HRC NSF250R 2012 Owner's Manual & Parts List
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HRC NSF250R 2012 Owner's Manual & Parts List

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Summary of Contents for HRC NSF250R 2012

  • Page 4 DANGER, WARNING, or CAUTION. damaged if you don’t follow instructions. These mean: The purpose of these messages is to help prevent damage to your HRC NSF250R, other property, or the environment. You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
  • Page 5 HRC NSF250R HRC NSF250R Owner’s Manual/Parts List Owner’s Manual/Parts List All information in this publication is based on the latest product information available at the time of approval for printing. All information in this publication is based on the latest product information available at the time of approval for printing.
  • Page 6 (1) FRAME SERIAL NUMBER (1) ENGINE SERIAL NUMBER The frame serial number is attached on the left side The engine serial number is stamped on the left side of the main frame as shown. of the crankcase.
  • Page 7 Contents 1. Operating Instruction Steering Stem 5–14 Fuel 1–1 Cleaning 3–24 Rear Wheel 5–19 Coolant 1–1 Storage 3–24 Rear Shock Absorber 5–20 Basic Operation 1–2 Nuts, Bolts, Fasteners 3–25 Suspension Linkage 5–24 Controls 1–4 Swingarm 5–25 4. Engine Servicing Brake Pad Replacement 5–32 2.
  • Page 8 Read this information carefully and don’t remove the labels. Hot coolant will scald you. Relief pressure valve begins to open at 108 If a label comes off or becomes hard to read, contact your HRC dealer for a kPa. replacement.
  • Page 9 To The New Owner Importance Of Proper Preparation How To Use This Manual By selecting a HRC roadracer NSF250R as your new Proper pre-competition preparation and regular The purpose of this Owner’s Manual is to help machine, you have placed yourself in a distin-...
  • Page 10 Memo...
  • Page 11 1. Operating Instruction (1) FILLER NECK (1) FUEL FILL CAP (1) RADIATOR CAP Fuel Coolant When filling the cooling system, be sure to bleed air completely so that the system can be sufficiently The engine of the NSF250R is a water-cooled type. filled.
  • Page 12 Operating Instruction (1) OVERFLOW CATCH TANK (1) ENGINE STOP SWITCH Basic Operation Before running, drain the coolant from the overflow 3. With the throttle closed, start the engine by push- catch tank. ing the machine. Starting The Engine 4. After the engine starts, shift the transmission into After running, check the radiator and coolant pas- neutral, and run it for a few minutes, "blipping"...
  • Page 13 Operating Instruction (1) ENGINE STOP SWITCH (1) TACHOMETER (2) WATER TEMPERATURE METER Warm Engine Starting Warming-up The Engine Break-In Procedure Follow the cold engine starting procedure. • Do not rev the engine more than necessary or engine damage may result. New Machine Stopping The Engine •...
  • Page 14 Operating Instruction (1) CLUTCH LEVER (1) LOCK NUT (2) ADJUSTER (A) INCREASE (B) DECREASE Controls Reconditioned Machine 2. Minor adjustments can be made with the cable • After replacing the cylinder and crankshaft, oper- end adjuster. ate the machine for the first 95 km (57 mi; about Clutch Loosen the lock nut and turn the adjuster.
  • Page 15 Operating Instruction (1) LOCK NUT (2) ADJUSTER (1) THROTTLE GRIP (1) LOCK NUT (2) ADJUSTER (C) INCREASE (D) DECREASE (A) DECREASE (B) INCREASE 3. Major adjustments can be made at the integral Throttle Grip Adjustment is made with the upper adjuster. cable adjuster.
  • Page 16 Operating Instruction (1) ARROW (2) INDEX MARK (3) ADJUSTER (1) LOCK NUT (2) ADJUSTING BOLT (1) LOCK NUTS (2) CHANGE ROD (A) RAISE THE PEDAL HEIGHT (B) LOWER THE PEDAL HEIGHT Front Brake Lever Brake Pedal Height Gearshift Pedal Height The distance between the tip of the brake lever and The brake pedal height can be adjusted to the rider's The gearshift pedal height can be adjusted to the...
  • Page 17 Operating Instruction 1-UP AND 5-DOWN (1) CHANGE ARM (2) CHANGE ROD (1) STEERING DAMPER (2) ADJUSTER (1) THICK WASHER (2) SPHERICAL BEARING (3) GEARSHIFT PEDAL (A) HARD (B) SOFT Steering Damper • When installing the damper on the frame, pay 1-DOWN AND 5-UP careful attention to prevent the piston rod from Turn the adjuster clockwise to increase damping,...
  • Page 18 Memo...
  • Page 19 2. Service Data Specifications Item Specification Item Specification Dimensions Fuel System Overall length 1,809 mm (71.2 in) Throttle body type GQD1A Overall width 560 mm (22.0 in) Throttle bore 50 mm (2.0 in) Overall height 1,037 mm (40.8 in) Drive Train Wheelbase 1,219 mm (48.0 in) Clutch operating system...
  • Page 20 Service Data Service Data Unit: mm (in) Unit: mm (in) Item Standard Service Limit Item Standard Service Limit Lubrication System Cylinder Head/Valves Suggested engine oil Honda 4-stroke motorcycle oil – Valve clearance 0.2 ± 0.02 (0.008 ± 0.001) – or equivalent 0.3 ±...
  • Page 21 Service Data Unit: mm (in) Unit: mm (in) Item Standard Service Limit Item Standard Service Limit Hydraulic brakes Wheels/Tires Axle runout – 0.5 (0.02) Specified brake fluid DOT4 brake fluid – Wheel rim runout Radial – 0.3 (0.01) Front Brake disc thickness 5.0 (0.20) 4.5 (0.18) Axial...
  • Page 22 Service Data Optional Parts Item Description Mainshaft/M1 gear (standard: 16T) 16, 17T M2 gear (standard: 21T) 17, 18, 19T M3/4 gear (standard: 23/24T) 20/20, 20/21, 20/22, 20/24, 21/20, 21/21 21/22, 21/24, 22/20, 22/21, 22/22, 22/24 23/20, 23/21, 23/22T M5 gear (standard: 26T) 20, 23, 25T M6 gear (standard: 24T) 23, 26, 27T...
  • Page 23 Service Data Torque Values Engine Standard Torque Threads Torque Item Item Q’ty Remarks N•m (kgf•m, lbf•ft) Dia. (mm) N•m (kgf•m, lbf•ft) 5 mm bolt and nut 5.1 (0.5, 3.8) Maintenance: 6 mm bolt and nut 10 (1.0, 7) Spark plug 14 (1.4, 10) 8 mm bolt and nut 22 (2.2, 16)
  • Page 24 Service Data Engine Cylinder stud bolt Cylinder head stud bolt Threads Torque Item Q’ty Remarks Dia. (mm) N•m (kgf•m, lbf•ft) Reference value: Cylinder head/valve: 105.6 ± 1 mm Cam chain tensioner: (4.16 ± 0.04 in) Adjust bolt See page 4-41 Note 4 Adjust bolt tightening nut 10 (1.0, 7)
  • Page 25 Service Data Frame Threads Torque Threads Torque Item Q’ty Remarks Item Q’ty Remarks Dia. (mm) N•m (kgf•m, lbf•ft) Dia. (mm) N•m (kgf•m, lbf•ft) Engine removal/installation: Front wheel/suspension: Engine hanger adjusting bolt 15 (1.5, 11) Stem bearing adjusting nut 6 (0.6, 4.4) Engine hanger lock nut 40 (4.1, 30) Steering stem nut...
  • Page 26 Service Data Insulator band Fuel pump set plate bolt Threads Torque Item Q’ty Remarks Dia. (mm) N•m (kgf•m, lbf•ft) 8.0 ± 1 mm Tightening order (0.31 ± 0.04 in) Hydraulic brake: Brake hose oil bolt 23 (2.3, 17) Brake hose bleeder (front) 23 (2.3, 17) Brake bleeder screw 6 (0.6, 4.4)
  • Page 27 Attachment, 42 x 47 mm 07746–0010300 Right mainshaft bearing Pilot, 12 mm 07746–0040200 Left mainshaft bearing The tool marked * is exclusive for HRC. Order directly from HRC. Pilot, 17 mm 07746–0040400 Left countershaft bearing Pilot, 25 mm 07746–0040600 Right mainshaft bearing...
  • Page 28 Service Data Description Tool number Applicability Description Tool number Applicability Front Wheel/Suspension/Steering: Rear Wheel/Suspension: Fork seal driver 07KMD-KZ30100 Fork Bearing remover head, 15 mm 07746–0050400 Wheel bearing removal *Fork seal driver attachment 07916-NX4-700 Bearing remover shaft 07746–0050100 *Fork set collar 51481-NX4-610 Driver 07749–0010000...
  • Page 29 Service Data Lubrication & Seal Points Engine Item Material Remarks Item Material Remarks Oil drain plug (Engine & transmission) Engine oil Left crankcase cover bushing I.D. Molybdenum disulfide Transmission holder bolt Connecting rod bearing sliding surface oil (A 50/50 mixture of Camshaft holder bolt Connecting rod small end I.D.
  • Page 30 Service Data Item Material Remarks Item Material Remarks Crankcase mating surface Sealant (TB1207B) Mainshaft/shift drum bearing set plate Locking agent Apply area: bolt threads 6.5 ± 1 mm Reed valve stopper bolt/washer threads Cylinder head torx bolt threads 6.5 ± 1 mm 1 –...
  • Page 31 Service Data Frame Frame Item Material Remarks Item Material Remarks Stem upper/lower bearings Urea based multi- Steering stem top thread 4-stroke engine oil Stem upper/lower dust seals purpose grease for Stem bearing outer race press area Left swingarm pivot bearing extreme pressure Fork inside Honda Ultra Cushion...
  • Page 32 Service Data Cable & Harness Routing CONDENSER 2P (BLACK) CONNECTOR BANK ANGLE SENSOR 3P (NATURAL) CONNECTOR HANDLEBAR SWITCH 2P (BLUE) CONNECTOR ENGINE STOP SWITCH 2P (GRAY) CONNECTOR CONDENSER TACHOMETER 3P (GREEN) CONNECTOR COOLANT TEMPERATURE METER 2P (BLACK) CONNECTOR PGM-FI INDICATOR 2P BANK ANGLE SENSOR (GREEN) CONNECTOR SHIFT-UP INDICATOR 2P...
  • Page 33 Service Data CLUTCH WIRE THROTTLE CABLES REGULATOR/RECTIFIER FUEL PUMP 5P (BLACK) CONNECTOR FRONT BRAKE HOSE RADIATOR OVERFLOW CATCH TANK 2-15...
  • Page 34 Service Data FUEL TANK OVERFLOW HOSE CLUTCH WIRE FUEL FEED HOSE FUEL TANK OVERFLOW CATCH TANK ALTERNATOR 5P (NATURAL) COOLANT TEMPERATURE METER WIRE ECT SENSOR CONNECTOR 2-16...
  • Page 35 Service Data CLUTCH WIRE MAP SENSOR SERVICE CHECK 4P (RED) CONNECTOR BARO SENSOR MAIN WIRE HARNESS THROTTLE CABLES IGNITION COIL CONNECTOR IAT SENSOR 2-17...
  • Page 36 Service Data THROTTLE SENSOR 3P (BLACK) CONNECTOR ENGINE BREATHER HOSE INJECTOR 2P (GRAY) CONNECTOR THROTTLE CABLES IACV 4P (BLACK) FUEL FEED HOSE CONNECTOR 2-18...
  • Page 37 Service Data IAT SENSOR FUEL FEED HOSE COOLANT TEMPERA- TURE SENSOR ECT SENSOR ALTERNATOR 5P (NATURAL) CONNECTOR 2-19...
  • Page 38 Service Data CLUTCH WIRE ENGINE BREATHER HOSE TRANSMISSION BREATHER HOSE BREATHER HOSE (AIR BOX) REAR BRAKE RESERVOIR HOSE 2-20...
  • Page 39 Service Data REAR BRAKE RESERVOIR HOSE REAR BRAKE HOSE 2-21...
  • Page 40 Memo...
  • Page 41 3. Service and Maintenance Maintenance Schedule Pre-ride Inspection Perform the Pre-ride Inspection at each scheduled maintenance period. For your safety, it is very important to take a few I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. L: Lubricate. moments before each ride to walk around your NSF250R and check its condition.
  • Page 42 Service and Maintenance Warming-up Inspection Replacement Parts When warming-up the engine: Parts Requiring Periodic Replacement Do not rev the engine more than necessary or When reachs the total running is 2,000 km, must be disassemble the engine and check each part. engine damage may result.
  • Page 43 Service and Maintenance Item Replacement Inspection Cause Remark Engine 2,000 km Disassemble check Transmission gear/collar/ Every 2,000 km – Wear or damage shaft/bearing Water pump drive gear Every 4,000 km – Wear or damage Water pump driven gear Every 4,000 km –...
  • Page 44 Service and Maintenance (1) BOLTS (2) AIR FILTER (1) FUEL FEED HOSE (1) DIRECT IGNITION COIL Fuel Line Air Filter Spark Plug Check the fuel feed hose for cracks, deterioration or Remove the air box cover (page 4-14). leakage. Remove the bolts and air filter from the air box. This machine’s spark plug is equipped with iridium Blow off any dust and dirt from the air filter.
