GENERAL INFORMATION

GENERAL SPECIFICATIONS
ITEM SPECIFICATION Page NO.
Overall length –
–
Overall height –
Wheelbase –
Seat height –
–
–
–
–
–
Page 3–23
–
Rear suspension Page 3–23
–
Rear damper –
Page 3–25
Page 3–25
–
–
–
Caster angle 25 –
–
–
–
–
–
Displacement 162.71 cm³ –
Compression ratio –
–
–
–
–
–
–
–
Air cooled –
–
–
Page 5–6
–
–
Cable operation Page 3–22
Page 11–6
–
–
1st –
2nd –
3rd –
4th –
5th –
–
Page 15–3
Page 16–1
–
Single phase output alternator Page 15–1

1-4
 GENERAL INFORMATION

LUBRICATION SYSTEM SPECIFICATIONS

ITEM STANDARD SERVICE LIMIT Page NO.
At draining – Page 3–11
– Page 3–11

Recommended engine oil –

Page 4–4
Oil pump rotor Page 4–4
Side clearance Page 4–4

FUEL SYSTEM SPECIFICATIONS

ITEM SPECIFICATIONS Page NO.
Page 1–3
#118 Page 5–11
#38 Page 5–11
Page 5–18
Page 5–12
–1
Page 5–18
Page 3–5

CYLINDER HEAD/VALVES SPECIFICATIONS

ITEM STANDARD SERVICE LIMIT Page NO.
–1
– Page 7–4
IN –
–
IN Page 7–13
Page 7–13
Page 7–14
valve guide IN Page 7–14
Page 7–14
Page 7–15
Page 7–13
Page 7–13
Shaft O.D. Page 7–11
Arm to shaft clearance Page 7–11
IN Page 7–8
Camshaft Cam lobe height
Page 7–8
– Page 7–13

1-5
GENERAL INFORMATION

CYLINDER/PISTON SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT Page NO.
I.D. Page 8–2
– Page 8–3
– Page 8–3
Warpage – Page 8–3
Page 8–4
Piston pin hole I.D. Page 8–4
Piston pin O.D. Page 8–5
Page 8–5
Page 8–5
piston ring Piston ring end gap Second Page 8–5
Page 8–5
Page 8–5
groove clearance Second Page 8–5
Page 8–4
Connecting rod small end I.D. Page 8–5
Page 8–5

CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS

ITEM STANDARD SERVICE LIMIT Page NO.
– Page 3–22
Spring free length
Clutch
–
Clutch outer I.D.
O.D.
Clutch outer guide
I.D.

ALTERNATOR/STARTER CLUTCH SPECIFICATIONS

ITEM STANDARD SERVICE LIMIT Page NO.
Starter driven gear boss O.D.

1-6
 GENERAL INFORMATION

CRANKCASE/CRANKSHAFT/TRANSMISSION/
KICKSTARTER SPECIFICATIONS
ITEM STANDARD SERVICE LIMIT Page NO.
Runout – Page 11–8
Connecting rod big end radial clearance
Connecting rod big end side clearance
Page 11–7
Page 11–7
C1 Page 11–7
C2 Page 11–7
C3 Page 11–7
C1 Page 11–7
C2 Page 11–7
C1 Page 11–7
clearance C2 Page 11–7
C1 Page 11–7
C2 Page 11–7
C1 Page 11–7
C2 Page 11–7
countershaft
O.D. Page 11–7
Page 11–7
C1 Page 11–7
clearance C2 Page 11–7
Page 11–8
Page 11–8
Page 11–8
Page 11–21
Page 11–21

FRONT WHEEL/ SUSPENSION/STEERING SPECIFICATIONS

ITEM STANDARD SERVICE LIMIT Page NO.
– Page 3–25
– Page 3–25
Cold tire pressure
Driver and passenger – Page 3–25
–
Radial – Page 12–11
Wheel rim runout
– Page 12–11
Spring free length Page 12–17
Pipe runout – Page 12–17
–
–
–
Steering head bearing preload – Page 12–27

1-7
GENERAL INFORMATION

REAR WHEEL/ SUSPENSION SPECIFICATIONS

ITEM STANDARD SERVICE LIMIT Page NO.
– Page 3–25
– Page 3–25
Cold tire pressure
Driver and passenger – Page 3–25
– Page 13–5
Radial – Page 13–6
Wheel rim runout
– Page 13–6
– Page 3–17
Drive chain
Page 3–16

BRAKE SYSTEM SPECIFICATIONS

ITEM STANDARD SERVICE LIMIT Page NO.
– Page 14–5
Page 14–8
–
Page 14–11
Page 14–11
Page 14–11
Page 14–11
Page 14–17
Page 14–15
Page 14–15
Page 14–17
Piston A Page 14–15
Page 14–15
– Page 14–5
Page 14–22
Page 14–22
Page 14–25
Caliper piston O.D. Page 14–25
– Page 14–23
–

