 1 | Note + Disconnect the connector and the wire fom the clamp ofthe lower radiate: 7 | nue 1 £2) | Cooling fan 1 | Note + When reassembling igh the fan motor shaft end the cutout inthe fa blade. (2) | Fan motor nut 3 (00) | Fan motor 1 | Nore instal te fan motor on the fan shroud with he water | rain hole facing down,‘Service Information 6. Fuel System 6-1 Carburetor Removal/Installation 68 ‘Troubleshooting 6-2 Carburetor Separation 6-10 Fuel Tank Disassombly/Assembly 6-3 Carburetor Combination 6-12 Fuel Valve Disassembly/Assembly 6-4 Carburetor DisassemblyiAssembly 6-14 Cleaner Removal/installation 66 Service Information ‘lames or sparks inthe work area oF where gasoline is stored can cause fie or explosion. ‘CAUTION Bending of twisting the contol cables wilimpair smooth operation and could cause the cables to stick or bind, resulting in loss ‘of vehicle contr + Be sure to remove the diaphragms before cleaning ait and fuel passages with compressed a The dlaphragms might be damaged, NOTE ~ hve to bo saad ore tan ove mo, Ge Fant bowls Foal oh te TosTbowis ay couwe Sage | fesuiting in hard starting or poor driveability. } ‘Carburetor isascembiy is not required for servicing the vacuum piston and the flost chamber Refer to section 2 for fuel tank removal and installation. ‘When disassembling fuel system parts, note the locations of the O-rings. Replace them with new ones on reassembly, Before disassembling the carburetor, place the suitable container under the carburetor drain bolt, then loosen the bolt and grain the carburetor ‘After removing the carburetor, wrap the intake por of the engine with a shop towel or cover it with piece of tape to prevent any foreign material from dropning into the engine. ‘Carburetor number Is sot so that it corresponds tothe cylinder number. 6-1Fuel System Troubleshooting Engine Won't Start + "No fuol to carburetors = fuel strainer logged — fuel tube clogged = faulty fuel valve = float level misadjusted = fuel tank cap breather hole clogged + Too much fuel getting tothe engine ~ air cleaner clogged = Hooded carburetors + Intake arte + Fuel contaminatedieterirated Stow circuit or bystartercieuit clogged Ignition mattunction Engine Stalls, Hard to Star, Rough ling + Fuel ine restricted + Ignition matfunetion + Fuol micure too leantich Fuel contaminated deteriorsted Intake ae leak Idle spate misediusted Por sorew misadjusted Slow circuit or bystarter cteult clogged Float lovel misagjusted Fuel tank breather tube clogged ‘Attorburm on Deceleration ‘Laan mixture in slow eireutt Backfiing or Misiring During Acceleration + Ignition system faulty + Fuel mixture too lean Poor Performance (driveability) and Poor Fuel Economy ‘+ Fuel system clogged + Ignition malfunction 6-2 Lean Mixture Fic Fuel ets clogged Float valve faulty Float level toa low Fuel line easvioned Carburetor air vent hole far tube) clogged Intake air leak ‘Vacuum piston foutey Throttie valve faulty, Mixture BBystarter valve in ON position Float valve foulty Float lvel too nigh Ar jts clogged Ar cleaner element contaminated Flooded carburetors EFuel System Fuel Tank Disassembly/Assembly Sane BS a 1 « cy Gasoline is extremely flammable: ‘and is explosive under certain condkions. Work in a well vated area. Smoking or allowing flames or sprke in the work area or where gasoline is stored can cause a fire or explosion. Requisite Service + Fuel tank emovatinstallation (page 2-5). Procedure Tor Reman ‘Disassembly Order “Reser eta oveae order of isesser. (0 | Botan cap m (2) | Foe! vawve bore 3 {31 | Ong + | nove | rien asserting the fue tank, tke care otto get the Oring caught or iced inthe part (4) | Fuol vate assombly 1 (5) | Breather tube joint + 16) | Feet tani 6-3 |Fuel System Fuel Valve Disassembly/Assembly e @ ‘+ Gosotine is extremely flammable ands explosive under certain conditions. Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasolin i etored can cause a fire oF explosion, Requisite Service + Fuel tank disassemblyiassembly (page 6-3). Procedure ow Remar Disassembly Order “Assembly isin the reverse order of disassembly. (1 | Fuel vale fever 1 (2) | Fuel fker i (3) | Diaphragm cover sere 4 | note + On assembly, tighten the eerews equally. 14) | Diapleagen cover 1 {1 | Spring 1 1) | Diaphragm 1 2) | Setpiate i (8) | Fuel valve body iFuel System (# MEMO 6-5Fuel System Air Cleaner Removal/installation—————————————— Feat Service earn mete 2) a Process Lev aera ‘Removal Order installation fs the reverse order of removal a | srgoee et or 1 | ee i | ssercaoe Sere: Vitex: « re 4 Ge . " : | i i 5 2 i 3Fuel System “+ Gasoline is extremely flammable and is explosive under certain conditions. Workin a wall ventilated area. Smoking or allowing flames of sparks inthe work area of where gasoline is stored can cause a fre or explosion. Nore After removing the carburetor, cover the engine Intake port with a shop towel or tape to prevent foreign materials from entering the engine through the port. Requisite Service + Air cleaner removaiinstallation (page 6-6) Procedure ownlaee Remorse Removal Order Tntalation isin the reverse order of removal. (1) | Aircieaner ease base screw 4 (2) | Aircloaner case base 1 (3) | Throttle cable 2 | Nore Loosen the adhuster. (4) | Choke cable 1 (6) | tneuiator band 4 | Note + Loosen the sorews on the carburetor side. Install the insulator bands as shown in the drawing (8) | Carburetor assembly 1 6-9Fuel System Carburetor Separation ACARURETOR (13) (©) corTeR PIN #3 CARBURETOR #1 CARBURETOR, 6-10Fuel System ee ‘Gasoline i extremely Flammable and is explosive under certain conditions. Work in a well ventilated area. Smoking oF allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion. Requisite Service + Carburetor removal (page 6-8) Procedure ay Remarks ‘Separation order : a) | Airchamber screw 8 (2) | Lock plate 4 (3) | Air chamberiair cleaner duct ue 14) | Dowel pin 8 (8) | Bracket screw 2 (6) | Corburetor set screw 2 | nore + Seperate the carburetors (7) | By-starter tine 1 | nore ‘+ Remove from the No. 2 end No. 3 carburetors. | 18) | Throttle fink 1 | NOTE + Disconnect from the No. 2 and No, 3 carburetors. (9) | Bystarer arm 2. | NOTE + Loasen the serews. (10) | 1-3? 2-4 trust spring 2 | nore + Loosen the synchronizing screws. | (14 | Fuel ube 1 phere (12) Air bant tube 1-1] + ‘Note and record the jcint pipe installation direction, 3) 2 6-11Fuel System Carburetor Combination @® one, commen ey - - - #3 CARBURETOR ‘#1 CARBURETOR ‘4 CARBURETOR a -@- 6 (A) THRUST WASHER, (8) PLASTIC SPRING WASHER (C) PLASTIC THRUST WASHER (©) COTTER PIN 6-12Fuel System Requisite Service + Carburetor instalation (pege 6-6) ‘CAUTION After assembling the carburetor check the throttle fink and the byetartet nk for smooth operation. {After assembling the carburetor, move the bystater ink lever to "CLOSED " position and be sue that the bystarter valve is not pulled by the bystarter rod claw, Procedure oy Remarks ‘Combination Order (| By-starter ink 1 | nore + Refer to the drawing forthe combination of the washer (2) | Throttle ink 1 (3) | Sub air cleaner tube 2 (@) | Airbent tube 1 (6) | Fuelzube 1 (8) | By-stator arm 2 | Nore ‘+ Set the law of the by-stater rod and arm on the by- starter valve securely. (71 | Carburetor set screw 2 | caurion 1+ Toke care not to damage the fuel joint pipe O-rings. 