  • Page 45 Service and Maintenance (1) TIMING HOLE CAP (1) CRANKSHAFT HOLE CAP Valve Clearance Flash Over If engine misfire occurs due to arcing, replace both Inspection the spark plug and the cap. Inspect and adjust the valve clearance while the engine is cold (below 35˚C/95˚F). Remove the engine from the frame (page 4-21).
  • Page 46 Service and Maintenance (1) INDEX MARK (2) "T" MARK (1) FEELER GAUGE (1) VALVE LIFTER (2) SHIM Measure the valve clearance by inserting a feeler If necessary, adjust the valve clearance. gauge between the valve lifter and cam lobe. Remove the valve lifters and shims. Valve clearance: IN: 0.20 ±...
  • Page 47 Service and Maintenance (1) VALVE LIFTER (1) SHIM (2) VALVE LIFTER Sixty-five different thickness shims are available Install the newly selected shim on the valve retain- from the thinnest 1.200 mm thickness shim to the thickest 2.800 mm shim in intervals of 0.025 mm. Apply molybdenum disulfide oil to the valve lifters and install them into the valve lifter bores.
  • Page 48 Service and Maintenance (1) CRANKSHAFT HOLE CAP (1) UPPER LEVEL MARK (1) OIL FILLER CAP (2) O-RING (2) LOWER LEVEL MARK (2) DRAIN BOLT Engine Oil/Oil Filter Oil Change Oil Level Inspection Change the engine oil with the engine warm. Support the machine using a maintenance stand to assure complete and rapid draining.
  • Page 49 Service and Maintenance (1) OIL FILLER CAP (1) BOLTS (2) OIL FILTER COVER (1) SPRING (2) OIL FILTER (3) OUTSIDE MARK 5. Pour the recommended engine oil slowly through the oil filler hole. Suggested engine oil: Honda 4-stroke motorcycle oil or equivalent Viscosity: SAE 10W-30 API Classification: SG or higher (except oils labeled as energy conserving on the...
  • Page 50 Service and Maintenance (1) OIL FILTER COVER (2) BOLTS (1) OIL FILLER CAP (2) DRAIN PLUG (1) DRAIN PLUG Transmission Oil Install and tighten the oil filter cover bolts. 3. Place an oil drain pan under the engine and Secure the drain plug and filter cap with lock wire. remove the drain plug.
  • Page 51 Service and Maintenance (1) TUBE DRAIN PLUG (1) OIL FILLER CAP (1) RADIATOR (2) OVERFLOW TUBE Crankcase Breather Coolant 6. Install the oil filler cap. 7. Secure the oil filler cap and drain plug with lock wire. The bottom of the air box serves as an oil catch tank Cooling System Inspection to trap oil bled from the crankcase through the breather tube.
  • Page 52 Service and Maintenance (1) INSPECTION HOLE (1) OVERFLOW TUBE (1) COOLANT TEMPERATURE METER (2) CATCH TANK 6. Check the water pump inspection hole front side Coolant Overflow Catch Tank Coolant Temperature Meter of the water pump for leakage. Make sure the hole remains open.
  • Page 53 Service and Maintenance (1) EXHAUST PIPE (2) MUFFLER (1) RADIATOR (2) COVERING (1) CLUTCH LEVER Clutch Exhaust Pipe/Muffler If the indication never changes from (–˚C), check the radiator coolant level and temperature (25 – 99˚C/77 – 210˚F), and then inspect the water temperature Operation Inspection sensor and harness (page 6-9).
  • Page 54 Service and Maintenance (1) RIVET (1) INNER PIPE (2) OUTER BODY (1) RIVET (3) GLASS WOOL (4) FRONT OUTER (5) WASHER (6) RIVET Glass Wool Replacement 3. Remove the glass wool. 5. Drive 7 stainless pop rivets (4.8 mm) through the Install the new glass wool onto the inner pipe.
  • Page 55 Service and Maintenance (1) DRIVE CHAIN SLACK (1) ADJUSTING BOLT (2) REFERENCE MARKS Drive Chain Drive Chain Slack Adjustment Drive Chain Slack Inspection Loosen the rear axle nut. Turn the adjusting bolt clockwise to increase slack or During the break-in period, drive chain slack should counterclockwise to decrease slack.
  • Page 56 Service and Maintenance Adjust the distance "aa" so it is equal on both side (1) BOLTS/NUTS (2) DRIVE CHAIN ROLLER In the illustration above, the handlebar is turned too (1) DRIVE CHAIN SLIDER (2) SCREW far toward the right. (3) LOCKING AGENT Drive Chain Slider/Roller Distance "aa"...
  • Page 57 Service and Maintenance (1) BOLT (2) SPROCKET COLLAR (1) SPRING WASHER (2) "OUTSIDE" MARK (1) DRIVE SPROCKET (2) NUMBER OF TEETH (3) SPRING WASHER (4) DRIVE SPROCKET Sprockets Install the drive sprocket with its etched number (number of teeth) facing outward. Drive Sprocket Replacement Remove the lower cowl.
  • Page 58 Service and Maintenance (1) DRIVE SPROCKET BOLT (1) DRIVEN FLANGE ASSEMBLY (1) COVER (2) LOWER LEVEL (2) SOCKET BOLT (3) DRIVEN SPROCKET (4) DRIVEN FLANGE Brake Fluid Shift the transmission into low gear, apply the rear Driven Sprocket Replacement brake. Tighten the drive sprocket bolt to the specified Remove the rear wheel (page 5–19).
  • Page 59 Service and Maintenance (1) VINYL TUBE (1) BRAKE PADS (1) BRAKE DISC Brake Pad Wear Brake System Rear Master Cylinder The rear master cylinder uses a vinyl tube in place of Inspect the brake pads visually to determine the pad Refer to page 1–6 for Brake Lever Adjustment.
  • Page 60 Service and Maintenance (1) TORQUE ROD (1) PINCH BOLT Handlebar And Steering Head Bearings Rear Brake Torque Rod Steering Head Bearings A floating type torque rod is used for the rear brake. Handlebar Support the machine with its front wheel off the The rod should be adjusted so that its length is 370 ground.
  • Page 61 Service and Maintenance (1) WHEEL (2) TIRE (1) REBOUND ADJUSTER (2) PRELOAD ADJUSTER Wheels And Tires Front Suspension Fork The optional wheels and tires are available. Inspection The machine is shipped with a light coating of grease The wheels and tires should be selected for track con- on the forks.
  • Page 62 Service and Maintenance (1) COMPRESSION ADJUSTER (1) COMPRESSION ADJUSTER (1) REBOUND ADJUSTER Rear Suspension • For optimum fork performance, we recommended • When your NSF is new, your suspension will that you disassemble and clean the fork after rid- break-in as you ride. ing your NSF for three hours.
  • Page 63 Service and Maintenance Cleaning Clean your NSF regularly to protect the surface fin- ishes and inspect damage, wear, and oil seepage. When washing your NSF, always use water and a mild detergent (such as diswashing liquid) to avoid discoloring decals. High pressure water (or air) can damage certain parts of the motorcycle.
  • Page 64 Service and Maintenance Storage 10. Stuff rags into the mufflers outlet. Then tie a plastic bag over the end of the mufflers to pre- vent moisture from entering. Extended storage, such as for winter, requires that 11. Cover your NSF and store in a place which is free you take certain steps to reduce the effects of non- of humidity and dust.
  • Page 65 Service and Maintenance (1) NG (2) OK (1) ENGINE OIL DRAIN PLUG (1) TRANSMISSION DRAIN PLUG • Use new 0.8 mm (0.03 in) stainless steel wire. • Secure the bolt as shown so that it cannot come loose. • Twisting the wire too tightly will break the lock- ing.
  • Page 66 Service and Maintenance (1) OIL LINE PLUG BOLT A (1) OIL FILTER COVER BOLTS (1) OIL LINE PLUG BOLT B 3-26...
  • Page 67 4. Engine Servicing Lubrication Diagram CAMSHAFT WATER PUMP GEAR PISTON BALANCER GEAR PISTON JET PRIMARY DRIVE GEAR PISTON JET CRANKSHAFT MAINSHAFT OIL FILTER PRESSURE RELIEF VALVE CLUTCH SCAVENGE PUMP OIL STRAINER OIL FEED PUMP COUNTERSHAFT...
  • Page 68 Engine Servicing (1) BOLT (2) OIL SEPARATOR PLATE (1) BOLT (2) OIL PUMP DRIVEN SPROCKET (1) PRESSURE RELIEF VALVE Oil Pressure Relief Valve Removal/Inspection Drain the engine oil (page 3-8). Remove the flywheel (page 4-67). Remove the bolt and oil separator plate. (1) BOLTS (2) OIL STRAINER (1) RELIEF VALVE PISTON (3) OIL PUMP COVER...
  • Page 69 Engine Servicing (1) O-RING (2) RELIEF VALVE (1) OIL PUMP COVER (1) OIL PUMP CHAIN (2) DRIVEN SPROCKET (2) O-RING (3) "OUT" MARK (4) SPROCKET BOLT (3) OIL STRAINER Install the oil pump drive chain to the drive sprocket on the crankshaft. Install the oil pump driven sprocket to the oil pump shaft with its "OUT"...
  • Page 70 Engine Servicing (1) DRIVEN SPROCKET (1) BOSS (1) INNER ROTOR (2) SPROCKET BOLT (2) OIL SEPARATOR PLATE (2) OUTER ROTOR (3) BOLT Oil Pump Tighten the oil pump sprocket bolt to the specified Install the oil separator plate while aligning its hole torque.
  • Page 71 Engine Servicing (1) OIL PUMP SHAFT (2) INNER ROTOR (3) OUTER ROTOR Inspection Check the oil pump driven gear for wear or damage. Check the oil pump shaft for wear or damage. Temporarily install the oil pump shaft, inner rotor and outer rotor into the crankcase.
  • Page 72 Engine Servicing (1) OUTER ROTOR (2) INNER ROTOR (1) INNER ROTOR (2) OUTER ROTOR (1) DOWEL PINS (3) OIL PUMP SHAFT (1) RELIEF VALVE (1) OIL PUMP COVER (1) CRANKSHAFT (2) OIL PUMP SHAFT (3) OUTER ROTOR (2) BOLT (2) BALANCER SHAFT (4) INNER ROTOR Assembly Install the dowel pins.
  • Page 73 Engine Servicing (1) 5P (BLACK) CONNECTOR (1) CONNECTOR COVER (1) RUBBER CAP (2) RETAINER (2) CLIP (2) CONNECTOR RUBBER (3) QUICK CONNECTOR Fuel Hose Removal/Installation Injector side: 1. Check the fuel feed hose quick connector for dirt, The fuel hose retainer must be replaced, if the fuel clean if necessary.
  • Page 74 Engine Servicing (1) FEED HOSE (2) RETAINER (1) FEED HOSE (2) RUBBER CAP (1) RETAINER (2) FEED HOSE (3) RETAINER 4. Move the fuel feed hose quick connector back and Fuel pump side: forth, check that the fuel feed hose connector is 1.
  • Page 75 Engine Servicing (1) FUEL FEED HOSE (1) CONNECTOR RUBBER (1) PRESSURE GAUGE (2) CONNECTOR COVER (2) MANIFOLD (3) FUEL JOINT Fuel Line Inspection Install the fuel pressure gauge between the fuel pump side fuel joint and fuel feed hose using the fol- Fuel Pressure Inspection lowing tools.
  • Page 76 Engine Servicing (1) FUEL HOSE (1) FUEL FEED HOSE (1) BREATHER HOSE (2) 5P (BLACK) CONNECTOR (2) CLIP (3) FUEL TANK Fuel Tank/Fuel Pump Fuel Pump Flow Inspection After inspection, remove the temporarily installed fuel hose and reconnect the fuel feed hose to the Disconnect the fuel hose from the fuel pump joint.
  • Page 77 Engine Servicing (1) 5P (BLACK) CONNECTOR (1) BOLTS (2) FUEL PUMP BASE (1) RETAINER (2) HOLDER (2) CLIP (3) BASE UNIT (1) CONNECTOR COVER (1) FUEL PUMP ASSEMBLY (1) WIRE TERMINALS (2) CONNECTOR RUBBER (2) FUEL PUMP MOTOR/FILTER (3) FUEL JOINT Disconnect the fuel pump 5P (Black) connector.
  • Page 78 Engine Servicing (1) FUEL FILTER SCREEN (1) FUEL PUMP BASE (2) HOLDER (1) O-RINGS (2) FUEL PUMP BASE (3) FUEL PUMP MOTOR WIRES (3) RETAINER (4) FUEL PUMP MOTOR (5) HOLDER Clean the fuel filter screen. Replace the O-rings whenever the fuel pump is Install the fuel pump holder to the fuel pump base.
  • Page 79 Engine Servicing (1) O-RING (2) FUEL PUMP (1) FUEL PUMP BASE (2) BOLTS (1) FUEL TANK (2) CLIP (3) INDEX MARK (4) ARROW MARK (3) BREATHER HOSE Install a new O-ring onto the fuel tank flange as Set the fuel tank onto the frame, install the fuel tank shown.
