Honda CB HORNET 160R 2015 Shop Manual

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SHOP MANUAL

CB HORNET 160R

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Summary of Contents for Honda CB HORNET 160R 2015

Page 1 SHOP MANUAL CB HORNET 160R CB HORNET 160R...
Page 2: Important Safety Precautions
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 the vehicle.
Page 3 A N D S P E C I F I C AT I O N S I N C L U D E D I N T H I S PUBLICATION ARE BASED ON THE LATEST PRODUCT TROUBLESHOOTING INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO., LTD. RESERVES INDEX THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER.
Page 4 Example: Molykote G-n paste manufactured by Dow Corning, U.S.A. ® Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease. Apply a locking agent. Use a middle strength locking agent unless otherwise specified.
Page 5: Table Of Contents
SPECIFICATIONS SERVICE RULES 1. Use genuine HONDA or HONDA–recommended parts and lubricants or their equivalents. Parts that do not meet Honda’s design specifications may cause damage to the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly.
Page 6: Model Identification
GENERAL INFORMATION MODEL IDENTIFICATION This manual covers 2 type of CBF 160 models STD and CBS...
Page 7: Serial Numbers
GENERAL INFORMATION SERIAL NUMBERS Frame Serial Number The Vehicle Identification Number (V.I.N.) is stamped other right side of the steering head. Vehicle Identification Number: ME4KC23 XXXXXXXXXX FRAME SERIAL NUMBER Engine Serial Number The Engine Serial Number is stamped on the lower left side of the crankcase.
Page 8: General Specifications
GENERAL INFORMATION GENERAL SPECIFICATIONS ITEM SPECIFICATION Page NO. 2041 mm (80.4 in) Overall length – Overall width 783 mm (30.8 in) – 1067 mm (42.0 in) Overall height – 1346 mm (52.9 in) Wheelbase – DIMENSIONS 794 mm (31.2 in) Seat height –...
Page 9: Lubrication System Specifications
Page 3–11 Engine oil capacity At disassembly 1.2 litre ( 1.3 US qt, 1.1 Imp qt) – Page 3–11 Honda 4-stroke oil or equivalent motor oil API service classification: MA Page 3–10 Recommended engine oil – Viscosity: SAE 10W–30 Tip clearance 0.15 (0.006)
Page 10: Cylinder/Piston Specifications
GENERAL INFORMATION CYLINDER/PISTON SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Page NO. 57.300 – 57.310 (2.2559 – 2.2563) 57.40 (2.260) I.D. Page 8–2 Out-of-round 0.10 (0.004) – Page 8–3 Cylinder Taper 0.10 (0.004) – Page 8–3 0.10 (0.004) Warpage –...
Page 11: Transmission/Kickstarter Specifications
Page 12–11 390.3 (15.366) 363 (14.291) Spring free length Page 12–17 0.20 (0.008) Pipe runout – Page 12–17 Honda Ultra Cushion Oil No.10 Recommended fluid Page 12–20 – Fork (BAHARAT SS-8) Fluid level 144 mm (5.66 in) Page 12–20 –...
Page 12: Rear Wheel/Suspension Specifications
GENERAL INFORMATION REAR WHEEL/ SUSPENSION SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Page NO. Minimum tire thread depth 2.0 (0.08) – Page 3–25 Driver only 175 kPa (1.75 kgf/cm², 25 psi) – Page 3–25 Cold tire pressure 200 kPa (2.00 kgf/cm², 29 psi) Driver and passenger –...
Page 13: Electric Starter Specification
GENERAL INFORMATION ELECTRIC STARTER SPECIFICATION Unit: mm (in) ITEM STANDARD SERVICE LIMIT Page NO. 10.00 – 10.05 (0.394 – 0.396) 6.5 (0.26) Page 10–11 Starter motor brush length IGNITION SYSTEM SPECIFICATIONS ITEM SPECIFICATION Page NO. Spark plug CPR8EA-9 (NGK) Standard Page 3–7 Spark plug gap 0.8 ~ 0.9 mm (0.03 –...
Page 14: Standard Torque Values
GENERAL INFORMATION STANDARD TORQUE VALUES TORQUE TORQUE FASTENER TYPE FASTENER TYPE N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft) 5 mm screw 5 (0.5, 3.6) 4 (0.4, 2.9) 5 mm bolt and nut 10 (1.0, 7.3) 6 mm screw 9 (0.9, 6.5) 6 mm bolt and nut (Include SH flange bolt) 6 mm flange bolt...
Page 15 GENERAL INFORMATION THREAD TORQUE ITEM PART NO. REMARKS Page NO. DIA. (mm) N·m (kgf·m, lbf·ft) CLUTCH/GEARSHIFT LINKAGE Clutch center lock nut 90202 – KRM – 840 83 (8.3, 61) NOTE 1 Page 9–11 90008 – KRM – 840 12 (1.2, 9) Page 9–11 Clutch lifter plate bolt Oil filter rotor lock nut...
Page 16 GENERAL INFORMATION FRAME THREAD TORQUE ITEM PART NO. DIA. REMARKS PAGE NO. N·m (kgf·m, lbf·ft) (mm) FRAME/BODY PANELS/EXHAUST SYSTEM Exhaust pipe stud bolt 90035 – KRM – 840 11 (1.1, 8) Page 2–9 Sari Guard flange bolt 95701 – 08014 – 07 22 (2.2, 16) Page 2–8 95701 –...
Page 17: Lubrication & Seal Points
GENERAL INFORMATION LUBRICATION AND SEAL POINTS ENGINE LOCATION MATERIAL REMARKS Crankcase mating area Liquid sealant 6.5 (0.26) Alternator wire grommet seating surface Engine oil Oil pump rotors Oil through sliding area Oil pump drive gear teeth Rocker arm shaft entire surface Rocker arm inner surface and roller surface Camshaft lobes Cam chain entire surface...
Page 18 1:1) Fork socket bolt threads Locking agent Ignition switch mounting bolt threads Combination and lock switch bolt Fork cap O–ring Fork fluid Fork oil seal lips Honda Bond A or equivalent Handlebar grip inner surface 1-14...
Page 19: Cable & Harness Routing
GENERAL INFORMATION CABLE & HARNESS ROUTING THROTTLE CABLE FRONT BRAKE HOSE CLUTCH CABLE CLUTCH SWITCH WIRE INSTRUMENT PANEL FRONT BRAKE LIGHT WIRING HARNESS SWITCH WIRE STARTER SWITCH WIRE HEADLIGHT CONNECTOR CONNECT BOOT FOR: – Left Handlebar switch – Turn signal light –...
Page 20 GENERAL INFORMATION SELF STARTER SWITCH LEFT HANDLEBAR SELF STARTER MAIN WIRE HARNESS SWITCH WIRE SWITCH WIRE CDI UNIT FRONT VIEW CLUTCH CABLE GUIDE MAIN WIRE HARNESS HORN WIRE CHOKE KNOB 1-16...
Page 21 GENERAL INFORMATION CBS TYPE: THROTTLE CABLE FRONT BRAKE SPARK PLUG WIRE HOSE REAR BRAKE LIGHT CLUTCH CABLE SWITCH WIRE FRONT BRAKE HOSE (CBS) 1-17...
Page 22 GENERAL INFORMATION STD TYPE: THROTTLE CABLE CLUTCH CABLE SPARK PLUG WIRE FRONT BRAKE HOSE REAR BRAKE LIGHT SWITCH WIRE 1-18...
Page 23 GENERAL INFORMATION BATTERY POSITIVE (+) MAIN FUSE AND STARTER MAG., SWITCH CONNECTOR FUEL HOSE RESISTOR COMP WIRE BATTERY NEGATIVE (–) CONNECTOR BATTERY BOX SUB FUSE (15A & 10A) CHOKE CABLE NEUTRAL SWITCH WIRE CONNECTOR BOOT: – IGNITION PULSE GENERATOR – ALTERNATOR 2P (WHITE) CONNECTOR BATTERY TRAY TUBE –...
Page 24 GENERAL INFORMATION SECONDARY AIR SUCTION HOSE THROTTLE CABLE REAR BRAKE LIGHT SWITCH WIRE CRANKCASE BREATHER PIPE REGULATOR AND RECTIFIER WIRE 1-20...
Page 25 GENERAL INFORMATION CONNECTOR BOOT: – REAR TURN SIGNAL LIGHT WIRE CONNECTOR – LICENCE PLATE LIGHT BRAKE/ TAIL LIGHT CONNECTOR CONNECTOR 1-21...
Page 26: Emission Control Systems
Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co., Ltd. utilizes appropriate carburetor settings as well as other systems, to reduce carbon monoxide and hydrocarbons. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere.
Page 27: Noise Emission Control System
GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of a pulse secondary air injection system and lean carburetor settings. No adjustment should be made except idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcase emission control system.
Page 28 GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM This device collects the fuel vapour from the fuel tank and is routed into the evaporative emission canister, where it is absorbed and stored while the engine is stopped. When the engine is running and evaporative emission (EVAP) one way valve is open, fuel vapour in the canister is drawn into the engine through the carburetor for reburning to avoid air pollution caused by fuel vapour diffused into the air.
Page 29 2. FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION FRONT FENDER TROUBLESHOOTING REAR GRIP FRONT COWL REAR GARNISH SET FRONT COWL DISASSEMBLY REAR COWL COVER HEADLIGHT RR REAR FENDER SEAT SARI GUARD RIGHT SIDE COVER SIDE STAND LEFT SIDE COVER EXHAUST PIPE/MUFFLER FUEL TANK ASSEMBLY MUFFLER PROTECTOR SERVICE INFORMATION GENERAL...
Page 30 FRAME/BODY PANELS/EXHAUST SYSTEM FRONT COWL BOSS 6P BLACK GROMMET CONNECTOR REMOVAL/INSTALLATION GROMMET Remove the front cowl pan screws (4 nos.). Align the grommet with Disconnect 6P black connector (Headlight). front cowl Carefully release the front cowl from the boss. Remove the front cowl. During the installation align boss with grommet in front cowl.
Page 31: Right Side Cover
FRAME/BODY PANELS/EXHAUST SYSTEM SEAT SEAT IGNITION KEY REMOVAL/INSTALLATION Insert the ignition key into the seat lock and turn it clockwise. Slide seat backward and remove the seat. Install the seat, while aligning its hook with the bracket on the frame and press it to lock and remove the ignition key. RIGHT SIDE COVER GROMMET REMOVAL/INSTALLATION...
Page 32: Fuel Tank Center Cover
FRAME/BODY PANELS/EXHAUST SYSTEM FUEL TANK CENTER COVER Remove the following : – Socket bolt (3 nos.)from fuel tank cap After removing – Screw (1 nos.) from fuel tank center cover rear side fuel filler cap – Trim clip (2 nos.) from fuel tank center cover front side cover the fuel tank opening Unlock the fuel tank cap by using ignition key and remove...
Page 33: Front Fender
FRAME/BODY PANELS/EXHAUST SYSTEM FRONT FENDER REMOVAL/INSTALLATION Remove the front wheel (page 12–9). Remove the pan screws (2 nos.) from both side and inner SCREWS bolts (2 nos.) from the front fender mounted on the forks. RUBBER FR FENDER MOUNTING Remove the following : –...
Page 34 FRAME/BODY PANELS/EXHAUST SYSTEM REAR GRIP MOUNTING BOLTS REMOVAL/INSTALLATION Remove the seat (page 2-3). Remove the mounting bolts (2 nos.) from right rear grip. REAR GRIP REAR GRIP Remove the mounting bolts (2 nos.) from left rear grip. RIGHT LEFT Installation is in the reverse order of removal. REAR GARNISH SET REAR GARNISH BOLTS...
Page 35: Rear Cowl
FRAME/BODY PANELS/EXHAUST SYSTEM REAR COWL REAR COWL REAR COWL ASSEMBLY CENTER REMOVAL/INSTALLATION MOUNTING While installing Remove the rear garnish from both side (page 2-6). BOLTS the rear cowl Remove the mounting bolts (4 nos.), collar (4 nos.), route the SCREWS rubber (4 nos.).
Page 36 FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY REAR WINKER Remove mounting screws (2 nos.) from rear side fender RIGHT set A and separate the rear side fender B. REAR SIDE REAR SIDE FENDER - A FENDER - B SCREWS REAR WINKER LEFT SARI GUARD REMOVAL/INSTALLATION Remove the mounting bolts (3 nos.) and sari guard.
Page 37 FRAME/BODY PANELS/EXHAUST SYSTEM Install a new gasket into the exhaust port. GASKET Install the exhaust pipe/muffler, then temporarily install the Always replace exhaust pipe joint nuts, muffler mounting bolts, washer, the exhaust pipe collar and nut. gasket Tighten the exhaust pipe joint nuts securely, then tighten with a new one the muffler mounting bolt to the specified torque.
Page 38 MEMO...
Page 39 1.0 litre ( 1.0 US qt, 0.9 Imp qt) Engine oil capacity At disassembly 1.2 litre ( 1.3 US qt, 1.1 Imp qt) Honda 4-stroke oil or equivalent motor oil API service classification: MA Recommended engine oil Viscosity: SAE 10W–30 Engine Idle speed 1,400 ±...
Page 40 MAINTENANCE TORQUE VALUES THREAD TORQUE ITEM PART NO. REMARKS PAGE NO. DIA. (mm) N·m (kgf·m, lbf·ft) 31916 – KRM – 841 16 (1.6, 12) Page 3–7 Spark plug Valve adjusting lock nut 90206 – 250 – 000 NOTE 1 Page 3–9 18 (1.8, 13.2) 90084 –...
Page 41: Maintenance Schedule
STEERING HEAD BEARINGS Page 3-25 Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is mechanically qualified. Refer to the official Honda Shop Manual ** In the interest of safety, we recommended these items be serviced only by your Honda dealer.
Page 42: Fuel Line
MAINTENANCE FUEL LINE Remove the left side cover (page 2–3). Replace the fuel line if it is cracked, damaged or leaking. Inspect the fuel line routing, kinks and bends which can restrict the fuel flow. Also inspect the position of clips used for locking.
Page 43: Throttle Operation
MAINTENANCE THROTTLE OPERATION Check for smooth throttle grip full opening and automatic full closing in all steering positions. Check the throttle cable and replace it if it is deteriorated, 2-6 mm (0.08 -0.24 in) kinked or damaged. Inspect the throttle cable, if throttle operation is not smooth. Measure the free play at the throttle grip flange.
Page 44: Air Cleaner Element
MAINTENANCE AIR CLEANER AIR CLEANER DUCT AIR CLEANER ELEMENT Remove the seat (page 2-3). INSPECTION: Air cleaner duct can be removed to do the visual inspection of air cleaner element. Clean the surrounding area of air filter with high pressure air.