18) | 1-3 #2-4 thrust spring 2 19) | Bracket serew 2 (10) | Dowel pia a (1) | Airchamber 1 (12) | Lock piate 4 (13) | Ale chamber screw 8 6-13Fuel System Carburetor Disassembly/Assembly oe ach a 6-14Fuel System SS ‘Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventisted area. Smoking or allowing {1 ames or spars nthe work ates or where gasoline is stored can cause 2 fe or exnlosion, sore : “= The service procedure is for the No. 2 carburetor on this page The procedures of the Na. 1 3, and 4 are the same as the No.2. ‘The vacuum chamber and float chamber can be serviced with the carburetor assembly “The pilot screws are factory pre-set and shouk! nt be removes urless the carburetors are overhauled. Tun each pilot sorew in and earelly count the number of turns before it eats lightly. Make o nots of this to use as 8 reference when reinstaling the pilot screws, I new pilot screws ar intales, rum plot serows out to the intl opening (page 1) Requisite Service + Carburetor removainstatation (page 68) Procedure ay Remarks Disassembly Order “Reser i inthe reverse order of isassombly Froat Chamber 9 | Serow 3 (2) | Froat chamber cover 4 (3) | Oring 1 () | Froat pia 1 (6) | Froat 1 (6) | Froat valve 1 7) | Valve seat 1 (8) | Washer i (a) | Fiter 1 (10) | Main jet 1 tnt) | Needle jet holter 1 192) | Siow jot 1 113) | Pict serewspring n (aa) | washerO-ing bow (15) | Thvotte cable holder 1 ‘Vacuum Piston | 11) | Vacuurn chamber cover serew 4 | nore | + Install with care not to pinch the diaphragm. | 1071 | vacuum chembor cover 1 128) | Spring 1 (08) | Vacuum piston 1 (20) Jet neecie hoder 1 | nore + Turn counterclockwise while pushing the holder light. | (20 | Spring 1 122)| Jet neecle th 6-15 | \7. Engine Removal/Installation Service Information 7-1 Engine installation T4 Engine Removat 72 Service Information '# A floor jack or other adjustable support is required to support and manewver the engine. CAUTION _ ae +_ Do not jack up the motoraycle using tho i iter. + To protect the engine, place @ rubber board or equivalent onthe floor before remavingfnstaling the engine * lace a jack under the engine and suppor the motoroyle socursly. Remove and install the engine with care not to damage the frame, engine, cables, and the harnesses. 3 the frame to protect it. + The following components can be serviced with the engine installed in the frame: = aerator (Section 14) = cinder head (Section) chitch (Section 9) = gearshift inkage (Section 8) = oi pump (Section 4) = starter motor (Section 16) - — water pump (Section 5) + The folowing components require engine removal for service: = connecting rod (Section 10), = crankshaft (Section 10}, stan (Section 8) transmission (Section 10),Cr)Engine Removal/installation CAUTION Place = jock under the engine and suppor the motoraycle securely “Tum the ignition switch OFF bofore dlsconnecting the cable from the battery negative (—) teninal ‘When placing the jack under the engine, taka care not to set the jack agaist the of iter, 1 Take care not to pinch the wire harnesses, NOTE + When the clutch lock nut primary dive gear bol, and the flywheel bol are removed after removing the engine loosen them inadvance to case removal Requisite Service Engin ail raining Docation: page 8.3, step: section ofthe Common Service Manual) {Exhaust pe removal (page 270) = Content eiing (pe 5S {Fast tant removal page 25) + Radar rmovel age 58) { Carbietor removal page 6-9 + loosen the dive chan (page 3:1 Procedure ey Reman Removal Order ct | Atemeto wire connector = =] 4 (2) | Pulse genaratr wire connector 1 (2) | Neural ewitch wie connector + | Nore + Disconnect the which is inegreted with the ol pressure wen (4) | Spark plug cap 7 (5) | Starter motor cable 1 | (6) | Gearshift piel join bot 1 17) | Goat spinel joint, : 18) | Chach cable 1 | sore | «Loosen the ower aster lok nut and remove (2) | Speedometer gee box | 1 | ote | + Remove the mounting bot (105 Dive sprocket cover 1 | «| Bave sprocket + | nore + Remove the sprocket and remove the dive cin. (12) Hea protector 1 | 113) Of pipe jon bot + 114) | Lower radiator stey i | 115) | Oi pipe bot 2 | {16} | Rear lower engine mounting nut 1 (17) | ~ adjusting bot lock nat 4 11} | = mourtingadusting bot + | nore 1 Tum counterclckwise together wth the mounting bol tnd vemove (19) | Rese upper bot lock nut 1 (20) ~ mounting bit 1 (20 | — sajsting bot +. | nore : {ose unt he bolt ene not exrung inside the | frame (2) tafe mounting boltotr an | nore + Font tot most be ightenes together wh the actor | bracket {23)| ight mounting blveotar 22 {20 | Engine esembiy + | nore + Lower the engine stright, hen rie the frame }Engine Removal/installation Engine Installation ° m2 © Quon oo ef D929 5165, 40, 8806.5, 40) a | ee & ps s.6mm : FRONT CYLINDER SS 4 CRANKCASE SIDE COLLAR Srerous neces wD uo29 FE Ton + The bolt must be tightened together with the radiator bracket. Check for the corect postion, 74Engine Removal/Installation CAUTION ‘Place jack under the engine and support the motoreycle securely. Take care not to damage the frame, engine, etc. {+ Tako care not to pinch the cable and wires. |When placing the jack under the engine, take care not to set the jack against the ol iter. Loosely tighten theall mounting bolts and cheok to see thatthe engine's placedin comtact postion. Tighten the mounting bolts fest that are tightened together with the adjusting bots (page 7-6. Requisite Service + Exhaust pipe installation fpage 2-0). + Radiator instalation ipage 5-6) + Carburetor installation (page 6-8). + Fucl tank instalation (page 2-5). Coolant refi (section 5 of the Commen Service Manta = i Procedure ay | Remarks Instatlation Order (11 | Engine assembly 1 (2) | Rearlower engine mounting bolvadfusting bor | 11 | NOTE + Insert the mounting bolt into the adjusting bol, engage ‘them, and tighten them together. (@) | — sojuct bot look nut 1 (4) | — mounting nt 1 (6) | Rear upper adjusting bott 1 | wove . + Loosely tighten (6) | — mounting bot 1 | Note + Loosely tighten the bok frst, tighten the sdjsting bolt ‘as much as it goes, and install he lock ut 17) | = tock mut 1 (8) | Lote mounting bolcoter sn | nore + The rearward bolt has a colar (15mm of with). ‘The forward bolt must be tightened together with the radiator bracket. Loosely tighten to cheok the correct in- staliation positon, (9) | Fight mounting botucolar 22_| NOTE + Install the collars in proper positions. 180) | Oi pipe bole 4 (1 | Lower rasiatr stay 1 | Note + Install the drive chain on the drive socket 112) | 01 pipe ola bate 2 | nove 1 lnteclock the ter arm withthe liter ro, 113) | Heat protector a 194) | Drive sprocket 1 (15) | Drive sprocket cover 1 106) | Chutch cate 1 {97 | Speedometer geer box 1 | wore + Engage with the drive sprocket bole (page 10-2) (18) | Gearshift spindle joint 1 (19) | Gearshift spindle joint bott 1 | nove ‘Install the punch mark on he arm aligned with the mark ‘on te spindle (page 10-2). (20}} Starter motor cable (21) | Spar plug exp (22)| Pulse generator wire connector {23} Attrator wire connector (241 Neutral switeh wire connector 7-5Engine Removal/installation Engine Mounting Bolt installation {Rear Upper Mounting Bott) Set the adjusting bolt over the mounting bolt and engage them, Push the mounting bolt into the place shown in the drawing as full as it goes ‘Tighten the mounting bolt and the ausing bolt by using @ hex wench. TORQUE: 11 fem (11 kg-m, 8 feb) Insta the lock put. Hold the adiustng bolt and tighten the lock nut by using the lock nut wrench. TORQUE: 55 Nem (5.5 kgm, 40 flab) LOCK NUT WRENCH ‘o7timamn70200 [Rear Lower Mounting Bolt) Apply a thn coat of grease to the mounting bolt. ‘Set the adjusting bolt over the mounting bolt and engage ther. Push the mounting bot into the place shown in the drawing es ull sit goes. Ti ADJUSTING BOUT Oh i (i) OCK NUT WRENCH i 4Removat/tnstaltation “Tighten the mounting bolt and the adjusting bolt by using @ hex wrench, ‘TORQUE: 11 Nem (14 kgm, 8 feb) Install the lock nut. Hold the mounting bolt and tighten the leek nut, by using the lock nut wrench. TORQUE: 55 Nm (5.5 kg-m, 40 feb) TOCK NUT WRENCH ‘o7unamn70200 Tighten the mounting nut on the other sida ‘TORQUE: 40 Win (4.0 kg-m, 29 feb) (LOCK NUT WRENCH (2) HEX WRENCH 778. Cylinder Head/Valves Service Information 8-1 Cylinder Head Disassembly/Assembly 8-6 ‘oubleshooting 8-1 Camshaft, Cam Gear Case Installation 8-8 Camshaft/Gam Gear Case Removal 8-2 Cam Gear Case Installation 8-10 __ |. Cylinder Head Removal/installation 8:3 _ Camshaft Installation at Service Information + The oylinder head, camshaft, and the eam gear case can be serviced with the engine mounted on the frema. {ifthe front or ear camshattis removed, be sure to check the valve timing onthe other cylinder from which the she is not removed, then reinstall the removed shaft — : “+ When servicing the onder head, note and record the shim rumbers and locetions so that they can be set in ther original posvon. + When assemaling the cylinder heed, epoly molybdenum disulfie grease tothe siding surfaces ofthe valve stem. rocker arm, rocker ‘arm shaft, ond the camshaft. + Be sure thatthe Na. 1 oylinde is atthe top dead centr of che compression stroke when