  • Page 80 Engine Servicing (1) CONNECTOR RUBBER (2) FUEL JOINT (1) 5P (BLACK) CONNECTOR (1) BARO sensor connector (2) CLIP (2) MAP sensor connector (3) IAT sensor connector (4) retainers Throttle Body/Air Box Connect the fuel pump 5P (Black) connector. Install the harness clip to the fuel pump base. Removal Remove the fuel tank (page 4-10) Remove the radiator (page 4-24)
  • Page 81 Engine Servicing (1) VACUUM HOSE (2) AIR BOX COVER (1) ALTERNATOR 5P (NATURAL) CONNECTOR (1) THROTTLE SENSOR CONNECTOR (2) BOLTS (3) AIR DUCT (2) IACV CONNECTOR Remove the alternator/ignition pulse generator 5P (Natural) connector from the air duct. Remove the bolts and then remove the air duct for- ward.
  • Page 82 Engine Servicing (1) GROMMET (1) THROTTLE CABLES (2) THROTTLE BODY (1) CRANKCASE/TRANSMISSION BREATHER HOSE Remove the throttle body from the insulator. Disconnect the throttle cables from the throttle drum, then remove the throttle body. Remove the fuel feed hose from the air box. (1) INSULATOR BAND SCREW (1) INSULATOR MOUNTING NUTS (2) INSULATOR...
  • Page 83 Engine Servicing (1) RETAINERS (1) BOLTS (2) INJECTOR HOLDER (1) IACV (2) BOLTS (3) FLAME TRAP Inspect the IACV for wear or damage. Replace the IACV if the valve has excessive wear or damage. (1) BOLTS (1) SCREWS (2) RETAINER PLATE (2) AIR FUNNEL (3) IACV Throttle Body Disassembly/Assembly...
  • Page 84 Engine Servicing (1) IACV (2) GUIDE PIN (1) O-RING (2) CUSHION RING (1) AIR FUNNEL (3) GROOVE (3) INJECTOR (4) HOLDER (2) BOLTS (1) IACV (2) RETAINER PLATE (1) HOLDER (2) BOLTS (1) FLAME TRAP (3) SCREWS (2) BOLTS (3) RETAINERS Install the IACV while aligning the guide pin into the Install the new o-ring and cushion ring to the injec- Install the air funnel to the throttle body, then install...
  • Page 85 Engine Servicing Assembly THROTTLE BODY AIR FILTER (1) O-RING (2) INSULATOR Installation is in the reverse order of removal. Replace the insulator O-ring with a new one. AIR BOX Refer to page 4-7 for fuel hose installation. AIR DUCT INSULATOR 4-19...
  • Page 86 Engine Servicing (1) EXHAUST PIPE SPRING (1) LOWER MOUNTING BOLT/NUT (1) EXHAUST PIPE JOINT BOLTS (2) EXHAUST PIPE (1) BOLT (2) BAND BOLT (1) TY-RAPS (2) HEAT PROTECTOR (1) GASKET (3) MUFFLER Muffler/Exhaust Pipe Remove the radiator lower mounting bolt/nut. Remove the exhaust pipe joint bolts and exhaust pipe.
  • Page 87 Engine Servicing (1) LOCK NUT WRENCH (1) HANGER NUTS (1) ENGINE (2) REAR UPPER HANGER BOLT (3) DISTANCE COLLAR Engine Removal Loosen the rear upper lock nut for the engine adjust- ing bolt. Support the machine using a safety stand or hoist. Loosen the rear lower lock nut for the engine adjust- ing bolt.
  • Page 88 Engine Servicing (1) ENGINE (2) FRONT HANGER BOLT (1) ADJUSTING BOLT (2) LOCK NUT WRENCH (1) REAR LOWER HANGER BOLT (2) ENGINE (3) DISTANCE COLLAR (3) SHIM (4) DISTANCE COLLAR Install the front engine hanger bolt and distance col- Use the right end of the engine (clutch side) as a ref- Temporarily install the rear lower engine hanger lar.
  • Page 89 Engine Servicing (1) HANGER NUTS (1) ADJUSTING BOLT (2) LOCK NUT WRENCH (1) FRONT ENGINE HANGER BOLT (2) FRONT ENGINE HANGER COLLAR (3) SHIM (4) HANGER NUT Turn the rear lower adjusting bolt in and adjust the Tighten the rear upper engine hanger nut to the Measure the clearance between the distance collar clearance to zero (0).
  • Page 90 Engine Servicing (1) LOWER RADIATOR HOSE (1) ECT SENSOR CONNECTOR (1) UPPER RADIATOR HOSE (2) THERMO SENSOR CONNECTOR (2) UPPER MOUNTING BOLT (2) BOLTS (3) BOLT/COPPER WASHER (4) WATER PUMP COVER Water Seal/Bearing Replacement Drain the transmission oil (page 3-10). Disconnect the lower radiator hose from the water pump cover.
  • Page 91 Engine Servicing (1) WATER PUMP SHAFT/GEAR (1) BEARING REMOVER, 12 mm (1) WATER SEAL DRIVER (2) IMPELLER (3) COPPER WASHER (2) REMOVER WEIGHT (2) WATER SEAL (3) OIL SEAL Hold the water pump gear using a suitable tool, Remove the water pump bearing using the follow- remove the impeller and copper washer.
  • Page 92 Engine Servicing (1) WATER PUMP SHAFT/GEAR (1) DOWEL PINS (2) NEW GASKET (1) WATER PUMP COVER (2) NEW COPPER WASHER (2) SEALING WASHER/BOLT (3) IMPELLER (3) BOLTS (4) LOWER RADIATOR HOSE Install the water pump shaft and new copper wash- Install the right crankcase cover (page 4-51).
  • Page 93 Engine Servicing (1) COVER BOLT/WASHER (1) SEALING BOLTS/WASHERS (1) TIMING HOLE CAP/O-RING (2) CYLINDER HEAD COVER (2) STOPPER TOOL Cylinder Head Cover/Camshaft Removal 19.0 mm (0.75 in) Remove the engine from the frame (page 4-21). 12.0 mm Remove the cylinder head cover bolts, washers and (0.47 in) cylinder head cover.
  • Page 94 Engine Servicing (1) PUNCH MARK (2) INDEX MARK (1) CAM SPROCKETS (2) INDEX LINES (1) BOLTS (2) CAM CHAIN GUIDE B (3) "T" MARK (4) INDEX MARK Remove the spark plug (page 3-4). Check that the index lines on the cam sprockets are Remove the bolts and cam chain guide B.
  • Page 95 Engine Servicing (1) SPROCKET BOLTS (1) HOLDER BOLTS (1) PACKING (2) HOLDER BOLTS/COPPER WASHERS (2) PACKING B (3) HOLDER A (4) HOLDER B (1) SPROCKET BOLTS (1) INTAKE CAMSHAFT (1) BOLTS (2) EXHAUST CAMSHAFT (2) BREATHER SEPARATOR If you plan to replace the camshaft and/or cam Make sure the piston at TDC (Top Dead Center) on Disassembly/Inspection sprockets, turn the crankshaft one full turn (360˚)
  • Page 96 Engine Servicing (1) SNAP RING (2) WASHER (1) CAM LOBES (1) VALVE LIFTER (3) DECOMPRESSER CAM PLATE (2) CAM JOURNALS (2) SHIM Cylinder Head Removal Check the cam lobe for wear or damage. Check the camshaft journal surface for wear or dam- age.
  • Page 97 Engine Servicing (1) 6 mm BOLTS (1) GASKET (2) DOWEL PINS (1) BOLT/COLLAR (2) CAM CHAIN GUIDE (2) NUTS AND SEALING WASHERS (3) BOLT/COLLAR (4) CAM CHAIN TENSIONER (3) CYLINDER HEAD (5) CAM CHAIN Remove the cylinder head mounting 6 mm bolts. Remove the gasket and dowel pins.
  • Page 98 Engine Servicing (1) VALVE SPRING COMPRESSOR (1) RETAINER (2) OUTER VALVE SPRING (1) RETAINER (2) VALVE SPRING (2) ATTACHMENT (3) INNER VALVE SPRING (4) SPRING SEAT (3) SPRING SEAT (4) EXHAUST VALVE (5) INTAKE VALVE (6) STEM SEAL (5) STEM SEAL Cylinder Head Disassembly Remove the following: Remove the following:...
  • Page 99 Engine Servicing (1) VALVE (1) VALVE LIFTER Cylinder Head Inspection This machine's intake and exhaust valves are titani- Check that the top and outer surface of the valve um with a special coating. lifter for wear or damage. Cylinder Head If the brown coating of the valve is removed, or the metal surface is appeared, replace the valve with a new one.
  • Page 100 Engine Servicing (1) VALVE GUIDE REAMER (1) VALVE LAPPING TOOL Valve spring Valve Seat Inspection/Refacing Apply a light coating of Prussian Blue to the valve seat. Check the valve springs for fatigue or damage. This machine's intake and exhaust valves are titani- Tap the valves and seats using a rubber hose or If the brown coating of the valve is removed, or the other hand lapping tool.
  • Page 101 Engine Servicing (1) VALVE SEAT WIDTH (1) CAM CHAIN TENSIONER (1) TENSIONER LIFTER (2) CAM CHAIN GUIDE Inspect the width of each valve seat. Tensioner lifter Check the tensioner lifter operation as follows: Valve seat width: – The tensioner shaft should not go into the body IN/EX: 1.0 mm (0.04 in) when it is pushed.
  • Page 102 Engine Servicing (1) SPRING SEAT (2) STEM SEAL (1) SPRING SEAT (2) STEM SEAL (1) VALVE SPRING COMPRESSOR (3) VALVE (4) INNER SPRING (3) VALVE (4) VALVE SPRING (2) ATTACHMENT (5) OUTER SPRING (6) RETAINER (5) RETAINER Cylinder Head Assembly Install the spring seats and new stem seals.
  • Page 103 Engine Servicing (1) PLASTIC PIN DRIVER (1) PIVOT COLLAR (1) PIVOT COLLAR (2) CAM CHAIN GUIDE (2) CAM CHAIN TENSIONER (3) PIVOT BOLT (3) PIVOT BOLT Cylinder Head Installation Tap the valve stems gently with plastic pin driver as Apply molybdenum solution to the sliding surface shown to seat the cotters firmly.
  • Page 104 Engine Servicing (1) DOWEL PINS (1) CYLINDER HEAD (1) SHIM (2) NEW CYLINDER HEAD GASKET (2) SEALING WASHERS/NUTS (2) VALVE LIFTERS (3) 6 mm BOLTS Camshaft/Cylinder Head Cover Install the dowel pins and new cylinder head gasket. Install the cylinder head onto the cylinder. Installation Apply engine oil to the cylinder head mounting nut threads and seating surface, then install the sealing...
  • Page 105 Engine Servicing (1) INTAKE CAMSHAFT (1) CAMSHAFT HOLDER A (1) CAMSHAFT HOLDER A (2) EXHAUST CAMSHAFT (2) CAMSHAFT HOLDER B (2) CAMSHAFT HOLDER B (3) HOLDER BOLTS (3) INDEX LINES (3) O-RING (4) COPPER WASHERS/BOLTS Install a new O-ring to the camshaft holder B groove. Apply molybdenum oil solution to the camshaft Apply engine oil to the camshaft holder bolt threads.
  • Page 106 Engine Servicing (1) CAM SPROCKET BOLTS (1) CAM CHAIN GUIDE B (1) GASKET (2) BOLTS (2) CHAIN TENSIONER LIFTER Install the cam chain guide and tighten the bolts. (1) CAM SPROCKET BOLTS (1) BOLTS (2) SEALING WASHER (3) SEALING BOLT If the cam sprocket bolts are loosen or removed, Install the gasket and cam chain tensioner lifter to apply oil to the cam sprocket bolt threads.
  • Page 107 Engine Servicing (1) ADJUSTER (1) O-RING (1) ADJUSTER HOLE CAP (2) LOCK NUT (2) ADJUSTER HOLE CAP To adjust the clearance, loosen the lock nut, turning Apply multi-purpose grease to the threads and seat- the adjuster. ing surface of the cam chain adjuster hole cap. After adjustment, hold the adjuster and tighten the lock nut to the specified torque.
  • Page 108 Engine Servicing (1) WASHER (1) CRANKSHAFT HOLE CAP (1) BREATHER SEPARATOR (2) BOLTS (2) "UP" MARK (2) O-RING (1) PACKING (1) CYLINDER HEAD COVER (1) TIMING HOLE CAP (2) PACKING B (2) BOLTS (2) O-RING If the breather separator was removed, install it to Install the washers with it's "UP"...
  • Page 109 Engine Servicing (1) CYLINDER (1) GASKET (1) PISTON PIN CLIP (2) DOWEL PINS (2) PISTON PIN (3) PISTON Cylinder, Piston Remove the gasket and dowel pins. Piston Removal Cylinder Removal Place a clean shop towel over the crankcase to pre- vent the clip from falling into the crankcase.
  • Page 110 Engine Servicing Reference value: 105.6 ± 1 mm (4.16 ± 0.04 in) (1) CYLINDER Spread the piston rings and remove them by lifting If the cylinder stud bolt was removed, install the up at a point just opposite the gap. stud bolts as shown.
  • Page 111 Engine Servicing (1) CONNECTING ROD Connecting Rod Check the connecting rod small end for wear or damage. (1) TOP RING (2) SIDE RAILS (3) SPACER (4) MARKING Piston Ring Installation • Do not damage the piston ring by spreading the ends too far.
  • Page 112 Engine Servicing (1) “IN” MARK (2) PISTON PIN (1) DOWEL PINS (1) CLUTCH CABLE HOLDER (3) NEW PISTON PIN CLIP (2) NEW GASKET (2) RELEASE ARM Piston Installation Place a shop towel over the cylinder opening to pre- vent dust or dirt from entering the engine. Clean any gasket material from the cylinder mating surfaces of the crankcase.
  • Page 113 Engine Servicing (1) CLUTCH CENTER HOLDER (1) DOWEL PINS (1) CLUTCH DISCS/PLATES (2) O-RING (2) LOCK NUT (1) BOLTS/SPRINGS (2) PRESSURE PLATE (1) JUDDER SPRING (1) LOCK WASHER (2) PLAIN WASHER (3) LIFTER PIECE (2) JUDDER SPRING SEAT (3) CLUTCH CENTER Remove the dowel pins and O-ring.
