Honda GP200H Manual
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How to use this manual
A Few Words About Safety
How to use this manual
Service Information
The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting
service or repairs without the proper training, tools, and equipment could cause injury to you and/or others. It could also damage
this Honda product or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures
require the use special tools. Any person who intends to use a replacement part, service procedure, or a tool that is not
recommended by Honda must determine the risks to their personal safety and the safe operation of this product.
If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend
that you do not use replacement parts of inferior quality.
For Your Customer's Safety
Proper service and maintenance are essential to the customer's safety and the reliability of this product. Any error or oversight
while servicing this product can result in faulty operation, damage to the product, or injury to others.
Improper service or repairs can create an unsafe
condition that can cause your customer or others to
be seriously hurt or killed.
Follow the procedures and precautions in this
manual and other service materials carefully.
For Your Safety
Because this manual is intended for the professional service technician, we do not provide warnings about many basic shop safety
practices (e.g., Hot parts-wear gloves). If you have not received shop safety training or do not feel confident about your knowledge
of safe servicing practices, we recommend that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we cannot warn you of every
conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should
perform a given task.
Failure to properly follow instructions and
precautions can cause you to be seriously hurt or
killed.
Follow the procedures and precautions in this
manual carefully.
Important Safety Precautions
Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and
using safety equipment. When performing any service task, be especially careful of the following:
• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills
required to perform the tasks safely and completely.
• Protect your eyes by using proper safety glasses, goggles, or face shields anytime you hammer, drill, grind, or work around
pressurized air, pressurized liquids, springs, or other stored-energy components. If there is any doubt, put on eye protection.
• Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe
burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.
• Protect yourself and others whenever you have equipment hoisted in the air. Anytime you lift this product with a hoist, make sure
that the hoist hook is securely attached to the product.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will
help eliminate several potential hazards:
• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.
• Burns from hot parts. Let the engine and exhaust system cool before working in those areas.
• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers, and clothing are out of the
way.
Gasoline vapors and hydrogen gasses from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when
working around gasoline or batteries.
• Use only a nonflammable solvent, not gasoline, to clean parts.
• Never store gasoline in an open container.
• Keep all cigarettes, sparks, and flames away from the battery and all fuel-related parts.
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Summary of Contents for Honda GP200H

  • Page 1 Honda must determine the risks to their personal safety and the safe operation of this product. If you need to replace a part, use Honda Genuine parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality.
  • Page 2: Table Of Contents

    CONTENTS SPECIFICATIONS SERVICE INFORMATION MAINTENANCE TROUBLESHOOTING FUEL SYSTEM GOVERNOR SYSTEM IGNITION SYSTEM STARTING SYSTEM MUFFLER ENGINE REMOVAL/INSTALLATION CLUTCH CYLINDER HEAD CYLINDER BLOCK HANDLE WHEEL/ROTOR/TRANSMISSION INDEX...
  • Page 3 How to use this manual REVISION HISTORY Date of revision Contents of revision January, 2021 Changed belt tension adjustment. (page 3-8)
  • Page 4 ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATSOEVER.
  • Page 5 How to use this manual SERVICE RULES • Use Honda Genuine or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda’s design specifications may damage the unit. • Use the special tools designed for the product.
  • Page 6 How to use this manual ABBREVIATIONS Throughout this manual, the following abbreviations are used to identify the respective parts or systems. Abbreviated Full term term Alternator Air Fuel Ratio American Petroleum Institute Approx. Approximately Assy. Assembly ATDC After Top Dead Center Automatic Transmission Fluid Attachment Battery...
  • Page 7 MEMO...
  • Page 8: Specifications

    dummytext 1. SPECIFICATIONS SERIAL NUMBER LOCATION ················· 1-2 DIMENSIONAL DRAWINGS ···················· 1-5 SPECIFICATIONS·································· 1-3 WIRING DIAGRAM ································ 1-6...
  • Page 9 SPECIFICATIONS SERIAL NUMBER LOCATION SPECIFICAT IONS The engine serial number is located on the cylinder block. The frame serial number is located on the handle column. Refer to these numbers when ordering parts and when making technical inquiries. FRAME SERIAL NUMBER ENGINE SERIAL NUMBER...
  • Page 10 *: Dimensions of overall length and overall height shall be determined when locating tightening position of handle pipe middle of movable range in vertical direction. ENGINE Model GP200H Description code GCATH Type 4-stroke, overhead valve, single cylinder, inclined by 25°...
  • Page 11 SPECIFICATIONS FRAME Model FQ650 Type code WH/DH Standard handle height 930 mm (36.6 in) Handle height adjustment 815 – 1,000 mm (32.1 – 39.4 in) Rear hitch width 100 mm (3.9 in) Rear hitch height 76 mm (3.0 in) Engine to transmission mechanism V-belt V-belt SB-38 / 17 x 980 (BT)
  • Page 12 SPECIFICATIONS DIMENSIONAL DRAWINGS Unit: mm (in) *1,475 (58.1) 300 (11.8) Each dimension shall be determined when tines with each rotor is on level surface with engine bed in a level position. *: Dimensions of overall length, overall height and handle height shall be determined when locating tightening position of handle pipe middle of movable range in vertical direction.
  • Page 13 SPECIFICATIONS WIRING DIAGRAM Bl: BLACK R: RED UNIT SPARK PLUG IGNITION COIL ENGINE STOP SWITCH...
  • Page 14: Service Information