the T! markis aligned with the alignment ‘markorrthe clutch caver (cutout) and the camehaft edge marks tovarcup [aligned withthe ecribe linen the camshaft holden Each mark should be positioned as shown in the crawing. — +The crankshaft should rotate clockwise anc the camshaft counterclockwise viewed from the clutch cover side {+ The cylinders should be arranged as shown in the drawing, 9 cosine (9 rr soe - OLS @ ero 2 a causnnrs nen cy evnoenannanGoMen eae GS camer “+ Besure that the No. 4cyinderis atthe top dead center ofthe compression stroke when the T2 marki aligned withthe alignment ‘mark onthe clutch cove (cutout and the camsbate edge mark is toward up i. aligned with the scribe ine onthe cemshaft holder ach mak shouldbe poshionad se shown inthe ereving. ee 2 ewe ‘SS S wee m7 a Troubleshooting 13) STARTER CLUTCH COVER “The oylinder head troubles con be detected bythe cylinder compression and the abnormal engine noise, Cylinder Compression Too Low Valve Cynder Compression Too High = Misadjusted valve clearance +" Carbon: deposits on the piston and in the combustion Seized or bent valve chamber = Damaged vale spring — Abnormal Not Improper valve timing + Misagjusted valve clearance = Improperly eeated valve sest + Seized valve or damaged valve spring + Cylinder hese + Damaged or worn camshaft holder and camshaft Leads trom the cylinder heed + Damaged or worn rocker az = Distorted or racked cylinder head + Damaged or worn cam gearCylinder Head/Valves Camshaft/Cam Gear Case Removal 2NOTE are removed. with IN or EX respectively Requisite Service + Radiator removal page 6-6) ~ Service on the front side Is described on this page. Perform the rear side service inthe same menner {Take care not to rap any part into the hole in the cam gear case {The cam gear Gase Ie stamped with the front and rear .D. marks. Do not confuse the front and rear gear cases when the both + When removing the camshaft holders, be sure that the camshat of one cylinder is at the top dead center ofthe compression stroke. Loosen the holder bolts onthe side ofthe other eyinde (which camshaft is atthe rap dead center ofthe exhaust stroke) equally In 2 of 3 stops, then loosen the remaining holder bolts inthe same manner. Remove the holders as straight as possible. + Each camahaftis stamped with the LD. mark F forthe front cylinder and R forthe rear cylinder. Alco each camshafts marked ‘Cylinder Head/Valves + Carburetor emovel ipage 6-8) 2 Water pipe. 1 Spark plug removal Procedure ay Remarks ‘Hemoval Order (1) | Carburetor insulator 2 (2) | Cylinder head cover bolewasher aia (3) | Cyieder head cover 1 (4) | Gasket 1 (6) | Camshaft holder bot 16 | nore + Check that the camshaft of one oyinder i at the top dead center of the compcession stoke. + Loosen the holder bolts on the side ofthe other cylinder hich camshaft is a the top dead center of the exhaust _soke in 2 or 3 stops equally then loosen the remaining holder bets (6) | Oitpipe stopper pla 2 ) | Oipipe 1 (@) | Camshaft assembly 2 | nove + Check for the cam gear and crive geer esgegement (9) | Cam holder dowel pin a | note + The cam holder dowel pins must not necessarily removed, 110) | Camshaft holder 4 | nove + Check the mark on the camshaft holder and erase elther front (E) 0 rar (R mark. (21) | Camsnate 2 | nore + Remove by aligning the cam lobe with the long hole in the com holder. (12) | Cam gear ease set bolt 1 | Nore «With copper washer (13) | Carn gear case mounting bolt 4 | Nore + With conical washer. Loosen in 2 or 3 stops equal (14) | Cam gear co 1 | Nore + Dornot confuse the font and rear when both are removed, 051 | Dowel pin (em) 2Cylinder Head/Valves. Cylinder Head Removal/Installation . 1212.9) a 3 : a a a4Cylinder Head/Valves ] L note 7 Service on the front side ls described on this page Perform the rear side service In the same menner. 1 When removingfnstaling the front engine mounting bot, be sure to protect the ol pen by attaching it with 2 suitable wood ‘board and support the engine with a jack to prevent load on the bolt. CAUTION 7 Apply engine oil to the threads and the seating feos of tho ovinder head bolt. Requisite Service + Operations related to the front cylinder: 1 Rodiatorremovalfnstalation (page 5-8) _+ Thermostat removainstallation ipage 5-4) 1 Operations related to the both cylinder + Camshaft holdercam gear case removal (page 8-2). s 1 Exhaust pipe removalénstalation (page 2-10) “Coolant draining (page 5-2). Carburetor removalfnstallaion (page 62). Engine mounting bolt removal. Procedure T Remarks Removal Order ~Tinatallation isin the reverse order of removal + Loosenighten the conical washer attached special | boits together withthe Gram bots in 2 or 3 steps | (0) | Cylinder head bole 8 x 84mm 4 | Note equaly, (2) | Cylinder head bold 6x 62mm 3 | (3) | Cylinder head assemiiy 1 | (a) | Gasket 1 | nore 1 + Install wth the “UP” mark facing up. (81 | Dowel pin 2Cylinder Head/Vaives Cylinder Head Disassembly/Assembly (on replacement, 8-6Cylinder Head/Vaives ~ cavTion Bete soeing he Sor hood ote and ecard de sien Ge knaos and Sona with swale to stale the shims inthe original poston + Dont compress the ave spings more than necessary. 1 Nowe the locaton of each pert and rental thm in her rgnal poston. + Wines mutton the valve springs, nal with de nanower col ph ie toward the combustion chamber + Deeutramove ts rocker stm haf up excop when is replaced a tha the tapered treads, When the rocker arm shat [t's renlacedappiy saing agent othe teas and stl NOTE + Servicing on the front bank is described on this page Perform the rear bank seivicd the same manner Requisite Service + Cylinder head removalinstallation (page 8-4) Procedure Remarks Disassembly Order - “Assombit is in the verse order of dsasserny. en | Shien 8 | Nove + Note the location end thickness ofthe shims. (2) | Rocker arm shatt 4 | Nove 5 +The rocker arm shaft can be easily removed by pressing the spring withthe two rocker arms and moving the shaft Inward, When instaling the rocker erm shaft align ‘the groove inthe cocker arm shafts withthe recess s100ve of the camshaft holder bots. (2) | Rocker arm 8 | note + Cheek for missing spring (4) | Thrust spring 4 (5) | Vane cotter 16 (6) | Valve retainer 8 (7) | Outer spring 3 | Note + Install them with the narrow pitch end facing down. (6) | inner spring 8 (@) | Outer spring seat 8. | Nove (60) | Inner essing seat 8 | + Insta ths, There should be no step between the spring seats. (19) | ster seat 8 (92) | Volve INIEX: 8 113) | Valve guide 8 8-7Cylinder Head/Valves Camshaft, Cam Gear Case Installation od | 12112, 9) L oe oo — = eee +The front cylinder service is described on this page Perform the reer cylinder service Inthe same manner + Check that the shimis instated on each vaive retainer securely. Take care not to drop any pat ino the holein the cam gear case: + When instaling the cam shaft holders, check thatthe camshaft of one cylinder i atthe ton dead center of the comprescion ‘stroke Loosely tighten the holder bolts on tha side ofthe ether eyinder which camshaftis atthe top dead center ofthe exhaust stroke in 2 or 3 steps equally, then tightan the remaining holder bolts (page 8-1, ‘The camshaft are marked with for front cyinder and forrearoyinder. Each camshaft is also marked with IN or EX respective: Wy tpage 8-10, = Requisite Service + Restor installation (page 5-6), + Carburetor installation page 6-8) + Water pine instalation {Spark plug installation, 8-8Cylinder Head/Valves Procedure Remarks a 2 3) «@ 6) ca a e) @ wo) a 2) (13) ay 03) Inotallation Ord Bowel pin (&mm) (cam gear case Cam gear case mounting belt ‘Cam gear case set bolt Camehatt Camshaft holder ‘Camshaft hokder dowel pin Camshaft assembly opps Oil pipe stopper plate ‘Camshaft holder bolt Gosket Cylinder heed cover Cylinder head cover washerfoott Carburetor insur Note + Push the dowel pins fully and instal NOTE {+ Check the flange for F (fr front oF (for rear) mark and install accordingly with the eet bolt installation hole toward the carburetor (page 8-0) NOTE + Loosely tighten, check for proper engagement of the se- ‘cond gear and the crankshaft timing goer, and push the cam geer case as much 2s it goes. NOTE + With copper washer. Loosely tighten ‘Tighten the can geer mounting bolts