Page 45: Crankcase Breather
MAINTENANCE CRANKCASE BREATHER Service more frequently when ridden in rain, at full throttle, or after the motorcycle is washed or overturned. Check the crankcase breather hose for deterioration, damage or loose connection. Make sure that the hoses are not kinked, pinched or cracked. BREATHER HOSE Loosen the drain hose clip and remove the drain hose from the air cleaner housing and drain deposits into a...
Page 46 MAINTENANCE INSPECTION Check the following and replace if necessary (recommended spark plug : page 3-7) CENTER ELECTRODE • Insulator for damage • Electrodes for wear • Burning condition, coloration – Dark to light brown indicates good condition – Excessive lightness indicates malfunctioning ignition system or lean mixture –...
Page 47 MAINTENANCE Rotate the crankshaft counter clockwise, and align the INDEX NOTCH “ ” mark on the flywheel with the index notch on the left crankcase cover. Make sure the piston is at TDC (Top Dead Center) on the compression stroke. This position can be obtained by confirming that there is ”...
Page 48: Engine Oil
If the oil level is below or near the lower level line on the dipstick, fill the recommended engine oil to the upper level line through the oil filler hole. UPPER LOWER RECOMMENDED ENGINE OIL: Honda 4 – Stroke oil or equivalent motor oil API service classification: MA Viscosity: SAE 10W–30 3-10...
Page 49: Engine Oil Change
MAINTENANCE Apply clean engine oil to a new O-ring, and install it on oil filler cap / dipstick. Reinstall and tighten the oil filler cap/dipstick securely. O-RINGS DIPSTICK ENGINE OIL CHANGE Change the oil Warm up the engine to normal operating temperature. with the engine Stop the engine, and remove the oil filler cap/dipstick.
Page 50 MAINTENANCE ENGINE OIL STRAINER SCREEN REMOVAL/INSTALLATION Remove the right crankcase cover (page 9-3). Be careful not to damage the Oil Pull the oil strainer screen out of the crankcase. strainer screen. Wash the oil strainer screen thoroughly in nonflammable or high flash point solvent until all accumulated dirt has been removed.
Page 51 MAINTENANCE Remove the gasket from the oil rotor cover. While pressing the oil through from the reverse side, then CLIP remove the clip. COVER/GASKET OIL THROUGH Remove the oil through and spring from the oil filter rotor cover. OIL FILTER ROTOR CAP Blow and clean the oil through using compressed air.
Page 52: Engine Idle Speed
MAINTENANCE ENGINE IDLE SPEED Inspect and adjust the idle speed after all other engine • maintenance items have been performed and are within specifications. The engine must be warm for accurate adjustment. Ten • minutes of stop-and-go riding is sufficient. Warm up the engine to normal operating temperature, shift the transmission into neutral and place the motorcycle on a level surface.
Page 53 MAINTENANCE Check the air suction hose between the PAIR control valve AIR SUCTION HOSE and air cleaner housing for deterioration, damage or loose connections. Make sure that the hose is not cracked. Remove and check the air suction hose. If the carbon deposits in the air suction hose, check the PAIR check valve.
Page 54: Drive Chain
MAINTENANCE DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION Turn the ignition switch “OFF”. Place the motorcycle on its Never inspect center stand and shift the transmission into neutral. the drive chain while the engine Check the slack at three places in the drive chain lower is running.
Page 55 Use any one of the following methods for lubricating drive chain: • SAE 80 or 90 gear oil • Honda recommended chain maintenance spray • Molten grease in greaselator Saturate each chain link joint so that the lubricant penetrates between the link plates, pins, bushings, and rollers.
Page 56: Brake Fluid
MAINTENANCE SPROCKET Installing a new chain on badly worn sprockets will cause WEAR a new chain to wear quickly. Inspect the drive and driven sprocket teeth for wear or damage, replace if necessary. Never use a new drive chain on worn sprockets. Both chain and sprockets must be in good condition, or the DAMAGE NORMAL...
Page 57 MAINTENANCE FRONT BRAKE FLUID LEVEL INSPECTION: SIGHT GLASS Support the motorcycle on its center stand. Turn the handlebar to the left until the reservoir is parallel to the ground. Check the brake reservoir level through the sight glass. When the fluid level is near the lower level line, check •...
Page 58 MAINTENANCE REAR BRAKE FREE PLAY ADJUSTMENT: No rear brake Check the brake pedal and brake rod for loose connections, excessive play, or other damage. Repair or replace if free play adjust- ment required necessary. in CBS varient Measure the rear brake pedal free play. due to rear disc brakes.
Page 59 MAINTENANCE FRONT BRAKE PADS (DISC) PADS Check the brake pads for wear by locking from the front side of the brake caliper. Replace the brake pads if either pad is worn to the bottom of wear limit groove. Refer to the brake pad replacement (page 14-7). REAR BRAKE PADS (DISC) Check the brake pads for wear by locking from the front side of the brake caliper.
Page 60 MAINTENANCE REAR BRAKE FITTING BRAKE HOSES DISC TYPE: Inspect the brake hose and fittings for deterioration, cracks and signs of leakage. Tighten any loose fittings. Replace hoses and fittings as required. Refer to the brake bleeding procedures (page 14-4). BRAKE LIGHT SWITCH BRAKE LIGHT SWITCH BODY The front brake light switch does not require adjustment.
Page 61 MAINTENANCE ADJUSTMENT ADJUSTING NUT LOCK NUT Adjustments are performed at the clutch lifter arm. Loosen the lock nut, and turn the adjusting nut. After adjustment, tighten the lock nut by holding adjusting nut. Check the clutch operation. If the proper free play cannot be obtained, or the clutch slips during the test ride, disassemble and inspect the clutch (page 9-8).
Page 62 MAINTENANCE Support the motorcycle securely and raise the rear wheel off the ground. Check for worn swingarm bearings by grabbing the rear wheel and attempting to move the wheel and attempting to move the wheel side to side. Replace the bearings if any looseness to noted. Refer to (page 13-13) for swingarm service.
Page 63: Steering Head Bearings
MAINTENANCE Check the tire pressure with a tire pressure gauge when the tires are cold. RECOMMENDED TIRE PRESSURE AND TIRE SIZE: FRONT REAR Driver only Tire pressure (1.75,25) (1.75,25) kPa (kgf/cm Driver and psi) (1.75,25) (2.00,29) Passenger 100/80- 140/70- Tire size 17M/C 52S 17M/C 66S Check the tires for cuts, embedded nails, or other damage.
Page 64 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM ROCKER ARM CAMSHAFT OIL FILTER ROTOR CRANKSHAFT OIL PUMP MAINSHAFT COUNTERSHAFT...
Page 65 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 API service classification: MA Recommended engine oil – Viscosity: SAE 10W-30 Tip clearance 0.15 (0.006)
Page 66: Oil Pump
LUBRICATION SYSTEM ENGINE OIL STRAINER SCREEN REMOVAL 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.
Page 67 LUBRICATION SYSTEM Remove the dowel pins (2 nos.). DOWEL PINS DISASSEMBLY 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...
Page 68 LUBRICATION SYSTEM INSPECTION 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 specified service limits, replace the oil pump and oil pump cover as an assembly.
Page 69 LUBRICATION SYSTEM OIL PUMP ASSEMBLY 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.
Page 70 LUBRICATION SYSTEM Install the oil pump cover and tighten the screw. TORQUE: 3 N·m (0.3 kgf·m, 2.2 lbf·ft) PUMP COVER SCREW INSTALLATION Install two dowel pins into the crankcase. DOWEL PINS Install the oil pump and tighten the mounting bolts to the specified torque.
Page 71 MEMO...
Page 72 FUEL SYSTEM COMPONENT LOCATION 27 N.m (2.8 kgf.m, 20 Ibf.ft)
Page 73 5. FUEL SYSTEM COMPONENT LOCATION CARBURETOR SERVICE INFORMATION PILOT SCREW ADJUSTMENT 5-15 TROUBLESHOOTING SECONDARY AIR SUPPLY SYSTEM 5-19 AIR CLEANER HOUSING EVAPORATIVE EMISSION CONTROL SYSTEM 5-20 STARTING ENRICHMENT(SE) VALVE FUEL STRAINER 5-22 SERVICE INFORMATION GENERAL • Bending or twisting the control cable will impair smooth operation of secondary air supply system, and could cause the cable to stick or bind, resulting in loss of vehicle control.
Page 74 TOOLS Carburetor float level gauge 070MJ-001-I110 TROUBLESHOOTING Engine won’t start After burn when engine braking is used • • Lean mixture in slow circuit Too much fuel getting to the engine • Faulty PAIR control valve – Air cleaner clogged –...
Page 75 FUEL SYSTEM AIR CLEANER HOUSING BREATHER HOSE RR BRAKE LIGHT REMOVAL SWITCH AIR VENT HOSE Remove the following: – Fuel tank (page 2-3) – Air cleaner element (page 3-6) Disconnect the air vent hose (page 5-5) from the carburetor and remove the hoses (Breather and air vent) from the frame clamps.
Page 76 FUEL SYSTEM Remove the mounting bolt (1 no.) from left side. Remove the air cleaner housing from right side. BOLT AIR CLEANER HOUSING INSTALLATION Install the air cleaner housing from right side to the frame. Install and tighten the mounting bolt (1 no.) from left side. BOLT AIR CLEANER HOUSING...
Page 77 FUEL SYSTEM Clamp the hose to the frame carefully and connect the air BREATHER HOSE While installing RR BRAKE LIGHT vent hose to the carburetor (page 5-16). the drain hose SWITCH Carefully route the wire from the clamp on the air cleaner AIR VENT HOSE route the housing and connect the rear brake light switch 2P...
Page 78 FUEL SYSTEM Handle the SE Install the SE valve to the carburetor body. CARBURETOR SE VALVE LOCK valve lock nut NUT/ SE VALVE Tighten the SE valve lock nut. with care that TORQUE: 2.3 N·m (0.2 kgf·m, 1.7 lbf·ft) can easily be damaged.
Page 79 FUEL SYSTEM Disconnect the one way valve hose. INSULATOR CARBURETOR Remove the carburetor. SCREW BAND ONE WAY SCREW VALVE HOSE DISASSEMBLY THROTTLE CABLE STAY THROTTLE CABLE STAY Remove the two screw and throttle cable stay. SCREWS VACUUM CHAMBER VACUUM CHAMBER COVER Take care of the Remove the two screws and vacuum chamber cover.
Page 80 FUEL SYSTEM Turn the needle holder counterclockwise and remove it. DIAPHRAGM/ NEEDLE HOLDER VACUUM PISTON Be careful not Remove the spring and jet needle from the vacuum piston. to damage the Check the following: JET NEEDLE diaphragm. – Jet needle for stepped wear –...
Page 81 FUEL SYSTEM Remove the float and float valve. FLOAT FLOAT VALVE JETS MAIN JET NEEDLE JET HOLDER Damaged SLOW JET Remove the followings: pilot screw – Main jet seat will occur – Slow jet if the screw – Needle jet holder is tightened against the seat.
Page 82: Carburetor Assembly
FUEL SYSTEM CARBURETOR CLEANING Blow open the fuel passage from the valve seat side with STRAINER SCREEN compressed air and clean the strainer screen. VALVE SEAT Blow open each air and fuel passages in the carburetor CARBURETOR BODY body using compressed air. Check each part for wear or damage, and replace them if necessary.
Page 83 FUEL SYSTEM JETS Install the pilot screw with the spring, washer and new Damage to the O-ring, and return it to its original position as noted during pilot screw seat removal. will occur if the pilot screw Perform the pilot screw adjustment if a new pilot screw is O-RING is tightened installed (page 5-15).
Page 84 FUEL SYSTEM Install the float pin through the carburetor body and float. FLOAT PIN With the float valve seated and float arm just touching the FLOAT LEVEL valve, then measure the float level using the special tool GAUGE as shown. FLOAT LEVEL: 13.0 mm (0.51 in) TOOL: Carburetor float level gauge 070MJ–001–I110...
Page 85 FUEL SYSTEM STARTING ENRICHMENT (SE) VALVE COVER SE VALVE COVER SE VALVE COVER Install the the new O-ring and SE valve cover. Install the two screws/washers. Tighten the screws. TORQUE: 3.4 N·m (0.4 kgf·m, 2.5 lbf·ft) SCREWS/ O-RING WASHERS VACUUM CHAMBER Install the jet needle into the diaphragm/vacuum piston.
Page 86 FUEL SYSTEM Be careful not Check that the spring installed correctly by pushing the COMPRESSION SPRING bottom of the piston with your finger and make sure that to pinch the diaphragm the piston returns back in place smoothly. under the chamber cover, and to keep the spring...
Page 87: Pilot Screw Adjustment
FUEL SYSTEM Connect the throttle cable end to the throttle drum and tighten the lock nut. LOCK NUT Check the throttle operation (page 3-5). THROTTLE DRUM CABLE END Connect the drain hose to the carburetor. DRAIN SCREW DRAIN HOSE After installation Connect the air vent hose and throttle sensor 3P connector THROTTLE SENSOR SE VALVE LOCK...
Page 88 FUEL SYSTEM ADJUSTMENT BY CO CONCENTRATION MEASUREMENT PIPE PROBE • Check the following items before inspection. – Air cleaner (page 3-6) – Spark plug (page 3-7) – Crankcase breather (page 3-7) – Secondary air supply system (page 5-19) – Ignition timing (page 16-5) Connect an appropriate pipe or hose (heat-resistant, chemical-resistant) to the muffler so that the probe can 60 cm (0.24 in)
Page 89 FUEL SYSTEM 6. Insert the probe into the muffler and measure the carbon-mono-oxide (CO%) concentration. CO MEASUREMENT TOOL CO measurement at idle: 0.7 – 0.8% If the CO concentration is exist, adjust the pilot screw as following. 7. Disconnect the vacuum hose of PAIR control valve, then VACUUM HOSE it connect the vacuum pump and plug the vacuum port.
Page 90 FUEL SYSTEM IDLE DROP PROCEDURE PILOT SCREW 1. Remove the left side cover (page 2-3) Damage to the pilot screw Turn the pilot screw until it seats lightly, then back it out to seat will occur the specification given. if the screw This is an initial setting prior to the final pilot “screw is tightened adjustment.
Page 91 FUEL SYSTEM SECONDARY AIR SUPPLY SYSTEM HOSE SYSTEM INSPECTION Warm up to the engine to normal operating temperature. Disconnect the air suction hose from the air cleaner housing. Check the air suction hose port is clean and free carbon deposits. If the port is carbon fouled, check the PAIR control valve.
Page 92 FUEL SYSTEM PAIR CONTROL VALVE AIR SUPPLY HOSE REMOVAL /INSTALLATION Disconnect the PAIR control valve vacuum hose and air supply hose. VACUUM HOSE Disconnect the air suction hose. Remove the bolts, nuts (2 nos.) and PAIR control valve. Installation is in the reverse order of removal. BOLTS AIR SUCTION HOSE...