  • Page 114 Engine Servicing (1) THRUST WASHER (2) CLUTCH OUTER (1) CLUTCH CENTER (2) CLUTCH OUTER (1) LIFTER PIECE (3) NEEDLE BEARING (4) CLUTCH OUTER GUIDE (3) OUTER GUIDE (4) NEEDLE BEARING (2) THRUST WASHER (3) THRUST NEEDLE BEARING Remove the right crankcase cover (page 4-51). Inspection Check the needle bearing operation by turning the thrust washer on the lifter piece.
  • Page 115 Engine Servicing (1) JUDDER SPRING SEAT (1) OUTER GUIDE (1) CLUTCH CENTER (2) JUDDER SPRING (3) CLUTCH DISC B (2) NEEDLE BEARING (2) THRUST WASHER (3) LOCK WASHER (4) CLUTCH PLATE (5) CLUTCH DISC A (4) "OUTSIDE" MARK (1) CLUTCH OUTER (1) CLUTCH CENTER HOLDER (1) JUDDER SPRING SEAT (2) THRUST WASHER...
  • Page 116 Engine Servicing (1) LIFTER PIECE (2) NEEDLE BEARING (1) PRESSURE PLATE (2) SPRINGS/BOLTS (1) OIL SEAL (2) WASHER (3) THRUST WASHER (3) RETURN SPRING (4) LIFTER ARM Apply engine oil to the clutch lifter piece needle Install the pressure plate assembly. Apply grease to the clutch lifter oil seal lips, then bearing.
  • Page 117 Engine Servicing (1) BOLTS (1) DOWEL PINS (2) NEW O-RING (1) RELEASE ARM (2) CLUTCH CABLE (3) CLUTCH COVER (2) RIGHT CRANKCASE COVER Right Crankcase Cover Connect the clutch cable end to the release arm. Set the clutch cable to the clutch cable guide. Removal Adjust the clutch cable (page 1-4).
  • Page 118 Engine Servicing (1) DOWEL PINS (2) COLLAR (1) RIGHT CRANKCASE COVER (1) GEAR HOLDER (3) NEW GASKET (2) WATER PUMP COVER (2) PRIMARY DRIVE GEAR BOLT (3) BOLTS Primary Drive Gear Remove the gasket and dowel pins. Install the right crankcase cover while aligning the water pump drive and driven gear by turning the Installation water pump impeller.
  • Page 119 Engine Servicing (1) GEAR HOLDER (1) BALANCER DRIVE GEAR (1) WIDE SERRATION (2) CUT-OUT (2) PRIMARY DRIVE GEAR (2) PRIMARY DRIVE GEAR (3) PUNCH MARK Remove the balancer drive gear from the crankshaft. Install the primary drive gear while aligning the Apply engine oil to the primary drive gear bolt wide serration between the primary drive gear and threads and seating surface.
  • Page 120 Engine Servicing (1) GEAR HOLDER (1) WATER PUMP DRIVE GEAR (1) BALANCER SHAFT (2) PRIMARY DRIVE GEAR (2) BALANCER DRIVEN GEAR (3) BALANCER DRIVEN GEAR Balancer Inspection Removal Turn the balancer shaft bearing inner race with your finger. Check that the bearing turns smoothly and quietly.
  • Page 121 Engine Servicing (1) BALANCER SHAFT (1) PUNCH MARK (1) GEAR HOLDER (2) WIDE CUTOUT (3) PUNCH MARKS (2) LOCK NUT Installation Apply engine oil to the balancer driven gear lock nut threads and seating surface. Install the balancer shaft into the left crankcase. Install the lock washer and lock nut to the balancer shaft.
  • Page 122 Engine Servicing (1) BOLT/NUT (1) GEARSHIFT SPINDLE (1) DOWEL PINS (2) GEARSHIFT ARM Transmission Removal Remove the clutch outer (page 4-46). Remove the drive sprocket (page 3-17). Prevent dust and dirt from entering the crankcase. Clean crankcase around the gearshift spindle. Remove the bolt/nut and gearshift arm from the gearshift spindle.
  • Page 123 Engine Servicing (1) CENTER BOLT (1) SHIFT FORK SHAFTS (2) SHIFT DRUM CENTER (2) SHIFT FORKS (3) SHIFT DRUM Remove the shift fork shafts and shift forks. Remove the mainshaft/countershaft as an assembly from the transmission holder. Check the transmission bearing and replace if nec- essary (page 4-59, 77).
  • Page 124 Engine Servicing Disassembly/Assembly • When installing the C5 and C6 gears to the coun- tershaft, make sure to align the oil holes of the C5, • Always install the thrust washers and snap rings C6 gears and countershaft. with the chamfered (rolled) edge facing away Also align the oil holes of M5 collar and main- from thrust load.
  • Page 125 Engine Servicing Transmission Holder Bearing Replacement Drive the holder bearings with their sealed side facing the right crankcase cover. To be bottomed To be bottomed To be bottomed Apply locking agent Apply locking agent (1) DRIVER (2) ATTACHMENT Drive the countershaft bearing out using the follow- ing tools.
  • Page 126 Engine Servicing (1) DRIVER (2) ATTACHMENT (1) SHIFT DRUM BEARING SET PLATES/BOLTS (1) MAINSHAFT/COUNTERSHAFT ASSEMBLY (2) MAINSHAFT BEARING SET PLATES/BOLTS Drive the mainshaft bearing in using the following Apply a locking agent to the shift drum bearing and Assembly tools. mainshaft bearing set plate bolt threads.
  • Page 127 Engine Servicing (1) RIGHT SHIFT FORK (2) CENTER SHIFT FORK (1) DRUM SHIFTER (2) SPRING (1) RETURN SPRING (2) WASHER (3) LEFT SHIFT FORK (3) PLUNGER (4) RATCHET PAWL (3) STOPPER ARM (4) BOLT (5) GUIDE PLATE If the shift drum has been removed, install the gearshift linkage as follows: Apply clean transmission oil to the ratchet pawls, plungers, springs and drum shifter.
  • Page 128 Engine Servicing (1) SHIFT DRUM CENTER PIN (1) SHIFTER COLLAR (1) DOWEL PINS (2) CENTER PIN (2) GUIDE PLATE/SHIFT DRUM ASSEMBLY (3) BOLTS Apply a locking agent to the shift drum center pin Place the shift drum center position other than neu- Install the dowel pins.
  • Page 129 Engine Servicing (1) TRANSMISSION ASSEMBLY (1) WASHER (1) GEARSHIFT ARM (2) BOLTS (2) GEARSHIFT SPINDLE (3) STOPPER PIN (2) BOLT/NUT (4) SHIFTER COLLAR Install the transmission holder assembly into the Install the washer onto the gearshift spindle. Install the gearshift arm and tighten the bolt/nut. crankcase.
  • Page 130 Engine Servicing (1) 6P (NATURAL) CONNECTOR (1) BOLTS (1) BOLTS (2) IGNITION PULSE GENERATORS (2) LEFT CRANKCASE COVER (3) SOCKET BOLTS (4) STATOR Left Crankcase Cover Disassembly/Assembly Removal Remove the ignition pulse generator flange bolts. Remove the stator mounting socket bolts. Disconnect the alternator/ignition pulse generator 6P (Natural) connector.
  • Page 131 Engine Servicing (1) SNAP RING (2) WASHER (1) BEARING REMOVER (1) BUSHING (2) O-RING (3) WASHER (4) SNAP RING Check the crankshaft bushing for wear or damage, Remove the crankshaft busing using the following Apply grease to a new O-ring, the install it into the replace if necessary.
  • Page 132 Engine Servicing (1) STATOR (2) IGNITION PULSE GENERATORS (1) DOWEL PINS (2) OIL COLLAR (1) LEFT CRANKCASE COVER (3) SOCKET BOLTS (4) BOLTS (3) NEW GASKET (2) BOLTS (5) GROMMET Install the stator/ignition pulse generator assembly Installation Install the left crankcase cover being careful not to into the left crankcase cover.
  • Page 133 Engine Servicing (1) 6P (NATURAL) CONNECTOR (1) FLYWHEEL HOLDER (1) FLYWHEEL PULLER ADAPTER (2) FLYWHEEL NUT (2) FLYWHEEL PULLER HOLDER (3) FLYWHEEL PULLER BOLT (4) FLYWHEEL Flywheel Connect the alternator/ignition pulse generator 6P (Natural) connector. Removal Pour transmission oil to the specified level. Remove the left crankcase cover (page 4-64).
  • Page 134 Engine Servicing (1) TAPER (1) FLYWHEEL HOLDER (2) FLYWHEEL NUT (1) COUNTERSHAFT COLLAR (2) WOODRUFF KEY Hold the flywheel with a flywheel holder and tighten Crankcase Separation/Disassembly the flywheel nut to the specified torque. Remove the engine from the frame. Tool: Flywheel holder 07725-0040001...
  • Page 135 Engine Servicing (1) CLUTCH OUTER (2) GEAR HOLDER (1) GEAR HOLDER (2) WATER PUMP DRIVE GEAR (1) PRIMARY DRIVE GEAR (2) BALANCER DRIVE GEAR (3) PRIMARY DRIVE GEAR (3) BALANCER DRIVEN GEAR (3) WATER PUMP DRIVE GEAR (4) BALANCER DRIVEN GEAR Temporarily install the clutch outer guide, needle Hold the primary drive and driven gear with the gear Remove the primary drive gear, washer, primary...
  • Page 136 Engine Servicing (1) BOLT (2) REED VALVE STOPPER (1) DOWEL PINS (1) INNER ROTOR (2) OUTER ROTOR (1) CRANKCASE BOLTS (1) CRANKSHAFT (1) BOLT (2) BALANCER SHAFT (2) OIL PUMP COVER Remove the bolt and reed valve/reed valve stopper. Place the left crankcase facing down, remove the Remove the scavenge pump inner and outer rotor right crankcase from the left crankcase.
  • Page 137 Engine Servicing (1) DOWEL PINS (2) RELIEF VALVE (1) BOLT (2) PISTON JET (1) CONNECTING ROD BOLTS (3) OIL PUMP SHAFT (4) INNER ROTOR (2) BEARING CAP (5) OUTER ROTOR Crankshaft Inspection Remove the connecting rod bolts, bearing cap and connecting rod.
  • Page 138 Engine Servicing (1) PLASTIGAUGE (1) BEARING CAP (2) CONNECTING ROD BOLT Crankpin Bearing Inspection Carefully install the connecting rod bearing cap, Tighten the bolts in 2 -3 steps alternately, then tight- aligning the dowel pins with the holes in the con- en the bolts to the specified torque.
  • Page 139 Engine Servicing (1) CONNECTING ROD I.D. CODE (1) CRANKPIN O.D. CODE Remove the connecting rod bolts and bearing cap, Bearing Selection If you plan to replace the crankshaft, record the cor- and measure the compressed plastigauge at its responding crankpin O.D. code letter (A, B and C). widest point on the crankpin to determine the oil The crankpin bearing must be selected, if the crank- clearance.
  • Page 140 Engine Servicing Cross-reference the connecting rod and crankpin codes to determine the replacement bearing color. Crankpin bearing selection table: Connecting Rod I.D. Code 38.000 - 38.006 mm 38.006 - 38.012 mm 38.012 - 38.018 mm (1.4961 - 1.4963 in) (1.4963 - 1.4965 in) (1.4965 - 1.4968 in) 34.997 - 35.003 mm (1.3778 - 1.3781 in)
  • Page 141 Engine Servicing Cross-reference the crankcase I.D. code and measured main journal O.D., calculate the main journal oil clear- ance. Main Journal Bearing Selection Table: Main journal O.D. Code 37.994 - 38.000 mm 37.988 - 37.994 mm 37.982 - 37.988 mm (1.4958 - 1.4961 in) (1.4956 - 1.4958 in) (1.4954 - 1.4956 in)
  • Page 142 Engine Servicing (1) BEARING HOLDER ASSEMBLY (1) BEARING HOLDER ASSEMBLY (1) BALANCER OIL SEAL (2) MAIN JOURNAL BEARING (2) BEARING FIT SPINDLE (2) CRANKSHAFT OIL SEAL Set the bearing with bearing holder assembly. Press the bearing into the crankcase while pushing the bearing using the 20.5 mm side of the bearing fit spindle as shown.
  • Page 143 Engine Servicing Crankcase Bearings/Oil Seals To be bottomed (10) (1) SCREW (2) SET PLATE To be bottomed To be bottomed Apply locking agent (11) To be bottomed To be bottomed (6) LEFT MAINSHAFT BEARING (1) WATER PUMP BEARING (7) LEFT COUNTERSHAFT BEARING (2) BALANCER OIL SEAL (1) BEARING REMOVER (8) LEFT COUNTERSHAFT OIL SEAL...
  • Page 144 Engine Servicing (1) DRIVER (1) DRIVER (1) SET PLATE (2) ATTACHMENT/PILOT (2) ATTACHMENT/PILOT (2) SCREW Drive the balancer bearings in using the following Drive the bearing in using the following tools. Apply a locking agent to the countershaft bearing tools. set plate screw threads.
  • Page 145 Engine Servicing (1) LEFT CRANKCASE (1) OIL SEAL (2) O-RING (1) PISTON JET (3) COUNTERSHAFT COLLAR (1) BALANCER OIL SEAL (1) RIGHT CRANKCASE (1) PISTON JET (2) BOLT (2) CRANKSHAFT OIL SEAL Crankcase Assembly Apply grease to the new dust seal lips. Install the piston jet to the left crankcase.