ofthe dowel pin ide fret, then the remaining mounting bolts diagonally. “Tighten the set bolt (page 8-101. NoTE Inetal by aligning the cam fobe with the long hole inthe ‘car holder. NOTE + Check the mark on the camshaft holder and ascomble with the comshatt accordingly. Note : + Check the timing mark on the starr elt, ‘Check the engagement ofthe cam gear and the dive ‘92a" and install by aligning the edge mark with the ‘scribe fine on the holder. Nore + Check that the camshaft of one cylinder is atthe top dead center ofthe compression stroks. Loosely tighten the holder bots onthe sie of the other cylinder which ‘camshafts at the top dead center of the exhaust stroke in 2 or $ steps equally, then tighten the cemining holder bots. The outer raws ofthe camshaft holder bolts tightened on the cyinder head are the stepped bolts Nore + Align the in mark with the matk on the cover end attach bby Using the recommended adhesive agent (page 3-0) NOTE {+ Inetall wah the IN mark toward the carburetor Nore Inetal the washer with the "UP" mark toward out Nore + Inetall with the “CARB” mark toward the carburetor and tho “UP” mark toward up. 8-9Cylinder Head/Valves “Cam Gear Case Installation TLD MAR EOR a Apa NOTE S = The cam gear case le marked with F or R on the flange. Install the gear ease marked F on the frant cylinder and the case marked Ron the rear cylinder. ‘+ When the identification mark is not cleat, the gear case ‘can be identified by the sub gear of the second geac. With the sub gear towerd you: — for front cylinder: the eub gears off 20 the left ade from the main gear = for rear cylinder: the sub gear is off tothe right side from the main gear Push the gear case dowel pins fully into the evlinder head, NOTE ~) (1) THIRD GEAR, ‘+ The second gear and the crankshaft timing gear do not engage properly when the dowel pins are not pushed (2) GEAR CASE into the full (3) SECOND GEAR” (Check the LD. mark on the gear case and install the case on the designate cylinder head. (Check for the proper engagement of the timing gear and the pw seconds gear in the following procedures. > LUghtly move the third gear beck and forth with the gear case | (4) CRANKSHAFT —> a lightiy pushed down, The engagement is corract ifthe lange TIMING GEAR of the gear case is pushed by the timing gear and raised off the oylinder head slighty. Romeve the gear case and reinstall it if necessary. Tighte® the four gear case mounting bolts fully with your (i) GEAR CASE MOUNTING BOLT fingers. Install and loosely tighten the gear case set bolt and the cop: por washer. NOTE + When tightening the set bolt, take care not to damage ‘the gear ose threads and the bolt threads. Tighte® the gear case mounting bolts of the dowel pin side to the specifled torque. ‘TORQUE: 36 Nm (8.6 kg-m, 26 felb) Then tighten the remining mounting bolt, Tighte® the gear ese set bok. tm BOLTS TORQUE: 12 Nem (1.2 kg-m, 9 ft-ib) me (2) WASHER 8-10 |inder Head/Valves Camshaft Installation Remove the lower fairing (page 2-4). Remove the timing hole cap, ‘When both front and reer cylinders are disassembled: CAUTION Install all the came right crankcase cov with the edge mark 0 Apply motybdennum disulfide solvent to the sliding surface fof the camshaft, eamehaft holder, and the rocker arm. Refer to the marks on the camshaft holders end the cylinder head and note each camshaft holder instalation position, CAUTION a : + ‘The camshaft holders make up the oll passat . ‘oinstall them in the corect postions as instructed with ‘CAMSHAFT HOLDERS ‘the marks. ore CCheck the 1.0. marks of each bank’s camshaft and assemble ‘the camshafts with the respective camshaft holders. LD. MARKS: RR: Reer bank FR: Front bank IN: Int EX: Exhaust e (9) CAMSHAFT LD. MARK 8-11Cylinder Head/Valves ” Align the cam Tobe with the long hole in the camehart holder and insert the camshaft into the camshaft holder. CAUTION (3) CAMSHAFT HOLDER + Apply molybdoum disulfide solution to the eam lobe, ‘camshaft, and the camshaft holder journal and insert the camshaft with care not to damage them. [Rear bank side installation) Rotate the crankshaft clockwise and align the starter clutch ‘T1 mark (serbe line) withthe cutout (alignment mark) in the ‘ight crankcase cover. (The No.1 cylinder should be atthe top dead center of the compression stroke. CAUTION, * Be sure to Install tho camshaft holder of the No.3 ‘ylinder frst, as it i at the top dead conter of the ex hhaust stroke Install the assembled intake side and exhaust side camshaft holders on the cylinder head with the camshaft edge marke ‘acing up and aligned with the scribe line on the holders. — ‘caUTION + Be sure each shim is installed propery. + Check for proper engagement of the cam gear and the ‘camshaft side driven gear, and install with care not to let the edge marks out ofthe alignment with the scribe lines. | + Do not strike to install the camshaft holder. | BEE cd earl ee ‘Set the oil pipe and the pipe plate between the camshaft holders and loosely tighten all the camshaft holder bolts. CAUTION *+ Before loosely tightening the camshaft holder bolts, be ‘sure that the bott holes atthe cylinder hoad comers align ‘with the recess holes for fixing the rocker arm shafts. + After confirming the the bolt holes, ins ignment of the recess holes and 6 rum pin into the holes to ease the reat bank side installation. move the eealing plug. + Do not (3) LONG HOLE (2) CAMSHAFT (1) STARTER CLUTCH COVER ag aN, sa (2) BOLTS (STEPPED) (3) BOLTS’ (STEPPED) (1) ROCKER ARM SHAFT (a) THRUST SPRING sa) 8-12Cylinder Head/Vaives. ‘Tighten the eight No.3 side camshatt older alts (IN and EX sidee) unt the camehaft holders closely set on the eylinder head. CAUTION + The camshafts on the No.3 eylindar they get “overlapped”. Tighten the eight holder bolts (No.3 side only) in 2 oF 3 eteps equally. + Tighten the stepped bolts atthe comers of the ovlinder head. Recheck that the both camshaft edge merks align with the '~~-~perbe lines on the camshaft holders. “Tighten all the camshaft holder bolts in 2 or steps diagonally. TORQUE: 12 Nam (1.2 kg-m, 9 1b) ‘CAUTION + ‘The No.1 cylinder is at the top dead conter of the com- pression stroke. Tighton the No.3 eylinder’s camshaft holder bolts fist until the No.3 camshaft holders close- {y 208 onthe cylinder head, then tighton the remaining bolts in 2 oF 3 stops equally. (1) BOLT (4) No.3 CAMSHAFT HOLDERS TipBOLT ‘After the installation, slowly turn the crankshaft 2 or 3 revo- lutions clockwise and adjust the shims to fit. Valve clearance adjustment: see page 3-7. = [Front bank side installation) ce Turn the crankshaft clockwise and align the starter clutch T1 atk (scribe Hine) withthe cutout (alignment mark) in the right ‘crankcase cover. Be sure that the eamshatt edge mark facing Lup and aligning with the seribe line on the camshatt holder. it not, align by tuning the crankshaft on emore clockwise revolution. (The No.1 cylinder houldbe atthe top dead center of the compression stroke.) “Turn the crankshaft further 90 degress clockwise and align the starter clutch T2 mark (sezbe line) with the cutout (align ‘ment mark) in the right erankcase cover. Be sure that the camshaft edge mark is facing up and aigning ‘with the seribe ne on the camshaft holder. (The No.4 cylinder should be at the top dead center of the compression stroke.) ‘Now install the carnshatt in tho follwoing procedures. Set the oil pipe and the pipe plate between the camshaft holders and tighten all the camshaft holder bolts. CAUTION ‘Before loosely tightening the camshaft holder bats, be ‘sure thet the bolt holes atthe eylinder head comers align ‘with the recess holes for fixing the rocker arm shafts, before loosely tightening the camshaft holder bots. Do not remove the sealing plug. (} STARTER CLUTCH COVER (1) ROCKER ARM ius (00 NoT REMOVE.) (a) ROCKER ARM SHAFT ey (3) 8OLT (sTEPPED)Cylinder Head/Valves ‘Tighten the eight Gamshatt holder bolts f both No.2 eyinder ccamhafts (IN and EX sides) until the camshaft holdere close ly set on the cylinder head,as did on the rear bank side. cauTION — * Be sure each shim Is inetalled propery. + Check for proper engagement of the cam gear and the ‘camshaft side driven gear, and install with care not to lot the edge marks out ofthe alignment with the