Page 93 FUEL SYSTEM INSPECTION SMALLER DIA Air must flow from bigger opening (from canister) to smaller AIR FLOW opening (to carburetor) not in reverse direction. • Don’t use compressed high pressure air for inspection. • Don’t drop the one way valve, if dropped replace. ONE WAY VALVE Connect one way valve to the hoses with its arrow mark...
Page 94 FUEL SYSTEM FUEL STRAINER REMOVAL Drain the fuel from the fuel tank into the approved gasoline container. Remove the left side cover (page 2-3). Remove the screw and plastic fuel valve knob. SCREWS FUEL KNOB Make sure not Remove the fuel tank (page 2-4). LOCK NUT to damage Loosen the fuel valve lock nut.
Page 95 FUEL SYSTEM INSTALLATION FUEL VALVE Install a new O-ring onto the fuel strainer, and install the fuel strainer into the fuel valve. Install the fuel strainer and fuel valve assembly into the FUEL STRAINER fuel tank. O-RING Tighten the fuel valve lock nut and apply the specified Torque.
Page 96 ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION 54 N.m (5.5 kgf.m, 40 Ibf.ft) 12 N.m (1.2 kgf.m, 9 Ibf.ft) 45 N.m (4.5 kgf.m, 33 Ibf.ft)
Page 97 6. ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION ENGINE REMOVAL SERVICE INFORMATION ENGINE INSTALLATION SERVICE INFORMATION GENERAL • When removing/installing the engine, tape the frame around the engine beforehand for frame protection. • The following components can be serviced with the engine installed in the frame. –...
Page 98: Engine Removal
ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL VS SENSOR NEUTRAL SWITCH CONNECTORS WIRE CONNECTOR Support the motorcycle on its center stand. Drain the engine oil (page 3-11). Remove exhaust pipe/muffler (page 2-8) Disconnect the following: – Spark plug cap (page 3-7) – Clutch cable (page 9-6) –...
Page 99 ENGINE REMOVAL/INSTALLATION Remove the gear shift pedal pinch bolt and gear shift pedal. PINCH BOLT PEDAL Remove the bolts (2 nos.) of choke cable stay. CHOKE CABLE STAY BOLTS Remove the bolts (2 nos.) of left crankcase rear cover and LEFT CRANKCASE remove it with bracket.
Page 100: Engine Installation
ENGINE REMOVAL/INSTALLATION The jack Support the engine using a jack or other adjustable support FRONT ENGINE height must to ease of engine hanger bolts removal. HANGER BOLTS/NUTS be continually Remove the following: adjusted to – Front engine hanger bolts and nuts relieve stress for ease of bolt –...
Page 101 ENGINE REMOVAL/INSTALLATION Install the plate, plate bolts and nuts. FRONT ENGINE HANGER BOLTS/NUTS Install the front engine hanger bolts and nuts. Tighten the front and rear engine hanger nuts to the specified torque. TORQUE: BOLTS/ NUTS Front engine hanger nut : 45 N·m (4.5 kgf·m, 33 lbf·ft) Rear engine hanger nut : 54 N.m (5.5 kgf.m, 37.6 lbf·ft) PLATE Install the drive chain onto the drive sprocket.
Page 102 ENGINE REMOVAL/INSTALLATION Install and tighten the bolts (2 nos.) on left crankcase rear CHOKE CABLE STAY cover. Install the choke cable stay and tighten the bolts (2 nos.). BOLTS LEFT CRANKCASE REAR COVER Install the gear shift pedal and tighten the pinch bolt. PINCH BOLT PEDAL Install the kickstarter pedal by aligning mark on the kick...
Page 103 ENGINE REMOVAL/INSTALLATION Connect the crank case breather hose. VS SENSOR NEUTRAL SWITCH Connect the neutral switch wire connector, pulse generator CONNECTORS WIRE CONNECTOR wire connector, alternator 2P (white) connector and VS sensor connectors. Connect and install the following: – ASV air supply hose (page 3-14) –...
Page 104 CYLINDER HEAD/VALVES COMPONENT LOCATION 10 N.m (1.0 kgf.m, 7.3 Ibf.ft) 9 N.m (0.9 kgf.m, 6.6 Ibf.ft) 30 N.m (3.0 kgf.m, 22 Ibf.ft) 12 N.m (1.2 kgf.m, 9 Ibf.ft) 9 N.m (0.9 kgf.m, 6.6 Ibf.ft)
Page 105 7. CYLINDER HEAD/VALVES COMPONENT LOCATION CYLINDER HEAD REMOVAL 7-10 SERVICE INFORMATION CYLINDER HEAD/ DISASSEMBLY/ASSEMBLY 7-12 TROUBLESHOOTING CYLINDER HEAD INSTALLATION 7-19 CYLINDER COMPRESSION CAM CHAIN TENSIONER LIFTER 7-21 CYLINDER HEAD COVER CAMSHAFT REMOVAL/INSTALLATION SERVICE INFORMATION GENERAL • This section covers service of the cylinder head, valves, rocker arms and camshaft. These services can be done with the engine installed in the frame.
Page 106 CYLINDER HEAD/VALVES TORQUE VALUES THREAD TORQUE ITEM PART NO. REMARKS PAGE NO. DIA. (mm) N·m (kgf·m, lbf·ft) Cylinder head cover bolt 96001 – 06035 – 00 10 (1.0, 7.3) Page 7–6 Rocker arm shaft bolt 90002 – KRM – 840 5 (0.5, 3.7) Page 7–12 Cam sprocket bolt...
Page 107 CYLINDER HEAD/VALVES TOOLS Valve guide driver Valve spring compressor Valve Seat cutter, 27.5 mm (45° EX) 070-GD-0061150 070-GE-001-I100 070GH-0031180 Valve Seat cutter, 29 mm (45° IN) Flat cutter, 27 mm (32° EX) Flat cutter, 30 mm (32° IN) 07780-0010300 07780-0013300 07780-0012200 Interior cutter, 26 mm (60°...
Page 108: Cylinder Compression
CYLINDER HEAD/VALVES CYLINDER COMPRESSION PLUG CAP SPARK PLUG Reference Warm up the engine to normal operating temperature. engine oil Stop the engine, disconnect the spark plug cap, and temperature: remove the spark plug (Page 3-7). 60 – 65°C (140 –149°F) To avoid Install a compression gauge attachment into the spark USING KICK START...
Page 109 CYLINDER HEAD/VALVES Remove the cylinder head cover and cover packing. PACKAGING Remove the PAIR passage O-ring from the cylinder head cover. HEAD COVER O-RING Remove the two bolts. O-RING Remove the air supply pipe and O-ring. BOLTS INSTALLATION O-RING Apply clean engine oil to a new O-ring. Install the new O-ring to the air supply pipe.
Page 110 CYLINDER HEAD/VALVES Install a new cover packing into the cylinder head cover PACKAGING O-RING groove. Install the cylinder head cover onto the cylinder head. HEAD COVER Install and tighten the head cover bolts to the specified AIR SUPPLY HOSE torque. TORQUE : 10 N.m (1.1 kgf.m, 7.3 Ibf.ft) BOLTS CAMSHAFT...
Page 111 CYLINDER HEAD/VALVES Remove the cam sprocket mounting bolts (2 nos.). BOLTS Remove the cam sprocket off the camshaft flange. Be careful not to let the sprocket CAM CHAIN Remove the sprocket from the cam chain. bolts fall into the crankcase. CAMSHAFT FLANGE SPROCKET Hold the cam chain with a piece of wire to prevent it from...
Page 112 CYLINDER HEAD/VALVES INSPECTION BEARING CAMSHAFT BEARING Turn the outer race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing inner race fits tightly on the camshaft. Replace the camshaft if the bearings do not turn smoothly, quietly, or if they fit loosely on the camshaft.
Page 113 CYLINDER HEAD/VALVES Install the camshaft retainer bolt and tighten it securely. Install the cam sprocket to the cam shaft. RETAINER BOLT CAMSHAFT Install the cam chain on cam sprocket. CAM CHAIN Install the cam sprocket on the camshaft flange. CAMSHAFT FLANGE SPROCKET Install the cam sprocket mounting bolts (2 nos.) to the specified torque.
Page 114: Cylinder Head Removal
CYLINDER HEAD/VALVES CYLINDER HEAD REMOVAL Remove the following : BOLTS – Exhaust pipe (page 2-8) – Fuel tank (page 2-4) – Camshaft (page 7-6) Remove bolts (2 nos.) of the intake manifold from cylinder head. Remove flange bolts (2 nos.). STUD BOLTS/NUTS Loosen the nut (4 nos.) and loosen the stud bolt (4 nos.).
Page 115 CYLINDER HEAD/VALVES Remove the cylinder head. CYLINDER HEAD Remove the gasket and dowel pins. DOWEL PINS GASKET ROCKER ARM REMOVAL SHAFT Remove the following : – Spark plug (page 3-7) – Exhaust pipe (page 2-8) BOLTS – Cylinder head cover (page 7-4) –...
Page 116 CYLINDER HEAD/VALVES Clean the threads of each rocker arm shaft thoroughly. Apply clean engine oil to each rocker arm inner, roller SHAFT surface and rocker arm shaft rotating surface. Set the rocker arm into the camshaft holder in the direction as shown, then install the rocker arm shaft with the threads facing the cam sprocket side into the cylinder head through BOLTS...
Page 117 CYLINDER HEAD/VALVES INSPECTION VALVE SPRING Measure the valve spring free length. SERVICE LIMIT: INNER: 35.14 mm (1.383 in) OUTER: 38.60 mm (1.519 in) CYLINDER HEAD Be careful not Check the spark plug hole and valve area for cracks. Check to damage the the cylinder head for warpage with a straight edge and a gasket surface.
Page 118: Valve Guide Replacement
CYLINDER HEAD/VALVES Measure and record each valve guide I.D. with a ball gauge or inside micrometer. SERVICE LIMIT: IN/EX: 5.04 mm (0.198 in) Calculate the stem-to-guide clearance. SERVICE LIMIT: 0.07 mm (0.003 in) 0.09 mm (0.004 in) • If the stem-to-guide clearance exceeds the service limit, determine if a new guide with standard dimensions would bring the clearance within tolerance.
Page 119 CYLINDER HEAD/VALVES Ream the new valve guides. VALVE GUIDE REAMER TOOL: Valve guide reamer 07984-MA60001 • Take care not to tilt or lean the reamer in the guide while reaming. Otherwise, the valve is installed slanted, that causes oil leaks from the stem seal and improper valve seat contact and results in the valve seat refacing not able to be performed.
Page 120 CYLINDER HEAD/VALVES The valve can- • Contact area (too high or too low area) not be ground- – Reface the valve seat. ed. If the valve face is burned or badly worn or if it contacts the seat unevenly, replace the valve.
Page 121 CYLINDER HEAD/VALVES Using 32 degree cutter, remove top 1/4 of the existing valve seat material. TOOLS: Flat cutter, 27 mm (EX) 07780-0013300 OLD SEAT Flat cutter, 30 mm (IN) 07780-0012200 WIDTH Cutter holder 07781-001040 32° Using 60 degree cutter, remove the bottom 1/4 of the old seat.
Page 122 CYLINDER HEAD/VALVES ASSEMBLY COTTERS SPARK PLUG 16 N.m (1.6 kgf.m, 12 lbf.ft) SPRING RETAINER VALVE SPRINGS SPRINGS SEAT STEM SEAL VALVE GUIDE CLIP EXHAUST VALVE INTAKE VALVE To avoid Clean the cylinder head assembly with solvent and blow damage to the through all oil passage with compressed air.
Page 123: Cylinder Head Installation
CYLINDER HEAD/VALVES Grease the Compress the valve spring and install the valve cotters. cotters to ease COTTERS TOOL: installation. To Valve spring compressor: 070-GE-001-I100 prevent loss of tension, do not compress the valve spring more than necessary. VALVE SPRING COMPRESSOR Tap the stems gently with two plastic hammer to firmly Support the cylinder head...
Page 124 CYLINDER HEAD/VALVES STUD BOLT After tightening the stud bolts and nuts to the specified torque, it is mandatory to maintain distance between top of the stud bolts and top of the nuts between the 7.4 mm – 12 mm specified limits as shown in illustration. Be careful not Rotate crankshaft counterclockwise, and align the “...
Page 125 CYLINDER HEAD/VALVES Install and tighten the intake manifold bolts (2 nos.) as per the specified torque. BOLTS TORQUE : 12 N·m (1.2 kgf·m, 9 lbf·ft) Install the following: – Cover cylinder head L-Side – Cylinder head cover – Exhaust pipe/muffler –...
Page 126 CYLINDER HEAD/VALVES INSPECTION Check the lifter operation: TENSIONER LIFTER • The tensioner shaft should not go into the body when it is pushed. • When it is turned clockwise with a stopper tool (page 7-6), the tensioner lifter shaft should be pulled into the body.
Page 127 MEMO...
Page 128 CYLINDER/PISTON COMPONENT LOCATION...
Page 129 8. CYLINDER/PISTON COMPONENT LOCATION TROUBLESHOOTING SERVICE INFORMATION CYLINDER/PISTON SERVICE INFORMATION GENERAL • The cylinder and piston services can be done with the engine installed in the frame. • Take care not to damage the cylinder wall and piston. • Be careful not to damage the mating surfaces when removing the cylinder. Do not strike the cylinder too hard during removal. •...
Page 130: Cylinder Removal
CYLINDER/PISTON CYLINDER/PISTON DOWEL PINS GASKET CYLINDER REMOVAL Remove the cylinder head (page 7-10). The cylinder can be serviced Remove the gasket with the engine installed in the Remove the cam chain guide. frame CAM CHAIN GUIDE Do not strike Lift the cylinder, and remove it, being careful not to damage the cylinder the piston.
Page 131 CYLINDER/PISTON Calculate the cylinder for taper and out of round at three levels in an X and Y axis. Take the maximum reading to determine the out of round. SERVICE LIMITS: Taper: 0.10 mm (0.004 in) Out of round: 0.10 mm (0.004 in) The cylinder must be re-bored and an oversize piston fitted MIDDLE if the service limit is exceeded.
Page 132 CYLINDER/PISTON Spread each piston ring and remove it by lifting it up at a point just opposite and gap. • Do not damage the piston ring by spreading the ends too far. • Be careful not to damage the piston when the piston ring removal.
Page 133 CYLINDER/PISTON Measure the piston pin O.D. at three points. SERVICE LIMIT: 13.96 mm (0.550 in) Calculate the piston-to-piston pin clearance. SERVICE LIMIT: 0.04 mm (0.002 in) PISTON PIN Measure the connecting rod small end I.D. SERVICE LIMIT: 14.06 mm (0.554 in) CONNECTING ROD Calculate the connecting rod small end-to-piston pin clearance.