  • Page 146 Engine Servicing (1) OIL JET (1) INNER ROTOR (2) OUTER ROTOR (1) RELIEF VALVE (2) OIL PUMP SHAFT (3) OUTER ROTOR (4) INNER ROTOR Apply engine oil to each pump rotors. If the oil jet is removed, apply a locking agent to the Install a new O-ring into the groove of the pressure oil jet threads.
  • Page 147 Engine Servicing (1) DOWEL PINS (1) INNER ROTOR (2) OUTER ROTOR (1) CRANKSHAFT (2) BALANCER SHAFT Place the left crankcase with the oil pump cover side Install the balancer shaft and crankshaft to the left facing down. crankcase. Install the right crankcase side scavenge pump inner and outer rotor onto the inside of the left crankcase.
  • Page 148 Engine Servicing 17 - 20 mm (0.7 - 0.8 in) (1) SEALANT (1) BOLTS (1) REED VALVE (2) REED VALVE STOPPER Install the right crankcase onto the left crankcase. Install the crankcase bolts. Tighten the crankcase bolts in a crisscross patten 2 - 3 steps.
  • Page 149 Engine Servicing (1) BALANCER DRIVE GEAR (2) PRIMARY DRIVE GEAR (1) CLUTCH OUTER (2) GEAR HOLDER (1) GEAR HOLDER (2) WATER PUMP DRIVE GEAR (3) BALANCER DRIVEN GEAR (3) PRIMARY DRIVE GEAR (3) BALANCER DRIVEN GEAR (4) WATER PUMP DRIVE GEAR Install the balancer drive gear and primary drive Temporarily install the clutch outer guide, needle Hold the primary drive and driven gear with the gear...
  • Page 150 Memo...
  • Page 151 5. Frame Servicing Disassembly/Assembly Less than 60 g (1) AXLE NUT (2) AXLE PINCH BOLTS Front Wheel Removal Remove the axle nut. Loosen the axle pinch bolts. Support the machine and front wheel off the ground. Torque: 12 N • m（1.2 kgf • m, Remove the axle and front wheel.
  • Page 152 Frame Servicing (1) DIAL GAUGE (1) BALANCE MARK (2) VALVE STEM (1) INSPECTION STAND Inspection Wheel/Tire Balance Mount the wheel, tire and brake disc assembly in an Wheel balance directly affects the stability, handling inspection stand. Wheel Rim and overall safety of the machine. Always check the Spin the wheel, allow it to stop, and mark the lowest Spin the wheel slowly and measure the runout balance when the tire has been removed from the...
  • Page 153 Frame Servicing (1) AXLE (1) AXLE NUT (2) AXLE HOLDER BOLTS Installation Hold the axle and tighten the axle nut to the speci- fied torque. Clean the surfaces where the axle and axle clamps contact each other. Torque: 70 N•m (7.1 kgf•m, 51 lbf•ft) Place the front wheel between the fork legs.
  • Page 154 Frame Servicing (1) HANDLEBAR (2) TOP BRIDGE (1) FORK BOLT (2) FORK SET COLLAR (1) STOP RING (3) BOTTOM BRIDGE (4) FORK LEG Fork Disassembly Removal Before disassembling the fork, clean the entire slid- ing surface and around the bottom socket bolt. Remove the front wheel (page 5-1).
  • Page 155 Frame Servicing (1) SPRING SEAT STOPPER (2) FORK BOLT (1) SPRING SEAT STOPPER (2) SPRING COLLAR (1) AXLE HOLDER (3) JOINT PLATE (4) FORK SPRING (5) LOCK NUT (6) REBOUND ADJUSTER Pull the fork spring seat stopper down to access the Hold the axle holder in a vise protected with a piece cut-out in the damping adjuster with an 17 mm open of wood or soft jaws to avoid damage.
  • Page 156 Frame Servicing (1) FORK DAMPER (2) CENTERING PLATE (1) STOP RING (1) SLIDER BUSHING (2) GUIDE BUSHING (3) SLIDER (3) BACK-UP RING (4) OIL SEAL (5) STOP RING Remove the following: Remove the slider bushing by prying the slot with a –...
  • Page 157 Frame Servicing (1) OUTER TUBE (2) FORK DAMPER (1) GUIDE BUSHING (2) BACK-UP RING (1) OIL LOCK VALVE Inspection Outer Tube/Fork Damper Check the oil lock valve for wear or damage. Check the outer tube for damage or deformation. ･ Do not disassemble the fork damper. Do not loose Check the damper rod of the damper for wear or the rebound adjuster lock nut or remove the damage.
  • Page 158 Frame Servicing (1) FORK SLIDER (1) NEW SLIDER BUSHING (2) GUIDE BUSHING (3) BACK-UP RING (4) NEW OIL SEAL (5) STOP RING Fork Slider Assembly Wrap the end of the slider with a tape. Install the stop ring. ･ Inspect the fork slider sliding surfaces for damag- ･...
  • Page 159 Frame Servicing (1) OIL SEAL DRIVER (2) ATTACHMENT (1) FORK SET COLLAR (1) CENTERING PLATE (2) FORK DAMPER (3) STOP RING (4) NEW OIL SEAL (5) BACK-UP RING (6) GUIDE BUSHING The slider can move up and down freely in the outer tube.
  • Page 160 Frame Servicing (1) AXLE HOLDER (1) OUTER TUBE (1) OIL LEVEL Hold the axle holder in a vise protected with a piece You must use the fork set collar for correct oil level Measure the oil level from the top of the slider. of wood or soft jaws to avoid damage.
  • Page 161 Frame Servicing (1) FORK SPRING (2) JOINT PLATE (1) NEW O-RING (2) FORK BOLT (1) FORK BOLT (3) SPRING COLLAR (4) SPRING SEAT STOPPER (3) CUT-OUT Install the fork spring with the identification mark Install a new O-ring onto the fork bolt. facing up.
  • Page 162 Frame Servicing (1) NEW O-RING (2) PRELOAD ADJUSTER (1) OUTER TUBE (2) TOP BRIDGE (1) FORK BOLT (2) TOP BRIDGE PINCH BOLT (3) HANDLEBAR (4) BOTTOM BRIDGE PINCH BOLTS Installation Tighten the fork bolt to the specified torque. Install the fork leg. Torque: 34 N•m (3.5 kgf•m, 25 lbf•ft) Raise the fork through the bottom bridge, handlebar and top bridge.
  • Page 163 Frame Servicing (1) FRONT FENDER (2) BRAKE CALIPER (1) SCREWS (2)COVER (1) SCREW (2) ENGINE STOP SWITCH Install the front fender and tighten the bolts. Install the brake caliper and tighten the bolts. Install the front wheel (page 5-3) (1) THROTTLE CABLES (2) THROTTLE PIPE (1) SCREW (2) CLUTCH LEVER BRACKET Handlebar...
  • Page 164 Frame Servicing (1) STEM BOLT (1) STEM BOLT (2) TOP BRIDGE (1) ADJUSTING NUT (2) TOP BRIDGE PINCH BOLTS (2) STEERING STEM SOCKET (3) HANDLEBAR PINCH BOLTS Steering Stem Remove the steering stem bolt. Loosen the top bridge pinch bolts and remove the top bridge.
  • Page 165 Frame Servicing (1) DRIVER SHAFT (2) NUT (3) COLLAR (4) ATTACHMENT, 47 MM (5) ATTACHMENT, 51 MM Outer Race Replacement Always replace the steering bearings and races as a set. If the machine has been involved in an accident, examine the steering stem and the area around the steering head for cracks.
  • Page 166 Frame Servicing (1) ADJUSTING NUT (2) LOWER BEARING (1) NEW DUST SEAL (1) LOWER BEARING (2) STEERING STEM (3) DUST SEAL (2) NEW LOWER BEARING (3) NEW UPPER BEARING (4) NEW DUST SEAL Lower Bearing Replacement Install the following: Installation Temporarily install the stem bearing adjusting nut –...
  • Page 167 Frame Servicing (1) BEARING ADJUSTING NUT (1) STEERING STEM (1) BEARING ADJUSTING NUT (2) STEERING STEM SOCKET Install the steering stem as follows: 2. Move the steering stem right and left, lock-to-lock 3. Loosen the bearing adjusting nut, so that the 1.
  • Page 168 Frame Servicing 6.2 mm (0.24 in) 4 mm (0.2 in) (1) STEERING STEM (1) ADJUSTING NUT (1) FORK LEGS (2) TOP BRIDGE (2) STEERING STEM SOCKET (3) STEM BOLT 5. Move the steering stem right and left, lock-to-lock Install the following: several times to seat the bearings.
  • Page 169 Frame Servicing Disassembly/Assembly Less than 60 g (1) AXLE NUT Rear Wheel (12) Removal To be Support the machine using the maintenance stand. bottomed to wheel Loosen the drive chain. (13) Torque: 41 N • m（4.2 kgf • m, Torque: 62 N • m（6.3 kgf • m, 30 lbf •...
  • Page 170 Frame Servicing (1) AXLE NUT (1) BOLT/NUT (1) UPPER MOUNTING BOLT/NUT (2) DRIVE CHAIN ADJUSTER (2) DRIVE CHAIN ROLLER (2) REAR SHOCK ABSORBER (3) LOWER MOUNTING BOLT/NUT Rear Shock Absorber Installation Remove the following: – upper mounting nut and bolt Place the rear wheel between the swingarm while Removal –...
  • Page 171 Frame Servicing 10 mm (0.4 in) (1) SPRING SEAT STOPPERS (2) SPRING SEAT (1) DAMPER ROD (2) MARK (1) RESERVOIR (2) VALVE CORE (3) SPRING GUIDE (4) SPRING (3) HYDRAULIC PRESS Disassembly Damper Nitrogen Releasing Procedure Check for oil leakage from the damper rod. Loosen the spring lock nut and adjuster.
  • Page 172 Frame Servicing (1) SPHERICAL BEARING DRIVER (1) PIVOT COLLARS (2) STOP RINGS (1) AIR TOOL (3) SPHERICAL BEARING DRIVER (2) STOP RING (3) SPHERICAL BEARING Spherical Bearing Replacement Inspect the spherical bearing prior to extensive use. If the movement is not smooth, be sure to perform Hold the shock absorber in a vise with a piece of braking-in procedures to the extent that the parts wood or shop towel.
  • Page 173 Frame Servicing (1) REBOUND ADJUSTER (1) UPPER MOUNTING BOLT/NUT (1) SPRING (2) SPRING GUIDE (3) SPRING SEAT (4) SPRING SEAT STOPPERS (2) REAR SHOCK ABSORBER Assembly Installation Install the O-ring onto the damper case. Install the rear shock absorber with its tension Install the shock absorber spring with tapered end adjuster facing to the right.
  • Page 174 Frame Servicing 5.1 – 5.4 mm (0.20 – 0.21 in) (1) LOWER MOUNTING BOLT/NUT (1) BOLTS/NUTS (2) LOWER MOUNTING BOLT/NUT (1) PIVOT COLLAR (2) DRIVE CHAIN ROLLER (3) SHOCK LINK (2) DUST SEALS (3) BOLT/NUT (4) SHOCK ARM PLATES (3) NEEDLE BEARING Shock Linkage Move the swingarm aligning the upper mount, then Bearing Replacement...
  • Page 175 Frame Servicing (1) SHOCK ARM PLATES (2) SHOCK LINK (1) TIE-WRAPS (1) BOLT/NUT (3) BOLTS/NUTS (2) DRIVE CHAIN ROLLER (4) LOWER MOUNTING BOLT/NUT Swingarm Installation Install the following: Removal – shock arm plates – shock arm-to-swingarm bolt/nut Remove the following: –...
  • Page 176 Frame Servicing (1) PIVOT BOLT (1) SCREWS (2) DRIVE CHAIN SLIDER (1) PIVOT NUT (2) ADJUSTING BOLT Turn the swingarm pivot bolt and loosen the pivot adjusting bolt. Remove the swingarm pivot bolt and swingarm. (1) LOCK NUT WRENCH (1) SCREWS (2) DRIVE CHAIN SLIDER Remove the swingarm pivot nut.
  • Page 177 Frame Servicing Swingarm Pivot Bearing Replacement ･ Replace the swingarm bearings as a set. 4.0 – 5.0 mm (0.16 – 0.20 in) To be bottomed (1) PIVOT COLLAR B (2) DUST SEALS (3) DISTANCE COLLAR (4) SNAP RING Remove pivot collar B. Remove the dust seals and distance collar.
  • Page 178 Frame Servicing 4.0 mm (0.16 in) (1) BEARING REMOVER SET (1) DRIVER (2) ATTACHMENT/PILOT (1) DRIVER (2) ATTACHMENT/PILOT Press a new left pivot bearing in using the special Press the new right pivot bearings in using the spe- tools. cial tools. Face the bearing with its marked side facing out.
  • Page 179 Frame Servicing 5.2 – 5.7 mm (0.20 – 0.22 in) (1) SNAP RING (2) RIGHT DUST SEAL (1) CHAIN GUARD (2) BOLTS (1) DRIVER (2) ATTACHMENT/PILOT (3) DUST SEALS (4) NEEDLE BEARING (3) DISTANCE COLLAR (4) LEFT DUST SEAL (5) PIVOT COLLAR B Press the shock arm plate pivot needle bearing out Assembly using the special tools.
  • Page 180 Frame Servicing (1) ADJUSTING BOLT (1) ADJUSTING BOLT (2) PIVOT BOLT (1) LOCK NUT WRENCH Installation Install the swingarm. Install and tighten the swingarm adjusting bolt lock Apply a thin layer of grease to the swingarm pivot nut to the specified torque. Apply grease to the swingarm adjusting bolt bolt surface.
  • Page 181 Frame Servicing (1) PIVOT NUT (1) SHOCK ARM PLATES (1) drive chain roller (2) SHOCK ARM PLATE BOLT/NUT (2) bolt/nut (3) LOWER MOUNTING BOLT/NUT Hold the pivot bolt and install and tighten the Install the following: Install the drive chain roller and tighten the bolt/nut. swingarm pivot nut to the specified torque.