    dummytext 2. SERVICE INFORMATION MAINTENANCE STANDARDS ················· 2-2 TOOLS ················································ 2-5 TORQUE VALUES ································· 2-3 CABLE/HARNESS ROUTING ·················· 2-7 LUBRICATION & SEAL POINT ················ 2-4 TUBE ROUTING ···································· 2-8...
  • Page 15 SERVICE INFORMATION MAINTENANCE STANDARDS SERVICE INFORMATION Unit: mm (in) Part Item Standard Service limit Engine Idle speed 1,250 – 1,600 min (rpm) – Maximum engine speed (at no load) 3,800 (rpm) – –200 Cylinder compression 0.35 MPa – (3.6 kgf/cm , 51 psi)/600 min (rpm) Cylinder...
  • Page 16 SERVICE INFORMATION TORQUE VALUES ENGINE TORQUE VALUES Tread Dia. Torque values Item Remarks N·m kgf·m lbf·ft Cylinder head bolt M8 x 1.25 Apply engine oil to the bolt threads and seating surface. Rocker arm pivot bolt M8 x 1.25 Rocker arm pivot lock nut M6 x 0.5 Crankcase cover bolt M8 x 1.25...
  • Page 17 SERVICE INFORMATION LUBRICATION & SEAL POINT ENGINE Material Location Remarks Engine oil Crank pin and gears Piston outer surface Piston ring whole surface Piston pin whole surface Cylinder inner surface Connecting rod big and small end bearing Connecting rod bolt threads and seating surface Camshaft cam profile and journal Valve lifter stem, stem end and slipper surface Valve stem sliding surface and stem end...
  • Page 18 SERVICE INFORMATION TOOLS Float level gauge Seat cutter, 27.5 mm (45° IN) Seat cutter, 24.5 mm (45° EX) 07401-0010000 07780-0010200 07780-0010100 Flat cutter, 28 mm (32° IN) Flat cutter, 25 mm (32° EX) Interior cutter, 26 mm (60° IN) 07780-0012100 07780-0012000 07780-0014500 Interior cutter, 22 mm (60°...
  • Page 19 SERVICE INFORMATION Pilot, 28 mm Driver Driver, 22 mm I.D. 07746-0041100 07749-0010000 07746-0020100 Valve guide driver, 5.5 mm Valve guide reamer, 5.510 mm 07742-0010100 07984-2000001...
  • Page 20 SERVICE INFORMATION CABLE/HARNESS ROUTING CLUTCH LEVER 10 mm (0.4 in) ENGINE STOP THROTTLE LEVER SWITCH 10 mm MAX (0.4 in MAX) UPPER SIDE 60 mm (2.4 in) 50 mm (2.0 in) 160 mm THROTTLE (6.3 in) CARBURETOR CABLE INSULATOR UPPER SIDE FUEL TUBE HIGH TENSION 160 mm...
  • Page 21 SERVICE INFORMATION TUBE ROUTING FUEL TUBE BREATHER TUBE HIGH-TENSION CORD...
  • Page 22: Maintenance

    dummytext 3. MAINTENANCE MAINTENANCE SCHEDULE ··················· 3-2 TRANSMISSION OIL CHANGE ·············· 3-10 ENGINE OIL LEVEL CHECK ··················· 3-3 LUBRICATION ···································· 3-11 ENGINE OIL CHANGE···························· 3-4 ENGINE IDLE SPEED CHECK/ADJUSTMENT························· 3-11 AIR CLEANER CHECK/CLEANING/REPLACEMENT ········ 3-5 SPARK PLUG INSPECTION/ADJUSTMENT/ REPLACEMENT ·································· 3-12 NUTS, BOLTS, TIGHTENS ······················...
  • Page 23: Maintenance Schedule

    MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE REGULAR SERVICE PERIOD (1) Perform at every indicated month or operating hour interval, whichever comes first. Refer to ITEM page Every 3 Every 6 Before First month Every year Each use months or months or season or 20 hrs.
  • Page 24: Engine Oil Level Check

    MAINTENANCE ENGINE OIL LEVEL CHECK • Check the engine oil level with the engine stopped. Place the tiller on a firm level surface with the tire or rotor set on the ground so that the engine becomes level. Remove the oil filler cap/dipstick [1] and wipe the dipstick clean.
  • Page 25: Engine Oil Change

    MAINTENANCE ENGINE OIL CHANGE • Drain the used engine oil while the engine is warm. Warm oil drains quickly and completely. Place a suitable container [1] under the engine oil drain bolt (10 x 15 mm) [2]. Remove the oil filler cap/dipstick [5], drain bolt, sealing washer (10 mm) [6] and drain the engine oil into the suitable container.
  • Page 26: Air Cleaner

    MAINTENANCE AIR CLEANER CHECK/CLEANING/ REPLACEMENT A dirty air filter will restrict air flow to the carburetor, reducing engine performance. If the engine is operated in dusty areas, clean the air cleaner more often than specified in the MAINTENANCE SCHEDULE (page 3- Operating the engine without the air filters or with the filter installed loosely will allow dirt to enter the engine, causing rapid engine wear.
  • Page 27: Nuts, Bolts, Tightens

    MAINTENANCE Tap the paper element [1] several times on a hard surface to remove dirt, or blow compressed air (not exceeding 207 kPa, 2.1 kgf/cm , 30 psi) through the paper element from the inside. Never try to brush off dirt; brushing will force dirt into the paper fibers.
  • Page 28 MAINTENANCE ADJUSTMENT Remove the belt cover (page 11-2). Do not locate the joint Set two V-belts [1] so that the V-belt joint area [2] is not area in these areas. located between the drive pulley [3] and driven pulley [4]. Squeeze the clutch lever [1] ten times.
  • Page 29: Belt Check/Adjustment

    MAINTENANCE BELT CHECK/ADJUSTMENT CHECK Remove the belt cover (page 11-2). Check that there is no crack and abnormal wear-out in the belt, and replace if it is abnormal (page 11-2). BELT TENSION ADJUSTMENT Remove the belt cover (page 11-2). Squeeze two V-belts [1] with force more than six times as shown.
  • Page 30 MAINTENANCE Adjust the distance [1] by moving the engine back or forward until the correct distance L is obtained. SPECIFIED DISTANCE 308.5 – 309.5 mm (12.15 – 12.19 in) SPECIFIED DISTANCE L: 49 – 59 mm (1.9 – 2.3 in) Recheck the distance L.
  • Page 31: Transmission Oil Level Check

    MAINTENANCE TRANSMISSION OIL LEVEL CHECK • Check the transmission oil level with the engine stopped. Place the tiller on a firm level surface with the tire or rotor set on the ground so that the engine becomes level. Remove the oil filler cap [1] and check the oil level is up to the lower edge [2] of the oil filler hole.
  • Page 32: Lubrication