Page 134: Piston Installation
CYLINDER/PISTON PISTON INSTALLATION Clean the piston heads, ring lands and skirts. Carefully install the piston rings onto the piston with their markings facing up: • Do not damage the piston ring by spreading the ends too far. • Be careful not to damage the piston when the piston ring installation.
Page 135: Cylinder Installation
CYLINDER/PISTON When cleaning Clean any gasket material from the cylinder mating surface of the crankcase. the cylinder mating surface, MATING SURFACE Place a shop towel over the crankcase opening to prevent place a shop piston pin clips from falling into the crankcase. towel over the cylinder opening to prevent dust...
Page 136 CYLINDER/PISTON Be careful not Apply clean engine oil to the cylinder inner surface, piston outer surface and piston rings. to damage the piston rings and Route the cam chain through the cylinder, and install the cylinder wall. cylinder over the piston while compressing the piston rings with your fingers.
Page 137 MEMO...
Page 138 CLUTCH/GEARSHIFT LINKAGE COMPONENT LOCATION 12 N.m (1.2 kgf.m, 9 Ibf.ft) 83 N.m (8.3 kgf.m, 61 Ibf.ft) 83 N.m (8.3 kgf.m, 61 Ibf.ft) 64 N.m (6.4 kgf.m, 47 Ibf.ft) 12 N.m (1.2 kgf.m, 9.0 Ibf.ft) 9 N.m (0.9 kgf.m, 6.6 Ibf.ft)
Page 139 9. CLUTCH/GEARSHIFT LINKAGE COMPONENT LOCATION CLUTCH SERVICE INFORMATION GEAR SHIFT LINKAGE 9-12 TROUBLESHOOTING PRIMARY DRIVE GEAR 9-14 RIGHT CRANKCASE COVER BALANCER DRIVE GEAR 9-15 SERVICE INFORMATION GENERAL • This section covers service of the clutch, gearshift linkage, kick starter. All services can be done with the engine installed in the frame.
Page 140 CLUTCH/GEARSHIFT LINKAGE TOOLS Clutch center holder Gear holder Holder gear drum stopper arm 070SRTKSP011 0706 - KRB - T7900 070SRTKSP010 TROUBLESHOOTING Faulty clutch operation can usually be corrected by adjusting the free play. Clutch lever difficult to pull in • Damaged, kinked or dirty clutch cable •...
Page 141: Right Crankcase Cover
CLUTCH/GEARSHIFT LINKAGE RIGHT CRANKCASE COVER LIFTER ARM REMOVAL CLUTCH CABLE The right Drain the engine oil (page 3-11). crankcase cover Remove the following: can be serviced – Kick starter pedal (page 6-2) with the engine installed in the Loosen the lock nut and adjusting nut, then disconnect the frame.
Page 142 CLUTCH/GEARSHIFT LINKAGE Rotate the lifter arm in anti clockwise direction then pull out the clutch lifter arm from the right crankcase cover, and remove the return spring. CLUTCH LIFTER ARM Remove the kick starter spindle dust seal. DUST SEAL Remove the clutch lifter arm and dust seal. Check the clutch lifter arm for wear or damage.
Page 143 CLUTCH/GEARSHIFT LINKAGE Install the clutch lifter piece into the clutch lifter arm groove by aligning the groove with the lifter piece hole. LIFTER PIECE RETURN SPRING INSTALLATION GASKET Clean off any gasket material from the mating surfaces of Be careful not the right crankcase and cover.
Page 144 CLUTCH/GEARSHIFT LINKAGE CLUTCH LOCK NUT WRENCH GEAR HOLDER REMOVAL Remove the following: – Right crankcase cover (page 9-3) – Oil filter rotor cover (page 3-12) Install the gear holder between the primary drive and driven gears as shown, and loosen the oil filter rotor lock nut using lock nut wrench.
Page 145 CLUTCH/GEARSHIFT LINKAGE Remove the special tools, lock nut and lock washer. WASHER LOCK NUT Remove the following: PRESSURE PLATE – Clutch center DISCS B – Clutch disc A – Clutch plates and discs B CLUTCH CENTER – Pressure plate DISC A PLATES DISC A Remove the following:...
Page 146 CLUTCH/GEARSHIFT LINKAGE INSPECTION LIFTER PLATE BEARING CLUTCH LIFTER BEARING Turn the inner race of the clutch lifter bearing with your finger. The bearing should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the clutch lifter plate. Replace the bearing if the inner race does not turn smoothly, quietly, or if the outer race fits loosely in the clutch lifter plate.
Page 147 CLUTCH/GEARSHIFT LINKAGE Replace the Measure the friction disc thickness of each clutch disc. clutch discs and SERVICE LIMIT: CLUTCH DISC plates as a set. Disc A, B: 2.6 mm (0.10 in) CLUTCH PLATE CLUTCH PLATE Check the plate for discolouration. Check the clutch plate for warpage on a surface plate using a feeler gauge.
Page 148 CLUTCH/GEARSHIFT LINKAGE INSTALLATION Apply molybdenum oil solution to the entire surface of the CLUTCH OUTER GUIDE clutch outer guide, and install it onto the mainshaft . Apply clean engine oil to the gear primary drive. Install the oil pump driven gear. GEAR PRIMARY DRIVE Install the clutch outer and washer.
Page 149 CLUTCH/GEARSHIFT LINKAGE Install the tabs Install the clutch center assembly into the clutch outer. OUTER CLUTCH of clutch disc A SHALLOW SLOT (out side) to the shallow slots of the clutch outer. DISC A (OUTSIDE) CLUTCH CENTER ASSEMBLY Install the lock washer. WASHER Apply clean engine oil to the threads and seating surface of the clutch center lock nut, and install it.
Page 150 CLUTCH/GEARSHIFT LINKAGE Clean the inside of the oil filter rotor. OIL FILTER ROTOR Install the oil filter rotor and washer onto the crankshaft. Apply clean engine oil to the threads and seating surface of the lock nut and install it with the chamfered side facing in. WASHER LOCK NUT Install the gear holder between the primary drive and driven...
Page 151 CLUTCH/GEARSHIFT LINKAGE Remove the following: RETURN SPRING – Dowel pins from the shift drum – Stopper arm bolt DOWEL PINS – Stopper arm – Washer – Return spring WASHER STOPPER ARM BOLT INSPECTION Check the gearshift spindle for wear or bend. Check the spindle plate for wear, damage or deformation.
Page 152 CLUTCH/GEARSHIFT LINKAGE Apply a locking agent to the gearshift cam bolt threads. Install and tighten the gearshift cam bolt to the specified BOLT torque. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) GEARSHIFT DRUM STOPPER Apply clean engine oil to the gearshift spindle journal GEARSHIFT SPINDLE rotating area.
Page 153 CLUTCH/GEARSHIFT LINKAGE INSTALLATION PRIMARY DRIVE GEAR Apply clean engine oil to the primary drive gear. Install the primary drive gear, while aligning the groove with the woodruff key. Install the clutch assembly (page 9-10). Align BALANCER DRIVE GEAR BALANSER DRIVE GEAR REMOVAL Remove the primary drive gear (page 9-14).
Page 154 ALTERNATOR COMPONENT LOCATION 74 N.m (7.5 kgf.m, 55 Ibf.ft) 10-0...
Page 155 10. ALTERNATOR COMPONENT LOCATION 10-0 STARTER CLUTCH 10-6 SERVICE INFORMATION 10-1 STARTER MOTOR 10-8 LEFT CRANKCASE COVER 10-2 STARTER / IGNITION PULSE GENERATOR 10-16 FLYWHEEL 10-4 SERVICE INFORMATION GENERAL This section covers the removal and installation of the flywheel and alternator stator. These services can be done with the •...
Page 156: Left Crankcase Cover
ALTERNATOR LEFT CRANKCASE COVER ALTERNATOR 2P IGNITION PULSE CONNECTOR GENERATOR REMOVAL CONNECTOR Remove the left side cover (page 2-3). Disconnect the alternator 2P (White) connector and ignition pulse generator connector. Remove the neutral switch wire from the left crankcase grooves. Remove the choke cable stay bolts (2 nos) and choke cable stay.
Page 157 ALTERNATOR INSTALLATION GASKET Install the new gasket and dowel pins. DOWEL PINS Install the left crankcase cover and tighten the bolt in a crisscross pattern in several steps. BOLTS LEFT CRANKCASE COVER Tighten the choke cable stay bolts (2 nos.) to the specified torque.
Page 158 ALTERNATOR FLYWHEEL FLYWHEEL HOLDER REMOVAL Remove the left crankcase cover (page 10-2). Hold the flywheel with the flywheel holder and remove the flywheel lock nut and washer. TOOL: Flywheel holder 070SRTKSP015 NUT/ WASHER Remove the flywheel using the flywheel puller. FLYWHEEL PULLER TOOL:...
Page 159 ALTERNATOR INSTALLATION NEEDLE BEARING WOODRUFF KEY Apply clean engine oil on the crankshaft. When install the woodruff key, Install the needle bearing and woodruff key. be careful not to damage the key groove and crankshaft. Install the flywheel with the oneway clutch assy., while aligning the woodruff key on the crankshaft.
Page 160: Starter Clutch
ALTERNATOR STARTER CLUTCH DISASSEMBLY Remove the flywheel (page 10-4). Remove the starter driven gear from the flywheel while turning the driven gear counterclockwise. STARTER DRIVEN GEAR Remove the starter clutch bolts while holding the flywheel with a flywheel holder. Tool: Flywheel holder 070SRTKSP015 FLYWHEEL...
Page 161 ALTERNATOR Check the spring for bend or damage. Check the roller for wear or damage. SPRING ROLLAR Check the roller contacting surface of the starter driven gear for abnormal wear or damage. Measure the starter driven gear boss O.D. SERVICE LIMIT: 45.60 mm (1.795 in) STARTER DRIVEN GEAR DRIVEN GEAR...
Page 162: Starter Motor
ALTERNATOR Install the clutch cover and starter clutch assembly to the flywheel, aligning the bolt hole of cover, starter clutch and CLUTCH COVER flywheel. STARTER CLUTCH ASSEMBLY Hold the flywheel using the flywheel holder. TOOL: Flywheel holder 070SRTKSP015 Clean and apply a locking agent to the stater clutch bolts threads.
Page 163 ALTERNATOR Remove the O-ring from the starter motor. O-RING DISASSEMBLY/INSPECTION Remove the starter motor case bolts and O-rings. BOLTS Remove the following: – Front cover assembly SEAL RING – Seal ring INSULATED – Lock washer WASHER – Insulated washer – Shims SHIMS LOCK WASHER FRONT COVER...
Page 164 ALTERNATOR Check the dust seal and needle bearing in the front cover for deterioration, wear or damage. DUST SEAL NEEDLE BEARING Check for continuity between the cable terminal and the insulated brush. There should be continuity. Check for continuity between the cable terminal and rear cover.
Page 165 ALTERNATOR Remove the insulator plates. INSULATOR Remove the following: – Nut NUTS – Washer – Insulators – O-ring BUSHING – Insulator plate – Brush terminal O-RING BRUSH TERMINAL Check the bushing in the rear cover for wear or damage. BUSHING Measure the brush length.
Page 166 ALTERNATOR Inspect the brush spring for excessive wear, fatigue or damage, replace if necessary. BRUSH SPRING Inspects the commutator bars of the armature for Do not use COMMUTATOR BARS discolouration. emery or sand paper on the commutator ARMATURE Check for continuity between pair of commutator bars. There should be continuity.
Page 167 ALTERNATOR ARMATURE SEAL RING INSULATED WASHER LOCK FRONT COVER WASHER O-RINGS SHIMS NUTS SHIMS WASHER INSULATOR O-RING REAR INSULATOR COVER PLATES MOTOR CASE BRUSH TERMINAL SEAL RING SPRING Install the following: – Insulator plate INSULATOR NUTS – Brush terminal – New O-ring –...
Page 168 ALTERNATOR Install the insulator plates. INSULATOR Install the brush holder, washer and tighten the screws with brush wire. SPRINGS Install the springs into the brush holder. BRUSH HOLDER BRUSH WIRE SCREWS/ WASHER Install the shims onto the armature shaft. SHIMS Install the shims properly as noted during removal.
Page 169 ALTERNATOR The coil may be damaged if the magnet pulls the armature against the case. SPRING Install the armature/rear cover into the motor case while Align the rear cover tab with holding the armature tightly to keep the magnet of the case from pulling the armature against it.
Page 170 ALTERNATOR Install the starter motor into the left crankcase cover and While installing STARTER MOTOR RUBBER CAP onto the crankcase . the starter motor CABLE cable, route the Install the mounting bolts with the ground cable, and tighten wire harness the bolts.
Page 171 ALTERNATOR Apply liquid sealant to the wire grommet seating surface, FLANGE BOLTS and install the wire grommet into the groove. Install the wire guide and ignition pulse generator. Apply a locking agent to the three bolt threads. Install the bolts and tighten it to the specified torque. TORQUE: 10 N·m (1.0 kgf·m, 7.3 lbf·ft) IGNITION GROMMET...
Page 172 CRANKCASE/TRANSMISSION/KICKSTARTER COMPONENT LOCATION 64 N.m (6.5 kgf.m, 47 Ibf.ft) 12 N.m (1.2 kgf.m, 9.0 Ibf.ft) 10 N.m (1.0 kgf.m, 7 Ibf.ft) 55 N.m (5.5 kgf.m, 44 Ibf.ft) 11-0...
Page 173 11. CRANKCASE/TRANSMISSION/KICKSTARTER COMPONENT LOCATION 11-0 TRANSMISSION 11-6 SERVICE INFORMATION 11-1 CRANKSHAFT 11-8 CRANKCASE ASSEMBLY 11-17 TROUBLESHOOTING 11-2 KICKSTARTER 11-21 CRANKCASE SEPARATION 11-4 SERVICE INFORMATION GENERAL • The following components must be removed before separating the crankcase: – Engine (page 6-2) –...
Page 174 CRANKCASE/TRANSMISSION/KICKSTARTER TORQUE VALUES THREAD TORQUE ITEM PART NO. REMARKS PAGE NO. DIA. (mm) N·m (kgf·m, lbf·ft) Balancer Shaft Nut (Right crankcase) 90202 – KRM – 840 64 (6.5, 47) Page 11–19 Balancer Shaft Nut (Left crankcase) 94002 – 12200 – 0S Page 11–20 55 (5.5, 44) Push plug bolt...
Page 175 CRANKCASE/TRANSMISSION/KICKSTARTER TOOLS Remover shaft, 12 mm Remover weight Driver 070MCKPLI410 070MCKPLI300 070GD004I100 Remover shaft, 12 mm 070MCKPLI400 Pilot, 12 mm Pilot, 17 mm Pilot, 20 mm 070GD004I130 070GD004I150 070GD004I160 Oil seal remover Fork seal driver Socket wrench steering 070SRTKSP002 070SRTKSP004 070SRTKSP001 Assembly collar Remover head, 17 mm...