  • Page 182 Frame Servicing (1) BRAKE HOSE (1) BOLTS (2) CALIPER (1) BRAKE PADS (1) TIE-WRAPS Brake Pad Replacement Route the brake hose properly, install the rear brake caliper bracket (page 5-35). Secure the brake hose using the tie-wraps as shown. Front Brake Pad Replacement Install the rear wheel (page 5-20).
  • Page 183 Frame Servicing (1) CALIPER PISTONS (1) BRAKE CALIPER (2) BOLTS (1) PAD PIN PLUGS (2) PAD PINS Install the caliper to the fork slider so the disc is posi- Rear Brake Pad Replacement tioned between the pads, being careful not to dam- age the pads.
  • Page 184 Frame Servicing (1) CALIPER PISTON (2) PAD SPRING (1) PAD PINS (2) PAD PIN PLUGS Push the piston all the way in to allow installation of Tighten the pad pins. new brake pads. Check the brake fluid level in the vinyl tube as this Torque: 18 N•m (1.8 kgf•m, 13 lbf•ft) operation causes the level to rise.
  • Page 185 Frame Servicing (1) OIL BOLT (2) BRAKE HOSE (1) BRAKE CALIPER (2) BOLTS (1) OIL BOLT (2) BRAKE HOSE (3) BOLTS (4) BRAKE CALIPER (3) BRAKE HOSE (4) NEW SEALING WASHERS (5) OIL BOLT Front Brake Caliper Rear Brake Caliper Never disassemble the caliper.
  • Page 186 Frame Servicing Disassembly/Assembly Torque: 12 N•m (1.2 kgf•m, 9 lbf•ft) Torque: Apply silicone grease 7 N•m (0.7 kgf•m, 5.1 lbf•ft) (1) TORQUE LINK (2) SNAP RING (3) WASHER (4) BRACKET (2) (3) Apply brake fluid Apply silicone grease Remove the rear brake torque link bolt/nut. Remove snap ring,...
  • Page 187 Frame Servicing (1) BRACKET COLLAR (1) BRAKE HOSE (2) NEW SEALING WASHERS (1) OIL BOLT (2) BOLTS (3) HOLDER (2) CALIPER BRACKET ASSEMBLY (3) OIL BOLT (4) MASTER CYLINDER (3) WASHER (4) SNAP RING Front Master Cylinder Installation Install the brake hose eyelet joint with new sealing washers.
  • Page 188 Frame Servicing Disassembly/Assembly (1) JOINT PIN (2) ADJUSTER (3) ADJUSTER ARM (4) PIVOT SCREW If the brake lever was disassembled, assemble as follows: 1. Install the joint pin with its arrow facing to the adjuster. 2. Apply silicone grease to the adjuster rod. 3.
  • Page 189 Frame Servicing (1) MASTER CYLINDER (2) UP MARK (1) TIE-WRAP (2) JOINT BOLT/NUT (1) OIL BOLT (2) SEALING WASHERS (3) NEW SEALING WASHERS (4) OIL BOLT (3) BOLTS (4) MASTER CYLINDER Rear Master Cylinder Installation Remove the brake hose oil bolt and disconnect the brake hose eyelet joint.
  • Page 190 Frame Servicing Disassembly/Assembly (1) MASTER CYLINDER (2) BOLTS (3) EYELET JOINT (4) NEW SEALING WASHERS (5) OIL BOLT Installation Install the master cylinder onto the bracket. Install and tighten the mounting bolts. Connect the brake hose eyelet joint with new sealing washers.
  • Page 191 Frame Servicing (1) JOINT BOLT/NUT (2) VINYL TUBE (3) TIE-WRAPS Connect the joint with the brake pedal. Install the washer and joint bolt/nut, then tighten the nut. Secure the vinyl tube with a tie wrap. Fill the reservoir and bleed the system. 5-41...
  • Page 192 Memo...
  • Page 193 6. Electrical Servicing (1) 5P (BLACK) CONNECTOR (1) 6P (NATURAL) CONNECTOR (1) 4P (RED) CONNECTOR Charging System Inspection If the resistance is out of specification, disconnect Regulated Voltage Inspection the alternator 6P (Natural) connector and measure Alternator Charging Coil the resistance between the terminals of the alterna- Disconnect the service check 4P (Red) connector.
  • Page 194 Electrical Servicing (1) 5P (NATURAL) CONNECTOR (1) 33P (BLACK) CONNECTOR (1) 2P (NATURAL) CONNECTOR (2) BOLTS (2) PGM-FI/IGN UNIT (2) DIRECT IGNITION COIL (3) REGULATOR/RECTIFIER Ignition System Inspection Regulator/Rectifier Removal/installation Disconnect the direct ignition coil 2P (Natural) con- nector. Disconnect the regulator/rectifier 5P (Black) connec- Disconnect the PGM-FI/IGN unit 33P (Black) connec- tor.
  • Page 195 Electrical Servicing (1) 2P (NATURAL) CONNECTOR (1) 33P (BLACK) CONNECTOR (1) 6P (NATURAL) CONNECTOR (2) DIRECT IGNITION COIL (2) PGM-FI/IGN UNIT Removal/Installation Ignition Pulse Generator Inspection If the resistance is out of specification, measure the resistance at the alternator 6P (Natural) connector. Remove the fuel tank.
  • Page 196 Electrical Servicing (1) CONDENSER (1) 2P (LIGHT GRAY) CONNECTOR (1) 2P (BLUE) CONNECTOR Condenser Inspection Engine Stop Switch Inspection Hand Shifter Switch Inspection If the engine does not start, check for the items Disconnect the engine stop switch 2P (Light gray) Disconnect the hand shifter switch 2P (Blue) connec- “engine does not start”...
  • Page 197 Electrical Servicing A-11 A-12 A-22 A-23 A-33 (1) 33P (BLACK) CONNECTOR PGM-FI System Inspection Place the motorcycle upright position and remove the rear fender. Disconnect the ECM 33P (Black) connector. Check for the following at the ECM terminals of the wire harness side. Item Terminal Standard...
  • Page 198 Electrical Servicing (1) INTERFACE UNIT ASSEMBLY (1) POWER SWITCH (1) POWER SWITCH (2) RED WIRE EYELET (3) GREEN WIRE EYELET (2) MIL (2) MIL (4) USB CONNECTOR (5) 4P (RED) CONNECTOR (3) WARNING/RESET SWITCH (3) WARNING/RESET SWITCH PGM-FI Turn the serial-USB interface unit warning/reset Self-diagnosis Reset Procedure switch to the warning side as shown.
  • Page 199 Electrical Servicing PGM-FI Self-diagnosis Malfunction Indicator Lamp (MIL) Failure Codes • The PGM-FI MIL denotes the failure codes (the number of blinks from 0 to 69). When the indicator lights for 1.3 seconds, it is equivalent to ten blinks. For exam- ple;...
  • Page 200 Electrical Servicing (1) SCREWS (1) ARROW/UP MARK (2) BANK ANGLE SENSOR (2) BANK ANGLE SENSOR Bank Angle Sensor Inspection Connect the bank angle sensor 3P (Natural) connec- Install the bank angle sensor in the reverse order of tor. removal. Remove the screws and bank angle sensor from the With the arrow mark on the bank angle sensor fac- Install the bank angle sensor with its arrow/UP mark sensor bracket.
  • Page 201 Electrical Servicing (1) 2P (BLACK) CONNECTOR (1) WATER TEMPERATURE SENSOR (1) PGM-FI 33P (BLACK) CONNECTOR Water Temperature Sensor Meter Inspection If there is no continuity, check the wire harness. If there is continuity, check the water temperature Sensor Inspection If the water temperature meter does not display, sensor.
  • Page 202 Electrical Servicing Wiring Diagram ENGINE HAND CONDENSOR STOP SWITCH SWITCH TEMP TACHO SHIFT METER METER FUEL INDICATOR INDICATOR PUMP CHECK DATA QSSW ( BLACK ) ( R ) ( Bu ) ( Gr ) ( Bl ) MINI MINI MINI ( Bl ) ( Gr ) ( Bu )
  • Page 203 7. Machine Setting Optional Transmission Gears Optional transmission gears are available for use the transmission. Care should be taken when substituting optional gears for the standard gears. The optional low gear/mainshaft has marking etched on the shaft end for identification. Identification for other gears is aided by a marking located on the side of the gear.
  • Page 204 Machine Setting Gear Identification Mark/Parts Number Teeth Main Counter Gear Ratio 3rd/4th 23445-NX4-000 23451-NX4-681 1.304 M4-P4 C4-P4 23464-NX4-681 1.238 23445-NX4-000 23451-NX4-681 1.304 M4-P4 C4-P5 23465-NX4-681 1.190 23445-NX4-000 C3-P3 23453-NX4-681 1.260 M4-P4 C4-P4 23464-NX4-681 1.238 23445-NX4-000 C3-P3 23453-NX4-681 1.260 M4-P4 C4-P5 23465-NX4-681 1.190 23446-NX4-000...
  • Page 205 Machine Setting Gear Identification Mark/Parts Number Teeth Main Counter Gear Ratio 3rd/4th M3-P4 23442-NX4-610 C3-P4 23454-NX4-681 1.409 M4-P4 C4-P4 23464-NX4-681 1.238 M3-P4 23442-NX4-610 C3-P4 23454-NX4-681 1.409 M4-P4 C4-P5 23465-NX4-681 1.190 M3-P4 23442-NX4-610 C3-P5 23455-NX4-681 1.318 M4-P4 C4-P4 23464-NX4-681 1.238 M3-P4 23442-NX4-610 C3-P5 23455-NX4-681...
  • Page 206 Machine Setting Speed List (13,500 rpm) Primary reduction: 21/62 Tire: R= 299 mm Gear Teeth Gear Ratio Drive Driven 2.000 1.937 1.875 1.812 1.764 1.705 1.611 1.555 1.523 1.500 1.473 1.409 1.350 1.318 1.304 1.285 1.260 1.238 1.208 1.190 1.166 1.150 1.136 1.120...
  • Page 207 Machine Setting Speed List (13,500 rpm) Primary reduction: 21/62 Tire: R= 299 mm Gear Teeth Gear Ratio Drive Driven 2.000 1.937 1.875 1.812 1.764 1.705 1.611 1.555 1.523 1.500 1.473 1.409 1.350 1.318 1.304 1.285 1.260 1.238 1.208 1.190 1.166 1.150 1.136 1.120...
  • Page 208 Machine Setting Speed List (13,500 rpm) Primary reduction: 21/62 Tire: R= 299 mm Gear Teeth Gear Ratio Drive Driven 2.000 1.937 1.875 1.812 1.764 1.705 1.611 1.555 1.523 1.500 1.473 1.409 1.350 1.318 1.304 1.285 1.260 1.238 1.208 1.190 1.166 1.150 1.136 1.120...
  • Page 209 Machine Setting Suspension Adjustment Standard Setting Always start from standard setting when adjusting the suspension. If you become confused about adjustment settings, return to the standard setting and start over. Shock Absorber Fork 18 mm 27.5 mm (0.7 in) (1.08 in) Height 15 mm adjuster...
  • Page 210 Machine Setting 4.0 mm (0.16 in) R: 9.5 mm (0.37 in) L: 14.5 mm (0.57 in) (1) TY-RAP (1) SUSPENSION STOPS POSITION (1) SUSPENSION STOPS POSITION (2) TY-RAP (3) O-RING (2) FULLY STROKE POSITION Suspension stroke is affected by lap times, tire grip, Inspect the stroke from stop position.
  • Page 211 Machine Setting 18 mm (0.7 in) 15 mm (0.6 in) (1) FORK PRELOAD ADJUSTER (1) REBOUND ADJUSTER (1) PRELOAD ADJUSTER (2) REAR SHOCK ABSORBER PRELOAD ADJUSTER (2) COMPRESSION ADJUSTER Adjust the suspension stroke using the spring pre- Front Suspension Adjustment Spring Preload Adjustment load adjuster.
  • Page 212 Machine Setting (1) FORK SET COLLAR (2) STOPPER RING (1) SPRING COLLAR (2) SPRING SEAT STOPPER (1) SPRING SEAT STOPPER (3) FORK BOLT (3) FORK BOLT (2) SPRING COLLAR (3) JOINT PLATE (4) FORK SPRING Fork Spring Replacement Push down on the spring collar and spring seat stop- Remove the following: Support the machine using the maintenance stand.
  • Page 213 Machine Setting Optional Spring Characteristics LOAD （kgf） STROKE (mm) Spring Identification (1) FORK SET COLLAR (2) DAMPER ROD (1) OIL LEVEL Fluid Level Adjustment Oil Level Characteristics Identification Fork fluid level should be checked with the Fork Set Spring rate Pre-load Color Collar installed.
  • Page 214 Machine Setting (1) COMPRESSION ADJUSTER (1) REBOUND ADJUSTER (1) LOCK NUT (2) ADJUSTER Rear Suspension Adjustment Rebound Damping Adjustment Spring Preload Adjustment The rebound damping adjuster is at the base of the Loosen the lock nut and turn the spring preload Make sure the rear shock reservoir is facing rear- shock absorber.
  • Page 215 Machine Setting HIGH RATE LOAD （kgf） STANDARD RATE HIGH RATE 1G POSITION STROKE (mm) PRELOAD (1) UPPER JOINT (2) LOCK NUT (1) PRELOAD LENGTH Ride Height Adjustment Spring Replacement Install the rear shock absorber spring (page 5-23). Make sure the suspension is not loaded when check- Remove the rear shock absorber, then remove the Adjust the ride height.
  • Page 216 Machine Setting Troubleshooting Suspension Set-up Symptom Suspected Causes Countermeasures Bottoming (a solid feeling) Poor performance • Check fork and rear shock absorber assembly performance. Confirm that the fork pipe and rod are not bent, If there is such trouble, modify or exchange the defective part. •...