scribe lines. + Do not strike to install the camshaft holder, Tighten the all botts including the camshaft holder bolts of the [No.4 oylinder side In 2 or 3 steps. ‘TORQUE: 12 Nem (1.2 kgm, 9 ftlb) cAUTION + No.4 eylinder is atthe top dead conter of the compres: lon stroke. to tighten the No.2 eylinder’s carn- shaft holder bolts frst until the camshaft holders closely set on the cylinder head, then tighten the remaining botts in 2 oF 3 stops equally. Valve clearance adjustment: see page 3-7. Head cover installation: s2e page 3-10. Apply the molybdenum disulfide aoution to the timing hole 8p O-zing and install the cap. (2 No.2 CAMSHAFT HOLDER (i) BOLT (STEPPED BOLT AT THE CORNERS) Wien the Wnt side is disassembled] ~~ Remove the rear cylinder head cover and cheok thatthe No.1 ‘cylinder is at the top dead center of the compression stroke (page 3-7). ‘Turn the crankshaft 90 degress clockwise from the timing marke 1 position and align the starter clutch T2 mark (scribe line) ‘with the cutout faignment mark) in the right crankcase cover (The No.4 cylinder should be atthe top dead center of the com. pression stroke.) ‘Now install the front camshett.Cylinder Head/Valves ee [when the rear side is disassembled) Remove the front cylinder head cover and be sure thatthe No.4 bylinder Is af the top dead center of the compression stroke. {he camshaft edge mark should face up at the T2 position.) (Page 3-7) ‘Turn the crankshaft clockwise 630 dogress fone revolution and 270 degrees! from the timing mark T2 positon and aign the Starter eksteh T1 mark (gerbe line) withthe coutout (alignment fark) on the tight crankoase cover. (The No.1 eylinder should be at the top deed center of the compression stroke.) Now install the rear camshaft. (1) Relationship between the top desd center marks eng cylinders Tring mark Camshaft Cylinder at top (etarter clutch) | edge mark | dead center = ‘Toward up a1 Tossed down | #3 Toward u #4 2 P Toward down | #29. Clutch Service Information 9-1 _ Clutch Removal 9-4 Troubleshooting 9-1 Clutch Installat 96 Right Crankcase Cover Removal/installation 92 Service Information Clutch masintenance can be done with the engine in the frame. Clean any gasket off the crankcase cover-crankcase mating surface. Do not damage the cover-case mating eurtace. Never allow foreign materials to get into the engine. It the transmission require servicing, remave the engine ond separate the crankesse (Section 10) Troubleshooting ‘Most ofthe clutch malfunction result from the imaroper clutch free play. Check the clutch free play and acjust, if necessary, before disassembling the clutch ce seen Acta a | Seance ee orca cietmeae ace Excessive engine oil Loose elutch lock mut Excessive engine oll or excessive ofl viscosity Clutch eable not routed properly ‘Clutch Operation is not Stabilized. Worn clutch cuter groove Gear Is Hard to Engage. | - + Clutch misagiusted oa (Clutch Lever is Heavy. + Poor clutch cable operation due to damage oF rust Damaged clutch liter mecha Damaged clutch lifter plate b« (Clutch cable not routed properly Bent eluteh lifter arm‘Clutch Right Crankcase Cover Removal/Installation Requisite Service Engine ol dining (drain bolt loeation: page 3-3, step: section 2 of the Common Service Menu) ‘A Lower fairing removal/nstalation (poge 2: Procedure ary Remarks Removal Order Installation isin the reverse order of removal 11 Right crankcase cover belt 2 2) | Right crankcase cover 1 31 | Gasket 1 41 | Dowel pin 2 9-2Clutch Clutch lock Nut Removal ‘Straighten the locking tabs of the lock nut with cere not to_ ‘domage the main shatt. NOTE ‘With engine mounted: move the shift lover to the 6th ‘speed, operate the rear brake, and loosen the Fock mu, ‘With engine dismounted: move the shift lever tothe 6th speed, hold the drive sprocket with a universal holder, and loosen the lack nut. ‘Loosen the lock nut by using the lock mut wrench. _ LOCK NUT WRENCH, 26 x 30mm 077160020203 EXTENSION BAR 07716-0020500 (2) EXTENSION BAR (17 LOCK NUT WRENCHClutch Clutch RemovalClutch Se Note 7” To loosen the clutch center lock nut, straighten the locking tebs with care not to demege them, then Move the shift lever to the 6th speed and operate the rear brake When the engine dismounted from the frame, mave the shift lever to the 6th speed end hold the drive sprocket with 2 universal holder or equivalent. + Loosen the oil pump driven sprocket bolt with the clutch assembly installed before removing the bolt. Note that the bolt threads are coated with the thread locking agent. + Note the connection and inetaliaion direction of the lifterrod once itis removed. Speciel alignment is required at the left ter cam connecting section (page 10-2). Requisite Serice «+ Right crankcase cover removalfinstallation {page 8-2). Starter clutch cemoval (page 17-2). Procedure ay Remarks Removal Order (n} Snap ring 1 | Nore s + When removing the oll pump driven sprocket bolt, loosen fe first with the clutch outer installed. (2)] Clutoh ttter plate 1 | Note + Remove the beating only on replacement, (2) Utter guide 1 | nore Remove the stapper ring only on replacement. (ay) Uitte roo 1 | Note + Do not depress the clutch lever with the rod removed. (6]] Cluteh center tock nut 1 | Note + Straighten the locking tabs frst (page 9-3) {6)| Lock washer 1 (i) Cluteh spring set plate 1 (6)] Diephcagm spring 3 | note ‘+ Roplace the three springs es a set (0)} Pressure plate 1 | Note + Remove the stopper ring only on replacement. (103) Thrust washer 1 Jani] clutch aise 10. | NoTE + Dise contact surface of the two end plates is black. }r1ai} clutch plate 8 113] Clutch center B 1 1(14)] One-way clutch assembly 1 | nore + De not disassemble unnecessarily. (759) Thrust washer 1 (169) Cluteh center A 1 (17}| Cluteh outer 1 172)] Oil pump driven epracket bolt 1 '19)] it pump driven sprocket 1 201] O11 puma erive chain/sprocket a | NOTE + Remove the oll pump drive chain and sprocket together. _— [c2n| ciuten outer guide 1Clutch Clutch Installation Install with the di 9-6Clutch NOTE + Tighten the clutch center lock nut 2s follows, Move the shift lever to the Gth speed, operste the rear brake, and tighten the clutch canter lock nut. When the engine dismounted from the frame, mave the shift lover to the 6th speed and hold the drive sprocket with 2 universal holder or equivalent. + Tighten the oll pump driven sprocker bolt with the clutch assembly installed. Apply the thread locking agent to the bolt 6.5 to 7.5 mm from the tip. + The dize contact eurface of the two clutch end discs ace eiferent in material (black). Do not interchange them. + install the lifter rod with the long iron ends toward left. Requisite Service + Right erankease installation (page 9-2) + Starter clutch installation (page 17-4) Procedure ary Remarks | Removal Order ] (1)] Clutch outer guide {2)] Oit pump drive chaintsprocket " {3}] Oi pump driven sprocket + | nore ¥ + Install wth 2 scribe tine onthe geor toward in and tighten with @ bok. | (ai] 01 pump driven srocker boke 1 (6) Clutch outer 1 | nove | + Engage with the dive sprocket and install (6)] Clutch center A 1 | note | + Take care not to demege the main shatt spine. | (71) Thrust washer 1 (@)] One-way clutch assembly 1 | wove + Coat the sprag roller and Inner with clean engine oil and fsssemble with the clutch center B with the roller flange towerd the case cover. (9)| Clutch center 8 1 (10}] Clutch disc 10 | note + Contact surface.of the both end plates is black. Coat the discs with celan engine oil and asemble with th clutch plates alternately. 1] Clutch plote 8 (12)] Thrust washer 1 (13)] Pressure plate 1 3 (14\] Disphragm spring Nore ‘+ “Install with the projected side toward out. (15)] Clutch spring set plate 1 | note + Set the theust washer on the stepped portion at the bot- tom of the set plate (page 3-81. (16) Lock washer 1 | note + Install with the OUTSIDE mark facing our. 07)| Lock nut 1 | cauTion + Check that the dive sprocket and the clutch outer properly engaged, then bend the locking tabs with care ot to damage the threads. 