Page 176: Crankcase Separation
CRANKCASE/TRANSMISSION/KICKSTARTER CRANKCASE SEPARATION BALANCER GEAR REMOVAL Refer to service information (page 11-1) for removal of necessary parts before disassembling the crankcase. Remove the cam chain tensioner set plate bolts (2 nos.) and tensioner set plate. Remove cam chain tensioner guide. CAM CHAIN SET PLATE BOLT Remove the cam chain.
Page 177 CRANKCASE/TRANSMISSION/KICKSTARTER Remove the balancer weight nut from ACG (left) side. BALANCER BOLT BALANCER GEAR INSPECTION Check the balancer gear for wear or damage. BALANCER GEAR Remove the left crankcase bolts in a criss cross pattern in BOLTS two or three step and remove them. Do not pry Place the crankcase assembly with the right side down.
Page 178 CRANKCASE/TRANSMISSION/KICKSTARTER TRANSMISSION DISASSEMBLY Separate the crankcase halves (page 11-4). Carefully remove the balancer shaft. BALANCER DRIVE SHAFT Pull out the shift fork shafts. SHIFT FORKS SHAFT Remove the shift forks and shift drum. SHIFT FORKS SHAFT SHIFT DRUM Remove the mainshaft and countershaft together. MAINSHAFT Disassemble the mainshaft and countershaft.
Page 179 CRANKCASE/TRANSMISSION/KICKSTARTER INSPECTION GEARS Check the gear dogs, dog holes and teeth for damage of excessive wear. Measure the I.D. of each gear. SERVICE LIMIT: 20.05 mm (0.789 in) 17.05 mm (0.671 in) 20.55 mm (0.809 in) 23.07 mm (0.908 in) 20.07 mm (0.790 in) BUSHING Check the bushings for wear or damage.
Page 180 CRANKCASE/TRANSMISSION/KICKSTARTER SHIFT FORK Check the shift forks for deformation or abnormal wear. Measure each shift fork claw thickness. SERVICE LIMITS: 4.500 mm (0.177 in) Measure I.D. of each fork. SERVICE LIMITS: 10.05 mm (0.396 in) SHIFT FORK SHAFT Check the shift fork shafts for damage and straightness. Measure the shift fork shaft for O.D.
Page 181 CRANKCASE/TRANSMISSION/KICKSTARTER BIG END SIDE CLEARANCE Measure the side clearance of the connecting rod big end with feeler gauge. SERVICE LIMIT: 0.80 mm (0.032 in) BIG END RADIAL CLEARANCE Measure the radial clearance of the connecting rod big end. SERVICE LIMIT: 0.05 mm (0.002 in) TIMING SPROCKET If the timing...
Page 182 CRANKCASE/TRANSMISSION/KICKSTARTER REMOVAL BOLTS/SETTING/ Remove the setting plate bolts and mainshaft bearing STOPPER PLATES MAINSHAFT setting plates from the right crankcase. BEARING Drive out the mainshaft & countershaft bearing from the right crankcase. with following tools. TOOLS: Remover shaft, 17mm 07936-3710330 Remover handle 07936-3710100 Remover weight...
Page 183 CRANKCASE/TRANSMISSION/KICKSTARTER OIL PASSAGES INSPECTION Clean the oil passages of each crankcase using the compressed air. OIL PASSAGE INSTALLATION Lubricate the all bearing with engine oil. ATTACHMENT Drive new bearings into the left crankcase with following DRIVER tools: TOOLS: RIGHT CRANKCASE Mainshaft bearing: PILOT Driver...
Page 184 CRANKCASE/TRANSMISSION/KICKSTARTER Apply locking agent to the threads of the setting plate bolt. Install the setting plates and bolts. BOLTS/SETTING Install the setting plates and bolts. STOPPER PLATES Tighten the bolts to the specified torque. TORQUE: 12 N.m (1.2 kgf. m, 9 Ibf.ft) BEARING REPLACEMENT OF CRANKSHAFT INSPECTION...
Page 185 CRANKCASE/TRANSMISSION/KICKSTARTER Lubricate the all bearings with engine oil. Drive new bearings into the right crankcase with following tools. DRIVER TOOLS: Crankshaft bearing: ATTACHMENT Driver 070GD-001I100 Attachment, 52 x 55 mm 07NAD-P200100 Pilot, 30 mm 07746-0040700 BEARING INSTALLATION Install the crankshaft into the right crankcase. Install the transmission.
Page 186 CRANKCASE/TRANSMISSION/KICKSTARTER MAINSHAFT MAINSHAFT 13 T M4 GEAR : EACH GEAR TEETH (30 T) SET RING : BUSHING AND SPLINE WASHER (20 mm) THRUST WASHER (17 mm) M5 GEAR (24 T) SPLINE WASHER (20 mm) M3 GEAR (20 T) CHAMFERED SIDE M2 GEAR (19 T) SPECIAL WASHER...
Page 187 CRANKCASE/TRANSMISSION/KICKSTARTER COUNTERSHAFT COUNTERSHAFT C5 GEAR (22 T) THRUST WASHER (20 mm) C2 GEAR C2 BUSH SPECIAL WASHER (34 T) (20 mm) (17 mm) COLLAR (20 mm) SET RING SPLINE (20 mm) WASHER (20 mm) C1 BUSHING (20 mm) C1 GEAR (40 T) C4 GEAR THRUST...
Page 188 CRANKCASE/TRANSMISSION/KICKSTARTER If the crankshaft removed, install the crankshaft first (page 11-13). Apply molybdenum oil solution to the shift fork grooves. Apply clean engine oil to the transmission gear teeth. Install the mainshaft and countershaft together into the right crankcase. Be sure to install the three end washers (mainshaft, left only countershaft, both ends.) MAINSHAFT COUNTERSHAFT...
Page 189: Crankcase Assembly
CRANKCASE/TRANSMISSION/KICKSTARTER Apply clean engine oil to the shift fork shafts, and insert SHIFT FORK SHAFTS them through the shift forks into the right crankcase. Rotate the mainshaft by hand to see the gears rotate freely. Assemble the crankcase. Carefully install the balancer shaft aligning with its groove with the groove given in the crankshaft.
Page 190 CRANKCASE/TRANSMISSION/KICKSTARTER Install the dowel pins. DOWEL PINS Do not force Install the left crankcase over the right crankcase. the crankcase halves together, if there is excessive force required, some thing is wrong. Remove the left crankcase and LEFT CRANKCASE check for misaligned parts.
Page 191 CRANKCASE/TRANSMISSION/KICKSTARTER Install the balancer drive gear by aligning the keyway of BALANCER DRIVE GEAR the gear and the crankshaft. Align Install the balancer driven gear by aligning the keyway of BALANCER DRIVEN GEAR the gear and the balancer shaft. Align Align the punch marks on the balancer drive gear and Align balancer driven gear for arranging the final timing for the...
Page 192 CRANKCASE/TRANSMISSION/KICKSTARTER Install the second weight ‘B’ by aligning the spline on the WEIGHT ‘B’ weight with the spline on the balancer shaft. Tighten the washer and nut to the specified torque. TORQUE : 55 N.m (5.5 kgf.m, 44 lbf.ft) Align When Apply molybdenum oil solution to the push plug.
Page 193 CRANKCASE/TRANSMISSION/KICKSTARTER KICKSTARTER SNAP RING REMOVAL Remove the right hand side crankcase (page 11-4). Remove the snap ring and spindle retainer. KICK STOPPER Pullout the kickstarter assembly to unhook the return spring LOCK WASHER RETURN SPRING from the crankcase. DISASSEMBLY RETAINER SPRING Remove the following: –...
Page 194 CRANKCASE/TRANSMISSION/KICKSTARTER RETAINER KICK SPINDLE SNAP RING KICKSTARTER SPINDLE KICKSTARTER WASHER DRIVE GEAR SNAP RING RATCHET STARTER DRIVE SNAP RING RETURN SPRING COLLAR WASHERS Apply molybdenum oil solution to the kickstarter drive gear inner surface, and install it. SNAP RING Install the washer and snap ring. WASHER DRIVE GEAR Apply molybdenum oil solution to the starter ratchet inner...
Page 195 CRANKCASE/TRANSMISSION/KICKSTARTER Hook the return spring to the hole of the kickstarter spindle, RETURN SPRING and there install the collar by aligning its cut-out with the spring. Install the lock washer, and press it. Install the lock washer in the groove of the kickstarter SPINDLE spindle.
Page 196 FRONT WHEEL/SUSPENSION/STEERING COMPONENT LOCATION 74 N.m (7.5 kgf.m, 55 Ibf.ft) 22 N.m (2.2 kgf.m, 16 Ibf.ft) 22 N.m (2.2 kgf.m, 16 Ibf.ft) 32 N.m (3.3 kgf.m, 24 Ibf.ft) 59 N.m (6.0 kgf.m, 44 Ibf.ft) 12-0...
Page 197 – 0.3 (0.01) Spring free length 390.3 (15.366) 363 (14.291) Pipe runout – 0.20 (0.008) Honda Ultra Cushion Oil No.10 (BAHA- Recommended fluid – Fork RAT SS-8) Fluid level 144 mm (5.66 in) – 310 cm³ ± 2.5 cm³ (11.0 ± 0.08 USoz, Fluid capacity –...
Page 198 FRONT WHEEL/SUSPENSION/STEERING TOOLS Attachment, 37x40 mm Attachment, 42x47 mm Pilot, 15 mm 070GD002I150 07746-0010300 07746-0040300 Driver Bearing remover shaft Bearing remover head, 15 mm 07749-0010000 07746-0050100 07746-0050400 Piston remover front cushion Fork seal driver Socket wrench steering 070SRTKSP003 070SRTKSP001 070SRTKSP004 Ball race remover Steering cone installer (Frame) T-stem cone remover...
Page 199 FRONT WHEEL/SUSPENSION/STEERING Steering cone installer 070SRTKSP006 TROUBLESHOOTING Hard steering • Steering stem adjusting nut too tight • Damaged steering head bearing/race Insufficient tire pressure • • Faulty tire Steers to one side or does not track straight • Bent fork •...
Page 200 FRONT WHEEL/SUSPENSION/STEERING HANDLEBAR REARVIEW MIRROR REMOVAL Remove the wire bands and rear view mirror. WIRE BAND Disconnect the front brake light switch connectors. MASTER CYLINDER Remove the bolts, holder and brake master cylinder. BOLTS HOLDER CONNECTORS Remove the starter switch housing screws and remove the HOLDER housing from the handle bar.
Page 201 FRONT WHEEL/SUSPENSION/STEERING Disconnect the throttle cable from the throttle pipe, then THROTTLE GRIP remove the handlebar. HANDLEBAR Remove the clutch wire connector. CLUTCH WIRE CONNECTOR Remove the screws and separate the left handlebar switch LEFT HANDLEBAR housing. SWITCH HOUSING SCREWS Pull out the handle bar grip with twisting movement in outward direction.
Page 202 Tighten the clutch lever bracket bolt. Align BOLT Allow the Apply Honda Bond A or its equivalent to the inside surface adhesive to dry of the grips and to the clean surface of the left handlebar. for 1 hour before Wait 3-5 minutes and install the grip.
Page 203 FRONT WHEEL/SUSPENSION/STEERING Install the left handlebar switch housing while aligning the locating pin in the housing with the hole in the handlebar. Align Install the screw and tighten the forward screw first, then the rear screw. SCREWS Connect the clutch wire connector. CLUTCH WIRE CONNECTOR Apply grease to the throttle pipe rotating area of the...
Page 204 FRONT WHEEL/SUSPENSION/STEERING Apply silicon grease to the throttle cable end. THROTTLE CABLE Connect the throttle cable end to the handlebar. HANDLEBAR Install the right handlebar switch housing, while aligning its locating pin with the hole on the handlebar. Install and tighten the throttle housing screws. SCREWS Align Install the starter switch housing on the handlebar while...
Page 205 FRONT WHEEL/SUSPENSION/STEERING Install the master cylinder bracket & holder with “UP” mark MASTER CYLINDER facing up. “UP” MARK Aligning the mating surface of the bracket holder with the punch mark on the handle bar. Tighten the holder bolt to the specified torque. TORQUE: 9 N.m (0.9 kgf.m, 6.6 Ibf.ft) BOLTS HOLDER...
Page 206: Wheel Bearing
FRONT WHEEL/SUSPENSION/STEERING Do not operate Loosen the front axle pinch bolt. the front brake Remove the front axle and front wheel. lever after the front wheel is removed. FRONT AXLE FRONT AXLE PINCH BOLT Remove the side collar from both side of front wheel. SIDE COLLAR INSPECTION AXLE...
Page 207 FRONT WHEEL/SUSPENSION/STEERING WHEEL RIM WHEEL RIM DISC RUNOUT Check the wheel rim runout by placing the wheel in a turning stand. Turn the wheel by hand and read the runout using a dial indicator. Actual runout is 1/2 the total indicator reading. SERVICE LIMITS: Axial: 0.3 mm (0.01 in) Radial: 0.3 mm (0.01 in)
Page 208 FRONT WHEEL/SUSPENSION/STEERING BRAKE DISC DUST SEAL BEARING BEARING ALLEN BOLT 42 N.m (4.3 kgf.m, 31 lbf.ft) DUST SEAL SIDE COLLAR SIDE COLLAR DISTANCE COLLAR Never install the Pack all bearing cavities with grease. old bearing once Drive in a new left bearing squarely with its sealed side the bearing has DRIVER facing up until it is fully seated.
Page 209 FRONT WHEEL/SUSPENSION/STEERING INSTALLATION Install the side collars both side onto the wheel hub. SIDE COLLAR Be careful not Install the front wheel between the fork legs so that the to damage the brake disc is positioned between the pads. pads. Install the front axle from left side.
Page 210 FRONT WHEEL/SUSPENSION/STEERING Tighten the front axle pinch bolt to the specified torque. TORQUE: 22 N·m (2.2 kgf·m, 16 lbf·ft) Check the brake operation. FRONT AXLE PINCH BOLT FORK REMOVAL Remove the following: – Front wheel (page 12-9) – Front fender (page 2-5) FRONT FENDOR Do not suspend...
Page 211 FRONT WHEEL/SUSPENSION/STEERING DISASSEMBLY DUST SEAL Remove the dust seal and stopper ring. Be careful not to STOPPER RING scratch the fork pipe. Remove the following: SPRING COLLAR FORK CAP – Fork bolt – O-ring – Spring collar – Spring seat O-RING SPRING SEAT Remove the fork spring.
Page 212 FRONT WHEEL/SUSPENSION/STEERING Do not Set the piston remover front cushion in a vise with a piece PISTON REMOVER SOCKET BOLT/ overtighten of wood or soft jaws to avoid damage. FRONT CUSHION SEALING WASHER the vise on the piston remover front cushion. If the fork piston Remove the fork socket bolt and sealing washer.