    MAINTENANCE LUBRICATION Apply grease to the following parts: RECOIL STARTER COVER BOSS/ RECOIL STARTER FRICTION SPRING DISASSEMBLY/ASSEMBLY: (page 8-4) CLUTCH LEVER PINS · PIN (8 x 27 mm) · PIN (6 x 24 mm) DISASSEMBLY/ASSEMBLY: (page 14-4) CHANGE LEVER HOLDER/HANDLE COLUMN PIVOT DISASSEMBLY/ASSEMBLY: (page 14-3) TENSION ARM SHAFT REMOVAL/INSTALLATION: (page 11-2)
  • Page 33: Spark Plug Inspection/Adjustment

    MAINTENANCE SPARK PLUG INSPECTION/ ADJUSTMENT/REPLACEMENT If the engine has been running, the engine will be very hot. Allow it to cool before proceeding. Clean any dirt from around the spark plug [1]. Remove the spark plug cap [2]. Remove the spark plug with a spark plug wrench. Visually inspect the spark plug.
  • Page 34: Throttle Cable Check/Adjustment

    MAINTENANCE THROTTLE CABLE CHECK/ ADJUSTMENT Check for any deterioration or damage to the throttle cable [1]. Check the throttle lever [2] for smooth operation. Measure the throttle lever free play at the lever tip. FREE PLAY: 1 – 7 mm (0.04 – 0.28 in) If the throttle lever free play is incorrect, loosen the lock nut [3] and turn the adjusting nut [4] in or out as 1 –...
  • Page 35: Valve Clearance

    MAINTENANCE Insert a thickness gauge [1] between the rocker arm [2] and valve stem [3] to check the valve clearance. VALVE CLEARANCE: IN: 0.15 ± 0.02 mm (0.006 ± 0.001 in) EX: 0.20 ± 0.02 mm (0.008 ± 0.001 in) If adjustment is necessary, proceed as follows.
  • Page 36: Fuel Tank And Filter Cleaning

    MAINTENANCE FUEL TANK AND FILTER CLEANING Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Remove the fuel tank (page 5-3). Remove the fuel filter joint [1].
  • Page 37 MEMO...
  • Page 38: Troubleshooting

    dummytext 4. TROUBLESHOOTING BEFORE TROUBLESHOOTING ··············· 4-2 FRAME TROUBLESHOOTING················· 4-5 ENGINE TROUBLESHOOTING ················ 4-2...
  • Page 39 TROUBLESHOOTING BEFORE TROUBLESHOOTING TROUBLESHOOTING • Check that the engine stop switch wire connector and ignition coil wire connector are connected securely. • Check for sufficient fresh fuel in the fuel tank. ENGINE TROUBLESHOOTING ENGINE DOES NOT CRANK Cannot be cranked Disassemble the engine and replace the faulty Remove the recoil starter (page 8-2) and check part(s) (page 13-4).
  • Page 40 TROUBLESHOOTING ENGINE CRANKS BUT WON’T START • Check the oil level before troubleshooting (page 3-3). Check for fuel tank joint or fuel tube (page 5-3). Loosen the carburetor drain screw and check the No fuel fuel flow from the fuel tank (page 5-3). Fuel Perform the spark test (page 7-7).
  • Page 41 TROUBLESHOOTING ENGINE SPEED DOES NOT INCREASE OR STABILIZE Check the air cleaner elements (page 3-5). Clogged Clean or replace the air cleaner elements (page 3- Clean Check the valve clearance (page 3-13). Abnormal Adjust the valve clearance (page 3-13). Normal Inspect the spark plug and adjust the spark plug Check the spark plug (page 3-12).
  • Page 42 TROUBLESHOOTING ENGINE DOES NOT STOP WHEN ENGINE STOP SWITCH IS TURNED OFF Replace the engine stop switch (page 7-8). Check the engine stop switch (page 7-9). Abnormal Normal Check the wire harness connecting the engine Replace the engine wire harness. No continuity stop switch and the ignition coil for open or short circuit.
  • Page 43 MEMO...
  • Page 44: Fuel System

    dummytext 5. FUEL SYSTEM TOOLS ················································ 5-2 CARBURETOR BODY CLEANING ··········· 5-7 FUEL TANK REMOVAL/INSTALLATION ··· 5-3 CARBURETOR INSPECTION ·················· 5-7 AIR CLEANER PILOT SCREW REPLACEMENT ·············· 5-8 REMOVAL/INSTALLATION ····················· 5-4 CHOKE REPLACEMENT ························ 5-9 CARBURETOR REMOVAL/INSTALLATION ····················· 5-5 CARBURETOR STUD BOLT REPLACEMENT ····································...
  • Page 45 FUEL SYSTEM TOOLS FUEL SYSTEM Float level gauge 07401-0010000...
  • Page 46 FUEL SYSTEM FUEL TANK REMOVAL/INSTALLATION Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Remove the fan cover (page 8-2). Place a suitable container under the carburetor.
  • Page 47 FUEL SYSTEM AIR CLEANER REMOVAL/INSTALLATION • Route the breather tube properly (page 2-8). WING NUT AIR CLEANER COVER OUTER FILTER (FOAM) WING NUT GROMMET BOLT (6 x 20 mm) INNER FILTER (PAPER) COLLAR AIR CLEANER ELBOW SEAL AIR CLEANER ELBOW REMOVAL/INSTALLATION: Remove and install the air cleaner elbow with the fuel...
  • Page 48 FUEL SYSTEM CARBURETOR REMOVAL/INSTALLATION Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. Remove the air cleaner elbow (page 5-4). Set a commercially available tube clamp to the fuel tube.
  • Page 49 FUEL SYSTEM CARBURETOR DISASSEMBLY/ASSEMBLY Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. • Keep heat, sparks, and flame away. • Handle fuel only outdoors. • Wipe up spills immediately. To prevent serious eye injury, always wear safety goggles or other eye protection when using compressed air.
  • Page 50 Check the container for instructions. If you are in doubt, do not use these products to clean Honda carburetors. • High air pressure may damage the carburetor body. Use low air pressure (206 kPa (2.11 kgf/cm , 30 psi) or less) when cleaning passages and ports.
  • Page 51 FUEL SYSTEM FLOAT VALVE Check the float valve and its seat [1] for wear or contamination. Check the valve seat [2] for clogs. Before installation, check for wear or a weak float valve spring [3]. Check the operation of the float valve. CLEAN REPLACE PILOT SCREW REPLACEMENT...
  • Page 52 FUEL SYSTEM CHOKE REPLACEMENT Remove the carburetor (page 5-5). Pull out the choke valve plate [1]. Remove the choke shaft [2] and install a new choke shaft. Insert a new choke valve plate into the slit [3] of the choke shaft. Be sure the choke shaft is in the position between the projections [4] of the choke valve plate.
  • Page 53 MEMO...
  • Page 54: Governor System