118)| Ute roa 1 | wote ‘+ Install with the long iron ends toward let. Apply molybde- ‘num disulfide grease to the eft end. Alignment with the liter cam: see page 10-2. (19)] Liter guide 1 [note ‘Assemble with the liter plate bearing (20) Liter platerbearing 1 i21)| Soap ting 1 |Clutch Clutch Diaphragm Spring Installation ‘When instating the clutch, intal the three diaphragm springs ‘om the pressure plate withthe projected side toward the lock rut, then assemble with the spring set plate, Be sure that the thrust washer is securely set on the stepped section at the bottom of the set plate cauTION Replace the three daphragm springs as a set. + Note that the thrust washer is set in the correct pos tion of the set plate. Otherwise, the diaphragm spring and the lock nut cannot be set property + Coat the thrust washer with claan engine oto oa stallation. ‘Clutch Lock Nut Installation Assemble the clutch (page 8-6), Note + With engine mounted: move the shift lever to the 6th ‘speed, operate the rear brake, and tighten the clutch= lock nut With engine cismounted: Move the shift laver othe 6th ‘speed, hold the drive sprocket with @ universal holder ‘or equivalent, and tighten the clutch lock nut. ‘Tighten’ the lock nut by using the lock nut wrench, LOCK NUT WRENCH, 26 x30 mm 07716-0020208 | > EXTENSION BAR 07716-0020500 Bent the locking tabs of the lock nut NOTE + Tae care not to damage the main shaft. | Neo eel O (4) PRESSURE PALTE (1) THRUST WASHER m (2) SPRING Ser PLATE (3) DIAPHRAGM SPRING (2) extention BAR (1) LOCK NUT WRENCH— 10. Gearshift Linkage Service Information TOA earn b Troubleshooting 10-1 Removal ed Drive Sprocket Cover Gearatit Linkage, Sit Drum n= Romowalnstelation 102 Service Information «+The gearshift linkage fincluding the shift drum, site fark, and the shift fork shaft) can be serviced with the engine mounted fon the frame. + Take care not to let dust, dirt, and any other foreign materials enter the engine. Separate the crankeage when the transmission sorvice ls requied. Troubleshooting Gear Stips Qut of Engagement. + Worn goat dos + Bent shift shaft + Damaged stopper arm + Bent or damaged shift fork + wioen shite drum groove Goar is Hard to Engage. + Bent shift fork + Damaged shift drum cam groove + Bent goar shift spindle claw 10-1Gearshift Linkage Drive Sprocket Cover Removal/Installation AlignGearshift Linkage Requisite Service + Lower fairing removalfinetallation (page 2-4), Procedure oy Remarks Removal Order ()| Clutch cable holder 1 (2) | Cutch cable a | note + Disconnect fromm the lifter arm. 43) | Speedometer gear box bolt 2 | (4) | Speedometer gear box. 1 | Note ‘+ Remove the gear box. 151 | Drive sprocket cover bott 4 {6} | Drive sprocket cove 1 (7 | Dowel pin 2 Installation Order (7) | Dowel pin 2 (6) | Deve sprocket cover 1 | Note : + Tum the lifter am counterclockwise and connect the cam : ang liter rod by engaging thelr projections and dents. Ap- ply molybdenum disulfide grease to the lifter rod end, (81 | Drive sprocket cover bolt 4 (4) | Speedometer gear box 1 | Nove + Connect the gear box side joint to the sprocket bolt. (3) | Speedometer gear box bolt 2 | NoTE (2)| Clutch cable (11 | Cluteh cable holder + Install with care not to disconnect tha joint. NOTE + Connect to the lifter arm, Nore + Install by aligning the hole with the stopper pin, 10-3Gearshift Linkage Gearshift Linkage, Shift Drum Removal 10-4Gearshift Linkage NOTE 7 The ohift fork, shift fork shat, and the shift drum ean be removed, installed, and/or disassembled with the engine mounted on the frame +The water pump mounting bolts must be removed to-service the gearshift linkage. However, it can be serviced without disconnecting the cocling system hosels). + Removefinstll the clutch assembly and the oll pan to remove/instll the shift fork, fork shat, and shift drum, Requisite service + Lower fairing removal [page 2-4). + Water pump removal (page 5-5 + Delve sprocket cover removal (page 10-2). + Oil pon remaval (page 4-4) + Clutch removal (page 9-4. Procedure oy Remarks Removal Order Gearshift Linkage | (1)] Gearshift epincle joint bottigearshit spindle i | ote wm | (2)| Gearshift linkage cover bolt ® (G)] Gearshitt linkage cover + | nove 5 Pall out straight with eare not to damage the dust seal. (4)] Dowel pin 2 {5}] Gasket i | 161] Gear shite spindte/spring wi | Note | + Do not remove the spring except on replacement. (2) Torust washer joa 48) Shitter collar 1 (2)] Bott 2 (10)] Guide plate/drum shifter assembly 1 | note + Remove slowly with care not to lt the plunger and spring ‘seater around from the shifter body. (11)) Thrust Washer od (123) Stopper arm spring 1 (13)| Stopper arm assembly 1 | Nove + Shop ring, washer, arm, and collar: Do not disassemble unnecessarily (14)] Spacer collar eld 1151] Dowel pin 2 36) shift drum set plate 1 (171) Shite tum canter bott 1 | Note + The threads are coated with the thread locking agent. t28)| shite dum center 1 499] Shife drum pin 1 Shift Dram (20)} Boit/stopper washer 1 | Note | +The bolt threads ae coated with the thread locking agent. (21)] shite fore share 1 | NOTE + Push out to the right side. t22)} shite fork a | (23)| Bearing/Shitt drum an | note + PUI out to the lott side. 10-5Gearshift Linkage, Shift Drum Installation Gearshift Linkage 114) 10-6Gearshift Linkage Nore When instaling the water pump, check the water pump shaft and oil pump shaft connection. Requisite Service + Oil pan instalation {page 4-4) + Clutch installation (pege 9-6), + Drive sprocket cover instalation (page 10-2) + Lower fairing installation ipage 2-49. + Water pump instalation (page 8-5), le Procedure oy Remarks ‘Removal Order Shift Oran (1)] Shift drumfbearing wn (2) Shitt fork 3 | Note + Install the left shift fork on the C6 gear, center shift fork fn the MSM gear, end the right shift fork on the C5 gear feepectively with the marks faxing right [page 11-4) (| Shift fork shaft 1 | ote + Apply engine olf and push in from the right side {a)| Stopper washeribolt m Gearahift Linkage le (61] Shite dram pin 1 | note. + Install the shift drum pin on the shit drum. (6)] Shite drum center 1 | caurion drum pin withthe longhole in (7)] Shite drum center bolt 1 (8) Doat pin 2 (@)] Shift drum set plate 1 110)} Spacer collar 1 11] Stopper arm assembiy/spring a | Nove Loosely tighten the two set bolts and install the roller on ‘the drum canter with the spring hook set on the acm and. the reese side set onthe crankcase. Remove the set bolts. (12)] Theust washer 1 [131] Guide pleterdeum shitter assembly at | Note + Assemble the shitter body, plunger, spring, and reatched aw with the shifter plate. Pushing the paw with your fingers, install the assembled plate on the shift drum center. 114] Bote 2 (15)] Shite colar . 1 116)] Thrust washer fea 1171] Gearshift spindlefspring vn | note | + Install aligning the long hole with the shifter collar and the two return springs with the stud pins on the case. 183) Gesker 1 [191] Dowel pin 1 (20}] Gearshitt linkage cover 1 | note = | + Install with care nat to damage the dust seal, |211] Gearshitetinkage cover bot 8 |1221] Gearshift spindle jointigearshite spindle joint bolt 1 | Note + Alga the puneh mark with the one on the shift arm and | t install on the spindle, 10-711. Crankshaft/Piston/Transmission Service Information 14-1. Countershaft Disassembly/Assembly 11-6 Trouble shooting 11-1 Piston Disassembly/Assembly 18 Crankease Separation 11-2 Bearing Selection 11-10 Shift Fork Installation 11-4 Crankcase Assembly 11-12 Mainshaft Disassembly/Assembly 118 Service Information «Reema sets urn en arte eae 138, « Ge tres seta een oan tte ne hanes San ke | Troubleshooting Cylinder Compression is Too Low. or Engine is Hard to =. Gear is Hard to Engage. Start +” Cluteh is misadiusted (excessive fee ply) + Blown out eylnder head gasket 5 Bent shit fork + Wein, stuck, or broken piston ring ent stft fork shatt + Worn or emaged cylinder or piston 2 Dameged gear shift spindle Bent valve, or bont and deteriorated valve soat_ __Demaged shift grum guide groove Cynder Compression ts Too High, or Engine Overheats + Damaged shife drum guide pin or Knocks. Gear Sipe ut of Engogermene. =" Carbon deposits on the cylinder head andlor piston ‘Worn ger dowel Piston Sounds, Bent shift fork shaft "Wom evlinder, piston, andor piston rng + Damaged shih um stopper + Worn piston pin hole and piston pin + Worn shift drum guide + Wor connecting rod small end ‘Worn shift fork groove of gear ‘Smokes from Muffler ‘Abnormal