BATTERY/CHARGING SYSTEM SPECIFICATIONS

ITEM SPECIFICATION Page NO.
Page 15–3
Page 15–7
Page 15–3
Needs charging Page 15–3
Page 15–8
Alternator
Page 15–8

1-8
 GENERAL INFORMATION

ELECTRIC STARTER SPECIFICATION

ITEM STANDARD SERVICE LIMIT Page NO.
Starter motor brush length

IGNITION SYSTEM SPECIFICATIONS

ITEM SPECIFICATION Page NO.
Standard Page 3–7
Page 3–7
Page 16–4
Page 16–4
Page 16–5
Input voltage Page 16–7
Page 16–7

LIGHTS/METER/SWITCHES SPECIFICATIONS
ITEM SPECIFICATION Page NO.
–
Position light –
–
–
Instrument light –
–
–
–
Neutral indicator –
–
Sub 15A & 5A –
Page 17–14
Page 17–14

1-9
 ROCKER ARM

CAMSHAFT

OIL FILTER ROTOR

CRANKSHAFT

OIL PUMP

MAINSHAFT

COUNTERSHAFT
 Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely
unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as
possible after handling used oil.
• The oil pump can be serviced with the engine installed in the frame.
• The service procedures in this section must be performed with the engine oil drained.
• When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine.
•
• After the oil pump has been installed, check that there are no oil leaks.
• Refer to the following:
– Engine oil level check (page 3-10)
– Engine oil change (page 3-11)
– Engine oil strainer screen cleaning (page 3-12)
–

Unit: mm (in)

At draining 1.0 liter (1.0 US qt, 0.9 lmp qt) –

Engine oil capacity At disassembly 1.2 liter (1.3 US qt, 1.1 lmp qt) –
Honda 4-stroke oil or equivalent motor oil
Recommended engine oil –
Viscosity: SAE 10W-30
Tip clearance 0.15 (0.006) 0.20 (0.008)
Oil pump rotor Body clearance 0.15 – 0.20 (0.006 – 0.008) 0.25 (0.010)
Side clearance 0.05 – 0.10 (0.002 – 0.004) 0.15 (0.006)

Oil pump plate screw 93901 – 34120 1 4 3 (0.3, 2.2) Page 4-6
Oil pump mounting bolt 95701 – 06035 – 00 2 6 12 (1.2, 9) Page 4-6

• High Oil consumption

• External oil leaks
• Worn valve guide or seal
• Worn piston rings or incorrect piston ring installation
• Worn cylinder

• Oil not changed often enough

• Clogged oil strainer
• Faulty cylinder head gasket
• Worn piston rings Poor performance
• Deformed exhaust system
• Exhaust gas leak
•
Remove the right crankcase cover (page 9-3).
Remove the oil strainer screen.
Installation is in the reverse order of removal.

OIL STRAINER SCREEN

Coat the screen rubber with engine oil and install it at

original direction. FLANGE SIDE THIN EDGE
Install the right crankcase cover (page 9-5).

CRANKCASE

TICK EDGE

Remove the right crankcase cover (page 9-3).

Remove the oil pump driven gear and rotor shaft assembly.

DRIVEN GEAR ROTOR SHAFT

Remove the oil pump mounting bolts (2 nos.) and oil pump
assembly.

MOUNTING BOLTS
Remove the dowel pins (2 nos.).

DOWEL PINS

Remove the oil pump cover screw (1 no.) and oil pump PUMP COVER
cover.

SCREW

Remove the inner rotor.

INNER ROTOR

Remove the outer rotor from the oil pump body.

OUTER ROTOR
 BODY CLEARANCE
• Measure at several places and use the largest reading
to compare to the service limit.
• If any portion of the oil pump is worn beyond the

pump cover as an assembly. Remove both side shroud

pan screw (1 no.).
Temporarily install the outer rotor, inner rotor and rotor shaft
into the oil pump body.
Measure the oil pump body clearance.

Measure the rotor tip clearance between the inner and

outer rotors. TIP CLEARANCE

Remove the rotor shaft.

SIDE CLEARANCE
Measure the side clearance using a straight edge and
feeler gauge.
 ROTOR SHAFT

DRIVEN GEAR

PUMP BODY

OUTER ROTOR

INNER ROTOR

PUMP COVER

3 N.m (0.3 Kgf.m, 2.2 Ibf.ft)

Apply clean engine oil to the outer rotor and install it into
the oil pump body.

OUTER ROTOR

Apply clean engine oil to the inner rotor and install them.

INNER ROTOR
Install the oil pump cover and tighten the screw.

PUMP COVER

SCREW

Install two dowel pins into the crankcase.

DOWEL PINS

Install the oil pump and tighten the mounting bolts to the
OIL PUMP

MOUNTING BOLTS

Apply clean engine oil to the oil pump driven gear teeth
and rotor shaft then align and install it.
Install the right crankcase cover (page 9-5).

DRIVEN GEAR ROTOR SHAFT