    dummytext 6. GOVERNOR SYSTEM CONTROL BASE/GOVERNOR ARM GOVERNOR ADJUSTMENT ···················· 6-3 REMOVAL/INSTALLATION ····················· 6-2 GOVERNOR REMOVAL/INSTALLATION··· 6-4...
  • Page 55 GOVERNOR SYSTEM CONTROL BASE/GOVERNOR ARM GOVERNOR SYSTEM REMOVAL/INSTALLATION Remove the fuel tank (page 5-3). Remove the air cleaner elbow (page 5-4). Disconnect the throttle cable (page 10-2). After installation, perform "GOVERNOR ADJUSTMENT" (page 6-3). GOVERNOR ROD/THROTTLE RETURN SPRING GOVERNOR SPRING When reassembly, install the REMOVAL/INSTALLATION: spring with the long end side...
  • Page 56 GOVERNOR SYSTEM GOVERNOR ADJUSTMENT Remove the fuel tank (page 5-3). Loosen the governor arm nut (6 mm) [1] and then move the governor arm [2] so that the throttle is completely open. Rotate the governor arm shaft [3] as far as it will go in the direction that it was just turned by the governor arm.
  • Page 57 GOVERNOR SYSTEM GOVERNOR REMOVAL/INSTALLATION Remove the crankshaft (page 13-4). GOVERNOR WEIGHT WASHER (6 mm) CHECK: After installing the governor weights, check to be sure they move freely. GOVERNOR WEIGHT PIN GOVERNOR HOLDER CLIP INSTALLATION: Install firmly into the groove of the governor holder shaft.
  • Page 58: Ignition System

    dummytext 7. IGNITION SYSTEM BEFORE TROUBLESHOOTING ··············· 7-2 IGNITION COIL AIR GAP CHECK/ADJUSTMENT··························· 7-6 IGNITION SYSTEM TROUBLESHOOTING ···························· 7-2 SPARK PLUG CAP INSPECTION············· 7-6 IGNITION COIL IGNITION COIL INSPECTION ·················· 7-7 REMOVAL/INSTALLATION ····················· 7-3 SPARK TEST········································ 7-7 COOLING FAN/FLYWHEEL REMOVAL/INSTALLATION ····················· 7-4 ENGINE STOP SWITCH REMOVAL/INSTALLATION ·····················...
  • Page 59: Before Troubleshooting

    IGNITION SYSTEM BEFORE TROUBLESHOOTING IGNITION SYSTEM • Check that the engine stop switch wire connector and ignition coil wire connector are connected securely. • Check that the engine stop switch is "ON" position. IGNITION SYSTEM TROUBLESHOOTING NO OR WEAK SPARK AT SPARK PLUG Check the following before troubleshooting: –...
  • Page 60: Ignition Coil Removal/Installation

    IGNITION SYSTEM IGNITION COIL REMOVAL/INSTALLATION Remove the following: – Fan cover (page 8-2) – Carburetor (page 5-5) • Route the engine wire harness and high-tension code properly (page 2-8). • After installation, check the ignition coil air gap (page 7-6). HIGH-TENSION CORD ENGINE WIRE HARNESS IGNITION COIL...
  • Page 61: Cooling Fan/Flywheel Removal/Installation

    IGNITION SYSTEM COOLING FAN/FLYWHEEL REMOVAL/INSTALLATION REMOVAL Remove the ignition coil (page 7-3). WOODRUFF KEY MAGNET PART COOLING FAN STARTER PULLEY (Threads and seating surface) NUT (14 mm) SIDE PLATE 75 N·m (7.5 kgf·m, 55 lbf·ft) REMOVAL: BOLT (6 x 22 mm) Hold the flywheel [1] with a commercially available strap wrench [2], being careful not to damage the magnet part.
  • Page 62 IGNITION SYSTEM INSTALLATION • Clean the tapered parts [1] of dirt, oil, grease, and other foreign material before installation. • Be sure there are no metal parts or other foreign material on the magnet part [2] of the flywheel. Set the woodruff key [3] in the key groove [4] of the crankshaft securely.
  • Page 63: Ignition Coil Air Gap Check/Adjustment

    IGNITION SYSTEM IGNITION COIL AIR GAP CHECK/ADJUSTMENT Remove the fan cover (page 8-2). 0.2 – 0.6 mm (0.01 – 0.02 in) Insert the feeler gauge [1] of proper thickness between the ignition coil [2] and the flywheel [3]. IGNITION COIL AIR GAP: 0.2 –...
  • Page 64: Ignition Coil Inspection

    IGNITION SYSTEM IGNITION COIL INSPECTION Remove the fan cover (page 8-2). PRIMARY SIDE Disconnect the ignition coil connector [1]. Measure the resistance of the primary coil by attaching one ohmmeter probe to the terminal [2] and the other at the iron core [3]. RESISTANCE: 0.6 –...
  • Page 65: Engine Stop Switch Removal/Installation

    IGNITION SYSTEM ENGINE STOP SWITCH REMOVAL/INSTALLATION • When installation, route the wire harness properly (page 2-7). ENGINE STOP SWITCH CABLE BAND (3) When reassembly, position to the specified range (page 2-7). INSPECTION: (page 7-9) ENGINE STOP SWITCH WIRE CONNECTOR ENGINE STOP SWITCH TAPPING SCREW (4 mm) (2) 1.5 N·m (0.15 kgf·m, 1.1 lbf·ft) BAND...
  • Page 66 IGNITION SYSTEM ENGINE STOP SWITCH INSPECTION Check for continuity between the engine stop switch wire connector [1] and ground terminal [2] in each switch position. Switch position Continuity No Continuity Continuity...
  • Page 67 MEMO...
  • Page 68: Starting System