Page 213 FRONT WHEEL/SUSPENSION/STEERING INSPECTION FORK SPRING Check the fork spring for fatigue or damage. Measure the fork spring free length. STANDARD: 363 mm (14.291 in) FORK PIPE/SLIDER FORK PIPE Check the fork pipe and slider for score marks, scratches, or excessive or abnormal wear. FORK SLIDER Place the fork pipe on V-blocks.
Page 214: Fork Assembly
FRONT WHEEL/SUSPENSION/STEERING GUIDE BUSHING/SLIDER BUSHING/BACK-UP RING SLIDER AND GUIDE BUSH Visually inspect the slider and guide bushings. Replace the bushings if there is excessive scoring or BACK-UP RING scratching, or if the teflon is worn so the copper surface appears on more than 3/4 of the entire surface. Check the back-up ring;...
Page 215 FRONT WHEEL/SUSPENSION/STEERING Do not open Install the slider bushing being careful not to damage the OIL SEAL the bushing coating of the bushing, if it has been removed. slit more than Remove the burrs from the bushing mating surface, being necessary.
Page 216 Install the dust seal. Pour the specified amount of recommended fork fluid into the fork pipe. RECOMMENDED FORK FLUID: Honda ULTRA CUSHION OIL No. 10 or equivalent FORK FLUID CAPACITY: 144 mm 310 ± 2.5 cm (11.0 ± 0.08 US oz, 11.5 ± 0.09 UK oz) (5.66 in)
Page 217 FRONT WHEEL/SUSPENSION/STEERING Pull the fork pipe up and install the fork spring with the tightly wound coil side facing down. FORK SPRING FORK PIPE DOWN Install the spring seat and spring collar. SPRING COLLAR SPRING SEAT Apply fork fluid to a new O-ring and install it onto the fork Tighten the FORK BOLT fork bolt after...
Page 218 FRONT WHEEL/SUSPENSION/STEERING Tighten the bottom bridge and top bridge pinch bolts to the specified torque. TORQUE: Bottom bridge pinch bolt: 32 N·m (3.2 kgf·m, 23 lbf·ft) BOTTOM BRIDGE BOLTS Top bridge fork socket bolt: 27 N·m (2.8 kgf·m, 20 lbf·ft) FRONT FORK BOLT If the fork bolt is loosened, tighten the fork bolt to the specified torque.
Page 219 FRONT WHEEL/SUSPENSION/STEERING Remove the steering stem nut, washer and top bridge. STEERING STEM NUT WASHER Loosen the adjusting nut using the special tool. SOCKET WRENCH TOOL: STEERING Socket wrench steering 070SRTKSP004 Hold the steering stem and remove the adjusting nut. STEERING STEM Be careful not to Remove the following top cone race...
Page 220 FRONT WHEEL/SUSPENSION/STEERING BALL RACE REPLACEMENT Remove the top & bottom ball races using the special tool. TOOL: Ball race remover 070SRTKSP005 Install a new top ball race and new bottom ball race using TOP BALL STEERING CONE the special tool. RACE INSTALLER TOOLS:...
Page 221 FRONT WHEEL/SUSPENSION/STEERING STEERING STEM ASSEMBLY 74 N.m (7.5 kgf.m, 55 lbf.ft) STEM NUT ADJUSTING NUT WASHER TOP CONE RACE UPPER STEEL BALLS (18) TOP BALL RACE BOTTOM BALL RACE LOWER STEEL BALLS (18) BOTTOM CONE RACE DUST SEAL STEERING STEM Apply grease properly to bottom cone race &...
Page 222 FRONT WHEEL/SUSPENSION/STEERING Install the adjusting nut and tighten it to the specified torque. ADJUSTING NUT TOOL: Socket wrench steering 070SRTKSP004 TORQUE: 24 N.m (2.4 kgf.m, 17.7 Ibf.ft) SOCKET WRENCH STEERING Turn the steering stem left and right several times. Refer to torque Temporarily loosen the adjusting nut completely, then ADJUSTING NUT retighten the adjusting nut to the specified torque.
Page 223 FRONT WHEEL/SUSPENSION/STEERING Loosen the Install the fork and temporarily tighten the top bridge bolts. bottom pinch STEERING Tighten the steering stem nut to the specified torque. STEM NUT bolts when tighten the stem TORQUE: 74 N.m (7.5 kgf.m, 55 Ibf.ft) nut.
Page 224 REAR WHEEL/SUSPENSION COMPONENT LOCATION 44 N.m (4.4 kgf.m, 33 lbf.ft) 54 N.m (5.4 kgf.m, 40 lbf.ft) 44 N.m (4.4 kgf.m, 33 lbf.ft) 88 N.m (8.8 kgf.m, 65 lbf.ft) 13-0...
Page 225 13. REAR WHEEL/SUSPENSION COMPONENT LOCATION 13-0 DRIVEN FLANGE 13-9 SERVICE INFORMATION 13-1 SHOCK ABSORBER 13-12 TROUBLESHOOTING 13-3 SWINGRAM 13-13 REAR WHEEL 13-4 SERVICE INFORMATION GENERAL Frequent inhalation of brake pad (shoe) dust, regardless of material composition could be hazardous to your health. •...
Page 226 REAR WHEEL/SUSPENSION SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Page NO. Minimum tire thread depth – 2.0 (0.08) Page 3–25 Driver only 175 kPa (1.75 kgf/cm², 25 psi) – Page 3–25 Cold tire pressure Driver and passenger 200 kPa (2.00 kgf/cm², 29 psi) –...
Page 227 REAR WHEEL/SUSPENSION TROUBLESHOOTING Rear wheel wobbling • Bent rim • Worn or damaged wheel bearings Worn or damaged driven flange bearing • • Faulty tire • Worn or damaged swingarm bushings • Bent frame or swingarm • Axle not tightened properly Insufficient tire pressure •...
Page 228 REAR WHEEL/SUSPENSION REAR WHEEL LOCK NUT AXLE NUT DISC TYPE REMOVAL Support the motorcycle on its center stand. Loosen the lock nut, drive chain adjusting nut,and rear axle nut. Push the real wheel forward and derail the drive chain from driven sprocket RIGHT ADJUSTING Remove the rear axle nut, rear axle and adjusting plates.
Page 229 REAR WHEEL/SUSPENSION INSPECTION Before inspection remove the wheel rubber dampers and wheel bearings. RUBBER DAMPERS WHEEL BEARING REMOVAL REMOVER SHAFT Install the remover head into the bearing. From the opposite side, install the bearing remover shaft and drive the bearing out of the wheel hub. BEARING Remove the distance collar and drive out the other bearing.
Page 230 REAR WHEEL/SUSPENSION WHEEL RIM Check the wheel rim runout by placing the wheel in a turning stand. Spin then wheel by hand, and read the runout using a dial indicator. SERVICE LIMITS: Radial: 0.3 mm (0.04 in) Axial: 0.3 mm (.04 in) BRAKE DISC Check the wheel rim runout by placing the wheel in a turning stand.
Page 231 REAR WHEEL/SUSPENSION ASSEMBLY OF DISC BRAKE COLLAR DUST SEAL BEARING AXLE NUT SWINGARM WASHER BEARING DAMPER BOLTS RUBBER DRIVEN SPROCKET REAR DISC ASSEMBLY COLLAR DISTANCE COLLAR SWINGARM WASHER O-RING AXLE BOLT ASSEMBLY OF DRUM BRAKE BEARINGS AXLE NUT BEARING DAMPER SWINGARM RUBBER DRIVEN SPROCKET...
Page 232 REAR WHEEL/SUSPENSION WHEEL BEARING Pack new bearing cavities with grease. Drive in a new left side bearing squarely with the sealed side facing up until it is fully seated. Apply a thin coat of grease to the distance collar and install it.
Page 233 REAR WHEEL/SUSPENSION DRUM TYPE Install the brake panel assembly from the right side of Do not apply wheel hub. grease on the brake drum and Install the driven flange assembly (page 13-11). shoe linings Slide the rear wheel such that the slot given on panel could PROTRUSION align with the protrusion given on swingarm and install the drive chain.
Page 234 REAR WHEEL/SUSPENSION Remove the driven sprocket nuts and driven sprocket. DRIVEN SPROCKET NUTS Check the condition of the driven sprocket teeth. Replace the sprocket if it is worn or damaged. • If the driven sprocket requires replacement inspect the drive chain and drive sprocket. •...
Page 235 REAR WHEEL/SUSPENSION DRIVEN FLANGE ASSEMBLY BEARING OIL SEAL DRIVEN FLANGE STUD BOLT 64 N.m (6.5 kgf.m, 47 lbf.ft) DRIVEN FLANGE BEARING Pack new bearing cavities with grease. Drive in a new bearing squarely until it is fully seated. TOOLS: Driver 070GD-001I100 Attachment.
Page 236: Shock Absorber
REAR WHEEL/SUSPENSION Apply grease to the lip of a new dust seal. DUST SEAL Install the dust seal. Install the collar. Install the rear wheel (page 13-8). SIDE COLLAR SHOCK ABSORBER SHOCK ABSORBER REMOVAL Place the motorcycle on its center stand. Remove the following: –...
Page 237 REAR WHEEL/SUSPENSION INSTALLATION Shock absorber MOUNTING NUT shall be installed Install the shock absorber. with adjust label BOLT right side. Install the upper mounting nut and bolt. TORQUE: 44 N.m (4.5 kgf.m, 33 Ibf. ft) Install the lower bolt and nut. SHOCK ABSORBER Tighten the lower mounting nut to the specified torque.
Page 238 REAR WHEEL/SUSPENSION Carefully hold the brake calliper slider. Remove the shock absorber lower mounting nut and bolt. SHOCK ABSORBER BOLT Remove the swingram pivot nut. Remove the swingarm pivot bolt and swingarm. PIVOT BOLT PIVOT NUT DISASSEMBLY Remove the chain slider while releasing the bosses DUST (3 nos.) from the tabs.
Page 239 REAR WHEEL/SUSPENSION Check the chain slider for wear or damage. The chain slider must be replaced if it is worn to the wear limit cutout. Remove the dust seal. DUST SEAL Remove the collars. COLLARS Inspect the swingarm dust seal, collar. DUST SEAL Check the swingarm for any damage.
Page 240 REAR WHEEL/SUSPENSION Remove the needle bearings from the swingarm. TOOLS: Bearing remover set, 20 mm 07936-3710600 Remover handle 07936-3710100 BEARING Remover weight 070MC-KPLI300 SWINGARM ASSEMBLY DUST SEAL SWINGRAM COLLAR NEEDLE BEARING DUST SEAL CHAIN SLIDER COLLAR NEEDLE BEARING DUST SEAL Apply grease to the new needle bearings.
Page 241 REAR WHEEL/SUSPENSION Apply grease to the collars surface and install them into swing arm pivots. COLLARS Apply grease to the dust seal. DUST SEAL Install the dust seal. Install the chain slider while aligning the bosses (3 nos.) with tabs. DUST SEAL BOSSES...
Page 242 REAR WHEEL/SUSPENSION Install the shock absorber lower mounting bolt and nut. SHOCK ABSORBER Tighten the nut to the specified Torque. TORQUE: 44 N.m (4.5 kgf.m, 33 Ibf.ft) BOLT Install the rear brake caliper hose and tighten the bolts (2 nos.). REAR BRAKE BOLTS HOSE...
Page 243 MEMO...
Page 244 BRAKE SYSTEM COMPONENT LOCATION 9 N·m (0.9 kgf·m, 6 lbf·ft) CBS FRONT BRAKE: 34 N·m (3.5 kgf·m, 25 lbf·ft) Calliper bleeder valve 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) CBS REAR BRAKE:...
Page 245 14. BRAKE SYSTEM COMPONENT LOCATION 14-0 FRONT BRAKE CALIPER 14-14 SERVICE INFORMATION 14-1 REAR BRAKE 14-19 TROUBLESHOOTING 14-2 REAR MASTER CYLINDER(CBS ONLY) 14-21 BRAKE FLUID REPLACEMENT/ REAR BRAKE CALIPER 14-24 AIR BLEEDING 14-3 BRAKE PEDAL 14-27 BRAKE PAD/DISK 14-7 REAR DRUM BRAKE 14-30 FRONT MASTER CYLINDER 14-9...
Page 246 BRAKE SYSTEM TORQUE VALUES THREAD TORQUE ITEM PART NO. REMARKS PAGE NO. DIA. (mm) N·m (kgf·m, lbf·ft) Caliper bleeder valve 43352 – 568 – 0030 5.4 (0.55, 4) Page 14–5 FR Master cylinder cap 93600 – 04012 – 1G 1.5 (0.15, 1.1) Page 14–6 RR Master cylinder cap 43516 –...
Page 247 BRAKE SYSTEM BRAKE FLUID LINE (CBS) FRONT MASTER CYLINDER BRAKE HOSE CONNECTOR FRONT BRAKE CALIPER REAR BRAKE CALIPER DELAY VALVE BRAKE HOSE CONNECTOR REAR MASTER CYLINDER BRAKE FLUID REPLACEMENT/ SET PLATE/ AIR BLEEDING DIAPHRAGM SCREWS Cover the BRAKE FLUID DRAINING painted parts FRONT DISC BRAKE: and the...
Page 248: Rear Brake Line
BRAKE SYSTEM COMBI BRAKE SYSTEM: SET PLATE/ DIAPHRAGM Do not allow Combine brake system (page 14-3) consist of two individual foreign material SCREWS hydraulic circuit, the front brake line and CBS line. to enter the • Front brake line - Draining procedure same as front system when brake non CBS filling the...
Page 249 BRAKE SYSTEM If a brake bleeder is not available then use the following NON CBS BLEED BLEED steps: HOSE HOSE Do not mix Fill the reservoir with DOT 3 or DOT 4 brake fluid from a different types of sealed container. fluid.
Page 250 BRAKE SYSTEM If a brake bleeder is not available then use the following steps: Connect the bleed hose to the rear calliper bleed valve. Add the brake fluid to the rear reservoir if the fluid level is below the lower mark. STEP 1: Pressurize the system with the rear brake pedal until lever resistance is felt.
Page 251 BRAKE SYSTEM BRAKE PAD/DISC DISC FRONT BRAKE PAD REPLACEMENT (CBS AND DISC) Always replace Push the caliper pistons all the way in to facilitate installation the brake pads of new brake pads (giving some space). in pairs to NOTE: assure even Check the brake fluid level in the brake master cylinder disc pressure.
Page 252 BRAKE SYSTEM Be careful not to Install the new brake pad into the caliper. DISC apply grease on brake pads. BRAKE PAD Lubricate the pad pin with silicone grease before installation. O- RING PAD PIN Install the brake pad pin by pushing the pads against the DISC pad spring to align the pad pin holes in the pads and caliper.