Engine Noise + "Worn, stuck, oF broken piston ring + Worn connecting rod lege end bearing + Weak waive stem seal Bent connecting rod + Worn exankshaft main bearing Worn transmission gear 11-1Crankshaft/Piston/Transmission Crankcase Separation (1) LOWER (GRANKCASE SIDE: (2) UPPER, CRANKCASE SIDE: - _ —CAUTION 7 Select and replace the main bearing by using the selection table to make it@ good match with the erankshafe main Journal (page 11-10), + Select and replace the connecting ted bearing by using the sefection table to make It a good match with the crankshaft (age 11-10) + Note the location of each part to reinstall them in their original position. {The gear shift linkage such as the shift fork and fork shaft can be removed after separating the crankshaft. + Ifthe crankcase cannot be separted by lighting tapping on the upper case. check whether the crankcase halves are stl tightened with a bot Requisite Service + Engine removal {page 7-2) Cylinder head removal (page 8). Primary drive gear rmovel (pege 17-4. + Gearshift tinkage removal (page 10-4) + Water pump removal ipage 6:8). + Oil pump removal (page 4-4). + Starter motor removal (page 17-71. + Alternator removal (sage 15-8) + Oil fiter removal Procedure ay Romans Removal Order Upper Case Side (1) | Mainshafe bearing set plate 1 (2) | 6 mm bole 8 LNoTe {3} | 8mm bolt 1-]]- Loosen the bolt in # crisscross pattern 2 or 9 steps (4) | 10 mm bore id Lower Case Side (8) | 6 mm bole 7 spNoTe (6) | 8mm bolt 10-J] Loosen the bolt in 9 erissoross pattern 2 or 3 stops, (7) | Lower crankeae 1 | NOTE + Set the erankease with the upper case toward down, Litt the lower ease to separate the upper and lower halves. 1a) | Dowel pin a (@) | Transmission assembly } (10) | Mainshatt bearing 1 111) | Bearing cap stop pin 1 (12) |-Countershaft of seal 1 (13) | Countershaft bearing 1 (14) | Thrust washer 1 (18) | Bearing stopper ring 1 (18) | Connecting rod bearing cap aut 8 197) | Bearing cap 4 | Nore + Do not remove the connecting rod caps with force but full thar out straight. Remove the bearing 18) | Crankshaft 1 | Note + Ramove with care not to demage the crankshaft journal (19) | Sie main bearing 4 | nore + Remove from the upper ond lower ceses and record the installation location. 420) | Center main bearing 4 21) | Connecting rodipiston an | note + Remave to the cylinder head side, Piston removall Installation: page 11-8 11-3Crankshaft/Piston/Transmission Shift Fork Installation 7B ‘Apply to each sling surface. Requisite Service + Crankcase separation (page 11-21 pone eT Seems Taian oe « [eae 1 afrere 63 |e iS] mismaCrankshaft/Piston/Transmission _ Mainshaft Disassembly/Assembly "\eblebhes e «2 (2h BEARING: 5205 7B + Apaty to each sliding surtace. Requi + Crankoase separation (page 11-2). Procedure oy Remarks “Assombly ls in the Taverse order of disassembly. a (2) | Mz gear (187) : (3) | Thrust washer (4) | M6 gear (227) (6) | Spline bushing 6) | Thrust washer/snap cing u (7) | Mans gear (227/207) (8) | Snap ring/thrust washer (9) | M5 bushing (10) | MB gear (237) (11) | Thrust washer (12) | Mainshate M1 gear (147)Crankshaft/Piston/Transmission Countershaft Disassembly/Assemly ae sg on aa 0) a2 oy a3) sliding surfece|Crankshaft/Piston/Transmission Requisite Service + Crankease separation (page11-2) Procedure ow “Romarks Disassembly Order ‘Assembly isin the reverse order of disassembly. (1)| Thrust washer 1 (2) Ct goar (417 1 (}| Needle bearing 1 (a)| Thrust washer 1 {8)] CS gear G37) 1 (6)| snap ringythrust washer m (| C3 gear (367) 1 (8)) Spline bushing 1 (9) Lock washer 1 | Nove + When assembly, insert the tong of the washer into the lock washer groove securely. (10)| Spline washer 1 110] C4 gear (857) 1 (12) Spline bushing 1 (13}) Thrust washer/anap ring nm (14)| C6 gear (297) 1 (18) Snap ringithrust wesher w (18)| “C2 gear (297) 1 (17)| C2 gear bushinghthrust washer mw (18)| Gountershate 1 aCrankshaft/Piston/Transmission | Piston Disassembly/Assembly FRONT SIDE: TOP RING SECOND RING 11-8Crankshaft/Piston/Transmission ‘care not to damage the pistons. ch oyfindor. fore assembling the piston pin with the conn Requisite Service + Crankease separation (page 11-2) {+ Number of Q'ty sted in the table indicates the numbers that a 1 tod, apply molybdenum disulfide oll to the siding surfaces. Select the appropriate connecting rod andior boarings by using the selection table to make a good match. Also select the connecting rods of the most appropriate weight by using the table (page 17-10). shown in the drawing. Procedure ay Remarks Disassembly Order ‘Resembly i in the reverse order of disassembly (1) | Front connecting rod bearing 1 | NoTE + Note the color codes of the connecting rod bearing and the connecting rod cap and store. (2) | Rear connecting rod bearing 1 | wore + Note the color codes af the connecting rod bearing ‘and the connecting rod cap and store. (3) | Piston pin oto 4 | Note + Do not lose. (a) | Pisbin pin 1 (6) | Front piston assembly 1 apnore (8) | Roar piston assembly 1]] "be not remove the piston ring except on replacement. ‘Assembly Order = 16) | Rear piston assembly 1 | note + Check the connecting rod I.D. mark, Install with the IN mark toward the carburetor and the connecting rod oil Jot port toward tho other side (6) | Front piston assembly i [Nore + Cheek the connecting rod I.D. mark, Install with the IN mark and the connecting rod oll jet port towerd the carburetor. (4) | Piston pin (31 | Fiston pin ctip 4 (2) | Rear connecting rod bearing 1 | Note ‘+ Install with the oll passage hole aligned with the con- recting rod hole. (1) | Front connecting rod bearing 1 | note Connecting rod beating sslection: soo page 11-10. 11-9Crankshaft/Piston/Transmission Bearing Selection Main Bearing Record the erankcase 1.D. code, Nore + Aor stamped on the No.d journal of the upper eran ‘case isthe .D. code of the journal. The code letter, from left to right, indicate each journal .0. respectively. (Refer to the drawing to the right.) Record the crankshaft main journal 0.0. code (or measure the main journal 0.D.). Note +f or 2 stamped on the crank weight fs the main journal .D. code. (Refer to the drawing to he right) Determine the bearing 1.D. code by referring to the case ID. ‘code and the main journal code E ‘Wain urna! 0.0. cade i __ 2 [2886830 0020. 00200,010re| 1. 1609—1.18120)|111612—1.121¢) (1) CRANKCASE (1) CRANKSHAFT (2) 1.0. cope [58.000—29.d08m| cose | § J.zas2—1.z895n| © Melon 8 iGront fends |g [88008-220160] 5 : 2 Jis2995—1.209¢ey| 6 Arend inal A (Brown!: 1,498—1.502 mm (0.0590—0,0591 in) B (Green): 1.494— 1.498 mm (0.0588 -0.0580 in) © (Yellow): 1.490—1.494 mm (0.0587 —0.0588 in) ‘Thickness of the bearing metal cari be identified by the color. code, Connecting Rod Bearing Record the connecting rod |.D. code number. (1) COLOR cove ay (2) LD. cope “(1} CONNECTING ROD 11-10ion iF Crankshaft/iston/ Transm 1cotd the crank pin 0.0. code number (or measure the cranic pn 0D) . NOTE ————————————————— ‘her B stamped on the crank weightis the crank pin ©.D. code] {Refer to the drawing to the right.) Select the appropriate bearing metal by refering to the crank pn 0.0. code letter and the connecting rod ID. code number. NOTE 7” Thore are two types of the connecting red bearings: one | — |" forthe front eylinder marked with the one .D. paint and ‘he other for the tear cylinder (marked with the two LD, paints}. Do not contuse, | (Th CRANK WeIGHT —T ae Ti FOR REAR CYLINDER (9) FOR FRONT CYLINDER Connecting 10. cose a T 2 Fi e80= 0.008 [ 008-2 TEs (i292 996n) | 2996~1 20980 c [= g|a)z2902-so0c0m| | 9, EIA to00—1 ers | retow | ew: is 5 8 es [$5],2ns00—z02000| 2 | aoa, ‘11805-1208 | ren | BS (9) BEARING METALS Setetive bearing metals: 2 (Grown) (Brown, Brownk: 1.494 1.498 mm 0.0888 - 0.0590 In} 8B (Green) (Green, Green|: 1.480 1.494 mm (0.0587 -0:0588 in} . { WYllow) (Yelow, Yelow: 1.486 - 1.480 mm (0.0585 - 0.0587 in} Connecting Rod Weight Selection a ‘The connecting rods are stamped with the merk A, B, or © which indicates the weight of the rod. When replacing the connecting rod, refer to the selection tar — = ble and select the connecting fod of the appropriate weight. Weight code of | Weight code of | Weight code of the connecting | the remaining con- | the new connect: fod which is to | necting rod on the | ing rod bevoplaced | samme crank pin 7 z 8 ABoo c ci (1) CONNECTING ROD A Bore 8 8 AB ore € AorB A Bare © 8 [AB ere (2) WEIGHT cone 11-11Crankshaft/Piston/Transmission Crankcase Assembly E ee Se D: Bene bo CONNECTING ROD BEARING MAIN BEARING LOWER CRANKCASE SIDE BOLTS, a7 \ 4 NY . 