    dummytext 8. STARTING SYSTEM RECOIL STARTER RECOIL STARTER REMOVAL/INSTALLATION ····················· 8-2 DISASSEMBLY/ASSEMBLY···················· 8-4 RECOIL STARTER INSPECTION ············· 8-2...
  • Page 69 STARTING SYSTEM RECOIL STARTER STARTING SYSTEM REMOVAL/INSTALLATION BOLT (6 x 10 mm) (7) FAN COVER RECOIL STARTER ASSEMBLY INSPECTION: (page 8-2) DISASSEMBLY/ASSEMBLY: (page 8-4) RECOIL STARTER INSPECTION RECOIL STARTER Remove the recoil starter (page 8-2). Check the operation of the two ratchets [1] by pulling the starter rope out several times.
  • Page 70 STARTING SYSTEM STARTER PULLEY Remove the recoil starter (page 8-2). Inspect the six square holes [1] of the starter pulley [2] for deformation. Install the recoil starter (page 8-2).
  • Page 71 STARTING SYSTEM RECOIL STARTER DISASSEMBLY/ASSEMBLY • Wear gloves and eye protection. • During disassembly/assembly, take care not to allow the spring to come out. DISASSEMBLY Remove the recoil starter (page 8-2). SET SCREW (inside) 8.8 N·m (0.90 kgf·m, 6.5 lbf·ft) RATCHET GUIDE FRICTION SPRING (Sliding surface)
  • Page 72 STARTING SYSTEM ASSEMBLY • Wear gloves and eye protection. • During reassembly, take care not to allow the spring to come out. Pass the recoil starter rope [1] through the hole [2] of the recoil starter reel [3], and then tie the rope as shown.
  • Page 73 STARTING SYSTEM Apply grease to the two starter ratchets [1]. Install the two starter ratchets and the two return springs [2] to the recoil starter reel as shown. Apply grease to the inside of the ratchet guide [1]. Set the friction spring [2] and the ratchet guide to the recoil starter reel in the direction as shown.
  • Page 74: Muffler

    dummytext 9. MUFFLER MUFFLER REMOVAL/INSTALLATION······ 9-2...
  • Page 75 MUFFLER MUFFLER REMOVAL/INSTALLATION MUFFLER The engine and muffler become very hot during operation and they remain hot for a while after operation. The muffler removal must be made while the engine is cold. Remove the inner belt cover (page 11-2). MUFFLER PROTECTOR MUFFLER PROTECTOR SCREW (5 x 8 mm) (4) 3 N·m (0.31 kgf·m, 2.2 lbf·ft)
  • Page 76: Engine Removal/Installation

    dummytext 10. ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL/INSTALLATION······· 10-2 10-1...
  • Page 77 ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL/INSTALLATION • When installation, route the wire harness properly (page 2-7) • After installation, adjust the V-belt tension (page 3- Remove the tension arm (page 11-2). Remove the air cleaner elbow (page 5-4). Move the throttle lever to the "LOW" position and disconnect the throttle cable [1] from the control plate [2].
  • Page 78: Clutch

    dummytext 11. CLUTCH PULLEY/V-BELT REMOVAL/INSTALLATION ··················· 11-2 11-1...
  • Page 79 CLUTCH PULLEY/V-BELT CLUTCH REMOVAL/INSTALLATION After installation, adjust the V-belt tension (page 3-8). (Sliding surface) TENSION ARM INNER BELT COVER INNER BELT COVER BOLT (6 x 12 mm) 6 N·m (0.6 kgf·m, 4.4 lbf·ft) BELT STOPPER B ADJUSTMENT: (page 3-9) BOLT (6 x 12 mm) (2) DRIVEN PULLEY REMOVAL/INSTALLATION: (page 11-3) DRIVE PULLEY:...
  • Page 80 CLUTCH DRIVE PULLEY REMOVAL/INSTALLATION • Take care not to damage the drive pulley with the strap wrench. Hold the drive pulley [1] with a commercially available strap wrench [2], remove the bolt (8 x 25 mm) [3] and the drive pulley washer [4]. Apply grease to the surface [5].
  • Page 81 MEMO...
  • Page 82: Cylinder Head

    dummytext 12. CYLINDER HEAD TOOLS ·············································· 12-2 CYLINDER HEAD/VALVES INSPECTION ······································ 12-5 CYLINDER HEAD REMOVAL/INSTALLATION ··················· 12-3 VALVE GUIDE REPLACEMENT············· 12-8 CYLINDER HEAD VALVE GUIDE REAMING ····················· 12-9 DISASSEMBLY/ASSEMBLY·················· 12-4 VALVE SEAT RECONDITIONING··········· 12-9 12-1...
  • Page 83: Tools

    CYLINDER HEAD TOOLS CYLINDER HEA D Valve guide driver, 5.5 mm Seat cutter, 27.5 mm (45° IN) Seat cutter, 24.5 mm (45° EX) 07742-0010100 07780-0010200 07780-0010100 Flat cutter, 28 mm (32° IN) Flat cutter, 25 mm (32° EX) Interior cutter, 26 mm (60° IN) 07780-0012100 07780-0012000 07780-0014500...
  • Page 84: Cylinder Head Removal/Installation

    CYLINDER HEAD CYLINDER HEAD REMOVAL/INSTALLATION Set the piston at top dead center of the cylinder compression stroke (page 3-13). Remove the following: – Fan cover (page 8-2) – Carburetor (page 5-5) – Control base (page 6-2) – Muffler (page 9-2) After installation, inspect following: –...
  • Page 85: Cylinder Head Disassembly/Assembly

    CYLINDER HEAD CYLINDER HEAD DISASSEMBLY/ASSEMBLY Remove the cylinder head (page 12-3). VALVE SPRING RETAINER REMOVAL: Push down and slide the valve spring retainer [1] to the side so that the valve stem [2] slips through the hole at the side of the valve spring retainer.
  • Page 86: Cylinder Head/Valves