Page 253: Front Master Cylinder
BRAKE SYSTEM Check the brake disc warpage using a dial indicator. SERVICE LIMIT: 0.10 mm (0.004 in) Check the wheel bearings for excessive play, if the warpage exceeds the service limit. Replace the brake disc if the wheel bearings are normal. FRONT MASTER CYLINDER BRAKE SEALING...
Page 254 BRAKE SYSTEM Remove the screw and brake light switch. BRAKE LIGHT SWITCH SCREW Remove the boot. Remove the snap ring from the master cylinder body using snap ring pliers. SNAP RING BOOT Remove the master piston and spring from the master MASTER CYLINDER cylinder.
Page 255 BRAKE SYSTEM INSPECTION Check the master piston for scoring, scratches or damage. Measure the master piston O.D. SERVICE LIMIT: DISC - 12.657 mm (0.4978 in) Keep the pis- Check the master cylinder for scoring, scratches or ton, spring, snap damage. ring and boot as Measure the master cylinder I.D.
Page 256 BRAKE SYSTEM INSTALLATION MASTER CYLINDER Apply clean brake fluid to the master piston. Install the spring onto the piston end, and install it into the SPRING master cylinder. MASTER PISTON Be certain the Install the snap ring into the groove in the master cylinder. snap ring is firmly seated in the groove...
Page 257 BRAKE SYSTEM Install and tighten the brake light switch screw to the specified torque. BRAKE LIGHT SWITCH TORQUE: 1.2 N·m (0.1 kgf·m, 0.9 lbf·ft) SCREW Apply grease to the brake lever pivot bolt rotating surface. Install the brake lever to the master cylinder. Install and tighten the pivot bolt to the specified torque.
Page 258: Front Brake Caliper
BRAKE SYSTEM FRONT BRAKE CALIPER CBS FRONT BRAKE REMOVAL BOLTS Drain the brake fluid from the hydraulic system (page 14-3). Remove the brake pads (page 14-7). OIL BOLT Remove the brake hose by removing the oil bolt and sealing washer. Remove the brake caliper mounting bolts and brake caliper.
Page 259 BRAKE SYSTEM INSPECTION CALIPER CALIPER CALIPER CYLINDER B CYLINDER A CYLINDER B Check the caliper cylinder for scoring, scratches or damage. Measure the each caliper cylinder I.D. SERVICE LIMIT: Caliper Cylinder A: 22.710 mm (0.8941 in) Caliper Cylinder B: 25.460 mm (1.0023 in) Check the caliper piston for scoring, scratches or damage.
Page 260 BRAKE SYSTEM ASSEMBLY PISTON Apply clean brake fluid to new piston and dust seals, and SEAL DUST SEAL install them into the seal grooves in the caliper cylinder. Apply clean brake fluid to the caliper pistons, and install them into the caliper cylinders with the opening side toward the pads CALIPER PISTONS...
Page 261 BRAKE SYSTEM DISASSEMBLY CALIPER BODY CALIPER BRACKET Remove the caliper bracket from the caliper body. Remove the pad spring and bracket pin boot from the PAD SPRING caliper body. If the bracket pin boot is hard or deteriorated, replace it with a new one.
Page 262 BRAKE SYSTEM FRONT BRAKE (NON CBS) ASSEMBLY CALIPER PIN BOOTS DUST SEAL CALIPER CALIPER PISTON BRACKET PISTON SEAL BLEED VALVE BRAKE CALIPER SLIDE PIN CALIPER BODY STOPPER RING PAD PIN PAD SPRING BRAKE PADS INSTALLATION DUST SEAL Apply clean brake fluid to new piston and dust seals, and PISTON SEAL install them into the seal grooves in the caliper cylinder.
Page 263 BRAKE SYSTEM INSTALLATION Install the brake caliper to the right fork leg so that the disc is positioned between the pads. Be careful not Install and tighten new brake caliper mounting bolts to the to damage the specified torque. pads. TORQUE: 30 N·m (3.1 kgf·m, 22 lbf·ft) BRAKE BOLTS...
Page 264 BRAKE SYSTEM INSTALLATION Install new brake pads so that their ends rest on the caliper bracket properly. BRAKE PAD Install new O-ring on to the pad pin groove and apply silicone grease O- RING PAD PIN Install the brake pad pin by pushing the pads against the pad spring to align the pad pin holes in the pads and caliper.
Page 265 BRAKE SYSTEM Check the wheel bearings for excessive play, if the warpage exceeds the service limit. Replace the brake disc if the wheel bearings are normal. REAR MASTER CYLINDER (CBS ONLY) JOINT HOSE OIL BOLT REMOVAL Support the motorcycle on its center stand. Drain the brake fluid from the hydraulic system (page 14-3).
Page 266 BRAKE SYSTEM Remove the push rod assembly, master piston and spring. PUSH ROD ASSEMBLY Clean the inside of the cylinder with clean brake fluid. MASTER PISTON SPRING INSPECTION Check the piston boot, primary cup and secondary cup for fatigue or damage. Check the master cylinder and piston for abnormal scratches.
Page 267: Brake Pedal Height
BRAKE SYSTEM ASSEMBLY PUSH ROD ASSEMBLY • Keep the piston, cups, spring, snap ring and boot as a set, do not substitute individual. Coat new piston cups and piston with clean brake fluid before assembly. Install the spring to the master piston. Install the spring and master piston assembly into the master cylinder.
Page 268: Rear Brake Caliper
BRAKE SYSTEM Install the brake rod joint on brake pedal by installing joint pin and split pin. Install right side step cover and right side cover. SPLIT PIN JOINT PIN REAR BRAKE PEDAL REAR BRAKE CALIPER OIL BOLT REMOVAL Drain the brake fluid from the rear brake hydraulic system (page 14-3).
Page 269 BRAKE SYSTEM Do not bring Lightly apply compressed air to the fluid inlet to get the the air nozzle piston out. too close to Place the shop rag under the caliper to cushion the piston the inlet or the when it is expelled. pistons may be forced out with Use the air in short spurts.
Page 270 BRAKE SYSTEM REAR BRAKE CALIPER ASSEMBLY DUST SEAL CALIPER PISTON CALIPER BRACKET PISTON SEAL BOOT BRAKE CALIPER SLIDE PIN CALIPER BODY BOOT O-RING PAD PIN PAD SPRING BLEEDER BLEEDER CAP SCREW PLUG PIN Coat the new piston seal and dust seal with clean brake fluid and install them in the seal grooves of the caliper.
Page 271 BRAKE SYSTEM Check the pad spring for damage and replace it if PAD SPRING necessary. Install the pad spring onto the caliper body. BRACKET INSTALLATION OIL BOLT Lubricate the Install the rear brake caliper bracket assembly onto the pad pin with swingarm by aligning the bracket slot with the boss on the swingarm.
Page 272 BRAKE SYSTEM INSTALLATION BRAKE PEDAL HOLDER SHAFT Align the brake pedal with holder shaft BRAKE PEDAL ALIGN Hook the rear brake pedal spring. Hook the rear brake light switch return spring. REAR BRAKE LIGHT SPRING Hook the cotter pin from pin D joint and brake pad holder shaft.
Page 273 BRAKE SYSTEM Remove the split pin, washer and brake pedal from the right step holder. WASHER BRAKE PEDAL SPLIT PIN RIGHT STEP HOLDER Remove the split pin and joint pin to separate brake pedal BRAKE PEDAL and brake rod. JOINT PIN BRAKE ROD SPLIT PIN INSTALLATION...
Page 274 BRAKE SYSTEM Install the washer and new split pin. WASHER BRAKE PEDAL SPLIT PIN RIGHT STEP HOLDER Route the brake light stop switch with spring and install the BRAKE LIGHT switch spring to the brake pedal. STOP SWITCH SWING RIGHT STEP ARM BOLT HOLDER BOLT...
Page 275 BRAKE SYSTEM REAR DRUM BRAKE ASSEMBLY SPRINGS BRAKE PANEL INDICATOR PLATE BRAKE SHOES 10 N·m (1.0 kgf·m, 7 lbf·ft) FELT SEAL BRAKE CAM BRAKE ARM BOLT DISASSEMBLY Expand the brake shoes and remove them from the brake Do not apply panel.
Page 276 BRAKE SYSTEM Remove the indicator plate, dust seal and brake cam. INDICATOR PLATE BRAKE CAM FELT SEAL Apply grease to the brake cam sliding surface. BRAKE CAM Install the brake cam to the brake panel. BRAKE PANEL Apply gear oil to a new dust seal, and install it onto the BRAKE PANEL brake panel.
Page 277 BRAKE SYSTEM If the brake Apply grease to the anchor pin and brake cam shoe BRAKE CAM shoes are contacting area. reused, the Assemble the brake shoes and springs as shown. shoes and springs must be Install the shoe assembly onto the brake panel. placed back in Wipe any excess grease off the brake cam and anchor pin.
Page 278 BATTERY/CHARGING SYSTEM COMPONENT LOCATION LIGHTING SWITCH CDI UNIT FUSE ALTERNATOR BATTERY REGULATOR/RECTIFIER SYSTEM DIAGRAM FUSE (20A) TO LIGHTING CIRCUIT ALTERNATOR 4P BLACK W : White Y : Yellow BATTERY R : Red REGULATOR/ G : Green RECTIFIER B : Black 15-0...
Page 279: Battery Testing
15. BATTERY/CHARGING SYSTEM COMPONENT LOCATION 15-0 BATTERY CHARGING 15-5 SYSTEM DIAGRAM 15-0 INDICATION TABLE FOR MF BATTERY CHARGER 15-7 SERVICE INFORMATION 15-1 CHARGING SYSTEM INSPECTION 15-7 TROUBLESHOOTING 15-2 ALTERNATOR CHARGING COIL 15-8 BATTERY 15-3 REGULATOR/RECTIFIER 15-9 BATTERY TESTING PROCEDURE 15-3 SERVICE INFORMATION GENERAL The battery gives off explosive gases;...
Page 280 BATTERY/CHARGING SYSTEM SPECIFICATIONS ITEM SPECIFICATION Page NO. 12 V – 4 Ah Page 15–3 Capacity Current leakage 0.02mA max Page 15–7 Battery Fully charged 12.5 - 13.0 V Page 15–3 Below 12.4 V Page 15–3 Needs charging 0.14kW / 5000 min-1(rpm) Page 15–8 Capacity Alternator...
Page 281 BATTERY/CHARGING SYSTEM BATTERY POSITIVE NEGATIVE (+) CABLE (-) CABLE VOLTAGE INSPECTION Remove the left side cover (page 2-3). Measure the battery voltage using a commercially available FBT 50 battery tester. VOLTAGE (20°C/68°F): Fully charged: More than 12.4 V Under charged: Below 12.4 V BATTERY If the battery voltage is below 12.4 V, charge the battery.
Page 282 BATTERY/CHARGING SYSTEM On connecting probes, the screen displays battery pin number. Use yellow arrow buttons to select the correct pin number. According to the reference table given on page (15-3). To check voltage press “V” button. VOLTAGE (20°C/68°F): Fully charged: More than 12.4 V Under charged: Below 12.4 V...
Page 283: Battery Charging
BATTERY/CHARGING SYSTEM BATTERY TEST RESULT RESULT – 1 Result indicator shows “Green light” with “OK”. This means battery is healthy ready to be used. RESULT – 2 Result indicator shows “Orange light” with “LOW”. This means battery is weak. Battery needs bench charging. RESULT –...
Page 284 BATTERY/CHARGING SYSTEM Avoid direct Connect charger red probe to positive and black to negative terminal. contact of battery with ground, use rubber mat or wodden block below the battery. Select the “New Battery” mode or “Used Battery” mode by the selector switch based on condition of the battery (New or Used) and switch on the charger.
Page 285 BATTERY/CHARGING SYSTEM INDICATION TABLE FOR MF BATTERY CHARGER SYSTEM INSPECTION NEGATIVE (–) CONNECTOR CURRENT LEAKAGE INSPECTION (BATTERY) Remove the left side cover (page 2-3). Turn the ignition switch “OFF”, and disconnect the negative (–) connector. Connect the ammeter (+) probe to the wire harness negative (–) connector and ammeter (–) probe to the battery negative (–) connector.
Page 286: Alternator Charging Coil
BATTERY/CHARGING SYSTEM CHARGING VOLTAGE INSPECTION POSITIVE (+) NEGATIVE (–) Remove the left side cover (page 2-3). CONNECTOR CONNECTOR Be sure the battery is in good condition before performing Reference (–) this test. engine oil temperature: Warm up the engine to normal operating temperature and –...
Page 287 BATTERY/CHARGING SYSTEM REGULATOR/RECTIFIER SYSTEM INSPECTION Remove the right side cover(page 2-3). (–) Disconnect the regulator/rectifier connector, and check it for loose contacts or corroded terminals. If the charging voltage reading (page 15-4) is out of the specification, check the following at the wire harness side connector: Specification Item...
Page 288 IGNITION SYSTEM COMPONENT LOCATION IGNITION SWITCH IGNITION COIL FUSE SPARK PLUG BATTERY SYSTEM DIAGRAM 16-0...
Page 289: Ignition System
16. IGNITION SYSTEM COMPONENT LOCATION 16-0 IGNITION TIMING 16-5 SYSTEM DIAGRAM 16-0 IGNITION COIL 16-6 SERVICE INFORMATION 16-1 CAPACITIVE DISCHARGE IGNITION 16-6 TROUBLESHOOTING 16-2 THROTTLE POSITION SENSOR 16-7 IGNITION SYSTEM INSPECTION 16-3 SERVICE INFORMATION GENERAL The CDI may be damaged if dropped. Also if the connector is disconnected when current is flowing, the excessive voltage may •...
Page 290 IGNITION SYSTEM TROUBLESHOOTING • Inspect the following before diagnosing the system. – Faulty spark plug – Loose spark plug cap or spark plug wire connections – Water got into the spark plug cap (Leaking the ignition coil secondary voltage) No spark at spark plug Unusual condition Probable cause (check in numerical order) The multimeter impedance is too low;...
Page 291: Ignition System Inspection
IGNITION SYSTEM IGNITION SYSTEM INSPECTION • If there is no spark at the plug, check all connections for loose or poor contact before measuring the peak voltage. • Use a recommended digital multimeter or commercially available digital multimeter with an impedance of 10 MΩ/DCV.
Page 292 IGNITION SYSTEM WIRE CONNECTOR IGNITION COIL Remove the right side cover (page 2-3). With the ignition coil primary wire connected, connect the peak voltage tester or adaptor probes to the ignition coil primary terminal and body ground. TOOL: Imrie diagnostic tester (model 625) or Peak voltage adaptor: 07HGJ-0020100 With commercially available digital multimeter (impedance 10 MΩ/DCV minimum)
Page 293 IGNITION SYSTEM Remove the right side cover (page 2-3). IGNITION COIL Disconnect the ignition pulse generator connector. (Blue/ Yellow) and connect the tester or adaptor probes to the ignition pulse generator side connector and body ground. In the same manner as at the CDI connector, measure the peak voltage and compare it to the voltage measured at the CDI connector.