  • Page 217: Table Of Contents

    2012-NSF250R PARTS LIST Contents Instructions for Use of Parts List..........8- 2 Fuel Hose, General Purpose Hoses and Vinyl Hose ....8- 3 FRAME GROUP ENGINE GROUP E- 1 CYLINDER HEAD ............8- 7 F- 1 METER................8- 35 F- 2 HANDLE LEVER / SWITCH / CABLE......

  • Page 218: Instructions For Use Of Parts List

    No. • The parts that have a dot "•" on the left side of the "Ref. No." are exclusive for HRC products. To purchase these parts, consult your Honda dealer. • The parts that have no dot are Honda products and can be pur- chased from your nearest Honda motorcycle dealer, or from HRC- JAPAN/EUROPE if you can't obtain the parts locally.

  • Page 219: Fuel Hose, General Purpose Hoses And Vinyl Hose

    Fuel Hose, general purpose hoses and vinyl hose • The standard part fuel hose, general purpose hose and vinyl hose may be substituted by the coiled bulk part. • When ordering the standard part fuel hose, general purpose hose and vinyl hose use the bulk part number written in the parts catalogue in brackets ( ) under- neath the part name, or use the catalogue below.
  • Page 220 Vinyl Tube Vinyl Tube Vinyl Tube Bulk Part Bulk Part Bulk Part Standard Part Bulk Part No. Inner Outer Standard Part Bulk Part No. Inner Outer Standard Part Bulk Part No. Inner Outer Length Length Length Diameter Diameter Diameter Diameter Diameter Diameter (mm) (mm)
  • Page 221 General Purpose Hoses General Purpose Hoses Bulk Part Bulk Part Inner Inner Standard Part No. Bulk Part No. Standard Part No. Bulk Part No. Length Length Diameter Diameter (mm) (mm) 95005-11xxx-3x 95005-11001-30M 11.0 95005-45001-10M 95005-11xxx-5x 95005-11001-50M 11.0 95005-45xxx-4x <95005-45003-10M> 95005-12001-10M <95005-45008-10M>...
  • Page 222 • Bulk part number of fuel hose, general purpose hose and vinyl hose. (Example) 95001 - 75001 - 50M Bulk part number: Refers to the bulk part. Marking code (hose type): (fuel hose and general purpose hose) Change code (for added hose): (Vinyl hose) •...

  • Page 223: Cylinder Head

    Block No. F-15 CYLINDER HEAD 2012 NSF250R F-22 Ref. Part No. Description Reqd. No. Remarks • 00X30-NX7-000 SET UP MANUAL PARTS LIST ........•...
  • Page 224 Block No. F-15 CYLINDER HEAD 2012 NSF250R F-22 Ref. Part No. Description Reqd. No. Remarks 90543-MV9-670 RUBBER, MOUNT ..........91356-425-005 O-RING, 29.7X2.4 .

  • Page 225: Camshaft / Valve

    Block No. CAMSHAFT / VALVE 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 12208-NX7-003 SEAL, VALVE STEM ......... . . Dark green / Black paint •...
  • Page 226 Block No. CAMSHAFT / VALVE 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks 14906-KT7-013 SHIM, TAPPET 1.325 ......... . . 14907-KT7-013 SHIM, TAPPET 1.35 .
  • Page 227 Block No. CAMSHAFT / VALVE 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks 14929-KT7-013 SHIM, TAPPET 1.90 ..........14930-KT7-013 SHIM, TAPPET 1.925 .
  • Page 228 Block No. CAMSHAFT / VALVE 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks 14952-KT7-013 SHIM, TAPPET 2.475 ......... . . 14953-KT7-013 SHIM, TAPPET 2.50 .

  • Page 229: Cam Chain / Tensioner

    Block No. CAM CHAIN / TENSIONER 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 14401-NX7-003 CHAIN, CAM ..........•...

  • Page 230: Cylinder

    Block No. CYLINDER 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 12101-NX7-000 CYLINDER ........... . •...

  • Page 231: Right Crankcase Cover

    Block No. RIGHT CRANKCASE COVER 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 11331-NX7-000 COVER, R. CRANKCASE ........•...

  • Page 232: Clutch

    Block No. CLUTCH 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 22100-NX7-000 OUTER COMP., CLUTCH ........•...

  • Page 233: Oil Pump

    Block No. OIL PUMP 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 15110-NX7-000 COVER COMP., OIL PUMP ........15122-KK0-000 ROTOR, OIL PUMP OUTER .

  • Page 234: Water Pump

    Block No. WATER PUMP 2012 NSF250R F-22 Ref. Part No. Description Reqd. No. Remarks • 19215-NX7-000 IMPELLER, WATER PUMP ........Left-hand thread •...

  • Page 235: Left Crankcase Cover

    Block No. LEFT CRANKCASE COVER 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 11340-NX7-000 COVER COMP., L. CRANKCASE ........•...
  • Page 236 Block No. LEFT CRANKCASE COVER 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks 91308-PW4-003 O-RING, 21.8X1.9 ..........91313-MN5-004 O-RING, 7.8X1.9 .

  • Page 237: Generator

    Block No. E-10 GENERATOR 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 31110-NX7-003 FLYWHEEL COMP..........•...

  • Page 238: Crankcase

    PLATE, ENG. NUMBER ......... . No sale by HRC •...
  • Page 239 Block No. E-11 F-15 CRANKCASE 40 41 36 36 2012 NSF250R F-16 Ref. Part No. Description Reqd. No. Remarks 91001-KA3-711 BRG., BALL, 6204 ..........•...
  • Page 240 Block No. E-11 F-15 CRANKCASE 40 41 36 36 2012 NSF250R F-16 Ref. Part No. Description Reqd. No. Remarks 96001-06065-00 BOLT, FLANGE, SH, 6X65 ........96001-06075-00 BOLT, FLANGE, SH, 6X75 .

  • Page 241: Crankshaft / Piston

    Block No. E-12 CRANKSHAFT / PISTON 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 13101-NX7-010 PISTON ............•...
  • Page 242 Block No. E-12 CRANKSHAFT / PISTON 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 15 13615-NX7-000 GEAR, PRIM., DRIVE ......... . . •...
  • Page 243 Block No. E-13 TRANSMISSION 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 23211-NX4-000 SHAFT COMP., MAIN ......... . •...
  • Page 244 Block No. E-13 TRANSMISSION 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 23436-NX4-700 GEAR, C-2ND PLAN-6 ......... . •...