    CYLINDER HEAD CYLINDER HEAD/VALVES INSPECTION CYLINDER COMPRESSION CHECK Start the engine and warm up to normal operating temperature. Turn the engine stop switch to the OFF position. Turn the fuel valve lever to the OFF position, and then loosen the drain screw of the carburetor to drain the fuel completely (page 5-3).
  • Page 87 CYLINDER HEAD VALVE SEAT WIDTH Remove the carbon deposits from the combustion VALVE LAPPER chamber (page 3-14). (Commercially available) Inspect each valve face for irregularities. If necessary, replace the valve. Apply a light coat of Prussian Blue or erasable felt- tipped marker ink to each valve seat.
  • Page 88 CYLINDER HEAD VALVE FACE/VALVE STEM O.D. Inspect each valve face [1] for irregularities. If necessary, replace the valve. Inspect each valve [2] for bending or abnormal stem wear. If necessary, replace the valve. Measure and record each valve stem O.D. STANDARD: IN: 5.468 –...
  • Page 89: Valve Guide Replacement

    CYLINDER HEAD PUSH ROD RUNOUT Check both ends of the push rod for wear. Check the push rod for straightness. If necessary, replace the push rod. VALVE GUIDE REPLACEMENT Chill the replacement valve guides in the freezer section of a refrigerator for about an hour. Use a hot plate or oven to heat the cylinder head evenly to 150°C (300°F).
  • Page 90: Valve Guide Reaming

    CYLINDER HEAD Remove new valve guides from the refrigerator one at a time as needed. Drive the exhaust valve guide [1] until the valve guide clip [2] is fully seated as shown from the valve spring side of the cylinder head. TOOL: Valve guide driver, 5.5 mm [3] 07742-0010100...
  • Page 91: Valve Seat Reconditioning

    CYLINDER HEAD VALVE SEAT RECONDITIONING Inspect the valve seat contact area (page 12-6). Using a 45° seat cutter, remove any roughness or 45° irregularities from the seat. If the contact area is too low on the valve, the seat must TOO LOW be raised using a 60°...
  • Page 92: Cylinder Block

    dummytext 13. CYLINDER BLOCK TOOLS ·············································· 13-2 PISTON DISASSEMBLY/ASSEMBLY······ 13-5 CRANKCASE COVER CRANKCASE COVER/CYLINDER BARREL/ REMOVAL/INSTALLATION ··················· 13-3 PISTON/CONNECTING ROD/CRANKSHAFT/ CAMSHAFT INSPECTION····················· 13-6 CRANKSHAFT/CAMSHAFT/PISTON REMOVAL/INSTALLATION ··················· 13-4 CRANKSHAFT BEARING/OIL SEAL REPLACEMENT ································· 13-13 13-1...
  • Page 93: Tools

    CYLINDER BLOCK TOOLS CYLINDER BL OCK Attachment, 37 x 40 mm Attachment, 52 x 55 mm Pilot, 25 mm 07746-0010200 07746-0010400 07746-0040600 Driver 07749-0010000 13-2...
  • Page 94: Crankcase Cover Removal/Installation

    CYLINDER BLOCK CRANKCASE COVER REMOVAL/INSTALLATION Drain the engine oil (page 3-4). CRANKSHAFT BEARING (6205) OIL FILLER CAP OIL FILLER CAP DOWEL PIN (2) PACKING CHECK: Replace if necessary. OIL FILLER CAP (With oil level gauge) OIL SEAL (Lips) OIL FILLER CAP PACKING CHECK: Replace if necessary.
  • Page 95: Crankshaft/Camshaft/Piston

    CYLINDER BLOCK CRANKSHAFT/CAMSHAFT/PISTON REMOVAL/INSTALLATION Remove the following: – Fuel tank (page 5-3) – Flywheel (page 7-4) – Cylinder head (page 12-3) – Crankcase cover (page 13-3) PISTON (Outer surface and big end bearing) INSTALLATION: Install the piston to the cylinder barrel with the mark [1] on the piston head toward the push rod hole [2] of the cylinder head.
  • Page 96: Piston Disassembly/Assembly

    CYLINDER BLOCK PISTON DISASSEMBLY/ASSEMBLY Remove the piston (page 13-4). MAKER MARK PISTON RING SET (Entire surface) TOP RING INSPECTION: (page 13-8) INSTALLATION: To install the oil ring, install the spacer [1] first, and then install the side rails [2]. Be sure that the top ring [3] and second ring [4] are not interchanged.
  • Page 97: Crankcase Cover/Cylinder Barrel/Piston/Connecting Rod/ Crankshaft/Camshaft Inspection

    CYLINDER BLOCK CRANKCASE COVER/CYLINDER BARREL/PISTON/CONNECTING ROD/ CRANKSHAFT/CAMSHAFT INSPECTION CAMSHAFT JOURNAL I.D. CRANKCASE COVER SIDE Measure the camshaft journal I.D. of the crankcase cover. STANDARD: 14.000 – 14.027 mm (0.5512 – 0.5522 in) SERVICE LIMIT: 14.048 mm (0.5531 in) If the measurement is more than the service limit, replace the crankcase cover.
  • Page 98 CYLINDER BLOCK PISTON SKIRT O.D. Measure and record the piston skirt O.D. at a point 10 mm (0.4 in) from the bottom of the skirt and 90° to the piston pin bore. 90° STANDARD: 67.965 – 67.982 mm (2.6758 – 2.6765 in) SERVICE LIMIT: 67.845 mm (2.6711 in) If the measurement is less than the service limit, replace the piston.
  • Page 99 CYLINDER BLOCK PISTON PIN O.D. Measure and record the piston pin O.D. at three points (both ends and middle). Take the minimum reading to determine piston pin O.D. STANDARD: 17.992 – 17.998 mm (0.7083 – 0.7086 in) SERVICE LIMIT: 17.954 mm (0.7068 in) If the measurement is less than the service limit, replace the piston pin.
  • Page 100 CYLINDER BLOCK PISTON RING WIDTH Measure each piston ring width. STANDARD: Top: 0.95 – 0.97 mm (0.037 – 0.038 in) Second: 0.94 – 0.96 mm (0.037 – 0.038 in) SERVICE LIMIT: Top: 0.93 mm (0.037 in) Second: 0.92 mm (0.036 in) If any of the measurements is less than the service limit, replace the piston rings (top, second, oil) as a set.
  • Page 101 CYLINDER BLOCK CONNECTING ROD SMALL END I.D. Measure the connecting rod small end I.D. STANDARD: 18.006 – 18.017 mm (0.7089 – 0.7093 in) SERVICE LIMIT: 18.07 mm (0.711 in) If the measurement is more than the service limit, replace the connecting rod. Inspect the piston pin O.D.
  • Page 102 CYLINDER BLOCK CONNECTING ROD BIG END OIL CLEARANCE Clean all oil from the crankpin and connecting rod big end surface. Apply engine oil to the connecting rod bolt threads and seating surface. Place a piece of plastigauge on the crankpin, install the connecting rod upper and the connecting rod lower, and tighten the connecting rod bolts to the specified torque.
  • Page 103 CYLINDER BLOCK CAMSHAFT CAM HEIGHT Measure the cam height of the camshaft. STANDARD: IN: 27.500 – 27.900 mm (1.0827 – 1.0984 in) EX: 27.547 – 27.947 mm (1.0845 – 1.1003 in) SERVICE LIMIT: IN: 27.45 mm (1.081 in) EX: 27.50 mm (1.083 in) If the measurement is less than the service limit, replace the camshaft.
  • Page 104: Crankshaft Bearing/Oil Seal