Page 294: Ignition Coil
IGNITION SYSTEM Coat a new O-ring with engine oil and install it onto the timing hole cap. TIMING HOLE CAP Install and tighten the timing hole cap to the specified torque. CRANCKCASE CAP TORQUE:10 N·m (1.0 kgf·m, 7 lbf·ft) O-RING IGNITION COIL WIRE CONNECTOR IGNITION COIL...
Page 295 IGNITION SYSTEM THROTTLE POSITION SENSOR THROTTLE POSITION SENSOR 3P CONNECTOR INSPECTION INPUT VOLTAGE Remove the left side cover (page 2-3). Remove the rubber boot. Disconnect the throttle position sensor 3P Grey connector from carburetor assembly. Turn the ignition switch “ON”. THROTTLE POSITION Check the following at the wiring harness side connector: SENSOR RUBBER BOOT...
Page 296 IGNITION SYSTEM REMOVAL/INSTALLATION SCREW Remove the left side cover (page 2-3). Remove the rubber boot. Disconnect the throttle position sensor 3P Grey connector. Remove the carburetor (page 5-6). Remove the screw and throttle position sensor. THROTTLE POSITION SENSOR THROTTLE POSITION 3P CONNECTOR SENSOR RUBBER BOOT Install the throttle position sensor while aligning the groove...
Page 297 IGNITION SYSTEM Connect the Remove the left side cover (page 2-3). positive terminal Remove the fuel tank (page 2-3). first and then the negative Disconnect the ignition pulse generator wire connector terminal. (page 10-16). Connect the positive terminal first and then the negative terminal.
Page 298 IGNITION SYSTEM Complete each Turn the throttle grip to the fully opened position, the step within 8 tachometer should indicate the 4,000 r/min. TACHOMETER seconds. THROTTLE 4000 r/min GRIP Complete each Turn the throttle grip to the fully closed position, the step within 8 tachometer should indicate the 5,000 r/min.
Page 299 MEMO...
Page 300 LIGHTS/METERS/SWITCHES COMPONENT LOCATION COMBINATION METER WINKER RELAY IGNITION SWITCH HEADLIGHT FRONT BRAKE SWITCH LIGHT SWITCH FUEL LEVEL SENSOR PASSING RELAY HORN SPARK PLUG NEUTRAL SWITCH REAR BRAKE LIGHT SWITCH SYSTEM DIAGRAM 17-0...
Page 301 17. LIGHTS/METERS/SWITCHES COMPONENT LOCATION 17-0 COMBINATION SWITCH 17-10 SYSTEM DIAGRAM 17-0 HANDLEBAR SWITCHES 17-11 SERVICE INFORMATION 17-1 LEFT HANDLEBAR SWITCH 17-11 HEADLIGHT 17-2 BRAKE LIGHT SWITCH 17-12 BRAKE /TAIL LIGHT 17-3 NEUTRAL SWITCH 17-12 TURN SIGNAL LIGHTS 17-4 FUEL GAUGE/FUEL LEVEL SENSOR 17-14 COMBINATION METER 17-5...
Page 302: Bulb Replacement
LIGHTS/METERS/SWITCHES HEADLIGHT BULB REPLACEMENT Remove the front cowl (page 2-2). Disconnect the headlight connector. CONNECTOR Remove the dust cover. Avoid touching halogen MARK Remove the bulb retainer. headlight bulb. DUST COVER Remove the headlight bulb. Finger prints can create hot Install the new bulb while aligning the tabs of the bulb with spots that cause the slots of the headlight unit.
Page 303 LIGHTS/METERS/SWITCHES HEADLIGHT UNIT REMOVAL/INSTALLATION Remove the headlight adjusting bolt. ADJUSTING BOLT Remove the front cowl (page 2-2). CLIPS Disconnect the headlight connector. Remove the clips and headlight unit. Installation is in the reverse order of removal. Adjust the headlight beam vertically (page 3-21) CONNECTOR BRAKE/TAIL LIGHT BRAKE/TAIL LIGHT...
Page 304: Turn Signal Lights
LIGHTS/METERS/SWITCHES TURN SIGNAL LIGHTS BULB BULB REPLACEMENT Remove the screw and remove signal light lens. Push the bulb in turn it counterclockwise and remove it. Replace the bulb with a new one. Installation is in the reverse order of removal. LENS SCREW REMOVAL/INSTALLATION...
Page 305: Combination Meter
LIGHTS/METERS/SWITCHES COMBINATION METER POWER/GROUND LINE INSPECTION If any indication in the combination meter is abnormal, check the following item. Remove the front cowl (page 2-2). Remove the dust cover. Disconnect the combination meter 16P (Gray) connector. Check the following at the wire harness side connector terminals of the combination meter.
Page 306 LIGHTS/METERS/SWITCHES REMOVAL/ INSTALLATION Remove front cowl (page 2-2). Remove the dust cover. Disconnect the combination meter Grey 16P connector assembly. TORQUE: 4.0 N.m (0.4 kgf.m, 2.9 lbf.ft) 16P CONNECTOR DUST COVER Remove the screws (3 nos.) and washers. Remove the combination meter assembly from front cowl stay.
Page 307 LIGHTS/METERS/SWITCHES SPEEDOMETER VS SENSOR SYSTEM INSPECTION Check the combination meter functions properly. If they do not function, perform the power and ground line inspection of the combination meter (page 17-5). Remove the dust cover. Check the connection/connector for correct fitment. 16P CONNECTOR DUST COVER VEHICLE SPEED SENSOR...
Page 308 LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION O-RING Disconnect the VS sensor 3 connectors (page 17-7).. Remove the VS sensor mounting bolt (1 nos.). Remove the VS sensor assy from the crankcase. Installation is in the reverse order of the removal. VS SENSOR TACHOMETER SYSTEM INSPECTION Check for loose or poor contact terminals at the combination meter 16P (Gray).
Page 309 LIGHTS/METERS/SWITCHES DIGITAL METER RESET RESET SELECT PROCEDURE TRIPMETER To reset the tripmeter proceed as follows: Press the select button to select tripmeter. – Reset button – Select button To reset the tripmeter, press and hold the reset button for more than 3 seconds when the display is in the “Trip”. DIGITAL CLOCK RESET SELECT...
Page 310: Combination Switch
LIGHTS/METERS/SWITCHES 6. To set the minute, press the reset button until the desired minute appears. – Quick setting - press and hold the reset button until the desired minute appears. 7. Press the select button when the display reaches the desired minute.
Page 311: Handlebar Switches
LIGHTS/METERS/SWITCHES HANDLEBAR SWITCHES 3P (BLACK) CONNECTORS LEFT HANDLEBAR SWITCH Remove the front cowl (page 2-2). Disconnect the handlebar switches 9P White and 3P Black from left handlebar. Check for continuity between the terminals in each switch position according to the table. 6P (WHITE) CONNECTORS DIMMER SWITCH...
Page 312: Neutral Switch
LIGHTS/METERS/SWITCHES BRAKE LIGHT SWITCH FRONT BRAKE LIGHTING SWITCH FRONT Disconnect the front brake light switch connectors. There should be continuity with the brake lever squeezed, and there should be no continuity when the brake lever is released. REAR Remove the right side cover (page 2-3). Disconnect the rear brake light switch connectors, and check for continuity between the terminals.
Page 313 LIGHTS/METERS/SWITCHES REMOVAL Remove the left crankcase rear cover (page 11-4). Disconnect the neutral switch connector. Remove the neutral switch mounting bolts (2 nos.) . BOLTS NEUTRAL SWITCH Remove the neutral switch and O-ring. O-RING NEUTRAL SWITCH Remove the drive piece and spring. DRIVE PIECE SPRING INSTALLATION...
Page 314: Fuel Level Sensor Inspection
LIGHTS/METERS/SWITCHES Apply clean engine oil to a new O-ring, and install it to the O-RING neutral switch. NEUTRAL SWITCH Carrying out as Install the neutral switch. shown that the Install the neutral switch mounting bolts (2 nos.) and direction of the tighten them.
Page 315 LIGHTS/METERS/SWITCHES 2. Fuel Level Sensor Output Line Inspection Remove the right side cover (page 2-3). Check the continuity between the fuel level sensor 2P (White) connector terminal and wire harness side of the combination meter. CONNECTION: Yellow/White – Yellow/White Green – Green Is there continuity? NO –...
Page 316 LIGHTS/METERS/SWITCHES Install the nuts, then tighten them. NUTS TORQUE: 9 N.m (0.9 kgf.m, 7 Ibf.ft) Install the fuel tank (page 2-3). FUEL LEVEL SENSOR UNIT HORN ADJUSTING SCREW INSPECTION Disconnect the wire connectors from the horn. Connect the battery voltage to the horn terminals. The horn is normal if it sounds when the battery voltage is connected across the horn terminals.
Page 317: Turn Signal Relay
LIGHTS/METERS/SWITCHES INSPECTION Connect the ohmmeter to the passing relay connector terminals. CONNECTION: A – D A – E Connect the battery to the passing relay connector terminals. CONNECTION: B – C Refer to the chart, and check for continuity between the terminals when 12V battery is connected.
Page 318 LIGHTS/METERS/SWITCHES FUSE BOX FUSE BOX REMOVAL/ INSTALLATION Remove the left side cover (page 2-3). Unhook the fuse box by pulling the fuse box lock outside from the battery box. Don’t pull the fuse box lock with excessive force, it may damage the lock permanently.
Page 319 MEMO...
Page 320 ELECTRIC STARTER SYSTEM ELECTRIC STARTER COMPONENT IGNITION SWITCH STARTER SWITCH HANDLEBAR SWITCH STARTER RELAY CLUTCH SWITCH NEUTRAL DIODE STARTER MOTOR NEUTRAL SWITCH VEHICLE SPEED SENSOR SYSTEM DIAGRAM 18-0...
Page 321: Electric Starter System
18. ELECTRIC STARTER SYSTEM ELECTRIC STARTER COMPONENT 18-0 STARTER RELAY SWITCH 18-3 ELECTRIC STARTER DIAGRAM 18-0 NEUTRAL DIODE 18-4 SERVICE INFORMATION 18-1 CLUTCH SWITCH 18-5 TROUBLE SHOOTING 18-1 RIGHT HANDLEBAR SWITCH 18-5 SERVICE INFORMATION GENERAL If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may be damaged.
Page 322 ELECTRIC STARTER SYSTEM 6. Starter Motor Inspection Connect the starter motor terminal to the battery positive terminal directly. (A large amount of current flows, so do not use a thin wire.) Does the starter motor turn? – GO TO STEP 9. –...
Page 323: Operation Inspection
ELECTRIC STARTER SYSTEM STARTER RELAY SWITCH NEGATIVE TERMINAL REMOVAL/INSTALLATION Remove the left side cover (page 2-3). Disconnect the negative (–) cable from the battery. Pull the starter relay from the battery tray. STARTER RELAY SWITCH Disconnect the starter relay switch 4P (Red) connector. SOCKET BOLTS Remove the socket bolts, battery cable and starter motor cable from the starter relay switch.
Page 324 ELECTRIC STARTER SYSTEM POWER INPUT LINE 4P (RED) CONNECTOR Connect the starter relay switch 4P (Red) connector. Turn the ignition switch to “ON”. Measure the voltage between the yellow/Red wire terminal (+) and ground (–). If the battery voltage appears only when the starter switch is pushed, the circuit is normal.
Page 325: Right Handlebar Switches
ELECTRIC STARTER SYSTEM CLUTCH SWITCH CLUTCH SWITCH INSPECTION Disconnect the clutch switch connectors. There should be continuity with the clutch lever applied, and there should be no continuity when the clutch lever is released. RIGHT HANDLEBAR SWITCHES 3P CONNECTOR Remove the front cowl (page 2-2). Disconnect the right handlebar switch 3P (Black) connector.
Page 326 MEMO...
Page 327 19. WIRING DIAGRAM STANDARD AND CBS (CB HORNET 160R) 19-1 19-1...
Page 328 20. TROUBLESHOOTING ENGINE DOES NOT START OR POOR PERFORMANCE AT HIGH SPEED 20-5 IS HARD TO START 20-1 POOR HANDLING 20-5 ENGINE LACKS POWER 20-2 POOR PERFORMANCE AT LOW AND IDLE SPEED 20-4 ENGINE DOES NOT START OR IS HARD TO START 1.
Page 329 TROUBLESHOOTING ENGINE LACKS POWER 1. Drive Train Inspection Raise the wheels off the ground, and spin them by hand. Does the wheel spin freely? – • Brake dragging • Worn or damaged wheel bearings • Bent axle – GO TO STEP 2. 2.
Page 330 TROUBLESHOOTING 8. Spark Plug Inspection Remove and inspect the spark plug. Are the spark plug in good condition? – • Plugs not serviced frequently enough • Incorrect spark plug used • Incorrect spark plug gap – GO TO STEP 9. 9.
Page 331 TROUBLESHOOTING POOR PERFORMANCE AT LOW AND IDLE SPEED 1. Pilot Screw Inspection Check the pilot screw adjustment. Is the adjustment correct? – See page –19 – GO TO STEP 2. 2. Intake Air Leak Inspection Check for leaking carburetor insulator. Is there leaking? –...
Page 332: Poor Performance At High Speed
TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED 1. Fuel Line Inspection Disconnect the fuel line at carburetor. Does fuel flow freely? – Faulty fuel system – GO TO STEP 2. 2. Carburetor Inspection Check the carburetor for clogging. Is the carburetor clogged? – Carburetor not serviced frequently enough –...
Page 333 MEMO...
Page 334 21. INDEX AIR CLEANER..............3-6 CRANKCASE SEPARATION ........11-4 AIR CLEANER HOUSING..........5-3 CYLINDER COMPRESSION ........AIR BLEEDING(CBS)............14-3 CYLINDER HEAD COVER ......... ALTERNATOR CHARGING COIL........15-8 CYLINDER HEAD DISASSEMBLY/ASSEMBLY ..7-12 BALANCER..............11-4 CYLINDER/PISTON ............ BATTERY DIGITAL METER RESET PROCEDURE ....17-9 BATTERY/CHARGING SYSTEM......15-5 DRIVE CHAIN ............
Page 335 INDEX PRIMARY DRIVE GEAR ..........9-14 SPEEDOMETER VS SENSOR ........17-7 PILOT SCREW ADJUSTMENT ........5-15 STANDARD TORQUE VALUES ........1-10 REAR GRIP ..............STARTER CLUTCH ............10-6 REAR DRUM BRAKE ............ 14-30 STARTER MOTOR ............10-8 REAR FENDER ............. STARTER RELAY SWITCH ..........

Honda CB HORNET 160R 2015 Shop Manual

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