  • Page 245: Transmission

    Block No. E-13 TRANSMISSION 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 10) 23456-NX4-681 GEAR, C-3RD PLAN-6 ......... . 27T / 23456-NX4-680 Cannot be used.
  • Page 246 Block No. E-13 TRANSMISSION 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 17 23501-NX4-010 GEAR, C-6TH ..........24T / 23501-NX4-000 Cannot be used.

  • Page 247: Gearshift Drum

    Block No. E-14 GEARSHIFT DRUM 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 24211-NX4-000 FORK R., GEAR SHIFT ......... . NX4R •...
  • Page 248 Block No. E-14 GEARSHIFT DRUM 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks 90435-HB3-000 WASHER, 6.1mm ..........90451-155-000 WASHER, 14mm .

  • Page 249: Throttle Body

    Block No. E-15 THROTTLE BODY 2012 NSF250R 17 14 F-15 F-13 Ref. Part No. Description Reqd. No. Remarks • 16141-NX7-000 FUNNEL ........... . . •...
  • Page 250 Block No. E-15 THROTTLE BODY 2012 NSF250R 17 14 F-15 F-13 Ref. Part No. Description Reqd. No. Remarks 94050-06000 NUT, FLANGE, 6mm ..........94101-06800 WASHER, PLAIN 6mm .

  • Page 251: Meter

    Block No. METER 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 34908-NX7-003 LED LAMP (BLUE) ..........•...
  • Page 252 Block No. HANDLE LEVER / SWITCH / CABLE 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 17910-NX7-000 CABLE COMP., A, THROTTLE ........•...

  • Page 253: Handle Lever / Switch / Cable

    Block No. HANDLE LEVER / SWITCH / CABLE 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks 93500-04045-0G SCREW, PAN, 4X45 ..........93500-05016-0A SCREW, PAN, 5X16 .

  • Page 254: Front Brake Master Cylinder

    Block No. FRONT BRAKE MASTER CYLINDER 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks 43352-568-003 SCREW, BLEEDER ..........43353-461-771 CAP, BLEEDER .
  • Page 255 Block No. FRONT BRAKE MASTER CYLINDER 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks 90114-MA5-671 BOLT, HANDLE LEVER ......... . 90145-MS9-612 OIL BOLT, 10X22 .

  • Page 256: Handle Pipe / Top Bridge

    Block No. HANDLE PIPE / TOP BRIDGE 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 53105-NF4-770 CAP, HANDLE PIPE ..........•...

  • Page 257: Steering Stem / Steering Damper

    Block No. STEERING STEM / STEERING DAMPER 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 50820-NX7-000 COVER, STRG. UNDER ......... •...

  • Page 258: Front Fender

    Block No. FRONT FENDER 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 61100-NX4-860 FENDER, FR........... 90108-GK1-000 BOLT, FLANGE, SH, 6X12 .

  • Page 259: Front Fork

    Block No. FRONT FORK 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 51400-NX7-003 FORK ASSY., R. FR..........•...
  • Page 260 Block No. FRONT FORK 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 19 51500-NX7-003 FORK ASSY., L. FR..........•...

  • Page 261: Front Brake Caliper

    Block No. FRONT BRAKE CALIPER 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 06451-NX4-860 SEAL SET, PISTON, 34 ......... •...

  • Page 262: Front Wheel

    WT., BALANCER, 1.25G ........No sale by HRC •...

  • Page 263: Rear Brake Caliper

    Block No. F-10 REAR BRAKE CALIPER 2012 NSF250R F-11 Ref. Part No. Description Reqd. No. Remarks • 42305-NX4-000 COLLAR, CALIPER BRKT........•...
  • Page 264 Block No. F-10 REAR BRAKE CALIPER 2012 NSF250R F-11 Ref. Part No. Description Reqd. No. Remarks 94050-08000 NUT, FLANGE, 8mm ..........94102-08000 WASHER, PLAIN, 8mm .

  • Page 265: Rear Brake Master Cylinder

    Block No. F-11 REAR BRAKE MASTER CYLINDER 2012 NSF250R F-10 Ref. Part No. Description Reqd. No. Remarks • 04601-ND5-760 CUP, PRIMARY ..........•...

  • Page 266: Rear Wheel

    TIRE, ASSY., RR. (BS) ......... . No sale by HRC •...
  • Page 267 Block No. F-12 REAR WHEEL 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 12 90102-NX7-000 BOLT, SOCKET, 10X16 ......... 90105-KR3-000 BOLT, FR.

  • Page 268: Fuel Tank / Fuel Pump

    Block No. 18 34 F-13 FUEL TANK / FUEL PUMP 2012 NSF250R E-15 Ref. Part No. Description Reqd. No. Remarks 06160-MEN-A31 KIT, FUEL FILTER ..........15604-MG7-000 GROMMET, OIL COOLER .
  • Page 269 Block No. 18 34 F-13 FUEL TANK / FUEL PUMP 2012 NSF250R E-15 Ref. Part No. Description Reqd. No. Remarks 17575-MEN-A30 COVER, FUEL CONNECTOR ........17576-MEN-A30 RUBBER, FUEL CONNECTOR .
  • Page 270 V-TUBE, 5X8X30 ..........No sale by HRC 95003-10047-31 V-TUBE, 5X8X470 .

  • Page 271: Seat / Seat Cowl

    Block No. F-14 SEAT / SEAT COWL 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks 33712-KC5-003 GROMMET, T/L MT..........61104-KA4-700 COLLAR, FENDER MT.

  • Page 272: Air Box

    Block No. E-15 F-15 AIR BOX E-11 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks 15772-292-010 CLIP, TUBE ........... 16958-MB0-000 JOINT, FUEL TUBE .
  • Page 273 V-TUBE, 8X12X40 ..........No sale by HRC...

  • Page 274: Exhaust Muffler

    Block No. F-16 EXHAUST MUFFLER 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks 14539-KCZ-300 TUBE, TENSIONER SPG......... 18291-MM5-860 GASKET, EXH.
  • Page 275 Block No. F-16 EXHAUST MUFFLER 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks 96001-06032-00 BOLT, FLANGE, SH, 6X32 ........8-59...

  • Page 276: Pedal

    Block No. F-17 PEDAL 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 24700-NF4-780 PEDAL COMP., CHANGE ........•...

  • Page 277: Step

    Block No. F-18 STEP 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 50600-NX4-770 HOLDER, STEP ..........•...

  • Page 278: Swingarm

    Block No. F-19 SWINGARM 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks 17936-921-000 WASHER, PIVOT ..........•...
  • Page 279 Block No. F-19 SWINGARM 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 21 90355-NX4-000 NUT, SWINGARM PIVOT ........90401-KZ4-890 WASHER, 18X32X2 .

  • Page 280: Rear Cushion

    Block No. F-20 REAR CUSHION 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks • 52400-NX7-003 CUSHION ASSY., RR......... . . •...
  • Page 281 Block No. F-20 REAR CUSHION 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks 87516-KS7-832 LABEL, RR. DAMPER WARNING ........87516-MCA-G60 LABEL, RR.

  • Page 282: Wire Harness

    • 13 38771-NX7-000 CD-ROM, HRC DATA SETTING TOOL ......• 14 38880-N1C-770 UNIT ASSY., SERIAL-USB I/F .
  • Page 283 Block No. F-21 WIRE HARNESS 2012 NSF250R F-24 Ref. Part No. Description Reqd. No. Remarks 95701-06025-08 BOLT, FLANGE, 6X25 ......... . . 8-67...

  • Page 284: Radiator

    F-21 Block No. F-22 RADIATOR 2012 NSF250R F-16 Ref. Part No. Description Reqd. No. Remarks • 19010-NX7-000 RADIATOR COMP..........J, AC •...
  • Page 285 V-TUBE, 5X8X230 ..........No sale by HRC 96001-06025-00 BOLT, FLANGE, SH, 6X25 .

  • Page 286: Frame Body

    PLATE, FRAME NO..........No sale by HRC 90004-GHB-620 BOLT, FLANGE, NSHF, 6X14 .

  • Page 287: Cowl

    Block No. F-24 COWL 2012 NSF250R Ref. Part No. Description Reqd. No. Remarks 17413-MBG-770 MAT, CANISTER PROTECTOR ........•...
  • Page 288 2012-NSF250R Part No. Index Part No. Block Part No. Block Part No. Block Part No. Block 00X30-NX7-000 E- 1 11346-NX7-000 E- 9 13217-NX7-003 E-12 14731-NX7-000 E- 2 00X31-NX7-670 E- 1 11350-NX7-000 E- 5 13218-NX7-003 E-12 14751-NX7-000 E- 2 00X32-NX7-650 E- 1 11391-NX7-000 E- 5 13310-NX7-010...
  • Page 289 2012-NSF250R Part No. Index Part No. Block Part No. Block Part No. Block Part No. Block 14925-KT7-013 E- 2 14956-KT7-013 E- 2 15772-292-010 F-15 17235-MEE-D00 F-15 14926-KT7-013 E- 2 14957-KT7-013 E- 2 17240-NX7-000 F-15 14927-KT7-013 E- 2 14958-KT7-013 E- 2 17250-NX7-000 F-15 14928-KT7-013...
  • Page 290 2012-NSF250R Part No. Index Part No. Block Part No. Block Part No. Block Part No. Block 17930-NX7-000 F-15 19130-NX5-770 F-13 23214-NX4-000 E-13 23445-NX4-610 E-13 17936-921-000 F-19 19215-NX7-000 E- 8 23215-NX4-000 E-13 23446-NX4-000 E-13 19221-NX7-000 E- 8 23221-NX4-010 E-13 23446-NX4-610 E-13 19229-NX7-000 E- 8 23225-NX4-000...
  • Page 291 2012-NSF250R Part No. Index Part No. Block Part No. Block Part No. Block Part No. Block 23493-NX4-000 E-13 24700-NF4-780 F-17 38771-MEN-A30 F-21 23494-NX4-000 E-13 24706-NX4-000 F-17 38771-NX7-000 F-21 23501-NX4-010 E-13 24710-NX4-000 F-17 38880-N1C-770 F-21 23502-NX4-010 E-13 24711-NX4-710 F-17 34908-NX7-003 F- 1 23503-NX4-010 E-13 24712-NX4-710...
  • Page 292 2012-NSF250R Part No. Index Part No. Block Part No. Block Part No. Block Part No. Block 42620-NX4-000 F-12 43517-KS6-701 F- 3 45504-410-003 F- 3 50803-NF4-610 F-24 42711-NX7-003 F-12 43541-ND5-750 F-11 45511-KV3-016 F- 3 50810-NX7-000 F- 1 42721-NX4-860 F- 9 45512-NX4-861 F- 3 50811-NX7-000 F- 1...
  • Page 293 2012-NSF250R Part No. Index Part No. Block Part No. Block Part No. Block Part No. Block 52459-NX4-003 F-20 52460-NX4-000 F-20 52465-NX4-000 F-20 52101-NX4-680 F-19 52471-NX4-000 F-20 57270-NX4-910 F-13 87131-NX7-000 F-23 52102-NX4-000 F-19 87208-ND4-000 F-13 52106-NX4-000 F-19 87516-KS7-832 F-20 52109-NX4-000 F-19 87516-MBL-610 F-20 52110-NX7-000...
  • Page 294 2012-NSF250R Part No. Index Part No. Block Part No. Block Part No. Block Part No. Block 90011-NX7-000 E- 1 90105-KJ9-000 F-23 F- 3 90454-MC7-000 F-22 90012-NX7-000 E- 1 90105-KR3-000 F-12 90303-HW1-671 F-21 90456-KA4-000 E- 6 90013-NN4-000 E-12 90106-NF4-770 F-24 90303-NX4-000 F- 4 90456-NX4-000 F-12...
  • Page 295 2012-NSF250R Part No. Index Part No. Block Part No. Block Part No. Block Part No. Block 90601-360-000 E-13 91003-NX7-003 E-11 91212-422-006 F- 3 91565-SEL-003 F-15 90601-ZE1-000 F- 3 91004-KY4-900 E-11 91214-MR7-003 F-19 91611-SE3-000 F-15 F-11 91005-NX7-003 E-11 91255-NX4-771 F- 7 91615-SA5-000 F-24 90602-360-000...
  • Page 296 2012-NSF250R Part No. Index Part No. Block Part No. Block Part No. Block Part No. Block F-16 95002-02120 F-11 96001-06020-00 F-14 96300-06028-07 F- 3 F-22 F-15 96001-06022-00 F- 4 94050-08000 F-10 95002-45000 F-13 F-17 94050-10000 F-23 F-22 96001-06025-00 E- 5 94101-05000 F-16 95002-50000...

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