    CYLINDER BLOCK CRANKSHAFT BEARING Turn the inner race of the bearing with your finger and check for play. Replace the bearing if it is noisy or has excessive play. CRANKSHAFT BEARING/OIL SEAL REPLACEMENT CRANKSHAFT BEARING Drive out the bearing (6205) from the cylinder block Cylinder block side: CYLINDER BLOCK SIDE: (page 13-4).
  • Page 105 CYLINDER BLOCK CRANKSHAFT OIL SEAL Remove the oil seal (25 x 41 x 6 mm) from the cylinder Cylinder block side: CYLINDER BLOCK SIDE: block (page 13-4). Remove the oil seal (25 x 41 x 6 mm) from the Crankcase cover crankcase cover (page 13-3).
  • Page 106: Handle

    dummytext 14. HANDLE HANDLE COLUMN ASSEMBLY CLUTCH LEVER REMOVAL/INSTALLATION ··················· 14-2 DISASSEMBLY/ASSEMBLY·················· 14-4 HANDLE COLUMN THROTTLE LEVER ASSEMBLY DISASSEMBLY/ASSEMBLY·················· 14-3 REMOVAL/INSTALLATION ··················· 14-5 14-1...
  • Page 107 HANDLE HANDLE COLUMN ASSEMBLY HANDLE REMOVAL/INSTALLATION Remove the following: – Air cleaner elbow (page 5-4) – Tension arm (page 11-2) Disconnect the throttle cable (page 10-2). • When installing the handle column assembly, route the wire harness properly (page 2-7). BOLT (8 x 20 mm) (4) THROTTLE LEVER ENGINE STOP SWITCH...
  • Page 108 HANDLE HANDLE COLUMN DISASSEMBLY/ASSEMBLY Remove the following: – Handle column assembly (page 14-2) – Engine stop switch (page 7-8) – Clutch lever (page 14-4) – Throttle lever (page 14-5) HANDLE PIPE SPRING WASHER HANDLE ADJUSTING LEVER HANDLE LOCK NUT When reassembly, install the GROMMET handle lock nut tab into the handle pipe hole.
  • Page 109 HANDLE CLUTCH LEVER DISASSEMBLY/ASSEMBLY L. HANDLE GRIP When reassembly, apply ThreeBond ® 1530C or Align equivalent to the inside. HANDLE PIPE SPLIT PIN (1.6 mm) (2) PIN (8 x 27 mm) When reassembly, apply grease to the sliding surface. CLUTCH LEVER PIN (6 x 24 mm) When reassembly, apply grease to the sliding...
  • Page 110 HANDLE THROTTLE LEVER ASSEMBLY REMOVAL/INSTALLATION Disconnect the throttle cable from the control plate (page 10-2). After installation, perform the "THROTTLE CABLE CHECK/ADJUSTMENT" (page 3-13). THROTTLE LEVER ASSEMBLY R. HANDLE GRIP When reassembly, position to When reassembly, apply the specified range (page 2-7). ThreeBond ®...
  • Page 111 MEMO...
  • Page 112: Wheel/Rotor/Transmission

    dummytext 15. WHEEL/ROTOR/TRANSMISSION TOOLS ·············································· 15-2 SUB FENDER REMOVAL/INSTALLATION ·················· 15-10 WHEEL REMOVAL/INSTALLATION ······· 15-3 TRANSMISSION/MAIN FENDER/ENGINE BED REMOVAL/INSTALLATION ·················· 15-11 WHEEL DISASSEMBLY/ASSEMBLY ······ 15-4 TRANSMISSION ROTOR REMOVAL/INSTALLATION ······· 15-6 DISASSEMBLY/ASSEMBLY················· 15-12 FRENCH ROTOR FRONT STAND/FRONT PIPE GUARD DISASSEMBLY/ASSEMBLY·················· 15-7 REMOVAL/INSTALLATION ··················...
  • Page 113: Tools

    WHEEL/ROTOR/TRANSMISSION TOOLS WHEEL/ROT OR/TRANSMISSION Pilot, 22 mm Pilot, 28 mm Driver 07746-0041000 07746-0041100 07749-0010000 Driver, 22 mm I.D. 07746-0020100 15-2...
  • Page 114: Wheel Removal/Installation

    WHEEL/ROTOR/TRANSMISSION WHEEL REMOVAL/INSTALLATION • The R. wheel and L. wheel can be removed in the same manner. R. wheel shown: SHAFT PIN (8 x 40 mm) LOCK PIN Up side view: Front R. WHEEL When installation, note the installation direction. DISASSEMBLY/ASSEMBLY: (page 15-4) 15-3...
  • Page 115: Wheel Disassembly/Assembly

    WHEEL/ROTOR/TRANSMISSION WHEEL DISASSEMBLY/ASSEMBLY WHEEL DISASSEMBLY • For disassembling the wheel, push the valve core and decrease the air pressure. BOLT (8 x 20 mm) (4) OUTER SIDE RIM TIRE ( 3.50 – 4 4P.R. ) VALVE CAP TIRE TUBE VALVE CORE INNER SIDE RIM WHEEL SHAFT SPRING WASHER (4)
  • Page 116 WHEEL/ROTOR/TRANSMISSION WHEEL ASSEMBLY Install the tire tube [1] to tire [2] so the valve [3] is in R. wheel: direction as shown. Assemble the outer side rim A [4], the inner side rim B [5] and the wheel shaft [6] as shown. •...
  • Page 117: Rotor Removal/Installation