4 oe SB 8 xem tana UPPER CRANKCASE SIDE BOLTS 11-12Crankshaft/Piston/Transmission CAUTION + Select and replace the main bearing by using the golection table to make it @ good match with the crankshaft main journal (page 11-10}. + Select and replace the connecting rod bearing by using the selection table to make ita good match with the crankshaft (page 11-10) + Clean the crankcase mating surfaces and apply the sealant to the outer mating surface of the crankcase halves with ‘care not to get the sealant on and around the main bearing. Assemble the crankcase halves, + Assomble the crankease halves with the upper case toward down. Ifthe upper and lower oases a properly, check the transmission assembly for proper installation, ot assembled Requisite Service ‘Atterstor installation (page 15-6). + Starter motor installation (page 17-71. il pump installation (page 4-4) + Geershitt linkage installation (page 10-6). Primary drive goer instalistion (poge 17-4) + Starter clutch instalation (page 17-4). Clutch installation Spage 2-6) + Cylinder head instalation (page 8-4), ‘Water pump installation (page 55), + Engine instalation (page 7-4) it filter instalation, Engine ol! filing Coolant filing, ra ay ia "bres he ning stn ihc | am aout Tis ar 11-13_ 12. Front Wheel/Suspension/Steering Service Information 12-1 Fork Removal/installation 12-40 ‘Troubleshooting 12-1 Fork Disassembly 12-12 Left Handlebar Disassembly/Assembly 12-2 Fork Assembly 12-43 Right Handlebar Disassembly/Assembly 12-4 Steering Stem Removal 1244 Front Wheel Removal/installation Front Wheel Disassembly/Assembly 12-6__ Steering Stem Installation 128 12-16 Service Information |___ [+ Riding on damaged rims impairs safe operation of the vehicle. + When servicing the front wheal, support the motorcycle securely with @ jack or other support under the engine. + When installing the front wheel, note the normsl rotating direction. a + Tubelegs tire removel, repair, and remounting procedures are covered in the Section 16 of the Common Service Manual. When remounting the tre, note the normel rotating direction. + Refer to the section 14 for brake system information, + Refer to the section 18 for ight, meter and switch information, Troubleshooting Hord Steering + Steering head bearing adjustment nut to0 tight Faulty steering head bearings Damaged steering stem races Ingufficient tie pressure : Faulty tre ‘Steers to One Side or Does Not Track Straight Bent fork + Bent front axle: whee! installed incorrectly + Faulty steering head bearings Bent frame Worn whee! bearing + Worn swingarm piver Front Wheel Wobbiing Bent rim Worn front wheel bearings Faulty tire Unbalanced tire end whee! ‘Wheel Tums Hard + Faulty wheel bearing Brake drag (page 14-1) + Bent fron axle Soft Suspension + Weak fork spring + Insutficene fuid In fork + Low fluid favel in fork + Low tire pressure Hard Suspension + Incoreect fluid weight + Bent fork tubes + Clogged fork fluid passage + High tre pressure Front Suspension Noisy + Insutficent ful in fork Loose fork fastenersFront Wheel/Suspension/Steering Left Handlebar Disassembly/Assembly 7 Q8n29 12-2Front Wheel/Suspension/Steering —_— Procedure ow] Remarks Disassembly Order (1) | Clutch switeh wire 2. | Disconnect from the switch terminals {2} | Clutch lever heider bolt 2 (@) | Clutch lever helderforackat wn (@) | Attaching serew 2 (6) | Lefe handlebar switch 1 (6) | Lefe handlebar weightiattaching screw | 111 | (7) | Left haclebar grip 1 (8) | Handlebar hotder pinch bok. 2. | Loosen the boits. {9} | Left handlebar pinch bolt 1 (10) | Left handlebar 1 | Nove + Spread the sit slightly and push the hendlebar out. Handleber holder removal order Installation fe In the reverse order of removal (a) | Lower fork pinch bolt 1 | Loosen the bott. (b) | Upper fork pinch bolt 1 | Loosen the bolt, Remove the wire bands, (e) | Lefe handlebor holder 1 | NOTE + Remove the front whee! {page 12-6) and lower the fork, ‘Assembly Order 470) | Left handleber 1 (9) | Left handleber pinch bott a () | Handieber holder pinch bott 2. | note {Align the locating pin on the holder with the groove in the fork top bridge, and tighten the upper bolt first (7) | Lete handlebar grip 1 (6) | Loft hadiebor weightiattaching screw. an | Nove + Apply locking agent to the screw thread. (6) | Left handlebar switeh 1 | Nove + Align the locating pin with the hole in the handleber 1) | attaching sorew 2 | nore + Tighten the front serew fet. (3) | Clutch lever hotder/bracket an | wore + Install the holder with the “UP” mark facing up. (2) | Clutch lever holder bolt = 2 | note + Tighten the upper bolt frst (2) | clutch switch wice 2__| Connect to the switch torminats 12-3Front Wheel/Suspension/Stecring Right Handlebar Disassembly/Assembly Dern Do20 12-4Front Wheel/Suspension/Steering | Procedure ow Remarks Disassembly Order = (2) | Front brake switch wire 2. | Disconnect from the switch terminals (2) | Master eyiinder hoider boit 2 {3} | Master cylinder holder 1 {4} | Brake master eylinder assembly 1 | caution + Keep the master oylinder upright. (6) | Throttle housing screw 2 (6) | Throtte grip 1 | Disconnect the throttle cable. (71 | Engine stop switch 1 | Remove the sorews. 18) | Right hendlebar weight/atteching screw | 1/1 19) | Handiaber holder pinch bole 2 | Loosen the bolts (101 | Fight handlebar pinch bolt 1 (11) | ight Randlobar 1 | note + Spread the slit slightly and puch the hendlebar out. Handlebar holder removal order Tstalation Is in the reverse order of removal {a)_| Lower fork pinch belt 1 | Loosen the bolt. {) | Upper fork pinch bolt + | Loosen the bolt. Remove the brake hose band (e) | Lefe handlebar holder 1 | Nove ‘+ Remove the front wheel (page 12-6] and lower the fot. ‘Resembly Order : (11) | Right handlebar 1 (10) | Right handlebar pinch bole 1 (9) | Handlebar holder pinch bolt 2 | Nove ‘Alghn the locating pin on the holder with the groove in the fork top bridge, and tighten the upper bol fist. (61 | Throtle grip Connect the throttle cables. {8} | Throttle housing screw 2) NOTE + Align the mating surface with the punch mark on the handlebar and tighten the front screw first. (7) | Engine stop switch 1 | note + Tighten the front attaching screw first. (4) | Brake master eylinder assombly 1 (3) | Mester cylinder holder 1 | note + Instoll with the “UP” mark facing up. (2) | Master cylinder bolt 2 | NoTE + Align the end of the holder with the punch mark on the handlebar and tighten the upper bolt first. (1) | Front brake switch wire 2 _| Connect to the switch terminals 12-5Front Wheel/Suspension/SteeringFront Wheel/Suspension/Steering ‘A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. + Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use en +0 ollean brake assembiles. ic hose or dry brush NOTE 7 Install the front wheel with the erow matk (etamped on the Fight side) facing to the normel roteting direction. + Do not depress the brake lever when the caliper is removed, o it wil be cifficult to refit the disc between the brake pads. Requisite Service + Raige the wheel off the ground by placing a jack or other support under the engine, Procedure ow Remarks Removal Order (1) | Catizer mounting bott 4 (2) | Front catipor assembly 2 | caution = Do not hang the caliper by the (3) | Right axle pinch bolt 2 | Loosen the botts. (@) | Aste boit 7 (6) | Lefpaxle pinch bole 2. | Loosen the bolts. (8) | Axte.shate 1 (7) | Front wheel assembly 1 | Disassembiy/assembly (page 12-8) (8)_| Side collar 2 Installation Order (8) | Side cote . 2 | nore + Right olde collar is longar than the left side collar. + Apply grease to the dust seal lips before installing (7) | Front wingal assembly 1 (6) | Axte shate 1 | note + Apply thin coat of grease, ta) | Axle bot 1 (6) | Lett axe pinch bolt 2 2 (3) | Right axe pinch bore Nore | + Tighten ater tightening the axle bolt. (2) | Front catiper assembly 2 | caution + Be careful not to damage the pads, (11 [Caliper mounting bot 4 12-7