    WHEEL/ROTOR/TRANSMISSION ROTOR REMOVAL/INSTALLATION • The right side rotor and left side rotor can be removed in the same manner. • After installation, make sure that the right and left rotors are symmetry (page 15-9). Right side shown: SHAFT PIN (8 x 40 mm) MARK When installation, make sure that the "R"...
  • Page 118: French Rotor Disassembly/Assembly

    WHEEL/ROTOR/TRANSMISSION FRENCH ROTOR DISASSEMBLY/ASSEMBLY R. ROTOR • When reassembly, assemble the tines with its identification marks ("G" and "H") facing inward. Tine G shape (6): Tine H shape (6): IDENTIFICATION MARKS TINE H (2) TINE G (2) FRENCH ROTOR NUT (8 mm) (4) 26.5 N·m (2.7 kgf·m, 20 lbf·ft) "R"...
  • Page 119 WHEEL/ROTOR/TRANSMISSION L. ROTOR • When reassembly, assemble the tines with its identification marks ("G" and "H") facing outward. Tine G shape (6): Tine H shape (6): IDENTIFICATION MARKS TINE H (2) TINE H (2) TINE G (2) FRENCH ROTOR NUT (8 mm) (4) 26.5 N·m (2.7 kgf·m, 20 lbf·ft) "L"...
  • Page 120: French Rotor Assembly Check

    WHEEL/ROTOR/TRANSMISSION FRENCH ROTOR ASSEMBLY CHECK Check that the tines are assembled properly as shown. • The right rotor and left rotor are symmetry. Out side view: L. ROTOR ASSEMBLY R. ROTOR ASSEMBLY "G" MARK "H" MARK Out side view: 15-9...
  • Page 121: Sub Fender

    WHEEL/ROTOR/TRANSMISSION SUB FENDER REMOVAL/INSTALLATION Remove the belt cover (page 11-2). Left side only: Left side shown: BOLT (6 x 12 mm) (5) COLLAR (3) BUSH (3) NUT (6 mm) (5) BACK BRACKET SUB FENDER 15-10...
  • Page 122: Removal/Installation

    WHEEL/ROTOR/TRANSMISSION TRANSMISSION/MAIN FENDER/ENGINE BED REMOVAL/INSTALLATION Remove the following: – Engine (page 10-2) – Handle pipe/handle column (page 14-2) HITCH PIN BOLT (8 x 32 mm) (2) TRANSMISSION HITCH ATTACHMENT LOCK PIN BOLT R. CASE (8 x 25 mm) (2) PROTECTOR BOLT (8 x 65 mm) (2) SHAFT PIN NUT (8 mm) (9)
  • Page 123: Transmission Disassembly/Assembly

    WHEEL/ROTOR/TRANSMISSION TRANSMISSION DISASSEMBLY/ASSEMBLY • The transmission case cannot be separated. For ease of transmission disassembly/assembly, turn the transmission as shown in the figure. • When assembling the transmission, position all gears in the case and then insert the shafts. • The gears on the final shaft and counter shaft and driven sprocket can be removed without removing the input shaft.
  • Page 124 WHEEL/ROTOR/TRANSMISSION LEFT SIDE: WATER SEAL (25 x 52 x 9.5 mm) REMOVAL: REAR SIDE: Take care not to damage the transmission case and wheel shaft. FRONT SIDE: RIGHT SIDE: INTERNAL CIRCLIP (52 mm) BEARING (6205) WHEEL SHAFT O-RING (43.5 x 2.6 mm) REMOVAL: Remove the water seal and circlip and withdraw...
  • Page 125 WHEEL/ROTOR/TRANSMISSION RADIAL BALL BEARING INSPECTION Clean the bearing with solvent and dry it thoroughly. Turn the inner race or outer race of the radial ball bearing with your finger and check for play. If it is noisy or has excessive play, replace the radial ball bearing (page 15-12).
  • Page 126 WHEEL/ROTOR/TRANSMISSION OIL SEAL (15 x 35 x 7 mm) Drive a new oil seal (15 x 35 x 7 mm) [1] from outside until it is flush with the transmission case surface by using the special tools. TOOL: Driver, 22 mm I.D. [2] 07746-0020100 WATER SEAL (25 x 52 x 9.5 mm)/WATER SEAL (25 x 41 x 9.5 mm) Install a new water seal (25 x 52 x 9.5 mm) [1]/water...
  • Page 127: Front Stand/Front Pipe Guard Removal/Installation

    WHEEL/ROTOR/TRANSMISSION FRONT STAND/FRONT PIPE GUARD REMOVAL/INSTALLATION BOLT (10 x 75 mm) (2) NUT (10 mm) (2) BOLT (8 x16 mm) (4) FRONT PIPE GUARD FRONT STAND 15-16...
  • Page 128: Front Stand Disassembly/Assembly

    WHEEL/ROTOR/TRANSMISSION FRONT STAND DISASSEMBLY/ASSEMBLY Remove the front stand (page 15-16). LOCK NUT (10 mm) MOUNT BASE WASHER (10 mm) (2) BOLT (10 x 45 mm) HANDLE RUBBER RETURN SPRING (2) MAIN PIPE 15-17...
  • Page 129 MEMO...
  • Page 130: Index

    INDEX dummytext INDEX AIR CLEANER CHECK/CLEANING/REPLACEMENT···3-5 HANDLE COLUMN DISASSEMBLY/ASSEMBLY······· 14-3 AIR CLEANER REMOVAL/INSTALLATION ················5-4 IGNITION COIL AIR GAP CHECK/ADJUSTMENT ·······7-6 BEFORE TROUBLESHOOTING IGNITION COIL INSPESTION ·································7-7 IGNITION SYSTEM ···········································7-2 IGNITION COIL REMOVAL/INSTALLATION···············7-3 TROUBLESHOOTING········································4-2 IGNITION SYSTEM TROUBLESHOOTING ················7-2 BELT CHECK/ADJUSTMENT··································3-8 LUBRICATION ··················································· 3-11 CABLE/HARNESS ROUTING ··································2-7 LUBRICATION &...

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